Training Rs Kalmar

A Foreword
B Safety
C Preventive maintenance
0 Complete machine
1 Engine
Workshop
manual 2 Transmission
3 Driveline/axle
4 Brakes
5 Steering
6 Suspension
7 Load handling
8 Control system
9 Frame, body, cab and accessories
10 Common hydraulics
11 Common electrics
12 Common pneumatics
D Error codes
E Schematics
F Technical data
G Terminologi och Index

A Foreword 1
A Foreword
Table of Contents A Foreword

mm mm mm mm mm mm
Foreword......................................................................................................... 3
About the Workshop Manual ...................................................................... 3
General ............................................................................................................. 3
Conditions ......................................................................................................... 3
Storage .............................................................................................................. 3
About machine version ...................................................................................... 3
Copyright ........................................................................................................... 3
Reading instructions ................................................................................... 4
Warning information .......................................................................................... 4
Important information ........................................................................................ 4
Read operator’s manual .................................................................................... 4
Read the Maintenance manual ......................................................................... 4
The workshop manual’s contents ...................................................................... 5
Function group structure ................................................................................... 6
References between different information types ............................................... 7
Product alternatives and optional equipment .................................................... 8
Machine card ..................................................................................................... 8
Function descriptions ........................................................................................ 9
About the documentation ......................................................................... 13
The documentation’s parts .............................................................................. 13
Ordering documentation .................................................................................. 13
Feedback .................................................................................................. 14
Form for copying ............................................................................................. 14
Workshop manual DRF 400-450 VDRF03.03GB

2 A Foreword
VDRF03.03GB Workshop manual DRF 400-450

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

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

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

tools. All lifting devices, such as slings, straps and ratchet blocks, must
meet governing national standards and regulations for lifting devices.
Cargotec will not accept any responsibility in the event of a modifica-
tion 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
page
–
NOTE
The workshop manual should be accessible to service personnel.
About machine version

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

sign and appearance at the time of delivery from Cargotec. Due to cus-
tomisations, there may be variations and/or deviations.
Cargotec reserves the right to modify specifications and equipment
without prior notice. All information and data in the 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 proper-

ty damage!
Only use equipment that is approved by Cargotec.
Copyright
page
–
Cargotec Sweden AB
Duplication of the content in this manual, in whole or in part, is strictly
prohibited without written permission from Cargotec Sweden AB.
All duplication by any means, such as copying, printing, etc., is
prohibited.

4 A Foreword – Reading instructions
Reading instructions
Warning information
page
–
Warnings provide information about potential dangers that, if the warn-

ings are not followed, could result in injury or product damage.
DANGER
Situation that could lead to severe personal injury or
death if regulation is not followed.
WARNING
Situation that could lead to personal injury if regula-
tion is not followed.
CAUTION
Situation that could lead to product damage if regula-
tion is not followed.
Important information
page
–
Important information is denoted with NOTE and is intended to facili-

tate the work process, handling or to increase understanding of the
information.
NOTE
Important information not related to safety.
Read operator’s manual

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

page
–
The symbol to the left is used in certain cases on the machine and re-
fers to important information in the Maintenance manual.
001128
Read the Maintenance manual

A Foreword – Reading instructions 5
The workshop manual’s contents

page
–
The Workshop Manual contains information to facilitate maintenance

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

Function group structure

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

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

References between different information types

page
–
The maintenance manual and workshop manual are mainly divided

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

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

(Technical description, normally in Workshop manual) (Section D)
Diagnostics Wiring diagrams

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

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

Product alternatives and optional equipment

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

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

equipment for more or improved functions.
Symbol for optional equipment
Information on optional equipment is described in separate segments
together with the standard equipment. The optional equipment descrip-
tion covers how the equipment affects standard function and what com-
ponents are added.
Machine card
page
–
NOTE
If the machine has been modified after delivery, information on
the machine card may be incomplete or incorrect.
The machine card indicates of which drawings the machine consists. In
many cases these can be associated to options and product alterna-
tives. For more information about handling of product alternatives and
optional equipment, see Product alternatives and optional equipment
page 8. The machine card is delivered with the parts catalogue.
The machine card is divided into the same function groups as the spare
parts catalogue, maintenance manual and workshop manual. For prac-
tical reasons, the machine card only uses the first and second level of
the function group register. The function groups are written in groups of
four characters, e.g., group 0107 refers to group 1.7 Cooling system in
the manual.
For more information about how the machine card is used for ordering
spare parts, see the spare parts catalogue’s foreword.
If the information on the machine card is not of any assistance, contact
Cargotec.
NOTE
All documents that accompany the machine are non-registered
documents and there will be no notification of changes.

Function descriptions
page
–
The function descriptions are schematic overviews that describe

how a function works as well as which components and signals work
together.
Function descriptions describe the function in a logical flow from input
signal to desired output signal. Most functions require that preset con-
ditions are fulfilled for the function to be activated. In these cases, the
conditions are listed above the illustration.
The function descriptions use symbols to illustrate components such
as valves, sensors, etc.
2 4 Bromsar – 4.3 Servobromssystem
5
B
13 P
7 D790-2
T
D 2
D797-R D797-F
11 10 8 C
Pa
12
C D D
9
4 Pa
3 7
3
B
ACC 6
C
6 2
P
4
1
B
004729
1. Bromsoljepump 8. Slutkontakt bromsljus (S216) 5

2. Bromsoljefilter 9. Brytkontakt bromsoljetryck (S204)
3. Ackumulatorladdningsventil 10. Reglerenhet ram fram (D797-F)
4. Ackumulatorer 11. Reglerenhet ram bak (D797-R)
5. Bromsventil 12. Bromsljus (H411L & H411R)
6. Bromscylindrar 13. Reglerenhet KIT (D790-2), Varningslampa bromstryck
7. Hjulbromsar
UDRF03.01S Underhållsmanual DRF 400–450

006453
Example of function description

1. Hydraulic force (solid double line)

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

Symbol explanation function descriptions

The following symbols are used in function descriptions. The symbols
1 2 are based on standard symbols 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 10 9. Accumulator
10. Disc brake
11. Filter
11 12
12. Radiator
D790-1 13. Bulb
13 14 14. Control and monitoring system, two control units with CAN bus
D797-F 15. Restriction
16. Adjustable restriction
15 16
17. Inductive position sensor
17 18 18. Electrically controlled servo valve
19. Thermal bypass valve
19 ˚C 20 ˚C
20. Temperature-controlled switch
˚C Pa 21. Temperature sensor
21 22
22. Pressure sensor
23 Pa 24 23. Pressure-controlled switch
24. Hydraulic cylinder
25 25. Double-acting hydraulic cylinder
26. Spring brake cylinder
27. Valve block
26 27
28. Shuttle valve
29. Non-return valve
28 29
000523

12 A Foreword – About the documentation
About the documentation

The documentation’s parts
page
–
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
page
–
Documentation is ordered from your Cargotec dealer.

Always indicate publication number when ordering.
For publication number, see machine card.

A Foreword – Feedback 13
Feedback
Form for copying
page
–
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. Thank you
for your cooperation!
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: .................................... - .................. - ..................
Manualinformation
Name / Publication number: ................................................................................................................
Section / page number: .......................................................................................................................
Suggestions,
views, remarks, ...............................................................................................................................................................
etc.
...............................................................................................................................................................
...............................................................................................................................................................
...............................................................................................................................................................
...............................................................................................................................................................
...............................................................................................................................................................

14 A Foreword – Feedback

B Safety 1
B Safety
Table of Contents B Safety

mm mm mm mm mm mm
Safety .............................................................................................................. 3
General safety information ......................................................................... 3
Safety concerns everyone! ................................................................................ 3
A near accident is a warning! ............................................................................ 3
Safety instructions ...................................................................................... 4
General ............................................................................................................. 4
Service position ................................................................................................. 4
Hydraulic and brake systems, depressurising ................................................... 5
Oils .................................................................................................................... 6
Fuel system ....................................................................................................... 7
Clothing, etc. ..................................................................................................... 8
Several mechanics on the same machine ......................................................... 9
Working under the machine .............................................................................. 9
Lifting heavy components ............................................................................... 10
Vibration .......................................................................................................... 10
Noise ............................................................................................................... 11
Dissolvent ........................................................................................................ 11
Fire and explosion risk .................................................................................... 12
Fluid or gas under pressure ............................................................................ 15
Coolant ............................................................................................................ 16
Refrigerant ...................................................................................................... 16
Air pollution ..................................................................................................... 17
Tensioned springs ........................................................................................... 18
Electric motors ................................................................................................. 18
Rotating components and tools ....................................................................... 18
Tyres and rims ................................................................................................. 20
Lifting equipment ............................................................................................. 20
Spare parts ...................................................................................................... 21
Non-ionised radiation ...................................................................................... 22
Environment ............................................................................................. 23
General ........................................................................................................... 23

2 B Safety

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

Safety concerns everyone!
page
–
The safety information applies to all who work with the machine! Per-
sons who do not follow the safety instructions given in this manual
must make absolutely sure that the work is performed without risks
of personal injury and without risks of damage to the machine or
property!
Remember to:
• follow the instructions in this manual
• be trained for the work in question
• follow local laws, safety rules and regulations
• use the correct equipment and tools intended for the work in
question
• wear the correct clothing
• use common sense and work carefully. Do not take any risks!
In this publication Cargotec has documented and warned for situations
and risks that may occur in connection with the use of, as well as serv-
ice or repair of, the machine during normal circumstances.
For this reason it is important that all who work with the machine, or
repair or service the machine, read and follow the information in the
Workshop manual and Operator’s Manual.
A near accident is a warning!

page
–
An incident (near-accident) is an unexpected event where neither per-

sons, machine or property are injured or damaged. However, an inci-
dent indicates that there is an injury risk and actions must be taken to
avoid the risk of injuries.

4 B Safety – Safety instructions
Safety instructions
General
page
–
Read and observe the following safety instructions below before start-
ing to work with the machine:
• Service position page 4
• Hydraulic and brake systems, depressurising page 5
• Oils page 6
• Fuel system page 7
• Clothing, etc. page 8
• Several mechanics on the same machine page 9
• Working under the machine page 9
• Lifting heavy components page 10
• Vibration page 10
• Noise page 11
• Dissolvent page 11
• Fire and explosion risk page 12
• Fluid or gas under pressure page 15
• Coolant page 16
• Refrigerant page 16
• Air pollution page 17
• Tensioned springs page 18
• Electric motors page 18
• Rotating components and tools page 18
• Tyres and rims page 20
• Lifting equipment page 20
• Spare parts page 21
• Non-ionised radiation page 22
Service position
page
–
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.
• Boom fully retracted and lowered to horizontal position.
• Engine off.
• Main electric power voltage turned off (with the battery
disconnector).
003603
Machine with fully retracted and lowered boom

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

page
–
1 Machine in service position.

2 Depressurise the hydraulic system.
Turn the start key to position I and activate extension out, a
strong hissing sound is heard if there is pressure in the hydraulic
system. Activate lift, extension, and sideshift several times.
3 Turn the start key to position 0 and switch off the main power.
4 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 top lift is closed before
starting the engine after finished work.
002269
The figure above shows closed valve.

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

accumulator charging valve.
NOTE
Keep the drain valve open as long as work is in progress.
NOTE
After the work has been finished, close the drain valve and
tighten the lock ring.
Oils
page
–
The following safety instructions must be followed for work when han-
dling oils.
WARNING
Hot and pressurised oil.
Always depressurise hydraulic and brake systems

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

Warm oil can cause burn injuries, rashes and irrita-
tion! The oil may also be corrosive to mucous mem-
branes in, e.g., the eyes, skin and throat.
IMPORTANT
Always clean the area around components and con-
nections before they are loosened. Dirt in oil systems
causes increased wear, resulting in subsequent ma-
terial damages.
Always take action to avoid spills. In places where

drain containers cannot be used, use a pump or hose
for safe handling.
Always check that plugs are sealed tightly before re-

ceptacles are moved.
Handle all oil as environmentally hazardous waste.

Oils freely released cause damage to the environment
and may also cause fires. Waste oils/fluids shall al-
ways be handled by an authorised company.

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

engine is warm since fuel can spill on hot surfaces
and may ignite.
Make sure that open flames, sparks, or red-hot/glow-

ing objects have been extinguished before starting
work on or near the fuel system.
Do not smoke near the machine during work on the

fuel system.
WARNING
The engine’s fuel system operates at very high pres-
sure. The pressure is so high that the jet can injure
the skin, which may result in serious injuries.
Risk of personal injury.
Use protective gloves and protective safety goggles,

avoid skin contact with fuel. If a component is to be
disconnected, hold a rag over the coupling as protec-
tion and collect the fuel. Fuel is corrosive to mucous
membranes in, e.g., eyes, skin, and throat.
CAUTION
Always clean the area around components and con-
nections before they are loosened. Dirt in the fuel may
cause malfunctions and engine failure in undesirable
situations as well as increase wear, resulting in sub-
sequent material damages.

IMPORTANT
Always take action to avoid spills. In places where
drain containers cannot be used, use a pump or hose
for safe handling.
Always check that plugs and connections are sealed

tightly before receptacles are moved.
Handle the fuel as environmentally hazardous waste.

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

(tie, scarf, etc.). Do not wear clothes with wide sleeves, wide trouser
legs, etc.
Remove jewellery as it may conduct electricity and get caught in mov-
ing parts.
Long hair must be tied up securely, otherwise it may easily get caught
in moving parts. Be careful when performing welding work or work re-
quiring open flames since hair catches fire easily.

Several mechanics on the same machine

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

page
–
Working under cab

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

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

Lifting heavy components

page
–
WARNING
Careless handling of heavy components may lead to
serious personal injury and material damage.
Use type-approved lifting tools or other devices to

move heavy components. Make sure that the device is
stable and intact.
Risks
Unsuitable 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, especially
when there are is such equipment adapted for certain work. See work-
shop manual for methods.
If lifting must be performed without lifting device:
• Lift near the body.
• Keep your back vertical. Raise and lower with legs and arms, do
not bend your back. Do not rotate your body while lifting. Ask for
assistance or help in advance.
• Use gloves. They’re often good protection to reduce crushing and
cutting injuries to fingers.
• Always use protective shoes.
Vibration
page
–
Use of vibrating tools, e.g. impact nut runner or grinder, for an extend-
ed period of time may cause injuries as vibration is transmitted from
the tool to hands - especially when fingers get cold.
Safety precautions
Use heavy gloves that protect against the cold and somewhat against
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
page
–
Noise louder than 85 dB (A) that lasts for longer than 8 hours is con-
sidered harmful to hearing. (Limit values may vary between different
countries.) High pitches (high frequencies) are more damaging than
low pitches at the same sound level. Impact noise can also be hazard-
ous, e.g., hammer blows.
Risks
At noise levels higher than the limits hearing damage can occur. In
more severe cases, hearing damage can become permanent.
Safety precautions
Use hearing protection. Make sure that it’s tested and protects against
the right noise level.
Limit noise with noise-absorbing screens, for example, noise-absorb-
ing materials in roof and on walls.
Dissolvent
page
–
Fluids that (as opposed to water) dissolve grease, paint, lacquer, wax,
oil, adhesive, rubber, etc. are called organic solvents. Examples:
White (petroleum) spirits, gasoline, thinner, alcohols, diesel, xylene,
trichloroethylene, toluene. Many solvents are flammable and consti-
tute a fire hazard.
Risks
Products containing solvents produce vapours that can cause dizzi-
ness, headaches and nausea. They may also irritate mucous mem-
branes in the throat and respiratory tracts.
If the solvent comes into direct contact with the skin, this may cause
drying and cracking. Risk of skin allergies increases. Solvents may
also cause injury if they penetrate through the skin and are absorbed
by the blood.
If the body is continuously exposed to solvents, the nervous system
may be affected. Symptoms include sleep disorders, depression,
nervousness, poor memory or general tiredness and fatigue. Continu-
ous inhalation of gasoline and diesel fumes is suspected to cause
cancer.
Safety precautions
Avoid inhaling dissolvent fumes by providing good ventilation, or wear-
ing 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 solvents with low content of aromatic substances. This reduces
the risk of injuries.
Avoid skin contact.
Use protective gloves.
Make sure that work clothes are dissolvent-resistant.

Fire and explosion risk

page
–
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 from fires makes you sleepy, suffocate, and

can kill! Smoke from fires can injure lungs and respi-
ratory organs even in small amounts.
Avoid inhaling smoke from fires, do not stand in the

smoke. Use breathing protection when putting out
fires and working with burnt materials.
Examples of fire and explosion prone substances are oils, petrol, die-
sel fuel oil, organic solvents (paint, plastics, detergents), rust preven-
tive agents, welding gas, gas for heating (acetylene), high
concentrations of dust particles consisting of combustible materials.
Rubber tires are flammable and cause explosive fires.

Risks
Examples of cause of ignition is welding, cutting, smoking, sparks
when working with grinders, contact between hot machine parts and
flammable materials, heat development in rag drenched with oil or
paint (linseed oil) and oxygen. Oxygen cylinders, lines and valves shall
be kept free from oil and grease.
Fumes from, e.g., gasoline, are heavier than air and may "run" down
a slope, or down into a grease pit, where welding flames, grinding
sparks or cigarette embers may cause an explosion. Evaporated
gasoline can cause an extremely powerful explosion.
Special cases
Diesel fuel oil with added gasoline has a lower ignition point. Risk of
explosion already at room temperature. The explosion risk for warmed
diesel fuel oil is higher than for gasoline.
When changing the oil in the engine, hydraulic system and transmis-
sion, keep in mind that the oil may be hot and cause burn injuries.
Welding on or near 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 charged, the battery fluid is divided into oxygen and
hydrogen gas. This mixture is very explosive. The risk of explosion is
especially high when using a booster battery or quick-charger, as this
increases the risk of sparks.
Today’s machines contain a lot of electronic equipment. When weld-
ing, the control units must be disconnected and the electric power
must be turned off with the battery disconnector. Powerful welding cur-
rents may otherwise short-circuit the electronics, destroy expensive
equipment or cause an explosion or fire.
Never weld on painted surfaces (remove paint, by blasting at least
10 cm around the welding or cutting point). Use gloves, breathing pro-
tection and protective goggles. In addition, welding work may not be
done near plastic or rubber materials without first protecting them from
the heat. Paints, plastics, and rubber develop a number of substances
that may be hazardous to health when heated. Be careful with ma-
chines 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 any flammable materials in the engine com-

partment as soon as they are discovered, be extra
thorough on hot surfaces such as exhaust systems,
manifolds, or turbo. If these is a leak of oil, fuel, or
coolant, determine the cause and take appropriate ac-
tion before starting the engine.
• Make a habit of visually checking the engine and engine compart-

ment before starting the engine and after operating, when the en-
gine has been turned off. This makes it easier to quickly notice if
anything abnormal has happened or is about to happen. Pay spe-
cial attention to oil, fuel, or coolant leaks, loose bolts, worn or
poorly tightened drive belts, loose connections, damaged hoses,
and electric cables. The check only takes a few minutes and can
prevent serious failures and expensive repairs.
• Store a hazardous substance in an approved and sealed
container.
• Make sure that there is no ignition source near flammable or ex-
plosive substances.
• Make sure that ventilation is adequate or there is an air extraction
unit when handling flammable substances.

Fluid or gas under pressure

page
–
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 cylinder subjected to careless handling may explode, for exam-
ple, if it falls onto a hard surface. Gas can 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.
Safety precautions
• Use protective goggles and protective gloves.
• Never work in a pressurised system.
• Never adjust a pressure limiting valve to a higher pressure than
the manufacturer’s recommendations.
• A hydraulic hose that swells, e.g. at a connection, shows that it is
about to rupture. Change as soon as possible! Check connections
thoroughly.
• Use fluid when checking for leaks.
• Never blow clothes clean with compressed air.
• Discarded pressure accumulators must first be punctured before
they are deposited as waste (to avoid risk of explosion). Carefully
drill a hole with 3 mm diameter after depressurising.
• Never use your hands to detect a leak. A fine high-pressure jet
from a hydraulic hose can easily penetrate a hand and causes
very severe injuries.

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

corrosion compound, and possibly anti-freeze fluid, for example, eth-
ylene glycol.
Coolant must not be drained into the sewer system or directly onto the
ground.
Risks
The cooling system operates at high pressure when the engine is
warm. Hot coolant can jet out and cause scalding in case of a leak or
when the expansion tank cap (filler cap) is opened.
Ingesting ethylene glycol and anti-corrosion compound is dangerous
and hazardous to health.
Safety precautions
• Use protective gloves and protective safety glasses if there is a
risk of splashing or spraying.
• First open the filler cap to release the high pressure. Be careful.
Hot steam and coolant may jet out.
• If possible, avoid working on the cooling system when the coolant
is hot.
Refrigerant
page
–
Refrigerant is used in the machine’s air conditioning system.

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

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

Tensioned springs
page
–
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 uncon-
trolled manner.
Gas springs and gas-charged shock absorbers are tensioned with
high force and can cause very severe accidents if they are accidentally
released in an uncontrolled manner.
Safety precautions
• Use protective safety glasses.
• Lock rings should be of a suitable type and in good condition.
• Follow the instructions in this and other manuals when performing
maintenance and replacing parts and components.
• Always use the tools recommended.
Electric motors
page
–
Safety precautions
Always switch off the battery disconnector when working on electric
motors.
Always block the machine’s wheels, make sure that the parking brake
is activated and that the gear selector is in neutral position before start-
ing any work on the machine.
Rotating components and tools

page
–
Examples of rotating components and tools:

• Cooling fan
• Drive belts
• Propeller shafts
• Drills
• Grinders

Risks
Rotating components, 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

page
–
DANGER
Tyres should be regarded as pressurised containers.
They constitute fatal danger if handled incorrectly.
Parts could be thrown out with explosive force and

cause severe injuries.
Never repair damaged tyres, rims or lock rings.

Tyre changes shall be performed by authorised
personnel.
Risks
Dismantling wheels: Tyres, rims or lock rings may be ejected.
Inflating wheels: Tyres, rims or lock rings may be ejected.
Safety precautions
• Always deflate the tyre before starting to work on the wheel.
• Check that tyres, rims and lock rings are not damaged. Never re-
pair damaged rims or lock rings.
• Wheels shall be inflated on the machine or in a protective device,
designed and dimensioned so that it can handle or dissipate a
shock wave from a tyre explosion as well as catch the ejected
parts.
• Use protective screen and protective safety glasses.
Lifting equipment
page
–
When working on the machine in general, and with the machine’s lift-
ing equipment in particular, the greatest caution must be exercised
with respect to securing the mast, boom, and attachment.
Therefore, always make a habit of having the boom fully lowered and
completely retracted when working on the machine.
Risks
If the machine’s lifting equipment is not lowered or secured, there is a
risk of crushing.
Risk of crushing is particularly great when depressurising the hydraulic
system, see Hydraulic and brake systems, depressurising page 5.
Safety precautions
• If possible, do not start to work before the boom is completely low-
ered and fully retracted.

Spare parts
page
–
WARNING
For safety reasons, the following spare parts may
only be replaced with genuine spare parts:
• Brake valve
• Drive axle
• Valve for mini-wheel/joystick control
• Steering valve (orbitrol)
• Steering valve incl. priority valve
• Steering axle
• Steering cylinder
• Rim
• Lift boom
• Boom nose extension
• Lift cylinder
• Valve block lift
• Extension cylinder
• Valve block extension
• Rotation motor unit
• Tilt cylinder
• Twistlocks, lift shoe
• Control breaker (for hydraulic function)
• Emergency stop
• Frame
• Accumulator
• Main valve load handling
• Accumulator charging valve
• All control units

Non-ionised radiation
page
–
WARNING
Optional equipment such as two-way radio, RMI, tele-
phone, etc. may emit non-ionising radiation.
Risk of interference with active or non-active medical

products.
Use two-way radio, RMI, telephone, etc. when no per-

sons with active or non-active medical products are in
the vicinity.
NOTE
When persons with active or non-active products are not nearby,
telephone and two-way radio may be used in the cab.
Equipment should not be used during operation or load handling
as this takes away from the operator’s concentration.
Cargotec will not assume any responsibility for installed optional
equipment, which is not installed by Cargotec or an installer ap-
proved by Cargotec.

B Safety – Environment 23
Environment
General
page
–
Ever-increasing industrialisation of our world is having a significant im-

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

Components such as batteries, plastics, and 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 environmental-
ly safe manner and according to national regulations.
Oils and fluids

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

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

24 B Safety – Environment
Declarations
The machine does not contain asbestos.
The machine contains lead in batteries and in electric cabling. Some
models have counterweights of cast lead.
If the machine is equipped with air conditioning, refrigerant of type
R134a is used, in an amount totalling between 1-3 kg.

C Preventive maintenance 1
mm mm mm mm mm mm
The information is available in the

page
–
Maintenance Manual
The information is available in the Maintenance Manual.
For information on how to order the Maintenance Manual, see the sec-
tion A Foreword.
Workshop manual DRF 400–450 VDRF03.03GB

2 C Preventive maintenance
VDRF03.03GB Workshop manual DRF 400–450

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

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

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

2 0 Complete machine

Complete machine 3
Complete machine
mm mm mm mm mm mm
Complete machine, description

page
–
The Kalmar DRF 400–450 is a "Reachstacker" for handling contain-

ers. The machine has a lift capacity of up to 40–45 metric tons depend-
ing on version.
The drive and power source is a six-cylinder, four-stroke, direct injec-
tion diesel engine.
The transmission is hydromechanical, with gears in constant mesh. It
has four forward gears and four reverse gears. Engine power is trans-
mitted by a torque converter.
The power transmission consists of a propeller shaft and a rigid drive
axle with hub reduction. The machine has front-wheel drive.
The service brake is of wet disc type, built together with drive wheel
hubs. The parking brake is of dry disc type and acts on the drive axle’s
input shaft.
Steering takes place with the rear wheels and a double-acting hydrau-
lic cylinder. The steering axle is oscillation-mounted in the frame.
The wheels are mounted on the hubs with nuts and clamps. Twin
wheels are mounted on the drive axle, while the steering axle has sin-
gle wheels.
Load handling are components and functions for handling loads.
Loads are lifted with an attachment mounted on a liftable telescopic
boom. Load handling is divided into lift/lower, extension, sideshift,
spreading, rotation, tilt, levelling, and load carrier functions.
• Lift/lower is the function for lifting and lowering the boom.
• Extension is the function for extending and retracting the boom.
• Sideshift is the function for moving the lift attachment sideways in
relation to the machine.
• Spreading is the function for adjusting the width between the at-
tachment’s lifting points.
• Rotation is the function for rotating the load in relation to the
machine.
• Tilt is to angle the load in the machine’s longitudinal direction.
• Levelling is to angle the load in the machine’s sideways direction.
• Load carrier is the function for holding on to a load.
The control system has functions for warning the operator of danger-
ous situations and malfunctions on the machine. The control system
has diagnostics that simplify troubleshooting.
The frame supports the machine. Mounted in the frame are the engine,
transmission, drive axle, and steering. The side of the frame has tanks
for fuel, hydraulic oil, and oil for the brake system. The cab is centrally
located and can be slid fore-aft.
As an option the cab is available in a side-mounted vertically adjusta-
ble version.

4 Complete machine
Troubleshooting, general work

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

Complete machine 5
Troubleshooting without an error

page
–
code, example
1 Choose suitable section 0–12 to locate the function and subfunc-
tion that have caused the symptom.
2 Read the function description for the function in question to get
an overall understanding of which components are affected and
how these interact.
3 Use the function description and check the signals for the func-
tion affected in order to locate where in the function chain that the
signal or reaction is incorrect.
4 The malfunction is probably between the two units where the sig-
nal is incorrect. Start by checking the component that should
send 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 7.
For hydraulic hoses, see Troubleshooting hydraulic hoses
page 8.
6 If the cables or hoses between the components seem to be intact,
then check the component that receives the signal.
Troubleshooting with an error code,

page
–
example
Error codes are strong indicators of malfunctions detected by the con-
trol system. Many error codes are connected to electrical malfunctions
but there are also error codes that interpret associations between one
or several signals that indicate a non-electrical malfunction. It is impor-
tant to not draw conclusions too fast based on an error code.
1 Read out error codes from the display, e.g. error code 34.
2 Use the error code lists and search information about the error
code, see "Example of error code information in error code list"
below.
The error code lists are available in section D Error codes.
For detailed instructions for reading out error code, see
section D Error codes.
3 Follow the instructions in the field "Action".
4 Use diagnostic menus and circuit diagrams to determine if the in-
put signal to the control unit is correct; see section 8 Control sys-
tem, group 8.4 Diagnostics as well as section E Schematics.

6 Complete machine
5 Use the function group to find more information if needed.

In section 0–12 there is a function description, the function’s in-
cluded components and their position as well as, in certain cases,
work instructions for how components are checked, cleaned or
adjusted.
6 If possible, eliminate component faults by testing the component
individually.
Electric components can sometimes be checked with resistance
measurements using a multimeter.
Hydraulic components are often checked by measuring pressure
(then described in the function group and indicated in the section
C Preventive maintenance). Sometimes valves can be activated
mechanically to determine if the malfunction is electric or
hydraulic.
7 If the component’s measurement values are correct, continue by
troubleshooting electric cables and hydraulic hoses.
For electric cables, see Troubleshooting cable harnesses
page 7.
For hydraulic hoses, see Troubleshooting hydraulic hoses
page 8.
8 If the wiring is not defective, then connect the cable to the control
unit.
NOTE
The main electric power must be turned off with the battery
disconnector!
9 Disconnect the cable harness from the component in question.
10 Turn on the main electric power with the battery disconnector.
11 Turn the ignition key to operating position.
12 Check that voltage reaches the component.
Table 1. Example of error code information in error code list
Connections Diagnostic Function

Code Description Limitation Action
and components menu group
34 Signal error from Parking brake Check cabling D791-1/K8:5 - HYD, menu 5 4.1.2 Parking
parking brake cannot be between the S107, K8:13 - S107 brake control
switch, indicates released. control unit
released and ap- and the com-
plied at same time ponent with
or nothing at all. diagnostic
menu.
Check
component.

Complete machine 7
Troubleshooting cable harnesses

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

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

troubleshooting using electronic cleaner 923836.0826
and re-grease them with connector grease
923836.0552.
4 Check if there is an open circuit.
NOTE
Some components cannot be checked without power supply
to the component. In such cases, proceed to step 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. Other-
wise there may be an open circuit or short-circuiting in cable
harness and/or component.
5 Check if there is a short circuit to the frame:
a. Unplug the connector at both the control unit and the compo-
nent in question.
b. Measure the resistance of one lead at a time. Measure be-
tween the lead and a frame-connected part of the machine.
c. The multimeter should show infinite resistance.

8 Complete machine
Troubleshooting hydraulic hoses

page
–
WARNING
Hot and pressurised oil.
Always depressurise hydraulic and brake systems

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

Warm oil can cause burn injuries, rashes and irrita-
tion! The oil may also be corrosive to mucous mem-
branes in, e.g., the eyes, skin and throat.
1 Depressurise the hydraulic and brake systems, see

section B Safety.
2 Study the hydraulic diagram in question, check between which
components the suspect hose is connected and if, and if so
where, it is spliced.
3 Locate the hose on the machine.
Start at one component and follow the hose to the next
component.
4 Inspect the entire hose and splicing points with respect to chafing
damage, pinching damage and leaks.
Change damaged hoses. When removing a hydraulic hose,
O-ring replacement is always recommended on the hoses where
they are installed (ORFS).

1 Engine 1
1 Engine
Table of Contents 1 Engine

mm mm mm mm mm mm
1 Engine ............................................................................................................. 3
1.1 Controls and instruments ......................................................................... 23
1.1.1 Ignition ................................................................................................. 23
1.1.2 Accelerator ........................................................................................... 24
1.2 Fuel system .............................................................................................. 25
1.2.1 Fuel tank .............................................................................................. 25
1.2.2 Sensor fuel level .................................................................................. 25
1.6 Air intake and exhaust outlet .................................................................... 26
1.6.1 Air cleaning system .............................................................................. 26
1.6.3 Exhaust system ................................................................................... 26
1.6.4 Intercooler ............................................................................................ 27
1.7 Cooling system ......................................................................................... 28
1.7.4 Radiator and expansion tank ............................................................... 29
1.7.5 Cooling fan ........................................................................................... 30
1.7.7 Coolant ................................................................................................ 33
1.7.10 Engine heater ...................................................................................... 39
1.9 Control system, engine ............................................................................. 40
1.9.1 Engine control unit ............................................................................... 40
1.11 Start/stop .................................................................................................. 41
1.11.1 Starter motor ........................................................................................ 41
1.11.2 Stopping device ................................................................................... 41

2 1 Engine

1 Engine 3
1 Engine
mm mm mm mm mm mm
Engine, general
page
–
Engine alternative
The machine can be equipped with one of the following engine
alternatives:
• Volvo TWD1240VE (stage II according to Directive 97/68/EC)
• Volvo TAD1250VE (stage III according to Directive 97/68/EC)
• Cummins QSM11 (stage III according to 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 be-
ing shown.
Volvo engines have many similarities. Descriptions and instructions
that are the same for both engine alternatives are designated "(engine
alternative Volvo)". If a description or set of instructions only applies to
one engine alternative then the whole engine designation is written
out, e.g., "(engine alternative Volvo TAD1250VE).
Component supplier documentation

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

4 1 Engine
Engine alternative Volvo, function

page
–
description
Condition Reference value Reference
Disconnected (when cable is in start lock-out is Engine heater, description page 39
Engine heater
activated)
˚C
0 . bar
P I
rpm
II kph
III D5
10 <˚ 1, 5
D10 D1
2, 11 6, 15 18, 21
D790-1 D790-2 D795
D793 D794 D797-R

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

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

1 Engine 5

5 The ignition key lock sends a voltage sig- U = 24 V Ignition key lock, description page 23
nal to Control unit KIT (D790-2) when the D5: Diagnostic menu, see section 8 Control
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 sig- Checked by control sys- Section 11 Common electrics,
nal on the CAN bus. tem, error shown with group 11.5.3.11 Control unit, KIT
error code.
7 The engine control unit (D794) supplies U = 24 V Starter motor, description (engine alterna-
power to the starter motor. tive Volvo) page 41
D7: Diagnostic menu, see section 8 Control
system, group 8.4.6.5 ENGINE menu 5
8 The starter motor cranks the engine. - Starter motor, description (engine alterna-
tive Volvo) page 41
9 The engine’s sensor sends signals to Con- Checked by control sys- Section 11 Common electrics,
trol unit, engine (D794) that controls the in- tem, error shown with group 11.5.3.10 Control unit, engine
jectors so the engine starts. error code.
10 The accelerator pedal sends a voltage sig- U = 0.5–4.5 V Section 9 Frame, body, cab and accesso-
nal proportional the depression to Control Lower voltage than ries, group 9.1 Controls and instruments
unit, cab (D790-1). 0.5 V and higher volt- D10: Diagnostic menu, see section 8 Con-
age than 4.5 V is used trol system, group 8.4.6.1 ENGINE menu 1
to detect faults in cable
harnesses and controls.
11 Control unit, cab (D790-1) sends a mes- Checked by control sys- Section 11 Common electrics,
sage with the rpm request on the CAN bus. tem, error shown with group 11.5.3.1 Control unit, cab
error code.
12 Control unit, engine (D794) increases the - Section 11 Common electrics,

engine speed. group 11.5.3.10 Control unit, engine
13 Make-contact (closing switch) coolant level U = 24 V Cooling system, description page 28

sends a voltage signal to Control unit, en-
gine (D794) if the coolant level is low in the
expansion tank.
14 Control unit, engine (D794) sends engine Checked by control sys- Section 11 Common electrics,
data and warning messages on the CAN tem, error shown with group 11.5.3.10 Control unit, engine
bus. error code. D14: Diagnostic menu, see section 8 Con-
trol system, group 8.4.6.6 ENGINE,
menu 6 and 8.4.6.7 ENGINE, menu 7
15 Control unit KID (D795) shows engine data - Section 11 Common electrics,
via display figures. group 11.5.3.12 Control unit, KID

6 1 Engine

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

1 Engine 7
Engine alternative Cummins QSM11,

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

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

1 The ignition sends a voltage signal to U = 24 V Ignition key lock, description page 23
Control unit, cab (D790-1) when the start D1: Diagnostic menu, see section 8 Control
key is turned to position 1. system, group 8.4.1.4 CAN/POWER,
menu 4 and 8.4.6.4 ENGINE, menu 4
2 Control unit, cab (D790-1) sends Ignition Checked by control sys- Section 11 Common electrics,
on as start message on the CAN-bus. tem, error shown with group 11.5.3.1 Control unit, cab
error code.
Control unit KIT (D790-2) when the start D2: Diagnostic menu, see section 8 Control
key is turned to start position. system, group 8.4.6.4 ENGINE menu 4
4 Control unit KIT (D790-2) sends a start Checked by control sys- Section 11 Common electrics,
signal on the CAN-bus. tem, error shown with group 11.5.3.11 Control unit, KIT
error code.

8 1 Engine

5 Control unit frame rear (D797-R) sup- U = 24 V Starter motor, description (engine alternative
plies voltage to the starter motor. Cummins) page 41
6 The starter motor cranks the engine. - Starter motor, description (engine alternative
Cummins) page 41
7 The engine’s sensor sends signals to - Section 11 Common electrics,

Control unit, engine (D794) that controls group 11.5.3.10 Control unit, engine
the injectors so the engine starts.
8 The accelerator pedal sends a voltage U = 0.5–4.5 V Section 9 Frame, body, cab and accessories,
signal proportional the depression to Lower voltage than group 9.1 Controls and instruments
Control unit, cab (D790-1). 0.5 V and higher voltage D8: Diagnostic menu, see section 8 Control
than 4.5 V is used to de- system, group 8.4.6.1 ENGINE menu 1
tect faults in cable har-
nesses and controls.
9 Control unit, cab (D790-1) sends a Checked by control sys- Section 11 Common electrics,
message with the rpm request on the tem, error shown with group 11.5.3.1 Control unit, cab
CAN bus. error code.
10 Control unit engine (D794) controls the - Section 11 Common electrics,

11 Make-contact (closing switch) coolant U = 24 V Cooling system, description page 28

level sends a voltage signal to Control
unit, engine (D794) if the coolant level is
low in the expansion tank.
12 Control unit, engine (D794) sends en- Checked by control sys- Section 11 Common electrics,
gine data and warning messages on the tem, error shown with group 11.5.3.10 Control unit, engine
CAN bus. error code. D12: Diagnostic menu, see section 8 Control
system, group 8.4.6.6 ENGINE, menu 6 and
8.4.6.7 ENGINE, menu 7
13 Control unit KID (D795) shows engine - Section 11 Common electrics,

data via display figures. group 11.5.3.12 Control unit, KID
signal proportional to the fuel level in Lower voltage than D14: Diagnostic menu, see section 8 Control
the tank to Control unit, frame rear 0.5 V and higher voltage system, group 8.4.3.7 CAB, menu 7
(D797-R). than 4.5 V is used to de-
15 The frame control unit rear (D797-R) Checked by control sys- Section 11 Common electrics,
sends fuel level on the CAN-bus. tem, error shown with group 11.5.3.3 Control unit frame rear
error code.
16 Control unit KID (D795) shows the fuel - Section 11 Common electrics,
level in the operating menu for the group 11.5.3.12 Control unit, KID
engine.

1 Engine 9

17 The output shaft sensor (B758) sends - D17: Diagnostic menu, see section 8 Control
the transmission control unit (D793) system, group 8.4.7.6 TRANSM menu 6
pulses with frequency proportional to the
rpm of the output shaft.
sends speed information on the tem, error shown with group 11.5.3.9 Control unit, transmission
CAN-bus. error code.
19 Control unit KID (D795) shows the - Section 11 Common electrics,

machine’s speed. group 11.5.3.12 Control unit, KID
20 If the speed is at the limit for the ma- Checked by control sys- Section 11 Common electrics,
chine’s speed limitation, Control unit, tem, error shown with group 11.5.3.1 Control unit, cab
cab (D790-1) sends an engine speed re- error code.
duction request on the CAN-bus.

10 1 Engine

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

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

Control unit, cab (D790-1) when the start D1: Diagnostic menu, see section 8 Control
key is turned to position 1. system, group 8.4.1.4 CAN/POWER, menu 4
and 8.4.6.4 ENGINE, menu 4
2 Control unit, cab (D790-1) sends Ignition Checked by control sys- Section 11 Common electrics,
on as start message on the CAN-bus. tem, error shown with group 11.5.3.1 Control unit, cab
error code.
Control unit KIT (D790-2) when the start D2: Diagnostic menu, see section 8 Control
key is turned to start position. system, group 8.4.6.4 ENGINE menu 4
4 Control unit KIT (D790-2) sends a start Checked by control sys- Section 11 Common electrics,
signal on the CAN-bus. tem, error shown with group 11.5.3.11 Control unit, KIT
error code.

1 Engine 11

5 Control unit frame rear (D797-R) sup- U = 24 V Starter motor, description (engine alternative
plies voltage to the starter motor. Cummins) page 41
6 The starter motor cranks the engine. - Starter motor, description (engine alternative
Cummins) page 41
7 The engine’s sensor sends signals to - Section 11 Common electrics,

Control unit, engine (D794) that controls group 11.5.3.10 Control unit, engine
the injectors so the engine starts.
8 The accelerator pedal sends a voltage U = 0.5–4.5 V Section 9 Frame, body, cab and accessories,
signal proportional the depression to Lower voltage than group 9.1 Controls and instruments
Control unit, cab (D790-1). 0.5 V and higher voltage D8: Diagnostic menu, see section 8 Control
than 4.5 V is used to de- system, group 8.4.6.1 ENGINE menu 1
9 Control unit, cab (D790-1) sends a Checked by control sys- Section 11 Common electrics,
message with the rpm request on the tem, error shown with group 11.5.3.1 Control unit, cab
10 Control unit engine (D794) controls the - Section 11 Common electrics,

11 Make-contact (closing switch) coolant Low coolant level: Cooling system, description page 28
level grounds the control spool on Relay UK322:85 = 0 V
coolant level (K322) if the coolant level is
low in the expansion tank.
12 Relay coolant level (K322) opens the cir- - Cooling system, description page 28
cuit to Control unit, engine (D794) if the
coolant level is low in the expansion
tank.
13 Control unit, engine (D794) sends en- Checked by control sys- Section 11 Common electrics,
gine data and warning messages on the tem, error shown with group 11.5.3.10 Control unit, engine
CAN bus. error code. D13: Diagnostic menu, see section 8 Control
system, group 8.4.6.6 ENGINE, menu 6 and
14 Control unit KID (D795) shows engine - Section 11 Common electrics,

data via display figures. group 11.5.3.12 Control unit, KID
signal proportional to the fuel level in Lower voltage than D15: Diagnostic menu, see section 8 Control
the tank to Control unit, frame rear 0.5 V and higher voltage system, group 8.4.3.7 CAB, menu 7
(D797-R). than 4.5 V is used to de-
sends fuel level on the CAN-bus. tem, error shown with group 11.5.3.3 Control unit frame rear
error code.

12 1 Engine

17 Control unit KID (D795) shows the fuel - Section 11 Common electrics,
level in the operating menu for the group 11.5.3.12 Control unit, KID
engine.
18 The output shaft sensor (B758) sends - D18: Diagnostic menu, see section 8 Control
the transmission control unit (D793) system, group 8.4.7.6 TRANSM menu 6
pulses with frequency proportional to the
rpm of the output shaft.
sends speed information on the tem, error shown with group 11.5.3.9 Control unit, transmission
20 Control unit KID (D795) shows the ma- - Section 11 Common electrics,
chine’s speed. group 11.5.3.12 Control unit, KID
21 If the speed is at the limit for the ma- Checked by control sys- Section 11 Common electrics,
chine’s speed limitation, Control unit, tem, error shown with group 11.5.3.1 Control unit, cab
cab (D790-1) sends an engine speed re- error code.
duction request on the CAN-bus.

1 Engine 13
Engine alternative Volvo

page
–
TWD1240VE, component positions

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

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

2. Sensor boost pressure and charge-air temperature 12. Fuel pre-filter
3. Control unit, engine (D794) 13. Drain, condensation water fuel prefilter and sensor
4. Intercooler water-in-fuel
5. Sensor coolant temperature 14. NO-switch fuel pressure
6. Oil dipstick 15. Fuel filter
7. Filling point engine oil 16. Extra coolant pump
8. Fuel connection (inlet) 17. Sensor oil pressure and oil temperature
9. Fuel connection (return) 18. Compressor air conditioning
10. Starter motor 19. Alternator

20. Sensor camshaft rpm

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

2. Air cleaner connection 10. Thermostat transmission oil cooler
3. Turbocharger 11. Connection radiator inlet
4. Connection exhaust system 12. Water pump
5. Connection radiator (outlet) 13. Coolant filter
6. Connection expansion tank 14. Drain plug engine oil
7. Thermostat 15. Shut-off valve coolant
8. Radiator 16. Oil filter (full flow)
17. Oil filter (bypass)

1 Engine 15
Engine alternative Volvo

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

2. Radiator 13. Sensor water in fuel
3. Transmission oil cooler 14. Fuel filter
4. Preheating coil 15. Control unit, engine (D794)
5. Sensor boost pressure and charge-air temperature 16. Sensor oil level
6. Filling point engine oil 17. Sensor crankcase pressure
7. Sensor coolant temperature 18. Drain plug engine oil
8. Starter motor 19. Sensor oil pressure and oil temperature
9. Sensor engine speed 20. Oil dipstick
10. NO-switch fuel pressure 21. Alternator
11. Fuel pre-filter

16 1 Engine
006400
10 9 8
Engine alternative Volvo TAD1250VE, left side (in the machine’s travel
direction)
1. Connection cab heating 6. Water pump

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

1 Engine 17

page
–
component positions
1 2 3
12
001643
11 10 9 8 7 6 5 4
Engine alternative Cummins, right side (in the machine’s travel
direction)
1. Position for air conditioning compressor 7. Drain condensation water fuel filter and sensor
2. Fuel connection (outlet) water-in-fuel
3. Control unit, engine (D794) 8. Fuel filter
4. Drain plug engine oil 9. Sensor fuel pressure
5. Starter motor 10. Fuel pump
6. Fuel connection (inlet) 11. Sensor oil pressure and oil temperature
12. Sensor crankshaft position

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

2. Oil dipstick 14. Inlet intercooler
3. Connection cab heating 15. Intercooler
4. Air cleaner connection 16. Radiator
5. Turbocharger 17. Thermostat
6. Connection intercooler (outlet) 18. Transmission oil cooler
7. Connection intercooler (inlet) 19. Connection radiator (inlet)
8. Sensor inlet temperature 20. Coolant pump
9. Connection exhaust system 21. Connection expansion tank
10. Sensor boost pressure 22. Thermostat housing
11. Connection expansion tank 23. Oil filter
12. Alternator (sensor coolant temperature behind 24. Coolant filter
alternator) 25. Shut-off valve coolant

1 Engine 19
Engine and transmission,

page
–
separating
(engine alternative Volvo)
Separation
1 Machine in service position, see section B Safety.
2 Disconnect the requisite hoses and cables before separating en-
gine and transmission.
NOTE
Drain and collect liquids before detaching hoses.
3 Attach hoisting equipment to the engine.
4 Use a jack to secure the transmission.
5 Remove the plugs in front of the flywheel.

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

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

9 Loosen the engine or transmission mounts and separate the en-
Assembly
10 Check that the holes for the flex plate’s mounting in the flywheel
are aligned directly opposite the flex plate’s attaching nuts.
The flex plate has eight attachment points to be connected with
the flywheel on the engine.
11 Install the engine or transmission mounts.
Tighten to a torque of 168 Nm.
12 Connect the engine to the transmission.
13 Install the bolts between the engine and transmission. Tighten

with torque 40 Nm.
14 Install the flex plate’s attaching bolts. Tighten with torque 40 Nm.
NOTE
The engine must be loosened from the engine mounts and
separated from the transmission in order to remove a
dropped bolt. Secure the bolt in the socket when installing.
15 Install the plugs in front of the flywheel.

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

1 Engine 21

page
–
separating (engine alternative

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

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

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

1.1.1 Ignition
Ignition key lock, description
page
–
P No function.
0 Stop position. Everything turned off, the key can be removed.
I Operating position.
Voltage to all electrical functions. The control units for engine and
transmission are now ready for start.
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.
In preheating position the engine’s inlet air is heated by the elec-
tric heater to a suitable temperature. The preheating light turns on
during preheating.
The signal can be checked via the diagnostic menu. See
0 section 8 Control system, group 8.4.6.4 ENGINE, menu 4.
III Start position.
P I
Engagement of starter motor for engine start.
II NOTE
The machine is equipped with an electric restart interlock,
which prevents engagement of the starter motor when the
engine is rotating.
000317
III
Condition for starter motor to engage is that the transmis-
sion is in neutral position and that the engine isn’t already
running.
section 8 Control system, group 8.4.6.4 ENGINE, menu 4.

24 1 Engine – 1.1.2 Accelerator
1.1.2 Accelerator
Accelerator pedal, changing
page
–

2 Pull one edge of the cover away to facilitate access to the accel-
erator pedal.
3 Disconnect the cable harness from the connector.
4 Unscrew the connector from the accelerator pedal.
5 Replace the accelerator pedal.
6 Install in 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
Accelerator pedal, calibration

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

1 Engine – 1.2 Fuel system 25
1.2 Fuel system

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

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

Sensor, fuel level, description
page
–

section 8 Control system, group 8.4.3.7 CAB, menu 7.
002289
1 2 3
1. Filling point fuel
2. Fuel tank
3. Sensor fuel level (behind air filter)

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

1.6.1 Air cleaning system
Air cleaning system, description
page
–
Combustion in the engine required air. Free unobstructed flow of fresh

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

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

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

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

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

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

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

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

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

28 1 Engine – 1.7 Cooling system
1.7 Cooling system

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

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

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

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

1. Radiator, engine
2. Radiator, transmission oil
3. Thermostat transmission oil
4. Condenser mounting (for AC)

30 1 Engine – 1.7.5 Cooling fan
1.7.5 Cooling fan

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

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

1 Engine – 1.7.5 Cooling fan 31
Drive belt, extra coolant pump, changing

page
–
(engine alternative Volvo TWD1240VE)

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

32 1 Engine – 1.7.5 Cooling fan
Fan belt, changing

page
–
(engine alternative Cummins QSM11)

4 Loosen the belt tensioner.
5 Remove the fan belt.
6 Install a new fan belt.
7 Tighten the fan belt with the belt tensioner.

1 Engine – 1.7.7 Coolant 33
1.7.7 Coolant
Changing coolant and cleaning the cooling system
page
–

Cooling performance is reduced due to deposits in the radiator and
cooling channels. Always clean the cooling system in connection with
coolant change.
WARNING
The cooling system is pressurised. Steam or hot fluid
may spurt out.
Risk or scalding or burn injuries!
Open the filler cap very carefully when the engine is

warm. Wait until the coolant has cooled down before
filling or topping up.
WARNING
Glycol and anti-corrosion agents are hazardous to
health.
Health hazard!
Handle with care. Avoid skin contact, use safety gog-

gles and protective gloves. In case of skin contact,
wash the skin.
IMPORTANT
Machines with ECC or AC are equipped with a com-
bined heating and cooling unit, which can result in a
risk of freezing if the machine is operated without
coolant.
Risk of freezing and damage to the heating and cool-

ing 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 before starting work with the cooling
system, see section B Safety.

34 1 Engine – 1.7.7 Coolant
NOTE
Before draining, stop the engine and remove the filler cap.
Draining
1 Remove the filler cap from the cooling system’s expansion tank.
2 Open all drain points. Drain the coolant from the radiator and en-
gine block with the drain hose. The drain nipples are located un-
der the radiator and on the engine block’s right side.
Drain point radiator

3 Check that all coolant drains out.
NOTE
There may be deposits inside the tap or plug, these must be
removed otherwise there is a risk that the coolant may re-
main and cause freezing damage.
Let the drainage taps or plugs remain open and make sure that
the heating control is set to full heat while cleaning.
4 Insert a hose in the filler hole in the expansion tank and flush with
clean water, until the draining water is clear.
Drain point, engine 5 If impurities remain after flushing for a long time, it’s possible to
clean with coolant. Otherwise, continue with step 10.
Cleaning with coolant

6 Fill the cooling system with concentrated coolant mixture. Use
only recommended concentrated coolant.
For volume and grade, see section F Technical data.
7 Drain the cooling system after 1-2 days of operation.
NOTE
To prevent dissolved material from clogging the system
again, drain the system quickly, within 10 minutes, without
the machine engine being stationary for a long time. Re-
move the filler cap from the expansion tank and also the low-
er coolant hose to increase drain speed.
8 Flush the system immediately and very thoroughly with clean
warm water to prevent impurities from settling again on the inner
surfaces. Flush until the draining water is completely clean. Make
sure that the heat control is at max. heat when cleaning.
9 Should impurities remain after flushing for a long time, it’s possi-
ble to clean with coolant, contact Cargotec Service.

NOTE
Only use cleaning agents approved by the engine manufac-
turer. Carefully follow the instructions on the package.
Filling point
10 When the cooling system is completely free from impurities, close
the drain valves.
CAUTION
Different types of coolant may not be mixed.
Risk of engine damage and damage to the cooling

system if different types of coolant are mixed.
When changing and topping up coolant, the same

type of coolant must be used as was used before.
11 Fill with ready-mixed recommended coolant so that the level ends

up between the MIN and MAX markings. For volume and grade,
see section F Technical data.
12 Start the engine, open the air bleed valves after start so that
trapped air can be vented.
Check that the water valve is fully open in order to bleed the heat-
ing system.
13 Stop the engine after approx. one hour and check the coolant lev-
el, top up if needed.

Changing coolant and cleaning the cooling system

page
–

The cooling performance is reduced due to deposits in the radiator and
cooling channels. Clean the cooling system in connection with coolant
change.
WARNING
The cooling system is pressurised. Steam or hot fluid
may spurt out.
Risk or scalding or burn injuries!
Open the filler cap very carefully when the engine is

warm. Wait until the coolant has cooled down before
filling or topping up.
WARNING
Glycol and anti-corrosion agents are hazardous to
health.
Health hazard!
Handle with care. Avoid skin contact, use safety gog-

gles and protective gloves. In case of skin contact,
wash the skin.
IMPORTANT
Machines with ECC or AC are equipped with a com-
bined heating and cooling unit, which can result in a
risk of freezing if the machine is operated without
coolant.
Risk of freezing and damage to the heating and cool-

ing 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 Remove the filler cap from the cooling system’s expansion tank.
2 Open all drain points. Drain the coolant from the radiator and en-
gine block. There is a drain nipple under the radiator and a drain
plug under the coolant inlet on the engine block.
NOTE
Do not remove the coolant filter. The engine shall be run with
coolant filter during this procedure.
Drain point radiator

3 Check that all coolant drains out.
NOTE
There may be deposits inside the tap/plug, which must be
cleaned away, otherwise there is a risk that the coolant may
remain and cause freezing damage.
Let the drain valves/plugs remain open and make sure that the
heating control is set to full heat while cleaning.
4 Check the condition of the hoses and clamps and check the radi-
ator for leaks. Replace and clean as necessary.
5 Close drain valves and plugs.
CAUTION
The system must be well-filled to prevent air pocket
formation. During filling, air must be vented out from
the cooling channels. Wait 2 to 3 minutes for the sys-
tem to vent, then top up the system.
1. Shut-off valve coolant
2. Coolant filter
3. Oil filter
6 Cleaning:
NOTE
Do not remove the coolant filter. The engine shall be run
with coolant filter during this procedure.
Fill the system immediately with a radiator cleaner approved by
the engine manufacturer.
NOTE
009735
Only use cleaning agents approved by the engine manufac-

turer. Carefully follow the instructions on the package.

7 Turn up the heat control in the cab to full heat, start and run the
engine for one to one and half hour with normal operating tem-
perature (at least 85 °C).
Turn off the engine and drain the cooling system immediately.
8 Fill the cooling system with clean water.
NOTE
Make sure that the system is properly bled when filling.
9 Start and run the engine for 5 minutes with coolant temperature
above 85 °C.
008022
Turn off the engine and drain the cooling system.
NOTE
If the water that drains out is still dirty, the system must be
flushed until the water is clean.
10 When the cooling system is completely free from impurities, close
the drain valves and plugs.
11 Filling:
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.
Fill with ready-mixed recommended coolant so that the level ends

up between the MIN and MAX markings. For volume and grade,
12 Install the pressure cap and start the engine when the cooling
system has been completely bled and filled.
Open all heat controls on the heater unit so that it is bled free
from air.
13 Run the engine until the coolant temperature reaches 82 °C and
check that there are no leaks.
14 Turn off the engine and let it cool.
15 Check the coolant level, top up if needed.

1 Engine – 1.7.10 Engine heater 39
1.7.10 Engine heater

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

A start-inhibitor function is available as an option if an engine heater is
installed. The function is activated when the heater is running.

40 1 Engine – 1.9 Control system, engine
1.9 Control system, engine

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

gine and supplier documentation, engine.

1 Engine – 1.11 Start/stop 41
1.11 Start/stop
1.11.1 Starter motor
Starter motor, description (engine alternative Volvo)
page
–
The starter motor cranks the engine until fuel combustion begins and
the engine starts.
The starter motor is supplied with voltage directly from the start batter-
ies. A relay on the starter motor (solenoid) is activated by control unit
engine (D794).
Starter motor, description (engine alternative

page
–
Cummins)
The starter motor cranks the engine until fuel combustion begins and
the engine starts.
The starter motor is supplied with voltage directly from the start batter-
ies. A relay on the starter motor (solenoid) is activated by control unit
frame rear (D797-R).
section 8 Control system, group 8.4.6.5 ENGINE, menu 5.
1.11.2 Stopping device

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

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

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

42 1 Engine – 1.11.2 Stopping device

2 Transmission 1
2 Transmission
Table of Contents 2 Transmission

mm mm mm mm mm mm
2 Transmission.................................................................................................. 3
2.1 Controls and instruments ......................................................................... 20
2.1.1 Gear selector and multi-function lever ................................................. 20
2.2 Torque converter/Clutch system .............................................................. 21
2.2.1 Flex plates ........................................................................................... 21
2.6 Lubrication system ................................................................................... 28
2.6.3 Oil cooler .............................................................................................. 34
2.7 Cooling system ......................................................................................... 36
2.7.3 Oil cooler .............................................................................................. 36
2.8 Control system, transmission ................................................................... 37
2.8.1 Transmission control unit ..................................................................... 37
2.8.2 Break contact (opening switch) declutch ............................................. 37
2.8.3 Transmission cable harness ................................................................ 37

2 2 Transmission

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

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

4 2 Transmission
Transmission, function description

page
–
(transmission alternative Dana TE32

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

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

1 The gear selector sends a voltage sig- Forward, Conn. F: U = 24 V Section 9 Frame, body, cab and accesso-
nal to Control unit KIT (D790-2). Reverse, Conn. R: U = 24 V ries, group 9.1 Controls and instruments
system, group 8.4.7.2, TRANSM menu 2
2 Control unit KIT (D790-2) transmits the Checked by control system, Section 11 Common electrics,
selected direction of travel (forward or error shown with error code. group 11.5.3.11 Control unit, KIT
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.
4 The transmission’s oil filter cleans the - -

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

2 Transmission 5

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

6 2 Transmission

21 Sensor speed drum (B7520) sends Checked by Control unit, D10: Diagnostic menu, see section 8 Con-
Control unit, transmission (D793) a transmission, error shown trol system, group 8.4.7.6 TRANSM
pulse signal with frequency proportion- with error code. menu 6
al to drum’s speed.
22 The output shaft speed sensor (B7580) Checked by Control unit, D10: Diagnostic menu, see section 8 Con-
sends the transmission control unit transmission, error shown trol system, group 8.4.7.6 TRANSM
(D793) a pulse signal with frequency with error code. menu 6
proportional to output shaft speed.
23 The torque converter temperature Checked by Control unit, D11: Diagnostic menu, see section 8 Con-
monitor (S2210) sends the transmis- transmission, error shown trol system, group 8.4.7.10 TRANSM
sion control unit (D793) a voltage sig- with error code. menu 10
nal if oil temperature in the torque
converter becomes too high.
24 Control unit, transmission (D793) con- Checked by Control unit, Section 11 Common electrics,
trols gear shifting according to selected transmission, error shown group 11.5.3.9 Control unit, transmission
shifting program. with error code.
25 The oil cooler cools the transmission - Oil cooler, description page 36
oil. A thermostat senses the oil’s tem-
perature and directs the oil back to the
transmission if the oil is cold.
26 Control unit, transmission (D793) Checked by control system, Section 11 Common electrics,
transmits temperature and speed data error shown with error code. group 11.5.3.9 Control unit, transmission
on the CAN bus.
27 Control unit KID (D795) shows trans- Checked by control system, Section 11 Common electrics,
mission information in operating error shown with error code. group 11.5.3.12 Control unit, KID
menus.
28 If the signal from sensor, speed output - D10: Diagnostic menu, see section 8 Con-
shaft (B7580) indicates that the ma- trol system, group 8.4.7.6 TRANSM
chine’s speed exceeds the speed limit, menu 6
sends Control unit, transmission
(D793) requests for reduced engine
speed on the CAN-bus.
29 Control unit, engine (D794) reduces - Section 11 Common electrics,

the engine speed. group 11.5.3.10 Control unit, engine
30 If the declutch pedal (S220-1) is de- U = 24 V Section 9 Frame, body, cab and accesso-
pressed, it sends a voltage signal to ries, group 9.1 Controls and instruments
Control unit, cab (D790-1). D30: Diagnostic menu, see section 8 Con-
trol system, group 8.4.7.1, TRANSM
menu 1
declutch drive on the CAN bus. error shown with error code. group 11.5.3.1 Control unit, cab

2 Transmission 7

32 Break-contact (opening switch) de- Brake pressure above Break contact (opening switch) declutch,
clutch (S220-2) sends a voltage signal 0.2 MPa: description page 37
to Control unit, frame front (D797-F) if Conn 1, U = 24 V D32: Diagnostic menu, see section 8 Con-
the brake pressure is high enough to trol system, group 8.4.7.1, TRANSM
Conn 2, U = 24 V
allow declutch of drive. menu 1
Brake pressure below
0.2 MPa:
Conn 1, U = 24 V
Conn 2, U = 0 V
33 Control unit, frame front (D797-F) Checked by control system, Section 11 Common electrics,
sends declutch approved on the error shown with error code. group 11.5.3.2 Control unit, frame front
CAN bus.
34 Control unit, transmission (D793) sup- Checked by Control unit, Section 11 Common electrics,
plies voltage to valve block transmis- transmission, error shown group 11.5.3.9 Control unit, transmission
sion control so that drive is declutched. with error code.

8 2 Transmission
Transmission shifting, function

page
–
description (transmission
alternative Dana TE32 full flow)
30
28
5
6 11 17
16 22
27 Pa Pa
29
7 12 18
26 8 13 19
24 25 3 4
31
Fwd 1st 3rd 2nd 4th
Rev
23 2
9 10 14 15 20 21
1
013040
1 Bottom strainer oil sump, separates particles - -
from the oil before the pumps.
2 The transmission’s oil pump 1 feeds the trans- 30.4 l/min at 685 rpm -
mission with control pressure for control of the
transmission.
3 The oil filter cleans the oil. - -
4 The bypass valve in the filter bracket leads the Opening pressure: 410-450 kPa -
oil past the filter if the resistance through the
filter becomes too high.
5 The pressure regulator releases pressure to Opening pressure: 2200 kPa -

the torque converter if the pressure becomes
too high.
6 Servo valve front/rear (Y6300) controls pres- - Diagnostic menu, see

sure to Valve travel direction, proportional to section 8 Control system,
the desired drive. group 8.4.7.7 TRANSM menu 7
7 Solenoid valve drive forward (Y6066F) or So- - Diagnostic menu, see

lenoid valve drive reverse (Y6066R) controls section 8 Control system,
Valve travel direction for drive forward or group 8.4.7.8 TRANSM, menu 8
reverse. and 8.4.7.9 TRANSM, menu 9
Depending on which solenoid valve is activat-
ed, Valve travel direction controls pressure to
drive clutch forward or drive clutch reverse.

2 Transmission 9

8 The accumulator evens out the pressure. - -
9 Drive clutch reverse locks the transmission in Drive reverse: 2200-2600 kPa -
reverse drive when the clutch is pressurised.
10 Drive clutch forward locks the transmission in Drive forward: 2200-2600 kPa -
forward drive when the clutch is pressurised.
11 Servo Valve 1/3 (Y6067) controls pressure to - Diagnostic menu, see

Solenoid valve gear selection gear 1/3 section 8 Control system,
(Y6075) proportional to the desired engage- group 8.4.7.8 TRANSM, menu 8
ment force. and 8.4.7.9 TRANSM, menu 9
12 Solenoid valve gear selection gear 1/3 - Diagnostic menu, see

(Y6075) pressurises Drive clutch gear 1 or section 8 Control system,
Drive clutch gear 3. group 8.4.7.7 TRANSM menu 7
14 Drive clutch gear 1 locks the transmission in Gear selected: 2200-2600 kPa -
gear position 1 when the clutch is pressurised.
16 Pressure sensor gear 1/3 (B6067) sends the - Diagnostic menu, see
transmission control unit (D793) a voltage sig- section 8 Control system, group
nal proportional to engagement pressure. 8.4.7.10 TRANSM menu 10
17 Servo Valve 2/4 (Y6069) controls pressure to - Diagnostic menu, see

Solenoid valve gear selection gear 1/3 section 8 Control system,
(Y6075) proportional to the desired engage- group 8.4.7.8 TRANSM, menu 8
ment force. and 8.4.7.9 TRANSM, menu 9
18 Solenoid valve gear selection gear 2/4 - Diagnostic menu, see

(Y6074) pressurises Drive clutch gear 1 or section 8 Control system,
Drive clutch gear 3. group 8.4.7.7 TRANSM menu 7
22 Pressure sensor gear 2/4 (B6069) sends the - Diagnostic menu, see
transmission control unit (D793) a voltage sig- section 8 Control system, group
nal proportional to engagement pressure. 8.4.7.10 TRANSM menu 10
23 The transmission’s oil pump pumps oil 15,8 l/min at 685 rpm -
through the cooler and supplies the torque
converter with oil pressure to drive the
machine.
24 The oil filter cleans the oil. - -

10 2 Transmission

25 The bypass valve in the filter bracket leads the - -
oil past the filter if the resistance through the
filter becomes too high.
26 The oil is distributed to different lubrication - -

points in the transmission.
27 The transmission oil cooler cools the oil. - -
28 The torque converter transmits the engine’s - -

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

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

age signal proportional to the oil temperature section 8 Control system, group
to Control unit, transmission (D793). 8.4.7.10 TRANSM menu 10

2 Transmission 11
Transmission, component location

page
–
(transmission alternative Dana TE32

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

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

12 2 Transmission
1 2 3 4 5
11
6
10 7
006752
1. Accelerator pedal (B690) 7. Control unit, transmission (D793)
2. Control unit KIT (D790-2) 8. Diagnostic socket transmission
3. Control unit, KID (D795) 9. Declutch pedal (S220-1)
4. Multi-function lever (S162) 10. Make-contact (closing switch) declutch (S220-2)
5. Control unit, cab (D790-1) 11. Control unit frame front (D797-F)
6. Control unit frame rear (D797-R)

2 Transmission 13
Transmission, function description

page
–
(transmission alternative ZF
5WG261)
F
R
<° 1
D1
20 5 D1
D20 D5
6, 21 2, 7 17
D790-1 D790-2 D795
D793 D794 D797-F

9, 16, 18, 24 19 23
D6
D22
D11 Pa
D12 14 8 11 12 13
°C 22
4 10
15
013041
1 The gear selector sends a voltage signal Forward, Conn. F: U = 24 V Workshop manual, section 9 Frame,
to Control unit KIT (D790-2). Reverse, Conn. R: U = 24 V body, cab and accessories,
group 9.1 Controls and instruments
D1: Diagnostic menu, see
section 8 Control system, group 8.4.7.2,
TRANSM menu 2
2 Control unit KIT (D790-2) transmits the Checked by control system, Workshop manual, section 11 Common
selected direction of travel (forward or re- error shown with error code. electrics, group 11.5.3.11 Control unit,
verse) on the CAN bus. KIT
TRANSM menu 2
3 The transmission’s oil pump pumps oil - -

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

from impurities.

14 2 Transmission

5 The accelerator pedal transmits a signal U = 0.5-4.5 V Workshop manual, section 1 Engine,
to Control unit, cab (D790-1). group 1.1.2 Accelerator pedal
section 8 Control system,
group 8.4.6.1 ENGINE menu 1
6 Control unit, cab (D790-1) transmits the Checked by control system, Workshop manual, section 11 Common
desired throttle application on the error shown with error code. electrics, group 11.5.3.1 Control unit
CAN bus. cab
7 Control unit KIT (D790-2) sends the se- Checked by control system, Workshop manual, section 11 Common
lected shifting program on the CAN bus. error shown with error code. electrics, group 11.5.3.11 Control unit,
KIT
8 Sensor engine speed (B7530) sends a Checked by Control unit, D6: Diagnostic menu, see
pulse signal with frequency proportional transmission, error shown section 8 Control system,
to the engine speed to Control unit trans- with error code. group 8.4.4.1 GEARBOX, menu 1
mission (D7930-2).
9 The transmission control unit (D7930-2) Checked by Control unit, Workshop manual, section 11 Common
supplies voltage to the transmission con- transmission, error shown electrics, group 11.5.3.9 Control unit
trol valve block to obtain desired function. with error code. transmission
10 Solenoid valves for travel direction and Checked by Control unit, -

gear position in valve block transmission transmission, error shown
control (A3) activate gears in the trans- with error code.
mission and the engine’s power is trans-
mitted to the transmission’s output shaft.
11 Sensor, turbine speed (B7510) sends Checked by Control unit, -

Control unit, transmission (D7930-2) a transmission, error shown
pulse signal with frequency proportional with error code.
to turbine speed.
12 Sensor speed drum (B752) sends Control Checked by Control unit, -

unit, transmission (D7930-2) a pulse sig- transmission, error shown
nal with frequency proportional to drum’s with error code.
speed.
13 The output shaft speed sensor (B7580) Checked by Control unit, D11: Diagnostic menu, see
sends the transmission control unit transmission, error shown section 8 Control system,
(D7930-2) a pulse signal with frequency with error code. group 8.4.4.1 GEARBOX, menu 1
proportional to output shaft speed.
14 Sensor oil temperature transmission Checked by Control unit, D12: Diagnostic menu, see
(B7660) sends a voltage signal propor- transmission, error shown section 8 Control system,
tional to the oil temperature to Control with error code. group 8.4.4.6 GEARBOX, menu 6
unit, transmission (D7930-2).
15 The oil cooler cools the transmission oil. - Workshop manual, section 2 Transmis-
sion, group 2.6.3 Oil cooler
16 Control unit transmission (D7930-2) con- Checked by control system, Workshop manual, section 11 Common
trols shifting according to the selected error shown with error code. electrics, group 11.5.3.9 Control unit
shifting program and sends temperature transmission
and speed information on the CAN-bus.

2 Transmission 15

17 Control unit KID (D795) shows transmis- Checked by control system, Workshop manual, section 11 Common
sion information in operating menus. error shown with error code. electrics, group 11.5.3.12 Control unit,
KID
18 If the signal from sensor, speed output - D10: Diagnostic menu, see
shaft (B7580) indicates that the ma- section 8 Control system,
chine’s speed exceeds the speed limit, group 8.4.7.6 TRANSM menu 6
sends Control unit, transmission
(D7930-2) requests for reduced engine
speed on the CAN-bus.
19 Control unit, engine (D794) reduces the - Workshop manual, section 11 Common
engine speed. electrics, group 11.5.3.10 Control unit
engine
20 If the declutch pedal (S220-1) is de- U = 24 V Workshop manual, section 9 Frame,

pressed, it sends a voltage signal to Con- body, cab and accessories,
trol unit, cab (D790-1). group 9.1 Controls and instruments
TRANSM menu 1
21 Control unit, cab (D790-1) transmits de- Checked by control system, Workshop manual, section 11 Common
clutch drive on the CAN bus. error shown with error code. electrics, group 11.5.3.1 Control unit
cab
22 Break-contact (opening switch) declutch Brake pressure above Workshop manual, section 2 Transmis-
(S220-2) sends a voltage signal to Con- 0.2 MPa: sion, group 2.8.2 Break-contact (open-
trol unit, frame front (D797-F) if the brake Conn 1, U = 24 V ing switch) declutch
pressure is high enough to allow declutch D32: Diagnostic menu, see
Conn 2, U = 24 V
of drive. section 8 Control system, group 8.4.7.1,
Brake pressure below TRANSM menu 1
0.2 MPa:
Conn 1, U = 24 V
Conn 2, U = 0 V
23 Control unit, frame front (D797-F) sends Checked by control system, Workshop manual, section 11 Common
declutch approved on the CAN bus. error shown with error code. electrics, group 11.5.3.2 Control unit,
frame front
24 Control unit, transmission (D7930-2) sup- Checked by Control unit, Workshop manual, section 11 Common
plies voltage to valve block transmission transmission, error shown electrics, group 11.5.3.9 Control unit
control so that drive is declutched. with error code. transmission

16 2 Transmission
Gearshifting transmission, function

page
–
description (transmission
alternative ZF 5WG261)
18 16 10 14 8 12
17 15 9 13 7 11
20
3
4
19
21
2
23 22
013043
24 1

1. Bottom strainer oil sump, separates - -
particles from the oil before the
pumps.
2. The transmission’s oil pump feeds the 1.6–1.8 MPa -

transmission with pressure. 115 l/min at 2000 rpm
3. The oil filters clean the oil. - -
4. The bypass valve in the filter bracket Opening pressure: -

leads the oil to the torque converter if 0.52–0.72 MPa
the resistance through the filter be-
comes too high.
5. The pressure governor releases pres- Opening pressure: -

sure to the torque converter if the 1.6–1.85 MPa
pressure becomes too high.
6. The pressure reducer reduces the 0.9 MPa -

feed pressure to servo pressure.
7. Servo valve drive forward pressurizes - Diagnostic menu, see section 8 Con-
clutch drive forward (KV) when travel trol system, group 8.4.4.5 GEARBOX,
direction forward is selected. menu 5
8. Clutch drive forward (KV) locks the Gear locked: 1.6-1.8 MPa -
transmission for drive forward.

2 Transmission 17

9. Servo valve gear 1 pressurizes clutch - Diagnostic menu, see section 8 Con-
gear position 1 (K1) when gear 1 is to trol system, group 8.4.4.5 GEARBOX,
be used. menu 5
10 Clutch gear position 1 (K1) locks the Gear locked: 1.6-1.8 MPa -
transmission in gear 1.
11 Servo valve gear 2 pressurizes clutch - Diagnostic menu, see section 8 Con-
be used. menu 5
be used. menu 5
be used. menu 5
16 Clutch gear position (K4) locks the Gear locked: 1.6-1.8 MPa -
17 Servo valve drive reverse pressurizes - Diagnostic menu, see section 8 Con-
clutch drive reverse (KR) when travel trol system, group 8.4.4.5 GEARBOX,
direction reverse is selected. menu 5
18 Clutch drive reverse (KR) locks the Gear locked: 1.6-1.8 MPa -
transmission for reverse drive.
19 The safety valve leads the oil back to Opening pressure: 0.9 MPa -
the sump if the pressure to the torque
converter becomes too high.
20 The torque converter transmits the en- - -

gine’s power to the transmission.
21 The pressure limiter ensures that the Opening pressure: 0.5 MPa -
back-pressure in the torque converter
is maintained at the right level.
22 The transmission oil cooler cools - -

the oil.
23 The bypass valve leads the oil past Opening pressure: 0.2-0.5 MPa -
the oil cooler if the resistance through
the oil cooler becomes too high.
24 The oil is distributed to different lubri- - -

cation points in the transmission.

18 2 Transmission
Transmission, component positions

page
–
(transmission alternative ZF
5WG261)
2 4
5
8
9 1
10
6
11 7
12
013042
14 13
1. Power take off 8. Valve unit transmission (A3)

2. Oil dipstick and filling point for transmission oil 9. Sensor turbine speed (B7510)
3. Transmission oil cooler 10. Sensor drum speed (B7520)
4. Thermostat 11. Make-contact (closing switch) transmission oil filter
(S2710)
5. Sensor engine speed (B7530) 12. Oil filter transmission
6. Coarse strainer transmission oil 13. Sensor speed output shaft (B7580)
7. Sensor oil temperature sump (B7660) 14. Output shaft

2 Transmission 19
1 2 3 4 5
10
6
9 7
013046
1. Accelerator pedal (B690) 6. Control unit frame rear (D797-R)
2. Control unit KIT (D790-2) 7. Control unit, transmission (D7930-2)
3. Control unit, KID (D795) 8. Declutch pedal (S220-1)
4. Multi-function lever (S162) 9. Make-contact (closing switch) declutch (S220-2)
5. Control unit, cab (D790-1) 10. Control unit frame front (D797-F)

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

20 2 Transmission – 2.1 Controls and instruments

2.1.1 Gear selector and multi-function
lever
Gear selector and multi-function lever, description
page
–
Selection of direction travel is made with the gear selector and multi-
F
function lever.
Selecting direction of travel:
• F – Forward
• N – Neutral
• R – Reverse
The switch is supplied with voltage by and sends signals to Control
unit KIT (D790-2).
002209
R
section 8 Control system, group 8.4.7.2 TRANSM, menu 2.

2 Transmission – 2.2 Torque converter/Clutch system 21
2.2 Torque converter/Clutch

system
2.2.1 Flex plates
Flex plates, changing (engine alternative Volvo with
page
–
Dana TE32 FF)

2 Attach the transmission to an overhead crane.
3 Remove the cover plate for the flywheel.
4 Remove the screws for the flex plate.

22 2 Transmission – 2.2.1 Flex plates
5 Remove the cover washer on the engine’s left side.

6 Rotate the engine for each bolt to the flex plate that has to be
removed.
7 Remove the bolts holding together the transmission and engine.
8 Loosen the engine or transmission mounts and carefully sepa-

rate the engine and transmission.

2 Transmission – 2.2.1 Flex plates 23
9 Remove the bolts holding the flex plate to the transmission.

10 Change the flex plate.
11 Install in reverse order. The bolted joint between engine and
transmission shall be installed with 40 Nm.
12 Before the machine is put into operation, the transmission must
be calibrated; see Transmission, calibration page 37.
Flex plate attachment Dana
Flex plates, changing (engine alternative Volvo with

page
–
ZF 5WG261)
3 Remove the cover plate for the flywheel.
5 Remove the cover washers on the engine’s left side.

removed.


Flex plate attachment ZF

Flex plates, changing

page
–

2 Remove the cover plate.
removed.



Flex plate attachment Dana.

Flex plate attachment ZF

28 2 Transmission – 2.6 Lubrication system
2.6 Lubrication system

Lubrication system, description
page
–
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 engine operation, the oil pump draws oil from the transmis-
sion’s oil sump through a strainer, and it then pumps it through two oil
filters to a control valve.
The control valve supplies oil at the correct pressure to the transmis-
sion’s valve housing to activate the clutch plates for FORWARD or RE-
VERSE and gear 1, 2, 3, or 4. The clutch plates require just a small
amount of the oil flow supplied by the pump. The remainder of the oil
is pumped through the torque converter circuit to the oil cooler and re-
turns to the transmission for lubrication.
See also supplier documentation, transmission.
Oil and oil filters, changing

page
–
(Transmission Dana TE32 FF)
NOTE
Read the safety instructions for oil before working, see
section B Safety.
NOTE
The transmission must not be over-filled!
1 Operate and warm up the transmission oil.
3 Remove the drain plug for transmission oil and and let the oil
drain into the container.
Drain point for transmission oil

2 Transmission – 2.6 Lubrication system 29
4 Change oil filter.

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

6 Remove the transmission’s oil 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.
7 Start the engine and allow it to idle for at least two minutes.
8 Check that the transmission oil drain plug is sealed.
9 Check the transmission oil level with the engine running at idle
and top up to the marking for low level.
Oil dipstick and filling point transmission oil

10 Warm up the transmission so that the display shows an oil tem-
perature between 60-65 C. Use the oil temperature operating
menu to check the transmission’s oil temperature.
a
11 Check the oil level and top up to the MAX mark.
000356
Operating menu oil temperature

a. Transmission oil temperature
b. Hydraulic oil temperature

Oil and oil filters, changing

page
–
(Transmission Z 5WG261F)
NOTE
section B Safety.
NOTE
The transmission must not be over-filled!
NOTE
The transmission shall be calibrated after the oil change.
1 Operate and warm up the transmission oil.
2 Machine in service position, see Maintenance manual
section B Safety.
3 Remove the drain plug for transmission oil and and let the oil
drain into the container.
Drain point for transmission oil

4 Change both oil filters.
Moisten the O-ring for the new oil filters with transmission oil.
Tighten until it makes contact and then another two-thirds of
a turn.
5 When the transmission oil has drained, install the drain plug.
Make sure that the washer for the oil plug is included.
010392
Oil filter transmission

6 Remove and clean the oil strainer with clean denatured alcohol.
Check that the strainer is not damaged, change if needed.
NOTE
Make sure that the strainer is completely dry and free from
particles before it is reinstalled.
010317
7 Install the oil strainer.

NOTE
Check that the O-ring is free from damage and in place.
Change if needed.
8 Remove the dipstick for the transmission oil and fill with new
transmission oil through the dipstick’s filler pipe until the oil level
is at the bottom mark on the oil dipstick marked "COLD".
The dipstick has three markings. The bottom is marked "COLD",
a rough estimate for a cold transmission. The two upper are
marked "HOT" and are markings for maximum, MAX, and mini-
mum, MIN, oil level at operating temperature. The oil level should
be between MIN and MAX.
For volume and quality, see Technical data 3.
9 Start the engine and run the engine at idle.
10 Check that the transmission oil drain plug is sealed.
11 Check the transmission oil level with the engine running at idle
and top up to the marking for "COLD".
013047

12 Warm up the transmission by operating the machine in all gears
so that the oil temperature is 80-90 C on the display. Use oper-
ating menu oil temperature to check the transmission oil temper-
a
ature (position a, upper horizontal row in display).
13 Check the transmission oil level and fill to the mark for the maxi-
000356
b
mum level, MAX.
Operating menu transmission and hydraulics 14 Calibrate the transmission; see Calibrate DRIVETRAIN page
a. Transmission oil temperature 203.
b. Hydraulic oil temperature

Oil level, checking (Transmission Dana TE32 FF)

page
–
NOTE
section B Safety.
The transmission’s oil filler pipe and dipstick are located under the
service hatch in front of the cab.
1 Check the oil level with the engine at idle, transmission in neutral
position and at operating temperature (approx. 60-65 C in the
display). The dipstick has two markings, MAX and MIN. The oil
level should be at MAX.
Wipe off the dipstick before checking.
NOTE
The oil dipstick is long. Wear gloves.
2 Fill transmission oil if needed (for volume and grade, see section
Technical data).
Fill – wait a moment – check the dipstick.
NOTE
Work carefully when filling transmission oil to prevent other
fluids or particles from contaminating the oil. Other fluids or
particles in the transmission oil means a risk of transmission
damage.

Oil level, checking (Transmission ZF 5WG261)

page
–
NOTE
Read the safety instructions for oil before working, see Mainte-
nance manual section B Safety.
The transmission’s oil filler pipe and dipstick are located under the
service hatch in front of the cab.
1 Check the oil level with the engine at idle, transmission in neutral
position and at operating temperature (approx. 80-90 C in the
display).
The dipstick has three markings. The bottom is marked "COLD",
a rough estimate for a cold transmission. The two upper are
marked "HOT" and are markings for maximum, MAX, and mini-
mum, MIN, oil level at operating temperature. The oil level should
be between MIN and MAX for warm transmission at idle in
neutral gear.
Wipe off the dipstick before checking.
013047
Oil dipstick and filling point transmission oil NOTE

The oil dipstick is long. Wear gloves.
2 Fill transmission oil through the filler pipe, if needed. For volume
and grade, see Technical data 3.
3 Fill – wait a moment – check the level markings on the dipstick.
NOTE
Work carefully when filling transmission oil to prevent other
fluids or particles from contaminating the oil, which means
risk of transmission damage.

34 2 Transmission – 2.6.3 Oil cooler
2.6.3 Oil cooler

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

Volvo TAD1250VE
1. Intercooler
2. Radiator engine
5. Condenser mounting (to AC) 2
003214
Cooling unit, engine alternative Volvo TWD1240VE

1. Radiator, engine
2. Radiator, transmission oil
3. Thermostat transmission oil
4. Condenser mounting (for AC)

2 Transmission – 2.6.3 Oil cooler 35
Thermostat transmission oil cooler, changing

page
–
NOTE
section B Safety.

2 Drain the oil from the transmission, see Oil and oil filters, chang-
ing (Transmission Dana TE32 FF) page 28 and Oil and oil filters,
changing (Transmission Z 5WG261F) page 30.
3 Loosen the cover plug and remove the thermostat.
4 Check the O-ring and the spring in the bottom, change if needed.
5 Install the new thermostat, and the cover plug.
IMPORTANT
007447
It is very important that the thermostat is turned with

the temperature bulb facing out as shown.
6 Fill with transmission oil; see Lubrication system page 28.

7 Start the engine and check for leaks.
8 Check the transmission oil level, see Oil level, checking (Trans-
mission Dana TE32 FF) page 32 and Oil level, checking (Trans-
mission ZF 5WG261) page 33.

36 2 Transmission – 2.7 Cooling system
2.7 Cooling system

2.7.3 Oil cooler
page
–
See Oil cooler, description page 34.

2 Transmission – 2.8 Control system, transmission 37
2.8 Control system, transmission

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

Control unit transmission, general
page
–
See section 11 Common electrics, group 11.5.3.9 Control unit, trans-

mission and supplier documentation, transmission.
2.8.2 Break contact (opening switch)

declutch
Break contact (opening switch) declutch, description
page
–
The NC switch for disengagement detects if the wheel brakes are

1 pressurised. The NC switch is located on the distribution block for the
10
2 brake system, above the drive axle’s differential.
1
3 The sensor can be checked via the diagnostic menu. See
3 section 8 Control system, group 8.4.7.1 TRANSM, menu 1.
4
5
5
9 6
8 7
000439
1. Brake cooling connection, return from wheel brake

2. Brake cooling connection, return to radiator
and tank
3. Brake cooling connection, to wheel brake
4. Brake cooling connection, from accumulator
charging valve
5. Brake cylinder connection, to wheel brake
6. Brake pressure connection, from brake valve
7. Make-contact (closing switch), declutch (S220)
8. NO switch, brake lights (S216)
9. Pressure check connection, brake pressure
10. Pressure check connection, brake cooling
back-pressure
2.8.3 Transmission cable harness

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

38 2 Transmission – 2.8.3 Transmission cable harness

3 Power transmission 1
Table of Contents 3 Power transmission

mm mm mm mm mm mm
3 Power transmission ....................................................................................... 3

3.2 Propeller shaft ............................................................................................ 3
3.3 Drive axle ................................................................................................... 4

2 3 Power transmission

3 Power transmission 3
mm mm mm mm mm mm
3.2 Propeller shaft

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

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

page
–

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

4 Fit the propeller shaft’s attaching bolts.
Tightening torque 156 Nm. Check-tighten the attaching bolts af-
ter 50 hours of operation.

4 3 Power transmission – 3.3 Drive axle
3.3 Drive axle

Drive axle, general
page
–

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

page
–
DANGER
Drive axle and machine are very heavy.
Risk of crushing!
It is not permissible to enter under a machine that has

been lifted by a jack, etc. For machine weights, please
refer to section F Technical data.
1 Park the machine with blocks behind the steering wheels.

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

3 Power transmission – 3.3 Drive axle 5
5 Detach the hydraulic hoses (position 1) and cable harness

(position 2) from the distribution block.
NOTE
Plug all connections immediately to protect the hydraulic
system from impurities.
004501
2
1. Hydraulic hoses
2. Cables
6 Remove the cover (position 3) on the parking brake.
3
004505
3. Cover, parking brake

7 Loosen the lock nut (position 4) and screw in the screw
(position 5), this compresses the brake spring. Screw until the
brake pads release from the brake disc. Reinstall the cover on the
6 parking brake (position 3).
8 Detach the hydraulic hose (position 6) from the parking brake.
5 NOTE
4 system from impurities.
004506
4. Lock nut
5. Release screw
6. Hydraulic hose parking brake

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

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

3 Power transmission – 3.3 Drive axle 7
16 Clean the contact surfaces on the drive axle and frame. Also
clean the bolts’ contact surface on the drive axle’s underside.
17 Remove the nuts for attaching the drive axle, blow clean and refit
the nuts.
18 Transfer the guide pins from the old axle to the new axle.
19 Lift the drive axle into place under the frame.
CAUTION
Crushing injury!
uncontrollably.
20 Lower the frame against the drive axle. Check that the guide pins
fit in the frame.
21 Install the new bolts that secure the drive axle in the frame. Tight-
en the bolts with a torque of 2820 Nm.
22 Install the drive wheels on the new axle.
23 Rustproof the bolts with suitable paint.
24 Connect hydraulic hoses (position 1) and cables (position 2) to

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


4 Brakes 1
4 Brakes
Table of Contents 4 Brakes

mm mm mm mm mm mm
4 Brakes ............................................................................................................. 3
4.1 Controls and instruments ........................................................................... 3
4.1.1 Brake pedal ............................................................................................ 3
4.3 Power-assisted brake system .................................................................... 5
4.3.1 Oil pump brake system .......................................................................... 7
4.3.2 Oil filter brake system .......................................................................... 15
4.3.3 Accumulator charging valve ................................................................. 16
4.3.4 Accumulator ......................................................................................... 19
4.3.5 Brake valve .......................................................................................... 23
4.3.6 Drive axle block ................................................................................... 27
4.3.7 Break-contact (opening switch) brake oil pressure .............................. 28
4.3.8 Make-contact (closing switch) brake lights .......................................... 29
4.3.9 Wheel brakes ....................................................................................... 31
4.3.10 Pipes and hoses .................................................................................. 34
4.5 Parking brake system ............................................................................... 35
4.5.1 Oil pump brake system ........................................................................ 36
4.5.3 Solenoid valve parking brake ............................................................... 37
4.5.4 Parking brake unit ................................................................................ 38
4.5.5 Break contact (opening switch) parking brake ..................................... 41
4.5.6 Pipes and hoses .................................................................................. 41
4.8 Temperature control, cleaning and oil for brake system .......................... 42
4.8.1 Brake oil tank ....................................................................................... 43
4.8.2 Tank heater .......................................................................................... 44
4.8.3 Oil pump brake system ........................................................................ 44
4.8.4 Accumulator charging valve ................................................................. 44
4.8.5 Drive axle block ................................................................................... 44
4.8.6 Wheel brakes ....................................................................................... 44
4.8.7 Oil cooler .............................................................................................. 45
4.8.8 Cooling fan ........................................................................................... 46
4.8.9 Thermal bypass valve .......................................................................... 46
4.8.10 Sensor brake oil temperature .............................................................. 47
4.8.11 Breather filter ....................................................................................... 48
4.8.13 Pipes and hoses .................................................................................. 50
4.8.14 Oil for brake system ............................................................................. 50

2 4 Brakes

4 Brakes 3
4 Brakes
mm mm mm mm mm mm

4.1.1 Brake pedal
Brake pedal, checking and adjustment
page
–
1 Clean the floor round the brake pedal and check that nothing is
obstructing the movement of the brake pedal.
2 Check that the brake pedal springs back adequately and that the
clearance between brake pedal and brake valve is 1–1.5 mm. If
needed, adjust the brake pedal’s stop bolt to correct clearance.
3 Check that the pedal moves 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. Change if needed.
6 Check the brake valve; see Brake valve, checking page 23.
Lubrication points, brake pedal. (The illustration

shows a loose brake pedal.)
Brake pedal, changing

page
–
NOTE
section B Safety.
1 Switch off the engine and switch off the main electric power.
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 Brakes – 4.1.1 Brake pedal
4 Remove the panel around the steering wheel shaft.
NOTE
There is a variant available with adjustable steering wheel
shaft.
5 Detach the steering valve from the pedal 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 shaft 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.
Mounting of steering wheel shaft and steering valve in 9 Transfer the pedal rubber to the new pedal.
pedal assembly.
10 Fit the new brake pedal.
Fit the pedal and fit the pedal’s attaching bolts.
11 Connect the steering valve to the brake pedal.
12 Connect the brake valve to the brake pedal.
13 Fit the clutch pedal to the brake pedal.
14 Close the drain valve on the accumulator charging valve.
NOTE
Check that the accumulator drain valve is fully closed and
15 Lubricate and adjust the brake pedal, see Brake pedal, checking
and adjustment page 3.

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

Power-assisted brake system, function
page
–
description
13
D790-2 5
B
P
T
D10 D797-R D797-F
10 9, 12 8 C5
Pa
D11 D8
C3
4 11
Pa
7
B
ACC 6
C1
3
P
006401
1 Oil pump brake system pumps oil from P = 20.5 1.0 MPa Brake oil tank, description page 43
the brake oil tank. Oil pump brake system for Dana and ZF,
description page 7
2 Oil filter brake system cleans the oil. - Oil filter brake system, description
page 49
3 The accumulator charging valve directs - Accumulator charging valve, description

oil to charging of accumulators or page 16
through the brake system’s cooling
circuit.
4 The accumulators store oil pressure. See the pressure plate, Ac- Accumulator, description page 19
cumulator pressure brake
system, on the left frame
member.
5 The brake valve directs pressure from - Brake valve, description page 23
the accumulators to the brake cylinders
proportional to the pressure on the
pedal.

6 4 Brakes – 4.3 Power-assisted brake system

6 The brake cylinders compress the discs See the pressure plate, Wheel brakes, description page 31
in the brake unit. Brake pressure, on the left
frame member.
7 The wheel brakes brake the machine. - Wheel brakes, description page 31
8 Make-contact (closing switch), brake Brake pressure above Make-contact (closing switch) brake
light (S216) closes the circuit when the 0.2 MPa: lights, description page 29
brake cylinders are pressurised. Conn. 1, U = 24 V D8: Diagnostic menu, see section 8 Con-
Conn. 2, U = 24 V trol system, group 8.4.5.4 HYD, menu 4

0.2 MPa:
Conn. 1, U = 24 V
Conn. 2, U = 0 V
9 Control unit, frame front (D797-F) sends Checked by control system, Section 11 Common electrics,
brake light request on the CAN-bus. error shown with error code. group 11.5.3.2 Control unit, frame front
10 The brake lights are activated by Control U = 24 V Section 9 Frame, body, cab and accesso-
unit, frame rear (D797-R). ries,group 9.6.4 Brake lights
D10: Diagnostic menu, see section 8
Control system, group 8.4.2.11 LIGHTS,
menu 11
11 Break-contact (opening switch) brake oil Brake pressure above Break-contact (opening switch) brake oil
pressure (S204) opens the circuit if the 11.5 MPa: pressure, description page 28
pressure in the accumulators is low. Conn. 1, U = 24 V D11: Diagnostic menu, see
Conn. 2, U = 24 V section 8 Control system,
group 8.4.5.4 HYD, menu 4
11.5 MPa:
Conn. 1, U = 24 V
Conn. 2, U = 0 V
a warning about low brake pressure on error shown with error code. group 11.5.3.2 Control unit, frame front
the CAN-bus.
13 Control unit KIT (D790-2) activates Checked by control system, Section 11 Common electrics,
Warning lamp brake pressure. error shown with error code. group 11.5.3.11 Control unit, KIT
Hydraulic diagram, basic machine

4 Brakes – 4.3.1 Oil pump brake system 7
4.3.1 Oil pump brake system

Oil pump brake system for Dana and ZF, description
page
–
The brake system has a gear-pump with fixed displacement. The oil
pump for the brake system is installed at the front on the left main
pump for Dana and on the right for ZF. The pump generates hydraulic
power, which is stored in the accumulators for brake force to the pow-
er-assisted brake and parking brake. It also generates the oil flow used
for cleaning and cooling. The switchover between power generation
and flow is regulated by the accumulator charging valve, see Accumu-
lator charging valve, description page 16.
The oil pump for the brake system is driven by the main pump’s shaft
from the transmission’s power take-off. The oil pump for the brake
system’s rpm is directly dependent on engine speed. The pump’s
1 flow increases with the engine speed and varies with the rpm of the
input shaft.
2
NOTE
000006
It is very important that the clearance between the gears and be-
1. Oil pump brake system Dana
tween the gear and the housing is correct. Clearance that is too
2. Pump cooling and filtration working hydraulics
small creates wear damage. Clearance that is too large reduces
the pump’s output.
1
014322
1. Pump cooling and filtration

2. Oil pump brake system ZF

8 4 Brakes – 4.3.1 Oil pump brake system
Oil pump brake system, checking

page
–
NOTE
section B Safety.
Checking pump pressure

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

6 Close the drain valve on the accumulator charging valve and
check the pump pressure during charging.
During charging the pressure should increase to 20.5 1.0 MPa
before the accumulator charging valve switches to cooling. When
the accumulator charging valve switches to cooling, the pressure
drops.
7 Check the pressure during cooling.
During cooling the pressure should be max. 1.0–1.5 MPa at max.
engine speed.
8 Turn off engine.
Close the accumulator charging valve
section B Safety.
10 Remove the pressure gauge and fit the protective cap on the
measuring outlet.
NOTE

Checking accumulator charging

section B Safety.
connection for accumulator pressure on the accumulator charg-
ing valve.
NOTE
16 Check that the pressure increases slowly to 20.5 1.0 MPa.
Pressure check connection accumulator pressure 17 Brake repeatedly and check at which pressure the accumulator
charging valve switches to charging.
The valve must switch to charging at 15.50.5 MPa.
section B Safety.
measuring outlet.
NOTE

Oil pump brake system, changing (Dana/Rexroth)

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

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

spacer ring, see section F Technical data.
10 Install the brake pump on the main pump.
Install the pump and check that the gear engages in the shaft and
that the spacer ring is installed directly against the brake pump.
Install the pump’s attaching bolts.
11 Connect the hydraulic hoses to the brake pump.
NOTE
Check that the O-rings are intact and are installed correctly.
NOTE
13 Turn on the main electric power and start the engine.

14 Check that the hose connections and seal between the hydraulic
oil pump and brake pump seal tight.
Check the feed pressure from the brake pump, see Oil pump
brake system, checking page 8.
15 Check the oil level in the brake system, fill if necessary.
NOTE
If the pump is replaced due to malfunction, change the oil
and filter in the brake system as well.
Oil pump brake system, changing

page
–
(Dana/Sauer-Danfoss)
NOTE
section B Safety.
1 Machine in service position, section B Safety.
section B Safety.
NOTE
4 Remove the attaching bolts, pull the pump backward and lift it
away.

6 Brush sealing silicone on the sealing face of the brake pump, see
section F Technical data.
Install the pump and check that the pump’s splines engage in the
shaft in the main pump.
NOTE
NOTE
NOTE

Oil pump brake system, changing (ZF/Rexroth)

page
–
NOTE
section B Safety.
section B Safety.
NOTE
014364
it away.
014365

4 Brakes – 4.3.2 Oil filter brake system 15
014361
NOTE
014346
NOTE
10 Start the engine.
NOTE
4.3.2 Oil filter brake system

Oil filter brake system, general
page
–
See Oil filter brake system, description page 49.

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

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

lator charging valve. The pressures are individual to each machine
1. Safety valve
and values are stated on the pressure plate on the left frame member,
2. Connection from pump (P)
see section 10 Common hydraulics. On the accumulator charging
3. Connection, wheel brake (T)
valve, there is also a parking brake solenoid valve (position 6), switch
4. Measuring outlet, pump pressure (P)
(NC) brake oil pressure (position 9) and switch (NC) parking brake
5. Measuring outlet, accumulator pressure (M)
(position 7).
6. Parking brake solenoid valve (Y642)
7. NC switch, parking brake (GHB) (S200) • Solenoid valve parking brake, description page 37
8. Connection, accumulators (ACC) • Break-contact (opening switch) brake oil pressure, description
9. NC switch, brake oil pressure (LB) (S204) page 28
10. Connection, parking brake calliper (HB) • Break contact (opening switch) parking brake, description
11. Drain valve page 41
12. Main valve charging
13. Pressure limiting valve
Accumulator charging, checking and adjustment

page
–
NOTE
section B Safety.

2 Check the accumulator’s charging, see Oil pump brake system,
checking page 8.

4 Brakes – 4.3.3 Accumulator charging valve 17
3 If necessary, adjust the accumulator charging pressure on the

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

NOTE
Accumulator charging valve, changing

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

18 4 Brakes – 4.3.3 Accumulator charging valve
6 Remove the accumulator charging valve.

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

to marking.
NOTE
10 Install the parking brake valve and break contact (opening
switch) parking brake.
11 Connect the cable harness to the accumulator charging valve.
NOTE
Check that the hydraulic connections are sealed tightly.
14 Check the charging and switching function, see Accumulator
charging, checking and adjustment page 16.

4 Brakes – 4.3.4 Accumulator 19
4.3.4 Accumulator
Accumulator, description
page
–
The accumulators store pressure so that there is a pressure reserve

in case of engine stop or brake system malfunction. The brake system
has four accumulators connected in parallel. These are installed at the
front in the engine compartment, above the drive axle.
The accumulators are of the diaphragm type. Each accumulator is di-
vided into two spaces by a diaphragm. One side of the diaphragm is
pressurised by nitrogen gas. The other side is pressurised by the hy-
draulic oil, which compresses the nitrogen gas.
The accumulator has pressure check connections for checking the
gas pressure on the opposite side of the pressure connection.
000001
Accumulator, checking
page
–
NOTE
section B Safety.

section B Safety.
3 The accumulators can be tested with separate test equipment or
in the machine. Primarily, separate test equipment should be
used since it is faster and more exact.
Test equipment can be ordered from Cargotec.
• Checking with test equipment: continue with step 4.
• Checking in machine: continue with step 6.

20 4 Brakes – 4.3.4 Accumulator
Checking with test equipment

4 Remove the accumulators and test them with the test equipment
designed for the purpose.
The accumulators’ gas pressure must match with the pressure
plate.
5 Continue with step 17.
MPa
MPa
MPa
MPa MPa MPa

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

Checking in the machine
6 Loosen three of the accumulators from the distribution blocks.
Plug the connections on the distribution blocks with plugs that
can handle high pressure. Plug the connections on the accumu-
lators to prevent contamination.
ing valve.
charge the accumulator until the accumulator charging valve
changes to cooling.
10 Check that the plugs seal tightly.
11 Turn off engine.
12 Lower the pressure by means of braking carefully several times
while checking the pressure on the pressure gauge.
When the pressure reaches approx. 10 MPa the pressure must
decrease immediately to 0 MPa.
If the pressure drops immediately when the engine is turned off,
then the accumulator does not have any precharge pressure.
This indicates internal leakage and the accumulator must be
changed.
If the pressure can be reduced slowly to a pressure below
10 MPa then the precharge pressure is too low and the accumu-
lator must be replaced or handed over to authorised personnel for
maintenance.

4 Brakes – 4.3.4 Accumulator 21

section B Safety.
14 Mark up and disconnect the tested accumulator. Plug the con-
nections. Connect one of the other accumulators to the distribu-
tion block.
15 Repeat steps 8-14 until all accumulators have been checked.
section B Safety.
Installation and final checking

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

22 4 Brakes – 4.3.4 Accumulator
4 Detach the accumulator’s clamp and remove the bolt.

5 Detach the accumulator from the distribution block.
NOTE
Hold the block firmly so that the other accumulator does not
work loose.
6 Bend the clamp away and remove the accumulator.
7 Fit the new accumulator.
NOTE
Check that the seal is intact and installed correctly.
8 Secure the accumulator’s clamp and tighten the bolt.

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

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

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

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

24 4 Brakes – 4.3.5 Brake valve
4 Connect a pressure gauge (0-25 MPa) to the pressure check

connection for brake pressure on the distribution block on the
front axle.
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 to the pressure plate on the left frame member.
8 Turn off engine.
9 Depress the pedal fully and keep it pressed down, check the
pressure.
The brake pressure must correspond with the value specified on
MPa the pressure plate and must not decrease from this value for
15 seconds.
10 Release the pedal, the brake pressure must decrease to 0 MPa
MPa
immediately. Otherwise the brake valve does not seal and can
cause the brakes to remain applied and then overheat during
operation.
MPa
MPa MPa MPa

MPa Replace the brake valve if it is not sealed.
MPa
section B Safety.
MPa MPa measuring outlet.
008214
NOTE

4 Brakes – 4.3.5 Brake valve 25
Brake valve, changing

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

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

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

26 4 Brakes – 4.3.5 Brake valve
NOTE
13 On machines with manual sliding cab. Secure the cab in the rear-
most position with the cab locks.
14 Turn on the main electric power and start the engine. Run the en-
gine at idle speed.
15 Test the brakes a couple of times.
16 Check that the brake valve’s connections are sealed tightly.
17 Bleed the wheel brakes’ brake cylinders, see Wheel brakes,
A bleeding page 32.
000270
B C
A. Position, lock handle
B. Lock pin
C. Lock handle for securing cab

4 Brakes – 4.3.6 Drive axle block 27
4.3.6 Drive axle block

Drive axle block, description
page
–
The drive axle block distributes oil flow and brake pressure to the right
1 and left wheel brakes. The drive axle block is located on a bracket
10
2 above the drive axle’s differential.
1
3 The drive axle block has a measuring outlet for brake pressure and for
3 measuring back pressure in the disc brake’s cooling circuit.
4
The drive axle block has a bypass valve which guides oil directly from
5
5 the cooling circuit intake to the cooling circuit return if the resistance in
9 the axle becomes too high. This protects the wheel brake seals, e.g.,
6 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 29 and NO switch (S220-2), see section Transmission,
group 2.8.2 NO switch declutch.
000439
1. Brake cooling connection, return from wheel brake

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

28 4 Brakes – 4.3.7 Break-contact (opening switch) brake oil pressure
4.3.7 Break-contact (opening switch) brake

oil pressure
Break-contact (opening switch) brake oil pressure,
page
–
description
Break-contact (NC) brake oil pressure switch (S204) detects the pres-
sure in the accumulators. The NC switch is located on the accumulator
charging valve on the lifting beam in front of the transmission in the en-
gine compartment.
When the pressure in the feed circuit is high enough to ensure braking
of the machine, the sensor closes an electric circuit. This is used to
warn for pressure-drop in the brake system. The sensor’s cut-out pres-
sure is chosen so that there is pressure for at least eight brake appli-
cations without additional feed from the pump after the light has
gone off.
The brake oil pressure NC switch (S204) is supplied power by the
frame control module front (D797-F). When the pressure increases
above the cut-off pressure, the voltage signal to frame control unit front
(D797-F) is cut off.
section 8 Control system, group 8.4.5.4 HYD, menu 4.
000435
Break-contact (opening switch) brake oil, adjusting

page
–
NOTE
section B Safety.
1 Operate and warm up the machine until the oil reaches operating
temperature, at least 50 C.
section B Safety.
4 Connect a pressure gauge (0-25 MPa) to the pressure check
ing valve.
6 Start the engine and fully charge the accumulators (the accumu-
lator charging valve changes to cooling).
7 Stop the engine and turn the start key to position I.
8 Brake several times, stop when the warning light for low brake
pressure comes on.
9 Read off the accumulator pressure. The pressure should be
approx. 11.5 MPa.
10 If necessary, adjust the warning level by turning the adjusting
screw in the rear edge of the sensor, between the contact pins.

4 Brakes – 4.3.8 Make-contact (closing switch) brake lights 29
NOTE
The setting is very sensitive, turn max. 1/4 turn at a time.
11 Repeat steps 6-10 until the warning light turns on at 11.5 MPa.
12 Seal the adjusting screw with locking fluid.
section B Safety.
measuring outlet.
NOTE
4.3.8 Make-contact (closing switch)

brake lights
Make-contact (closing switch) brake lights,
page
–
description
The brake light NO switch controls brake light activation when the ma-
chine brakes. The switch is located on the drive axle block, which is
located on a bracket above the drive axle’s differential.
The brake light NO switch (S216) is supplied power by and sends a
voltage signal to the frame control unit front (D797-F). When the pres-
sure increases above the closing pressure, a voltage signal is sent to
the frame control unit front (D797-F).
000439

30 4 Brakes – 4.3.8 Make-contact (closing switch) brake lights
Make-contact (closing switch) brake light, checking

page
–
NOTE
section B Safety.
1 Operate and warm up the machine until the brake oil reaches op-
erating temperature, at least 50 C.
3 Brake and check that the brake light is switched on.
section B Safety.
5 Connect a pressure gauge (0-25 MPa) to the measuring outlet for
brake pressure on the distribution block.
7 Start the engine.
8 Use the display, go to the diagnostic menu, see section 8 Control

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

4 Brakes – 4.3.9 Wheel brakes 31
NOTE
4.3.9 Wheel brakes

Wheel brakes, description
page
–
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 have so-called wet disc brakes (WDB). Wet disc
brakes require minimal maintenance and have a long service life due
to effective cooling. Maintenance requirements are minimised since oil
circulates in the brake system and prevents corrosion.
000015

32 4 Brakes – 4.3.9 Wheel brakes
The wheel brake has two main sections - disc pack and brake cylinder.
1 2
The disc pack performs the braking. The brake cylinder presses to-
gether the discs in the disc pack during braking.
000016
Wheel hub and brake, cross section

1. Disc pack
2. Brake cylinder
Wheel brakes, bleeding

page
–
NOTE
section B Safety.
IMPORTANT
Both the brake cylinder and disc brake must be bled
after work which involves the brake system being
opened or after work on the wheel brake.
Brake cylinder

4 Brakes – 4.3.9 Wheel brakes 33
2 Position a ring spanner on the bleed nipple and connect a trans-

parent hose to the bleed nipple.
Route the other end of the hose down into a receptacle.
3 Start the machine and depress the brake pedal, keep the pedal
depressed.
4 Open the bleed nipple and allow oil to run out of it until the oil is
free of air bubbles.
NOTE
The hydraulic hose between the brake pedal and brake is
approx. 7 metres long. Therefore, allow at least two litres of
oil to pass through the air bleeder nipple when bleeding to
ensure that no air pockets remain in the system.
Bleed nipple, brake cylinder, on top of the drive axle at 5 Close the bleed nipple.
the wheel hub’s inner short side (left-hand side).
6 Move the wrench and hose and repeat steps 1–4 on the
other side.
Disc brake
NOTE
Air bleeding of the disc brake is vital for the correct cooling of
the discs.
1 Start the engine and let it to idle. Wait until the brake accumula-
tors are fully loaded and the accumulating charging valve has
switched to brake cooling.
2 Remove the bleed screw for the disc brake and allow oil to flow
out of the hole until it is free of air bubbles. Install the bleed screw.
3 Repeat steps 1-3 on the other wheel.
Bleed nipple disc brake, brake cylinder, on top of

the drive axle by the wheel hub’s inner short side
(left side).

34 4 Brakes – 4.3.9.1 Disc pack
Wheel brake, changing

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

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

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

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

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

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

Parking brake system, function description
page
–
D5
5
6 12
D790-1 D790-2
D797-F
7 11
D8
D10
C3 8
4
Pa 10 9
ACC
C1 3
H
P
2 T
006402
1 Oil pump brake system pumps oil from P = 19 0.5 MPa Brake oil tank, description page 43
the brake oil tank. Oil pump brake system for Dana and ZF, de-
scription page 7
2 Oil filter brake system removes dirt from - Oil filter brake system, description page 49
the oil.
3 The accumulator charging valve directs Accumulator charging valve, description

through the brake system’s cooling
circuit.
4 The accumulators store oil pressure. See the pressure plate on Accumulator, description page 19
the left-hand frame beam.
5 Switch parking brake (S107) activates Switch activated: Section 9 Frame, body, cab and accesso-
the parking brake. Conn 1, U = 22–28 V ries, group 9.1 Controls and instruments
The switch uses two signals - one for ap- Conn 7, U = 0 V D5: Diagnostic menu, see section 8 Control
plied and one for released parking system, group 8.4.5.5 HYD, menu 5
Switch in home position:
brake. Both signals must be correct to
enable release of the parking brake. Conn 1, U = 0 V
Conn 7, U = 22–28 V


6 Control unit, cab (D790-1) sends re- Checked by control sys- Section 11 Common electrics,
lease or apply parking brake on the tem, error shown with er- group 11.5.3.1 Control unit, cab
CAN-bus. ror code.
7 The frame control unit front (D797-F) ac- U = 24 V Section 11 Common electrics,
tivates the solenoid valve parking brake group 11.5.3.2 Control unit, frame front
(Y642). D8: Diagnostic menu, see section 8 Control
system, group 8.4.5.5 HYD, menu 5
8 Solenoid valve parking brake (Y642) Pump pressure. Solenoid valve parking brake, description
acts on the valve slide which drains page 37
pressure in the parking brake’s brake D8: Diagnostic menu, see section 8 Control
caliper to tank. system, group 8.4.5.5 HYD, menu 5
9 The brake caliper is drained of pressure 0 MPa Parking brake unit, description page 38
and the spring applies the parking
brake.
10 Break-contact (opening switch) parking Applied parking brake: Break contact (opening switch) parking
brake (S200) closes the circuit when the Conn. 1: U = 24 V brake, description page 41
pressure decreases. D10: Diagnostic menu, see section 8 Control
Conn. 2: U = 0 V
Released parking brake:
Conn. 1: U = 24 V
Conn. 2: U = 24 V
11 Control unit, frame front (D797-F) sends Checked by control sys- Section 11 Common electrics,
parking brake applied on the CAN-bus. tem, error shown with er- group 11.5.3.2 Control unit, frame front
ror code.
12 Control unit KIT (D790-2) activates indi- Checked by control sys- Section 11 Common electrics,
cator light, parking brake (508). tem, error shown with er- group 11.5.3.11 Control unit, KIT
ror code.

Oil pump brake system, general
page
–
See group 4.3.1 Oil pump brake system.

Oil filter brake system, general
page
–
See Oil filter brake system, description page 49.

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

Solenoid valve parking brake, description
page
–
The parking brake solenoid valve (Y642) activates the parking brake.
The solenoid valve is installed on the accumulator charging valve,
which is installed on the lifting beam in front of the transmission in the
engine compartment, see Accumulator charging valve, description
page 16.
The solenoid valve opens a connection between the accumulators and
the parking brake calliper at activation. This means that the parking
brake calliper is pressurised and the parking brake is disengaged.
When the voltage feed to the solenoid valve is cut off, the connection
between the accumulators and parking brake calliper is terminated. In-
stead, a connection between the parking brake calliper and tank is
opened and the parking brake applied. This means that the parking
brake is applied if the machine loses electrical power or if the brake
system becomes depressurised.
The solenoid valve is supplied with voltage by the frame control unit
front (D797-F) at activation.
000437
Solenoid valve parking brake, checking

page
–
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 switch parking brake and check
that the parking brake’s brake caliper releases. The brake caliper
should be able to move.
4 Activate the parking brake with the switch for the parking brake
and check that the parking brake’s brake caliper is applied.

38 4 Brakes – 4.5.4 Parking brake unit
4.5.4 Parking brake unit

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

page
–
(drive axle alternative Kessler)
DANGER
The machine may start to roll.
Risk of crushing.

1 Start the engine and run up hydraulic pressure until the accumu-
lators are fully charged and the accumulator charging valve
switches to cooling.
2 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.

4 Brakes – 4.5.4.1 Parking brake caliper 39
6 Remove the cover from the brake caliper.
7 Loosen the lock nut.

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

Brake caliper, description
page
–
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. In turn, this means that the machine is
braked if a serious malfunction occurs.
000020
1. Brake pads
2. Release cylinder
3. Application spring
4. Release screw
5. Adjusting washer

40 4 Brakes – 4.5.4.2 Parking brake pads
4.5.4.2 Parking brake pads

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

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

1 Machine in service position and wheels blocked, see

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

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

4 Brakes – 4.5.4.3 Parking brake disc 41
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
adjusting (drive axle alternative Kessler) page 38.
4.5.4.3 Parking brake disc

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

parking brake
Break contact (opening switch) parking brake,
page
–
description
The parking brake NC switch (S200) detects whether the parking
brake is applied or released. The NC switch is fitted on the accumula-
tor charging valve, which is installed on the lifting beam in front of the
transmission in the engine compartment, see Accumulator charging
valve, description page 16.
Break-contact parking brake (S200) senses the pressure in the park-
ing brake circuit. When the pressure is so high that the parking brake
is released, the sensor opens an electric circuit. This is used to indi-
cate that the parking brake is released.
The parking brake brake NC switch (S200) is supplied with power by
and sends voltage signal to the frame control module front (D797-F).
When the pressure increases above the cut-off pressure, the voltage
signal to frame control unit front (D797-F) is cut off.
NOTE
Gears cannot be engaged when the parking brake is applied.
000436

page
–

42 4 Brakes – 4.8 Temperature control, cleaning and oil for brake system
4.8 Temperature control,

cleaning and oil for brake
system
Temperature control, cleaning and oil for brake
page
–
system, function description
12
D793
11
D790-1 D795
D797-F
9
D8 D10
C4
C1
3 4
P T
2
5
1
6 10
8 7
C M
012490
C

1 Oil pump brake system pumps oil from P = 19 0.5 MPa Oil pump brake system for Dana and ZF, de-
the brake oil tank. scription page 7
Brake oil tank, description page 43
2 Oil filter brake system cleans the oil. - Oil filter brake system, description page 49
3 The accumulator charging valve directs Max. 0.1 MPa Accumulator charging valve, description
through the brake system’s cooling cir-
cuit.
4 The oil cools the wheel brake. - Wheel brakes, description page 31
5 The bypass valve in the distribution - Drive axle block, description page 27
block leads oil past the drive axle if the
back pressure through the wheel brake
is too great.
6 The cooler cools the oil. - Oil cooler, description page 45
7 The thermal bypass valve leads oil past approx. 50 C Thermal bypass valve, description page 46
the cooler if the temperature is low.

4 Brakes – 4.8.1 Brake oil tank 43

8 The temperature sensor (B762) detects R = 25 k at 20 C Sensor brake oil temperature, description
the oil temperature and sends a voltage page 47
signal proportional to the oil temperature D8: Diagnostic menu, see section 8 Control
to Control unit, frame front (D797-F). system, group 8.4.5.2 HYD, menu 2
oil temperature information on the tem, error shown with er- group 11.5.3.2 Control unit, frame front
CAN-bus. ror code.
10 When the oil is hot, Control unit, frame U = 24 V with activated Cooling fan, description page 46
front (D797-F) activates the cooling fan fan D10: Diagnostic menu, see section 8 Control
(M674) and increases the airflow Starts at 65 C system, group 8.4.5.2 HYD, menu 2
through the cooler.
Stops at 55 C
11 If the temperature is high Control unit Checked by control sys- Section 11 Common electrics,
KID (D795) activates a warning for high tem, error shown with er- group 11.5.3.12 Control unit, KID
brake oil temperature on the display. ror code.
12 If the temperature is high then the Con- Checked by control sys- Section 11 Common electrics,
trol unit, transmission (D793) limits the tem, error shown with er- group 11.5.3.9 Control unit, transmission
machine’s speed in order to protect ror code.
the brakes.
4.8.1 Brake oil tank

Brake oil tank, description
page
–
The brake oil tank stores oil in the brake system and is installed on the
left side of the machine in front of the fuel tank.
The brake system is separate from other hydraulics and has its own
tank and oil filter. This makes it possible to keep additives out of the
brake system fluid.
Brake oil is filled directly in the tank. A drain plug is located at the bot-
tom of the tank. Hatches on top of the tank facilitate internal cleaning.
The tank is equipped with a filtered breather that allows volume chang-
es in the tank, due to temperature variations and use. See Breather fil-
ter, description page 48.
The tank has a sight glass for checking oil level.
000012

44 4 Brakes – 4.8.2 Tank heater
4.8.2 Tank heater

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

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

page
–
The brake oil tank can be equipped with a tank heater, which heats the
brake oil in the tank and is located in a flange on the front short side of
the tank. The tank heater is designed for use in cold climates.
The tank heater is powered by high voltage. Heater output is adapted
through different connections and adaptation to different operating
voltage - 110, 230, or 400 V AC. Higher voltage generates higher heat-
er output.
The tank heater can be equipped with a programmable thermostat
001872
which maintains the temperature at an even level. The thermostat

is fitted directly onto the heating element and can be adjusted
with a knob on the junction box. Recommended temperature setting
is 20–30 C.

Oil pump brake system, general
page
–
See group 4.3.1 Oil pump brake system.
4.8.4 Accumulator charging valve

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

Drive axle block, description
page
–
See Drive axle block, description page 27.
4.8.6 Wheel brakes

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

4 Brakes – 4.8.7 Oil cooler 45
4.8.7 Oil cooler

page
–
The oil cooler cools the oil in the brake system in order to maintain
brake performance. The oil cooler is located inside of the side panel
on the left side behind the front fender.
The brake system uses a flow-through cooler with electric cooling fan.
The brake system’s oil is cooled when it passes the cooler. Openings
in the frame panel allow air to pass through the cooler.
The cooling fan is bolted onto the cooler. See Cooling fan, description
page 46.
000010
Oil cooler brake system, changing

page
–
NOTE
section B Safety.

2 Drain the oil from the brake oil tank, see Oil brake system, chang-
ing page 50.
3 Mark up and disconnect hydraulic hoses from the cooler. Let the
oil in the cooler drain into the collection container.
NOTE
4 Disconnect the cable harness from the cooling fan.
5 Remove the attaching bolts and lift away the cooler.
6 Transfer the cooling fan to the new cooler.
7 Fit the cooler.
8 Connect the cable harness to the cooling fan.
9 Connect the hydraulic hoses to the cooler.
1. Cooling fan
NOTE
2. Connector
Check that the O-rings are intact and installed correctly.
3. Cooler

46 4 Brakes – 4.8.8 Cooling fan
10 Fill oil in the brake oil tank, see Oil brake system, changing
page 50. The oil level should be visible in the sight glass.
4.8.8 Cooling fan

Cooling fan, description
page
–
The cooling fan (M674) is a suction electric fan. The fan draws air from
the outside of the machine through the cooler and increases airflow
through the oil cooler as needed. The cooling fan is mounted inside the
cooler inside the side panel behind the left drive wheel.
The cooling fan (M674) is supplied voltage by the front frame control
unit (D797-F). The cooling fan is activated when temperature of the oil
in the brake oil tank is 65 C and the fan turns off when the tempera-
ture is 55 C.
000009
4.8.9 Thermal bypass valve

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

4 Brakes – 4.8.10 Sensor brake oil temperature 47
Thermal bypass valve, changing

page
–
NOTE
section B Safety.

section B Safety.
ing page 50.
4 Remove the thermal bypass valve that is installed in the hydraulic
oil tank.
NOTE
Note how the valve is installed.
5 Fit in reverse order.
4.8.10 Sensor brake oil temperature

Sensor brake oil temperature, description
page
–
Sensor brake oil temperature (B762) senses the temperature of the oil
in the brake system. The sensor is mounted on the rear short side of
the brake oil tank and therefore takes the accumulated heat in the
brake system’s oil into account.
Sensor brake oil temperature (B762) is supplied with voltage by, and
sends a voltage signal proportional to the temperature to, Control unit,
frame front (D797-F).
001091
Sensor brake oil temperature, changing

page
–
NOTE
section B Safety.

ing page 50.
3 Disconnect the cable harness from the oil temperature sensor.
4 Change the oil temperature sensor.
NOTE
5 Connect the cable harness to the sensor.

48 4 Brakes – 4.8.11 Breather filter
6 Fill oil in the brake oil tank, see Oil brake system, changing
page 50. The oil level should be visible in the sight glass.
4.8.11 Breather filter

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

page
–
1 Clean the area around the brake tank’s breather filter.

2 Remove the cover from the filter holder.
Remove the bolt in the middle and lift away the cover.
3 Remove the old filter insert.
4 Clean the filter holder.
NOTE
Be careful so that impurities do not enter the tank.
5 Install a new filter insert.
1. Filling point oil brake system 6 Reinstall the cover for the filter holder.
2. Breather filter brake oil tank

4 Brakes – 4.8.12 Oil filter brake system 49

Oil filter brake system, description
page
–
Oil filter brake system cleans the oil in the brake system from impuri-
ties. The filter is mounted on a bracket in front of the transmission un-
der the lifting beam.
The brake system’s oil filter is a high-pressure filter with removable fil-
ter insert. It is located between the pump and accumulator charging
valve. The oil is cleaned when it is forced through the (fibreglass) ma-
terial of the filter insert before reaching the accumulator charging
valve.
A bypass valve located between the intake and outlet protects the in-
sert. If resistance through the filter surface becomes too high, the by-
pass valve opens a passage past the insert. The bypass function
opens if the oil is viscous (cold or too low/high viscosity) or if the filter
insert is clogged with dirt.
NOTE
When the filter is clogged, the oil is directed past the filter without
cleaning. It is therefore very important to replace the filter at the
prescribed interval.
000018
Oil filter brake system, changing

page
–
NOTE
section B Safety.
IMPORTANT
The filter protects the brake system against contami-
nants. It is vital that new contaminants do not enter
the brake system when changing filter.

section B Safety.
NOTE
Leave the valves open when changing.

50 4 Brakes – 4.8.13 Pipes and hoses
3 Remove the drain plug on the underside of the filter.

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

page
–
4.8.14 Oil for brake system

Oil brake system, general
page
–
See section F Technical data.
Oil brake system, changing

page
–
NOTE
section B Safety.
section B Safety.
3 Remove the filler cap and drain the brake oil tank.
4 Remove the drain plug and let the last of the oil to drain into a
container.
5 Install the drain plug, using a new gasket washer.
6 Fill brake oil until the oil level is in the middle of the level glass.
For volume and grade, see section F Technical data.
7 Install the filler cap.
1. Filling point oil brake system
2. Breather filter brake oil tank

5 Steering 1
5 Steering
Table of Contents 5 Steering

mm mm mm mm mm mm
5 Steering........................................................................................................... 3
5.1.2 Mini-wheel .............................................................................................. 3
5.1.3 Joystick .................................................................................................. 4
5.2 Power assisted system ............................................................................... 6
5.2.1 Hydraulic oil pump ............................................................................... 13
5.2.2 Priority valve ........................................................................................ 14
5.2.3 Steering valve ...................................................................................... 19
5.2.4 Steering cylinder .................................................................................. 22
5.2.5 Steering axle cradle ............................................................................. 25
5.2.6 Link arm ............................................................................................... 26
5.2.7 Wheel spindle ...................................................................................... 26
5.2.8 Wheel hub ............................................................................................ 26
5.2.9 Shuttle valve ........................................................................................ 26
5.2.10 Control valve mini-wheel/joystick control ............................................. 27
5.2.11 Shuttle valve for mini-wheel/joystick control ........................................ 30
5.2.12 Sensor steering wheel movement ....................................................... 31
5.2.13 Pipes and hoses .................................................................................. 31

2 5 Steering

5 Steering 3
5 Steering
mm mm mm mm mm mm

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

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

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

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

menus; see section 8 Control system, group 8.5.1 Initiation.
1. Joystick
2. Travel direction selector (F / N / R) Joystick position (left, centre, right) can be calibrated with the diagnos-
3. Switch, joystick activation tic menus; see section 8 Control system, group .8.5.2.2 Calibrate
4. Horn steering.
5. Armrest
Joystick activation switch
The joystick activation switch (position 3) activates steering with the
joystick. The switch is supplied with voltage by and sends a voltage
signal to the cab control unit (D790-1).

5 Steering – 5.1.3 Joystick 5
Travel direction selector

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

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

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

5 Steering – 5.2 Power assisted system 7
Power-assisted steering system, function

page
–
description (Dana/ Sauer-Danfoss and ZF/

Rexroth)
2
PP P
C1
CF LS
5
P T
LS T L R
3
1 6
007428
1 Hydraulic oil pump 2 pumps oil to the pri- See the pressure plate on Section 10 Common hydraulics,
ority valve. the left-hand frame beam. group 10.4.2 Axial piston pump with varia-
ble displacement
2 The priority valve prioritises pressure Checked by control sys- Priority valve, description (Dana/Rexroth)
supply to the steering valve before the tem, error shown with er- page 14
working hydraulics. The priority valve ror code.
also sends a control signal to hydraulic
oil pump 2.
3 The shuttle valve selects the strongest Checked by control sys- Section 10 Common hydraulics,
load signal for the hydraulic pumps if hy- tem, error shown with er- group 10.5.3 Shuttle valve
draulic functions are activated at the ror code.
same time as the steering wheel is
turned.
5 The steering valve pumps pressurised - Steering valve, description page 20

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

Joystick steering/mini-wheel, function

page
–
Mini-wheel or joystick control is a steering option that makes it possible

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


Joystick steering Voltage signal from mini-wheel/ Mini-wheel, description page 3 or Joystick, description page 4
activated joystick control switch. Diagnostic menu, see section 8 Control system,
group 8.4.11.4 EL-STEERING, menu 2
Steering wheel No signal from the steering angle Sensor, steering wheel movement, description page 32
stationary sensor.
Speed Below 3 km/h (at engagement) -
Control breaker Not activated Section 11 Common electrics, group 11.2.3 Control breaker
1
D12 D1
11
13 2
D790-1
D790-2 D790-3
D797-O
12 3
D3 4 D4
C7 8
PP
P P
LS
P CF
LS
TP
5, 9
LS T
T1
T L R A B
10
006404

1 The joystick switch or Mini-wheel switch Signal 1, U = 0.5-4.5 V Mini-wheel, description page 3 or Joystick,
sends a voltage signal to the Control unit Signal 2, U = 0.5-4.5 V description page 4
cab (D790-1). (mini-wheel only) D1: Diagnostic menu, see section 8 Control
On machines with Combi attachment system, group 8.4.11.4 EL-STEERING,
the signal is sent to Control unit cab menu 1
option (D790-3).
2 Control unit, cab (D790-1) sends the de- Checked by the control Section 11 Common electrics,
sired steering angle on the CAN-bus. system, error indicated group 11.5.3.1 Control unit, cab
On machines with Combi attachment with error code.
the cab control unit option (D790-3)
sends steering angle on the CAN-bus.


3 Control unit, frame option (D797-O) sup- I = 350-550 mA Section 11 Common electrics, group
plies voltage to the solenoid valve for 11.5.3.4 Control unit frame option
steering right (Y636R) or the solenoid D3: Diagnostic menu, see section 8 Control
valve for steering left (Y636L). system, group 8.4.11.4 EL-STEERING,
menu 4 and 5
4 The solenoid valve, steering right - Control valve for joystick control or mini-
(Y636R) or solenoid valve, steering left wheel, description page 28
(Y636l) pressurises the steering slide in D4: Diagnostic menu, see section 8 Control
the solenoid valve for lever steering or system, group 8.4.11.4 EL-STEERING,
mini-wheel. menu 4 and 5
5 The solenoid valve for joystick control or - Control valve for joystick control or mini-
mini-wheel sends a load signal to shuttle wheel, description page 28
valve, steering.
6 The shuttle valve selects the strongest - Shuttle valve for mini-wheel or joystick con-
load signal for the hydraulic oil pumps 3 trol, description page 31
and 4 if hydraulic functions are activated
at the same time as the steering wheel
is turned.
7 Hydraulic oil pump 3 and 4 pump oil See the pressure plate on Section 10 Common hydraulics,
from the hydraulic oil tank. the left-hand frame beam. group 10.4.2 Axial piston pump with varia-
ble displacement
8 The priority valve prioritises pressure See the pressure plate on Priority valve page 14
supply to the steering valve over the the left-hand frame beam.
working hydraulics. The priority valve
also transmits a control signal to the hy-
draulic oil pump 3 and 4.
9 The steering slide changes position and - Control valve for joystick control or mini-
pressurises the steering cylinder. wheel, description page 28
12 The steering shaft sensor sends a volt- U = 24 V Sensor, steering wheel movement, descrip-
age signal to Control unit cab (D790-1). tion page 32
D12: Diagnostic menu, see section 8 Con-
trol system, group 8.4.11.4 EL-STEERING,
menu 3
13 Control unit, cab (D790-1) sends abort Checked by the control Section 11 Common electrics,
steering on the CAN-bus. system, error indicated group 11.5.3.1 Control unit, cab
with error code.
Hydraulic diagram, joystick steering

Joystick control/mini-wheel, function

page
–
description (Dana/Sauer-Danfoss and ZF/

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

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


Joystick steering Voltage signal from mini-wheel/ Mini-wheel, description page 3 or Joystick, description page 4
activated joystick control switch. Diagnostic menu, see section 8 Control system,
group 8.4.11.4 EL-STEERING, menu 2
Steering wheel No signal from the steering angle Sensor, steering wheel movement, description page 32
stationary sensor.
Speed Below 3 km/h (at engagement) -
Control breaker Not activated Section 11 Common electrics, group 11.2.3 Control breaker
1
D12 D1
11
13 2
D790-1
D790-2 D790-3
D797-O
12 3
D3 4 D4
C7 8
PP
P P
LS
P CF
LS
TP
5, 9
LS T
T1
T L R A B
10 006404

1 The joystick switch or Mini-wheel switch Signal 1, U = 0.5-4.5 V Mini-wheel, description page 3 or Joystick,
sends a voltage signal to the Control unit Signal 2, U = 0.5-4.5 V description page 4
cab (D790-1). (mini-wheel only) D1: Diagnostic menu, see section 8 Control
On machines with Combi attachment system, group 8.4.11.4 EL-STEERING,
the signal is sent to Control unit cab menu 1
option (D790-3).
2 Control unit, cab (D790-1) sends the de- Checked by the control Section 11 Common electrics,
sired steering angle on the CAN-bus. system, error indicated group 11.5.3.1 Control unit, cab
On machines with Combi attachment with error code.
the cab control unit option (D790-3)
sends steering angle on the CAN-bus.


3 Control unit, frame option (D797-O) sup- I = 350-550 mA Section 11 Common electrics,
plies voltage to the solenoid valve for group 11.5.3.4 Control unit frame option
steering right (Y636R) or the solenoid D3: Diagnostic menu, see section 8 Control
valve for steering left (Y636L). system, group 8.4.11.4 EL-STEERING,
menu 4 and 5
4 The solenoid valve, steering right - Control valve for joystick control or mini-
(Y636R) or solenoid valve, steering left wheel, description page 28
(Y636l) pressurises the steering slide in D4: Diagnostic menu, see section 8 Control
the solenoid valve for lever steering or system, group 8.4.11.4 EL-STEERING,
mini-wheel. menu 4 and 5
5 The solenoid valve for joystick control or - Control valve for joystick control or mini-
mini-wheel sends a load signal to shuttle wheel, description page 28
valve, steering.
6 The shuttle valve selects the strongest - Shuttle valve for mini-wheel or joystick con-
load signal to Hydraulic pump 2 if hy- trol, description page 31
draulic functions are activated at the
same time as the steering wheel is
turned.
7 Hydraulic oil pump 2 pumps oil from the See the pressure plate on Section 10 Common hydraulics,
hydraulic oil tank. the left-hand frame beam. group 10.4.2 Axial piston pump with varia-
ble displacement
8 The priority valve prioritises pressure See the pressure plate on Priority valve page 14
supply to the steering valve before the the left-hand frame beam.
working hydraulics. The priority valve
also sends a control signal to hydraulic
oil pump 2.
9 The steering slide changes position and - Control valve for joystick control or mini-
pressurises the steering cylinder. wheel, description page 28
12 The steering shaft sensor sends a volt- U = 24 V Sensor, steering wheel movement, descrip-
age signal to Control unit cab (D790-1). tion page 32
trol system, group 8.4.11.4 EL-STEERING,
menu 3
13 Control unit, cab (D790-1) sends abort Checked by the control Section 11 Common electrics,
steering on the CAN-bus. system, error indicated group 11.5.3.1 Control unit, cab
with error code.
Hydraulic diagram, joystick steering

14 5 Steering – 5.2.1 Hydraulic oil pump
5.2.1 Hydraulic oil pump

Hydraulic oil pump, general (Dana/Rexroth)
page
–
Steering is supplied with oil from hydraulic oil pump 3 and 4, see
section 10 Common hydraulics, group 10.4 Pumps.
Hydraulic oil pump, general (Dana/Sauer-Danfoss

page
–
and ZF Rexroth)
Steering is supplied with oil from hydraulic oil pump 2, see
section 10 Common hydraulics, group 10.4 Pumps.
5.2.2 Priority valve

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

page
–
NOTE
section B Safety.
1 Operate and warm up the machine so that the hydraulic oil reach-
es operating temperature, 50 C.
˚C 3 Depressurise the brake and hydraulic systems, see
section B Safety.
˚C
000475
Operating menu, hydraulic oil temperature

5 Steering – 5.2.2 Priority valve 15
4 Connect the pressure gauge to the pressure check connection

for hydraulic oil pump 3 or 4.
5 Start the engine and increase engine speed to approx. 1200 rpm.
Pressure check connections, hydraulic oil pumps

1. Hydraulic oil pump 1
6 Turn the steering wheel fully and read off the pump pressure.
Compare this to the steering pressure on the hydraulics plate.
The max. pressure measured on the pump should be 1.5 MPa
higher than the steering pressure on the hydraulics plate.
7 Turn off engine.
MPa
section B Safety.
MPa
measuring outlet.
MPa
MPa MPa MPa

MPa
MPa
MPa MPa
001033
920643.0024

16 5 Steering – 5.2.2 Priority valve
Priority valve, description (Dana/ Sauer-Danfoss and

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

Steering pressure, checking (Dana/ Sauer-Danfoss

page
–
and ZF/Rexroth)
NOTE
section B Safety.
es operating temperature, 50 C.
˚C 3 Depressurise the brake and hydraulic systems, see
section B Safety.
˚C
000475
4 Connect the pressure gauge to the pressure check connection
for hydraulic oil pump 2.
5 Start the engine and increase engine speed to approx. 1200 rpm.
Pressure check connections, hydraulic oil pumps

6 Turn the steering wheel fully and read off the pump pressure dur-
ing steering wheel movement. Compare this to the steering pres-
sure on the hydraulics plate. The max. pressure measured on the
pump should be 1.5 MPa higher than the steering pressure on the
MPa hydraulics plate.
MPa 7 Turn off engine.
section B Safety.
measuring outlet.
MPa
MPa
MPa MPa MPa MPa MPa MPa MPa
A49195.0400

18 5 Steering – 5.2.2 Priority valve
Priority valve, changing

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

function.
10 Install the priority valve’s attaching bolts.

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

NOTE
15 Close the relief valve for top lift.
CAUTION

010475
Check that relief valve top lift is closed before starting

the engine.
Relief valve for top lift, the figure shows a closed valve.
16 Start the engine and check that the hydraulic connections at the
priority valve seal tight.
17 Check the oil level in the hydraulic oil tank with the lift cylinders
completely down and the extension cylinder completely in. The
oil level should be in the middle of the level glass. Top up if nec-
essary, for grade see section F Technical data.
CAUTION
Overfilling of oil, leakage, and environmental damage.
The hydraulic oil level is checked with the boom com-

pletely lowered and retracted.
18 Check the steering pressure, see Steering pressure, checking

(Dana/Rexroth) page 14.

20 5 Steering – 5.2.3 Steering valve
5.2.3 Steering valve

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

with load signal connection to the priority valve.
The load signal generates load-dependent control of oil flow from the
priority valve to the steering valve. "Closed centre" means that the
steering valve is closed in its neutral position. This is necessary so that
signal pressure can be connected to the steering valve.
The steering valve consists of a gear pump and a distribution valve.
When the steering wheel is turned, oil flows from the main pump over
the gear pump to the distribution valve, which guides oil to the steering
cylinder. The gear pump ensures that the oil flow supplied to the cylin-
der is proportional to the steering wheel angle.
In the steering valve there are 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 vacuum on the piston’s rear
side, which otherwise can lead to cavitation.
001082

5 Steering – 5.2.3 Steering valve 21
Steering valve, changing

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

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

Lock the cab in its rearmost position with both lock catches.
000270
B C
B. Lock pin
NOTE
CAUTION

010475

the engine.

5 Steering – 5.2.4 Steering cylinder 23

16 Check that the connections on the steering valve are sealed
tightly.
17 Steer very carefully a few times right - left, to bleed the steering
valve and steering cylinder.
CAUTION
Do not overfill!
Leakage and environmental damage!

5.2.4 Steering cylinder

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

24 5 Steering – 5.2.4 Steering cylinder
Steering cylinder, changing

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

2. Hydraulic connection
6 Remove the steering cylinder’s attaching bolts.
7 Change the steering cylinder. Lift aside the steering cylinder.
NOTE
The steering cylinder is heavy, use lifting equipment.
8 Support the new steering cylinder so that the holes in the
attaching bolts are lined up directly opposite the holes in the
steering axle.
9 Lubricate and install the steering cylinder’s attaching bolts. Tight-
en the bolts crosswise a few times with increasing torque to
680 Nm.
Attaching bolts steering cylinder. 10 Transfer parts to the new steering cylinder.
NOTE
Check that the O-rings are intact, clean and in the correct
position.

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

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

2. Hydraulic connection
NOTE
CAUTION

010475

the engine.

26 5 Steering – 5.2.5 Steering axle cradle
16 Check the hydraulic oil level with the lift cylinders completely
down and the extension cylinder completely in. The oil level
should be in the middle of the level glass. Top up if necessary, for
grade see section F Technical data.
CAUTION
Do not overfill!

Hydraulic cylinders, repairs

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

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

5 Steering – 5.2.6 Link arm 27
5.2.6 Link arm

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

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

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

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

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

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

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

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

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

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

page
–
changing
NOTE
section B Safety.
section B Safety.
3 Mark and disconnect the hydraulic hoses from the control valve.
1
NOTE
6 2 Plug all connections immediately to protect the hydraulic
5 3 4 Mark and disconnect the cable harness from the control valve.
5 Remove the control valve.
4
Remove the attaching bolts and lift away the valve. Place the
valve on a clean and protected surface.
6 Transfer parts to the new control valve.
NOTE
Check that the O-rings on the hydraulic connections are in-
tact and installed correctly.
NOTE
002205
Transfer one adapter part at a time so that the marking is not

1. Load signal (LS)
mixed up.
3. Tank return (T) 7 Mark up the servo valves on the new control valve.
4. Connection, steering cylinder (B) 8 Fit the valve.
5. Tank return (TP)
9 Connect the cable harness to the control valve according to the
6. Connection, steering cylinder (A)
marking.
10 Connect the hydraulic hoses to the control valve according to the
marking.
NOTE

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

010475

the engine.

14 Check the function.
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.
CAUTION


5 Steering – 5.2.11 Shuttle valve for mini-wheel/joystick control 31
5.2.11 Shuttle valve for mini-wheel/joystick

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

valve for the hydraulic oil pumps’ control signal cables. The shuttle
1 valves are installed on the bracket for oil filling and oil dipsticks be-
tween engine and transmission.
2 The shuttle valve sends the control signal from the control valve to the
main pumps.
3
4
002203
Shuttle valves on attachment plate between engine

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

32 5 Steering – 5.2.12 Sensor steering wheel movement
5.2.12 Sensor steering wheel movement

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

page
–
See section 7 Load handling.

page
–

6 Wheel suspension 1
6 Wheel suspension
Table of Contents 6 Wheel suspension

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

2 6 Wheel suspension

6 Suspension 3
6 Suspension
mm mm mm mm mm mm
6.2 Suspension
Bushing steering axle mounting, changing
page
–
DANGER
Steering axle and machine are very heavy.
Risk of crushing!
It is not permissible to go enter a machine which has

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

3 Remove the counterweights on the rear of the machine.
NOTE
Mark the locations of the counterweights so that they can be
reinstalled in the same location. This is important for the ma-
chine’s stability.
4 Support under the steering axle so that it cannot fall over.
5 Attach hoisting equipment to the rear of the machine and take up
the slack so that the steering axle’s mounts are relieved.
NOTE
Do not lift so much that the wheels are off the ground.
6 Remove the pins holding the steering axle.
7 Lift the machine up so that the frame is lifted away from the axle.
8 Support the machine under the frame.
9 Move the steering axle so that the mountings can be accessed.
NOTE
If necessary, disconnect the cable harness for the sensors
on the steering axle.
The illustration shows rear mounting.

4 6 Wheel suspension – 6.2 Suspension
10 Remove the washers that hold the bushing in place.

11 Press out the bushing.
12 Clean the bearing surfaces on the steering axle.
The illustration shows front mounting.

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

6 Wheel suspension – 6.2.1 Steering axle cradle 5
6.2.1 Steering axle cradle

Steering axle cradle, description
page
–
The oscillating steering axle has a double-acting steering cylinder. The

1 2 3 4 5 6 7 8 design has a minimum of moving parts for fewer service points and
simpler maintenance.
The suspension in the chassis is made up of maintenance-free ele-
ments. The rear suspension is designed with a leading knee which is
used to indicate too low load on the steering axle, a so-called mechan-
ical overload system, see section 8 Control system, group 8.2.1 Over-
load System.
001446
1. Wheel hub
2. Wheel spindle
3. Link arm
4. Steering axle
5. Front mounting
7. Rear mounting
8. Counterweight
Steering axle cradle, changing

page
–
DANGER
Steering axle and machine are very heavy.
Risk of crushing!
It is not permissible to go enter a machine which has

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

section B Safety.
5 Remove the counterweights on the rear of the machine.
NOTE
Mark the locations of the counterweights so that they can be
reinstalled in the same location. This is important for the ma-
chine’s stability.

6 6 Wheel suspension – 6.2.1 Steering axle cradle
6 Connect the lifting equipment to the rear section of the machine.

7 Tension the lifting equipment, do not lift so much that the wheels
are off the ground.
8 Support the machine’s rear section.
9 Disconnect the wiring from the overload sensor (applies only to
machines with mechanical overload system).
10 Detach the hydraulic hoses from the steering cylinder.
NOTE
11 Remove the pins holding the steering axle.
12 Lift the machine up so that the frame is lifted away from the axle.
13 Lift out the steering axle.
CAUTION
The steering axle may start to roll.
Crushing injury!
Make sure that the steering axle does not roll away
uncontrollably.
14 Adjust the support so that the machine is secured in the new

position.
15 Lift the steering axle into place under the frame.
16 Remove the support under the frame.
17 Lower the rear section of the machine.
18 Fit the pins at the steering axle mountings.
19 Connect the hydraulic hoses to the steering cylinder.
NOTE
Check that the O-rings are intact and that they are installed
correctly.
20 Connect the wiring to the overload sensor (applies only to ma-
chines with mechanical overload system).
21 Remove the lifting equipment from the machine.
22 Install the counterweights.
NOTE
Make sure that all counterweights are reinstalled and that
they are installed in the exact same location as before. The
machine’s stability is affected if the counterweights are
changed.

6 Wheel suspension – 6.2.2 Wheel spindle 7
6.2.2 Wheel spindle

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

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

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

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

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

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

1
13 Press out the old bearing bushings. Note how the old bearing
bushings are installed so that the new ones can be positioned the
same way with the gap in the same place.
14 Clean the surfaces in the steering axle.
15 Press in the new bearing bushings. Make sure that the gap is in
the same location as before.
NOTE
The upper bearing bushing must protrude (4.5-4.8 mm) so
that it is level with the thrust bearing’s wear washer.
004517
1. Wear washer thrust bearing

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

Brush grease on the spindle bolt and press it into place.
NOTE
Check that the spindle bolt is turned so that the holes for the
guide bolts align with the holes in the wheel spindle. It is im-
portant that the spindle bolt is in correct position before the
lock bolts are installed. It is not possible to "tighten" the spin-
dle bolt into place.

10 6 Wheel suspension – 6.2.2 Wheel spindle
22 Install the lock bolts and tighten the lock nut. Tighten with 250 Nm
(oiled bolt).
23 Brush grease in the space between the wheel spindle and
steering axle.
24 Install the O-rings.
25 Install the remaining bolts for the thrust bearings’ washers. Install
1
the bolts as shown. Tighten with torque 25 Nm (oiled bolt).
004517
1. Wear washer thrust bearing

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

6 Wheel suspension – 6.2.3 Wheel hub 11
6.2.3 Wheel hub

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

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

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

4 Remove the hub cover.
5 Wipe off grease from hub cover and hub nut. Handle it as envi-
ronmentally hazardous waste.

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

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

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

12 Remove the seal from the hub.

13 Remove the bearings’ outer races from the hub.
Use a drift and press out the bearing races.
14 Clean the hub and line the inside with universal grease "EP2".
15 Fit new outer races in the hub.
Use a drift and press in the bearing races. Never strike 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 Install the inner bearing’s inner race and rollers on the wheel
spindle. Pack the bearing with universal grease "EP2".
18 Fill the empty space in the hub with universal grease "EP2".

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

Pack 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 bear-
ing with oil (SAE 80W/140).
B. Tighten the nut with torque 250 Nm (oiled bolt).
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 Install the lock nut and tighten with at least 250 Nm (oiled bolt)
or then on to engage the lock washer in the closest groove. Lock
the bearing nut and lock nut with the lock washer.

25 Install the bearing cap and fill it with grease.

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

16 6 Wheel suspension – 6.3 Tyres and rims
6.3 Tyres and rims

Tyres and rims, safety
page
–
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.
Deflate the tyre before removal. Otherwise the lock

ring and lock lugs may release and shoot out when
the pressure is changed. With tandem wheels, both
tyres must be deflated!
The air should always be released via the valve. If this

is not possible - drill a hole in the tread to deflate.
Damaged tyres may explode.
Never stand directly in front of the wheel when deflat-

ing or inflating. The lock ring or lock lugs may release
and shoot out when the pressure is changed.
Never fit damaged tyres or rims.
It is prohibited to repair rims with welding.
It is prohibited to operate the machine if one of the

tyres is flat.
Wheels, tyres, and rims are dimensioned and select-

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

6 Wheel suspension – 6.3 Tyres and rims 17
CAUTION
When removing wheels, the wheel nuts should be left
in place after loosening. If the wheel nuts are removed
immediately, the wheel may release from the hub.
When removing drive wheels, make sure that the

wheels are secured in position when the spacer rings
are removed. If the wheels move they may displace
the spacer rings, with crushing injuries as a result.
When fitting drive wheels, ensure that the clamps

clamp straight on the spacer ring.
Wheel nuts should be check-tightened after 4-5 oper-

ating hours.
Always follow the tyre manufacturer’s or other ap-

proved instructions when changing tyres.
Never use a steel hammer to install or remove rim

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

ficient 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.

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

dept. with authorization for tyre handling!
The rims must be checked when tyres are changed. See Maintenance
manual DRF 400–450 section 6 Suspension.

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

20 6 Wheel suspension – 6.3.3 Nut, washer and clamp
6.3.3 Nut, washer and clamp

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

6 Wheel suspension – 6.3.3 Nut, washer and clamp 21
Wheel bolt, changing

page
–

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

5 Replace the bolt.

22 6 Wheel suspension – 6.3.3 Nut, washer and clamp

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

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

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

7.5.3 Control valve, attachment ..................................................................... 78
7.5.4 Shuttle valve ......................................................................................... 78
7.5.5 Valve block spreader motor .................................................................. 79
7.5.6 Spreader motor .................................................................................... 79
7.5.7 Spreader chains ................................................................................... 83
7.5.8 Spreader beam ..................................................................................... 91
7.5.9 Main beam attachment ......................................................................... 93
7.5.10 Position sensor, spreading ................................................................... 93
7.5.11 Relief valve, attachment ....................................................................... 93
7.5.12 Pipes and hoses ................................................................................... 93
7.5.13 Buzzer, automatic spread 20'-40' ......................................................... 94
7.6 Rotation ..................................................................................................... 95
7.6.1 Hydraulic oil pump ................................................................................ 98
7.6.3 Control valve, attachment ..................................................................... 99
7.6.4 Shuttle valve ......................................................................................... 99
7.6.5 Valve block rotation motor .................................................................. 100
7.6.6 Rotation motor unit ............................................................................. 101
7.6.7 Rotation yoke ..................................................................................... 104
7.6.8 Ring gear ............................................................................................ 107
7.6.9 Side shift frame .................................................................................. 108
7.6.10 Sensor rotation stop ........................................................................... 109
7.6.11 Relief valve, attachment ..................................................................... 109
7.6.12 Pipes and hoses ................................................................................. 109
7.7 Tilt ........................................................................................................... 110
7.7.1 Hydraulic oil pump .............................................................................. 115
7.7.2 Valve block top lift hydraulics ............................................................. 115
7.7.3 Damping block tilt ............................................................................... 116
7.7.4 Lock valve tilt ...................................................................................... 118
7.7.5 Control valve, attachment ................................................................... 119
7.7.6 Shuttle valve ....................................................................................... 119
7.7.7 Tilt cylinder ......................................................................................... 120
7.7.8 Lift boom ............................................................................................. 120
7.7.9 Rotation yoke ..................................................................................... 120
7.7.10 Relief valve, attachment ..................................................................... 120
7.7.11 Pipes and hoses ................................................................................. 120
7.8 Levelling .................................................................................................. 121
7.8.1 Hydraulic oil pump .............................................................................. 125
7.8.2 Valve block top lift hydraulics ............................................................. 125
7.8.3 Control valve, attachment ................................................................... 126
7.8.4 Shuttle valve ....................................................................................... 127
7.8.5 Overcentre valve levelling .................................................................. 127
7.8.6 Valve block levelling cylinders ............................................................ 127
7.8.7 Levelling cylinders .............................................................................. 128
7.8.8 Side shift frame .................................................................................. 128

7 Load handling 3
7.8.9 Relief valve, attachment .................................................................... 128

7.8.10 Pipes and hoses ................................................................................ 128
7.9 Load carrier ............................................................................................ 129
7.9.1 Twistlocks .......................................................................................... 129
7.9.2 Lift jacks ............................................................................................. 143
7.10 Other functions ....................................................................................... 171
7.10.1 Support jacks ..................................................................................... 171
7.10.2 Weight indicator ................................................................................. 180
7.10.3 Container counter .............................................................................. 186
7.10.4 Synchronised lift ................................................................................ 191

4 7 Load handling

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

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

9. Sensor support jacks up
2. Sensor rotation 6. Sensor spreader 10. Sensor support jacks 14. Sensor knee
stop down
3. Sensor, alignment 7. Sensor damping 11. Sensor lift jacks
15. Sensor lowered cab
end-position
4. Sensor steering wheel 8. Sensor, steering axle 12. Sensor, alignment
16. Sensor overheight-jacks up
movement

6 7 Load handling

2 Check that the sensor in question is free of damage and dirt.
3 Check that the distance between the position sensor and indica-
tor is 41 mm. Adjust if necessary.
008209
IMPORTANT
It is very important that the bolt head on the steering
axle sensor is lined up directly opposite the centre of
Adjusting position sensor - indicator the sensor and that the bolt head is turned so that the
edge is parallel with the top of the sensor.

7 Load handling – 7.1 Controls and instruments 7

7.1.1 Control lever
Control lever, description
page
–
The control lever (S815) is used to control the boom and attachment.
The lever sends voltage signals to the cab control unit (D790-1).
1 2 The control lever has three or four potentiometer-controlled functions
3
and six on/off functions.
4
Lift and lower
5 Lift/lower is controlled by moving the control lever forward (lower
7 boom) or backward (lift boom). See Lifting/lowering, function descrip-
6 tion page 11.
8 section 8 Control system, group 8.4.8.1 BOOM, menu 1.
Extension
Extension is controlled by moving the control lever right (boom out) or
000442
left (boom in). See Extension, function description (Rexroth) page 37.
1. Tilt lock (S815-T3.1) section 8 Control system, group 8.4.8.1 BOOM, menu 1.
2. Levelling lock (S815-T3.2)
3. Rotation (S815-P3) Sideshift or spreading
4. Sideshift right (S815-T1.2) When switch (position 4) is pressed down sideshift right is activated,
5. Sideshift left (S815-T1.1) and when switch (position 5) is pressed down sideshift left is activated.
6. Opening of twistlocks (S815-T2) at full contact See Side shift, function description page 56.
7. Tilt (S815-P4) If the pistol trigger (position 8) is pressed in at the same time as side-
shift right (position 4), spreading out is activated. If the pistol trigger
8. Pistol trigger(S815-T4): Activates weighing ,
(position 8) is pressed in at the same time as sideshift left (position 5),
changes function of sideshift to spreading out
spreading in is activated. See Spreading, function description
(S815-T1.2) and spreading in (S815-T1.1) as well as
page 71.
lift to synchro-lift
section 8 Control system, group 8.4.9.2 ATTACH, menu 2.
Rotation
When the potentiometer (position 3) is pressed down on the left side
rotation clockwise is activated, and when the right side is pressed
down rotation counter-clockwise is activated. See Rotation, function
description page 95.
Opening twistlocks
When the switch (position 6) is activated, the twistlocks are opened if
the conditions for this are fulfilled. See Twistlocks, function description
page 129.

8 7 Load handling – 7.1.1 Control lever
As an option the machine can be equipped with sensors on the

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

tilt out is activated. When the bottom edge is pressed down, tilt in is
activated. See Tilt control, function description page 113.
Tilt lock
When the switch (position 1) is pressed down, the tilt lock is activated.
The light in the switch remains lit while the lock is active. See Tilt lock,
function description page 111.
Levelling
When the rotation potentiometer (position 3) is pressed down on the

left side at the same time as the pistol trigger (position 8) is pressed in
then levelling right is activated. When the right side is pressed down at
the same time as the pistol trigger is pressed in, levelling left is activat-
ed. See Hydraulic levelling, function description page 121.
Levelling lock
When the switch (position 2) is pressed down, the levelling lock is ac-
tivated. The indicator light in the switch remains lit while the lock is ac-
tive. See Levelling lock, function description page 124.

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

equipped with a weight indicator. See Weight indicator, description
page 180.
The pistol trigger also changes the function of other buttons on the
control lever.
If sideshift is activated at the same time as the pistol trigger is pressed
in, spreading is activated. See Spreading, function description
page 71.
If lift is activated at the same time as the pistol trigger is pressed

in, synchronised lift is activated if the machine is equipped with this op-
tion. See Synchronized lift, function description page 191.
7.1.2 Switch lock twistlocks

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

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

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

Switch, automatic spreader, description
page
–
Switch (S1012) for automatic spreader activates automatic spreader.

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

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

Switch, stop at 30' or 35', description
page
–
Switch, stop at 30' or 35' (S1004) activates 30 and 35 feet stop.

When the switch is pressed the function for spreading is changed from
20'–40' to stop at 30'.
35
30- The switch is supplied with power by and sends a voltage signal to the
cab control unit (D790-1).
000447

7 Load handling – 7.2 Lift and lower 11
7.2 Lift and lower

Lifting/lowering, function description
page
–

Control breaker Disengaged Section 11 Common electrics,
group 11.5.1.4 Emergency stop switch voltage
Twistlocks Locked or unlocked, not intermediate position Twistlocks, description page 136
Overload system Boom up: passive Section 8 Control system, ,group 8.2.1 Overload
Boom down: passive or bypass activated system
Alignment Boom down: no alignment Twistlocks, function description page 129
Bypassed or boom height lower than height Section 8 Control system, group 8.2.4 Height
Height limitation
limitation. limitation
D1
1
2, 4 5 24 D23
D790-1 D794 D791-1
D797-F D797-R
3 13, 18 D22
D18
D3
D17
6 6 D13 14 19
11 C10 22 23
12
PSS PSL
10 PP C-M Pa 16, 21
A1 VA
C-
P B1 T
C+
LS D
8 Pa
7 C+M
17
C9 15, 20
9
010492

12 7 Load handling – 7.2 Lift and lower

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

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

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

7 Load handling – 7.2 Lift and lower 13

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

Sensor, hydraulic pressure lift cylinder, der, description page 32
UB768-L1/2 = 0 V
piston side left (B768-L1) sends a voltage D17: Diagnostic menu, see
UB768-L1/5 = 0.5-4.5 V
signal proportional to the oil pressure to section 8 Control system,
Control unit, frame front (D797-F). Regeneration is activated group 8.4.10.3 OP, menu 3
when the pressure in the lift
NOTE cylinders is 8.5 MPa. Regen-
eration is stopped if the pres-
Regeneration is not possible near
sure reaches 18.5 MPa.
end-position or in case of overload.
18 Control unit, frame front (D797-F) acti- U = 24 V Section 11 Common electrics, group
vates Solenoid valve, regeneration right 11.5.3.2 Control unit, frame front
(Y6051) and Solenoid valve, regeneration D18: Diagnostic menu, see
left (Y6052) if the pressure is sufficiently section 8 Control system,
low for regeneration. group 8.4.8.3 BOOM, menu 3
19 Servo valve, regeneration pressurises the - Valve block lift cylinder, description
regeneration valve. page 23
20 The regeneration valve changes position - Valve block lift cylinder, description
and leads oil from the rod side of the lift page 23
cylinder to the piston side.

14 7 Load handling – 7.2 Lift and lower

21 Lift speed increases. - -
22 Damping Checked by control system, Section 8 Control system,

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

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

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

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

page
–
DANGER
The lowering speed must match. If lowering speed is
too high there is a risk of rollover.
The machine must absolutely not be operated before

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

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

with variable displacement.

16 7 Load handling – 7.2.2 Servo filter
7.2.2 Servo filter

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

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

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

2. Pressure check connection servo pressure
3. Pressure feed from servo filter
4. Return to tank
5. Servo pressure to control valve
6. Adjusting screw servo pressure
7. Pressure reducer

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

page
–
NOTE
section B Safety.
1 Operate and warm up the machine so that the hydraulic oil is at

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

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

the symbols are the same.

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

en the lock nut and turn the adjusting screw.
NOTE
If the servo pressure is too high, a load handling function
must be activated so that servo pressure is used from the
accumulator for a reduction on the adjusting screw to be
seen on the pressure gauge. Sometimes the engine has to
be turned off between the checks.
Clockwise: reduce pressure.
Anticlockwise: increase pressure.
measuring outlet.
7.2.4 Accumulator servo circuit

Accumulator servo circuit, description
page
–
The accumulator stores pressurised oil and ensures that there is servo
pressure for activating control valve functions. The accumulator is lo-
cated on the pressure reducer to the right on the lifting beam in the en-
gine compartment.
The accumulator is a diaphragm type and is divided into two spaces
by a diaphragm. One side of the diaphragm is pressurised with nitro-
gen gas. The other side is pressurised by hydraulic oil which com-
presses the nitrogen gas.
At the top on the accumulator there is a connection for checking gas
pressure and filling gas.
001095
Accumulator servo circuit, changing

page
–
NOTE
section B Safety.
section B Safety.

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

4 Change accumulator.
NOTE
CAUTION

010475

the engine.

20 7 Load handling – 7.2.5 Control valve lift, lower, and extension
CAUTION
Do not overfill!

7.2.5 Control valve lift, lower, and

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

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

2. Servo valve, boom in (Y6007) The lift slide controls the direction and flow of the oil to the lift cylinder.
3. Servo valve, lower (Y6004)
4. Servo valve, lift (Y6005) Servo valve, lift
5. Connection, rod side, right lift cylinder (B2) The lift servo valve controls servo pressure to the lift slide so that it
6. Connection, piston side, right lift cylinder (A1) controls oil pressure for lifting. The valve is controlled electrically with
7. Connection, feed from hydraulic oil pumps (P) the lift solenoid valve (Y6005), which is activated by Control unit, frame
8. Connection, rod side, extension cylinder (B1) front (D797-F).
9. Connection, piston side, extension cylinder (A1)
The signals can be checked via the diagnostic menu. See
section 8 Control system, group 8.4.8.4 BOOM, menu 4.

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

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

page
–
(model year 2009-)

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

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

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

page
–
DANGER

After changing Control valve lift, lower, and extension, or parts of the
valve, lowering speed must be checked. See Lowering speed, check-
ing page 15.
7.2.6 Shuttle valve

page
–

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

Valve block lift cylinder, description
page
–
Valve block lift cylinder directs oil to the lift cylinder and is mounted di-
1
rectly on the lower part of the lift cylinder. The valve block contains
2 blocking valve, regeneration valve, non-return valve, and shock valve.
3 Blocking valve
The blocking valve prevents unwanted lowering and angling of the lift
4 cylinders. The blocking valve holds the load by ensuring that the con-
nection to the lift cylinder’s piston side is closed. (The pressure passes
5
through a restriction as blocking pressure and holds the valve slide
6 closed.)
9 Servo valve blocking acts on the blocking valve. The servo valve is
7 controlled electrically with Solenoid valve, blocking left (Y6002) and
Solenoid valve, blocking right (Y6001), which are activated by Control
8
unit, frame front (D797-F).
Regeneration valve
The regeneration valve directs oil from the rod side of the cylinder back
to the piston side. This allows the oil to be re-used during lifting. For
more information on regeneration, see Lifting/lowering, function de-
000473
scription page 11. The regeneration valve is controlled by the regen-

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

24 7 Load handling – 7.2.7 Valve block lift cylinder
Valve block lift cylinder, changing

page
–
NOTE
section B Safety.
section B Safety.
4 Mark and disconnect the cable harness from the valve block.
5 Remove the cable harness’s clamping at the valve block.
6 Mark up and detach the hydraulic hoses from the valve block.
NOTE

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

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

marking.
NOTE
position.

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

marking.
12 Clamp the cable harness as before.
NOTE
CAUTION

010475

the engine.

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

cavitation.
17 Check for leaks.

CAUTION
Do not overfill!

19 Check the lowering speed, see Lowering speed, checking

page 15.
7.2.8 Lift cylinder

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

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

page
–
DANGER
A lift cylinder weighs approx. 2 tonnes.
Extreme danger!
Use wooden blocks as protection between the cab

and lift cylinder when the lift cylinder is lowered or lift-
ed. Secure the lift cylinders with tensioning straps be-
tween them.
DANGER
The boom may move when the pins are removed.
Risk of personal injury!
Make sure that the pins are relieved of weight bearing.

Stand to the side of the boom mounting so that
the boom mounting protects you in case of any
movement.
DANGER
The boom may drop.
Be certain to compensate for the lift cylinder’s sup-

port of the boom by lifting the boom’s leading edge
with the lifting equipment.
1 Move the cab into the front position.

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

7 Mark up and disconnect the hydraulic hoses from the lift cylinder.
8 Connect the lifting equipment to the lift cylinder.
9 Remove the upper pin for the lift cylinder.

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

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

NOTE
CAUTION

010475

the engine.

21 Carefully activate the lift function.
CAUTION
product damage.

cavitation.
22 Check for leaks.

CAUTION
Do not overfill!

24 Check the lowering speed, see Lowering speed, checking

page 15.

page
–

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

cylinder
Sensor hydraulic pressure lift cylinder, description
page
–
Sensor, hydraulic pressure lift cylinder measures the pressure in the

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

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

page
–
NOTE
section B Safety.
section B Safety.
3 Disconnect the cable harness from the sensor for hydraulic pres-
sure lift cylinder.
4 Remove the sensor for hydraulic pressure lift cylinder.
NOTE
5 Install the new sensor.

7 Load handling – 7.2.9 Sensor hydraulic pressure lift cylinder 33
NOTE
position.
6 Connect the cable harness to the sensor for hydraulic pressure.
7 Clamp the cable harness as before.
NOTE
CAUTION

010475

the engine.

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

cavitation.
12 Check that the hydraulic connections of the valve block seal tight
and lift/lower works correctly.
CAUTION
Do not overfill!

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

7 Load handling – 7.2.10 Lift boom 35
7.2.10 Lift boom

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

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

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

page
–

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

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

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

7 Load handling – 7.3 Extension 37
7.3 Extension
Extension, function description (Rexroth)
page
–

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

38 7 Load handling – 7.3 Extension

1 The control lever (S815-P2) sends the Boom in: Control lever, description page 7
cab control unit (D790-1) a voltage sig- US815/P2 = 0.5-2.0 V D1: Diagnostic menu, see
nal proportional to lever movement. section 8 Control system,
Zero position:
US815/P2 = 2.0-3.0 V group 8.4.8.1 BOOM, menu 1
Boom out:
US815/P2 = 3.0-4.5 V
0.5 V is the fastest retraction

speed and 4.5 V is the exten-
sion lift speed. Lower voltag-
es than 0.5 V and higher
voltages than 4.5 V are used
to detect malfunctions in ca-
bling and controls.
2 Control unit, cab (D790-1) transmits the Checked by control system, Section 11 Common electrics,
request for Boom out or Boom in with error shown with error code. group 11.5.3.1 Control unit, cab
the speed information on the CAN-bus.
3 Control unit, frame front (D797-F) acti- I = 380–650 mA Control valve lift, lower, and extension
vates Servo valve, boom out (Y6006) or page 20
Servo valve, boom in (Y6007). D3: Diagnostic menu, see
For retraction of the boom, Control unit, section 8 Control system, group
frame rear (D797-R) activates Solenoid 8.4.8.6 BOOM, menu 6, 8.4.8.7 BOOM,
valve, pump unloading (Y6062). menu 7, and 8.4.8.2 BOOM, menu 2
4 Control unit, cab (D790-1) transmits a Checked by control system, Section 11 Common electrics,
request for increased engine speed on error shown with error code. group 11.5.3.1 Control unit, cab
the CAN bus.
5 Control unit, engine (D794) increases Checked by control system, Section 11 Common electrics,
the engine speed. error shown with error code. group 11.5.3.10 Control unit, engine
6 Servo valve, boom out (Y6006) or Servo - Control valve lift, lower, and extension
valve, boom in (Y6007) pressurises the page 20
control valve’s extension slide with ser- D6: Diagnostic menu, see section 8
vo pressure. Control system, group 8.4.8.6 BOOM,
menu 6 and 8.4.8.7 BOOM, menu 7
7 The control valve’s extension slide - Control valve lift, lower, and extension
changes position and pressurises valve page 20
block extension cylinder and sends a
load signal to the hydraulic oil pumps.
8 When the boom is retracted the valve - Valve block, pump relief, description (hy-
block, pump relief load signal drains two draulic oil pump alternative Dana/
of the hydraulic oil pumps to the tank so Rexroth) page 51
that only one pump generates pressure.
9 The shuttle valve sends on the strongest - Section 10 Common hydraulics,

load signal if several functions are acti- group 10.5.3 Shuttle valve
vated at the same time.


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

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

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


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

tion page 47
24 Damping - Section 8 Control system,

When the extension is about 0.4 m from group 8.2.1.6 Sensor, boom length
the end-position damping is activated. Mechanical overload system:
Mechanical overload system: D24: Diagnostic menu, see
Sensor, boom length (B769-3 or B769- section 8 Control system,
4) sends a voltage signal to Control unit, group 8.4.10.1 OP, menu 1,
frame rear (D797-R) which sends damp-
ing on the CAN-bus.
Mechanical overload system with ana-
logue position sensors or Electronic
Mechanical overload system with ana- overload system:
logue position sensors or Electronic D24: Diagnostic menu, see
overload system: section 8 Control system, group
Sensor, boom length (B777) sends a 8.4.10.4 OP, menu 4 and 8.4.10.6 OP,
voltage signal proportional to the boom menu 6
extension to Control unit, frame rear
(D797-R) which sends damping on the
CAN-bus.

Extension, function description (Sauer-Danfoss)

page
–

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


1 The control lever (S815-P2) sends Boom in: US815/P2 = 0.5-2.0 V Control lever, description page 7
the cab control unit (D790-1) a volt- D1: Diagnostic menu, see section 8 Control
Zero position:
age signal proportional to lever system, group 8.4.8.1 BOOM, menu 1
US815/P2 = 2.0-3.0 V
movement.
Boom out:
US815/P2 = 3.0-4.5 V
0.5 V is the fastest retraction

speed and 4.5 V is the exten-
sion lift speed. Lower voltag-
es than 0.5 V and higher
voltages than 4.5 V are used
to detect malfunctions in ca-
bling and controls.
the request for Boom out or Boom in error shown with error code. group 11.5.3.1 Control unit, cab
with the speed information on the
CAN-bus.
3 Control unit, frame front (D797-F) ac- I = 380–650 mA Control valve lift, lower, and extension
tivates Servo valve, boom out page 20
(Y6006) or Servo valve, boom in D3: Diagnostic menu, see section 8 Control
(Y6007). system, group 8.4.8.6 BOOM, menu 6,
For retraction of the boom, Control 8.4.8.7 BOOM, menu 7, and
unit, frame rear (D797-R) activates 8.4.8.2 BOOM, menu 2
Solenoid valve, pump unloading
(Y6062).
4 Control unit, cab (D790-1) transmits a Checked by control system, Section 11 Common electrics,
request for increased engine speed error shown with error code. group 11.5.3.1 Control unit, cab
on the CAN bus.
5 Control unit, engine (D794) increases Checked by control system, Section 11 Common electrics,
the engine speed. error shown with error code. group 11.5.3.10 Control unit, engine
6 Servo valve, boom out (Y6006) or - Control valve lift, lower, and extension
Servo valve, boom in (Y6007) pressu- page 20
rises the control valve’s extension D6: Diagnostic menu, see section 8 Control
slide with servo pressure. system, group 8.4.8.6 BOOM, menu 6 and
7 The control valve’s extension slide - Control valve lift, lower, and extension
changes position and pressurises page 20
valve block extension cylinder and
sends a load signal to the hydraulic oil
pumps.
8 When the boom is retracted the valve - Valve block pump unloading, description
block, pump relief load signal drains (hydraulic oil pump alternative Dana/Sau-
one of the hydraulic oil pumps to the er-Danfoss + ZF/Rexroth) page 52
tank so that only one pump generates
pressure.


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

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

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

44 7 Load handling – 7.3.1 Hydraulic oil pump

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

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

When the extension is about 0.4 m group 8.2.1.6 Sensor, boom length
from the end-position damping is Mechanical overload system:
activated. D24: Diagnostic menu, see Workshop
Mechanical overload system: manual section 8 Control system,
Sensor, boom length (B769-3 or group 8.4.10.1 OP, menu 1
B769-4) sends a voltage signal to
Control unit, frame rear (D797-R)
which sends damping on the Mechanical overload system with analogue
CAN-bus. position sensors or Electronic overload
system:
Mechanical overload system with an- trol system, group 8.4.10.4 OP, menu 4
alogue position sensors or Electronic and 8.4.10.6 OP, menu 6
overload system:
Sensor, boom length (B777) sends a
voltage signal proportional to the
boom extension to Control unit, frame
rear (D797-R) which sends damping
on the CAN-bus.

page
–

7.3.2 Servo filter

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

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

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

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

page
–
(model year -2008)

The control valve has two sections: one for the lift function and one for
9 boom extension. The sections have many similarities but are de-
scribed separately for each function.
8 For general information on the control valve, see Control valve lift, low-
er, and extension page 20.
7 1
Extension slide
6 2
The extension slide controls direction (in or out) and oil flow to valve
5 block extension cylinder.
3
Servo valve, boom out
4 Servo valve boom out, controls servo pressure to the extension slide
so that it controls oil pressure for extension.
Servo valve boom out is controlled electrically with Solenoid valve,
boom out (Y6006) which is activated by Control unit, frame front
(D797-F).
000529
Servo valve, boom in

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

46 7 Load handling – 7.3.6 Shuttle valve

page
–
(model year 2009-)

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

6 5
Servo valve boom out, controls servo pressure to the extension slide
so that it controls oil pressure for extension.
Servo valve boom out is controlled electrically with Solenoid valve,
boom out (Y6006) which is activated by Control unit, frame front
(D797-F).
010490

1. Connection, rod side, extension cylinder (B1) section 8 Control system, group 8.4.8.7 BOOM, menu 7.
2. Servo valve, boom out (Y6006)
Servo valve, boom in
3. Servo valve, lift (Y6005)
4. Connection, rod side, right lift cylinder (B2) Servo valve boom in, controls servo pressure to the extension slide so
5. Connection, piston side, right lift cylinder (A2) that it controls oil pressure for boom retraction.
6. Servo valve, lower (Y6004) Servo valve boom in is controlled electrically with Solenoid valve,
7. Servo valve, boom in (Y6007) boom in (Y6007) which is activated by Control unit, frame front
8. Connection, feed from hydraulic oil pumps (P) (D797-F).
Shock valve, extension

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

page
–

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

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

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

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

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

page
–
NOTE
section B Safety.
Removing
2 Run out the boom until the inspection holes in the side of the in-
ner boom become accessible.
3 Depressurise the brake and hydraulic system, see
section B Safety.
4 Remove the lock rings and press out the pin for the front cylinder
mounting in the inner boom.
5 Machine with analogue sensor boom length.

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

7 Load handling – 7.3.8 Extension cylinder 49
Installing
14 Clean and lubricate all bearing surfaces with grease.
15 Measure how far the old extension cylinder is extended and ex-
tend the new cylinder to the same length.
NOTE
If this is not done, then the front cylinder mounting will not
reach far enough.
16 Lift the extension cylinder into place.
CAUTION
Use the dual lifting devices to achieve balance during
lifting. The front should be positioned behind the sup-
port at the front edge of the cylinder so that it can be
slid into the boom.
17 Install the pin at the front cylinder mounting in the inner boom.
NOTE
Lubricate the pin with grease before installing.
18 Install the locks on the pin.
19 Install the pins at the rear cylinder mountings.
NOTE
Lubricate the pin with grease before installing.
20 Install the locks on the pins.
21 Install the valve block on the extension cylinder.
NOTE
22 Connect the hydraulic hoses and the cable harness to the exten-
sion cylinder.
23 Machine with analogue sensor boom length.

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

50 7 Load handling – 7.3.8 Extension cylinder
NOTE
CAUTION

010475

the engine.

CAUTION
Do not overfill!

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

page
–

7 Load handling – 7.3.9 Valve block pump unloading 51
7.3.9 Valve block pump unloading

Valve block, pump relief, description (hydraulic oil
page
–
pump alternative Dana/Rexroth)

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

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

52 7 Load handling – 7.3.9 Valve block pump unloading
Valve block pump unloading, description

page
–
(hydraulic oil pump alternative Dana/Sauer-Danfoss

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

pressure(Y6003)
4. Tank drain
9. Tank drain

7 Load handling – 7.3.10 Lift boom 53
7.3.10 Lift boom

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

page
–
NOTE
When adjusting the side-mounted slide plates, it is important to
check the clearance for the whole travel of the boom and that the
inner boom is centred in the outer boom.
Front slide plates
1 Position the boom to the lowest position with the inner boom ex-
tended approx. 50 cm.
2 Remove the cover plate for the side-mounted slide plates and re-
move the spacer plates and slide plate.
4 Check the clearance between the boom and slide plate, the clear-
ance should be 1 mm, adjust with spacer plates as required.
NOTE
1. Side-mounted slide plates The inner boom must be centred in the outer boom.
2. Lower slide plates 5 Remove the lock bolts and the slide plates’ brackets, and pull out
the upper slide plates and the spacer plates.
6 Unload the lower slide plates, lift the inner boom at the front edge
and use wooden spacers.
WARNING
Risk of crushing!
Secure the inner boom in relation to the outer boom

with wooden blocks.
7 Remove the lock bolts, slide plates’ brackets and pull out the low-
er slide plates.
8 Transfer the nuts for the lock bolts for the lower slide plates to the
new slide plates.
9 Install the new lower slide plates, lock bolts, and brackets.
10 Remove the wooden blocks and let down the inner boom so that
it rests on the lower slide plates.
11 Transfer the nuts for the lock bolts for the upper slide plates to the
new slide plates.
12 Install the new slide plates, spacer plates, lock bolts, and
brackets.

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

Measuring points, levelling, attachment is straight.
Rear slide plates
18 Start the engine and run in the boom completely (fully retracted).
19 Remove the cover plate for the side-mounted slide plates and re-
move the spacer plates and slide plate.
21 Check the clearance between the boom and slide plate, the clear-
ance should be 1 mm, adjust with spacer plates as required.
22 Unload the lower slide plates, use wooden spacers.
WARNING
1. Upper slide plates
2. Side-mounted slide plates
3. Lower slide plates Risk of crushing!

with wooden blocks.
23 Remove the cover plates, spacer plates, and the lower slide
plates.
24 Install new slide plates, spacer plates and cover plate.
25 Unload the upper slide plates, use wooden spacers.
WARNING
Risk of crushing!

with wooden blocks.

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

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

page
–

56 7 Load handling – 7.4 Side shift
7.4 Side shift

Side shift, function description
page
–
Condition Reference Reference

value
Control breaker Disengaged Section 11 Common electrics, group 11.5.1.4 Emergency stop switch voltage
1
D1
2
D790-1
D797-R D791-1
3 7 D7
D3 8
C6
P1 A
10
9
4
T1 B
5
C6
6
006407
1 The control lever (S815-T1.1) sends a Left: US815-T1.1 = 24 V Control lever, description page 7
voltage signal to the Cab control unit D1: Diagnostic menu, see section 8 Control
Right: US815-T1.2 = 24 V
(D790-1). system, group 8.4.9.2 ATTACH, menu 2
2 Control unit, cab (D790-1) transmits Checked by control sys- Section 11 Common electrics,
side shift left or right on the CAN bus. tem, error shown with er- group 11.5.3.1 Control unit, cab
ror code.
3 Control unit, frame rear (D797-R) acti- U = 24 V Section 11 Common electrics,

vates Solenoid valve, engagement of group 11.5.3.3 Control unit frame rear
hydraulics for top lift (Y6003). D3: Diagnostic menu, see section 8 Control
4 Solenoid valve, engagement of hy- - Valve block, top lift hydraulics, description
draulics for top lift (Y6003) opens and page 58
pressurises valve block, lift cylinder D3: Diagnostic menu, see section 8 Control
and sends a load signal to hydraulic oil system, group 8.4.5.6 HYD, menu 6
pump 2.


5 The shuttle valve sends on the strong- - Section 10 Common hydraulics,
est load signal if several hydraulic oil group 10.5.3 Shuttle valve
pumps are activated at the same time.
6 Hydraulic oil pump 2 pumps oil from See the pressure plate on Section 10 Common hydraulics, group 10.4.2
the hydraulic oil tank. the left-hand frame beam. Axial piston pump with variable displacement
7 The attachment control unit (D791-1) U = 24 V Section 11 Common electrics,

activates the servo valve sideshift left group 11.5.3.5 Control unit, attachment
(Y6020) or the servo valve sideshift D7: Diagnostic menu, see section 8 Control
right (Y6021). system, group 8.4.9.8 ATTACH, menu 8
8 The servo valve sideshift left (Y6020) - Attachment control valve, description
or the servo valve sideshift right page 59
(Y6021) pressurises the side shift D7: Diagnostic menu, see section 8 Control
spool in the attachment control valve. system, group 8.4.9.8 ATTACH, menu 8
9 The control valve’s side shift slide - Attachment control valve, description
changes position and pressurises the page 59
side shift cylinders.
10 The sideshift cylinders push in the - Side shift cylinder, description page 64
main beam sideways in relation to the
sideshift frame.
Hydraulic diagram top lift

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

page
–


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

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

1. Solenoid valve connection hydraulic
pressure(Y6003)
4. Tank drain
9. Tank drain

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

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

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

attachment.
The attachment control valve controls hydraulic functions on the at-
tachment. The control valve is located in the middle on the back of the
attachment. Electric servo valves control flow from the valve.

60 7 Load handling – 7.4.3 Control valve, attachment

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

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

Servo valve sideshift left controls pressure to the sideshift slide so that
the sideshift slide opens and pressurises the sideshift cylinder.
Servo valve sideshift left (Y6020) is controlled electrically with sole-
noid valve sideshift left and is activated by the attachment control unit
(D791-1). The servo valve triggers servo pressure to the sideshift slide
in proportion to the control current to the solenoid valve.
Servo valve, side shift right

Servo valve sideshift right controls pressure to the sideshift slide so
that the sideshift slide opens and pressurises the sideshift cylinder.
Servo valve sideshift is controlled electrically by solenoid valve side-
shift right (Y6021) and is activated by the attachment control unit
(D791-1). The servo valve triggers servo pressure to the sideshift slide
in proportion to the control current to the solenoid valve.

Control valve attachment, changing

page
–
NOTE
section B Safety.
section B Safety.
NOTE
4 Mark and disconnect the cable harness from the control valve.
6 Transfer the connection adapters to the new control valve.
NOTE
NOTE
Transfer one adapter at a time so that the marking is not
mixed up.
7 Mark up the servo valves on the new control valve.
8 Fit the valve.
Lift the valve into place and install the attaching bolts.
marking.
10 Connect the hydraulic hoses to the control valve in according to
the marking.
NOTE

NOTE
CAUTION

010475

the engine.

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

cavitation.
CAUTION


7 Load handling – 7.4.4 Shuttle valve 63
Control valve attachment, checking hydraulic

page
–
pressure
NOTE
section B Safety.
1 Operate and warm up the machine so that the hydraulic oil is at

operating temperature, at least 50 C. As an alternative, operate
until the cooling fan is activated.
˚C 2 Machine in service position, see section B Safety.
˚C
000475
3 Connect a pressure gauge to pressure check connection PL on
control valve attachment.
4 Start the engine and let it idle. Check the pressures in the attach-
ment’s different functions by letting each function go to its end-
position, then read off the pressure gauge.
Function Pressure
Side shift 16.0 MPa
Spreading (positioning) 12.0 MPa
Rotation 15.0 MPa

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

page
–

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

Side shift cylinder, description
page
–
The sideshift cylinders are two inter-connected hydraulic cylinders

1 which extend the attachment’s main beam laterally in relation to the
sideshift frame. The sideshift cylinders are located along the front and
10 rear of the attachment and are used to centre the load’s centre of
gravity.
9
8 2
3
4 001500
7 6 5
1. frame
2. Sideshift cylinder
3. Position sensor, spreading
4. Sensor alignment
5. Twistlock
6. Twistlock sensor
7. Lock cylinder, twistlocks
8. Spreader boom
9. Spreader motor
10. Main beam, attachment

page
–

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

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

2. Ring gear
The sideshift frame is located in the rotation yoke with four hydrau-
3. Rotation motor unit
lic cylinders which mean that the levelling can be controlled for ad-
4. Rotation yoke
aptation to angled containers. Sideshift 800 mm. Se Side shift
5. Control valve attachment
frame, description page 128.
6. Sideshift frame

66 7 Load handling – 7.4.6 Side shift frame
Slide plates, sideshift frame, changing

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

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

7 Load handling – 7.4.6 Side shift frame 67
9 Install the cover plate.

10 Repeat steps 7-10 on the other slide plates.
Lubrication
004875
Slide surfaces, attachment
11 Lubricate the slide surfaces on the attachment with white lubricat-
ing paste.
12 Operate full sideshift from right to left approx. 10 times.
slide surfaces.

Lower slide plates, sideshift frame, changing

page
–
1 Position axle stands or similar under the attachment’s spreader

booms and lower the attachment on the stands so that the side-
shift frame’s lower slide plates are exposed.
DANGER
Risk of crushing!
Place spacers between the cross member and the at-

tachment’s main boom on both cross members.
3 Remove the attaching bolts and remove the slide plates.

4 Install new slide plates.
5 Remove the spacer.
7 Lift the attachment and remove the stands.
Lubrication
The figure shows loose cross member
004875
Slide plates, attachment

ing paste.
9 Operate full sideshift from right to left approx. 10 times.
slide surfaces.

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

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

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

70 7 Load handling – 7.4.9 Pipes and hoses

page
–

7 Load handling – 7.5 Spreading (positioning) 71
7.5 Spreading (positioning)

Spreading, function description
page
–

Twistlocks Unlocked or bypass Twistlocks, description page 136

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

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

72 7 Load handling – 7.5 Spreading (positioning)

4 Solenoid valve, engagement of hydrau- - Valve block, top lift hydraulics, description
lics for top lift (Y6003) opens and sends page 58
a load signal to the hydraulic oil pumps. D3: Diagnostic menu, see section 8 Control
5 The shuttle valve forwards the strongest - Section 10 Common hydraulics,

load signal to the hydraulic oil pumps if group 10.5.3 Shuttle valve
several functions are activated
simultaneously.
6 Hydraulic oil pump 2 pumps oil from the See the pressure plate on Section 10 Common hydraulics, group
hydraulic oil tank. the left-hand frame beam. 10.4.2 Axial piston pump with variable
displacement
7 Control unit, attachment (D791-1) acti- I = 350–600 mA Section 11 Common electrics, group
vates Servo valve, spreading out 11.5.3.5 Control unit, attachment
(Y6018) or Servo valve, spreading in D7: Diagnostic menu, see section 8 Control
(Y6019). system, group 8.4.9.13 ATTACH, menu 13
and 8.4.9.14 ATTACH, menu 14
8 Servo valve, spreading out (Y6018) or - Attachment control valve, description

Servo valve, spreading in (Y6019) pres- page 59
surises the spreader slide in the attach- D7: Diagnostic menu, see section 8 Control
ment’s control valve. system, group 8.4.9.13 ATTACH, menu 13
9 The control valve’s spreader slide - Attachment control valve, description

changes position and direct pressure to page 59
the spreader motor.
10 The motor valve block directs the pres- - Valve block spreader motor, description
sure to the motor and prevents the motor page 79
from pumping (rotating faster than sup-
plied pressure).
11 The motor drives the chains that extend - Spreader motor, description page 79
or retract the spreader beams.
12 The sensor for end position 20'-40' Sensor directly opposite Position sensor spreading, description
(B769) sends a voltage signal to the at- indicator plate: U > 24 V page 93
tachment control unit (D791-1). D12: Diagnostic menu, see section 8 Con-
trol system, group 8.4.9.5 ATTACH, menu 5
13 Control unit, attachment (D791-1) reduc- - Section 11 Common electrics, group

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


14 Servo valve, spreading out (Y6018) or - Attachment control valve, description
Servo valve, spreading in (Y6019) re- page 78
duces the pressure to the spreader slide D7: Diagnostic menu, see section 8 Control
in the attachment’s control valve. system, group 8.4.9.13 ATTACH, menu 13
15 The control valve’s spreader slide - Attachment control valve, description

changes position and reduces the pres- page 78
sure to the spreader motor.
16 The speed of the spreader motor is re- - Spreader motor, description page 79
duced.

levelling

Spreading 30' stop, function description

page
–

Twistlocks Unlocked or bypass Twistlocks, description page 136

activated Section 8 Control system, group 8.2.2 Bypass
2
1
D2
30-35
D1 3
D790-1
D791-1 D5 D7
6, 8
D8
5 7
006409
1 The switch for stop at 30'-35' (S1004) Switch in on position: Switch, stop at 30' or 35', description
sends a voltage signal to the cab control Conn. 1: U = 0 V page 10
unit (D790-1). D1: Diagnostic menu, see section 8 Control
Conn. 5: U = 24 V
system, group 8.4.9.2 ATTACH, menu 2
Switch in off position:
Conn. 1: U = 24 V
Conn. 5: U = 24 V
2 The control lever (S815-T1.2 and Spreading: Control lever, description page 7
S815-T4) sends a voltage signal to the US815-T4 = 24 V D2: Diagnostic menu, see section 8 Control
cab control unit (D790-1). system, group 8.4.9.2 ATTACH, menu 2
Out: US815-T1.2 = 24 V
In: US815-T1.1 = 24V
3 Control unit, cab (D790-1) sends Checked by control sys- Section 11 Common electrics,
spreading 30’ on the CAN bus. tem, error shown with error group 11.5.3.1 Control unit, cab
code.
4 Spreading is activated in the same way - Spreading, function description page 71

as the normal spreading steps 3–11.


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

dampens the speed in the same way as
in normal spreading, steps 13-16.
7 When spreading is in the 30' position, Sensor directly opposite Position sensor spreading, description
the 20'-40' end-position sensor (Y769) indicator plate: U = 24 V page 93
sends voltage signal. D7: Diagnostic menu, see section 8 Control
8 Spreading is interrupted by the attach- U=0V Attachment control valve, description

ment control unit (D791-1) cutting the page 78
current to the servo valve for spreading D8: Diagnostic menu, see section 8 Control
out (Y6018) or spreading in (Y6019). system, group 8.4.9.13 ATTACH, menu 13

levelling

Automatic spreading 20-40 foot, function

page
–
description

Control breaker Not activated Section 11 Common electrics, group 11.5.1.4 Emergency stop switch voltage
Twistlocks Unlocked or bypass Twistlocks, function description page 129

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

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


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

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

tive, the KID control unit (D795) ac- group 11.5.3.12 Control unit, KID
tivates the Automatic Spreading
event menu.
10. When spreading is at the 20', 30', or Sensor directly opposite Position sensor spreading, description page 93
40’ mark, the sensor for end-posi- indicator plate: U = 24 V D10: Diagnostic menu, see section 8 Control
tion 20'-40' (B769) sends a voltage system, group 8.4.9.5 ATTACH, menu 5
(D791-1).
11. Control unit, attachment (D791-1) I = 0 mA Attachment control valve, description page 78
cuts the control current to Servo D4: Diagnostic menu, see section 8 Control sys-
valve, spreading out (Y6018) or tem, group 8.4.9.13 ATTACH, menu 13 and
Servo valve, spreading in (Y6019). 8.4.9.14 ATTACH, menu 14

levelling


page
–


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

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

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

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

Servo valve spreading in controls the pressure to the spreader slide so
that it opens and pressurises the spreader motor.
The servo valve is controlled is controlled electrically with solenoid
valve spreader in (Y6019) and is activated by the attachment control
unit (D791-1). The servo valve triggers servo pressure to the spreader
Control valve attachment, replacement

page
–
See Control valve attachment, changing page 61.
7.5.4 Shuttle valve

page
–

7 Load handling – 7.5.5 Valve block spreader motor 79
7.5.5 Valve block spreader motor

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

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

80 7 Load handling – 7.5.6 Spreader motor
Spreader motor, changing

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

7 Load handling – 7.5.6 Spreader motor 81
10 Mark up and disconnect the hydraulic hoses from the valve block
for the spreader motor.
11 Remove the spreader motor unit.
12 Transfer the valve block to the new motor unit.
NOTE
13 Clean the contact surfaces between the planetary gear and the
attachment’s main beam.
14 Install the motor unit. Tighten the bolts crosswise in steps with in-
creasing torque to 117 Nm.
15 Connect the hydraulic hoses to the valve block on the motor.

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

the chain runs straight in the sprocket on the hydraulic motor.
17 Tension the spreader chain to the same extent as before.
19 Check that the hydraulic connections are sealed tightly.
20 Check that spreading works.
21 Install the protective plate over the motor.
22 Brush grease on the spreader chain.
23 Install the cover plates on the attachment’s main beam.
NOTE
CAUTION

010475

the engine.
CAUTION
Do not overfill!


7 Load handling – 7.5.7 Spreader chains 83
7.5.7 Spreader chains

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

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

extension beams must be checked so that the chain mountings
are not damaged. See Maintenance manual, section7 Load han-
dling, group 7.5.8 Spreader beam.
20-foot position
2 Start the engine, run spreading in to the 20-foot position and turn
off the engine.
3 Check that both spreader beams run against the 20-foot stop and
that the distance between the spreader beam and the spreader
motor mounting is at least 3 mm.
4 Check the C-C measurement between the twistlocks.
C-C 20 feet: 58533 mm.
If the 20-foot setting is correct proceed to step 8.

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

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

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

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

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

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

16
If the machine is equipped with a 30 or 35 foot stop: start the en-
gine, run out spreading to the 30 or 35 foot position, turn off the
engine and check the C-C measurement between the twistlocks.
C-C 30 feet: 8918 3 mm
C-C 35 feet: 10488 3 mm
IMPORTANT
Check the distance at stop from both 20' and 40'.
17 Brush grease on the spreader chain.

Spreader chain, changing

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

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

5 Loosen the chain tensioner of the defective chain and remove the
chain from the tensioner.
NOTE
Measure and note the chain tensioners’ length to attain the
correct chain tension when reinstalling.
005105
6 Remove the chain wheel for the defective chain.
NOTE
Note position of the spacer ring.
If the chain wheel on the engine side must be removed, first re-
move the spreader motor. See Spreader motor, changing
page 80.
7 Pull the chain out through the hole for the chain wheel so that the
chain runs along the spreader beam.
8 Temporarily fasten the chain along the cable rack to prevent the
chain from being pinched.

9 Pull out the spreader beam.

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

11 Remove the hydraulic hoses’ clamping on the attachment’s main
beam.
12 Disconnect the cable rack from the attachment’s main beam.

Support the cable rack so that it is not damaged.
13 Pull out the spreader beam until the chain mounting becomes
accessible.
14 Disconnect the chain from the spreader beam and cable rack.
15 Connect the new chain to the spreader beam.

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

installed.
19 Install the extension stop.
20 Connect the cable rack to the attachment’s main beam.
21 Install the hydraulic hoses’ clamping on the attachment’s main
beam.
22 Slide in the spreader beam until it is extended the same amount
as the other one. This facilitates installation of the chains.
23 Disconnect the chain from the cable rack and insert it through the
chain wheel’s hole.
24 Install the sprocket. The spacer ring should be located on the un-
derside of the sprocket.
If the rotation motor has been removed, reinstall it. See Spreader
motor, changing page 80.
NOTE
Check that the chain runs straight in the chain wheels.

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

27 Tension the spreader chain to the same extent as before. Tighten
the lock nut.
28 If the slide plates have been removed, reinstall them.
30 Check that spreading works correctly.
31 Turn off engine.
32 Check chains’ tension. See Spreader chains, checking page 83.

7 Load handling – 7.5.8 Spreader beam 91
7.5.8 Spreader beam

Spreader beam, description
page
–
The spreader beams are the part of the attachment that grips the con-
1 tainer. Two spreader beams run along the main beam. The spreader
beams are extended and retracted with the spreader motor and
10 spreader chains.
The spreader beam houses twistlocks. See Twistlocks, description
9
page 136.
8 2
3
4
001500
7 6 5
1. frame
4. Sensor alignment
5. Twistlock
6. Twistlock sensor
8. Spreader boom
9. Spreader motor
Slide plates extension beam, changing

page
–

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


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

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

6 Place the new slide plate in the correct position.
Check the clearance between the extension beam and the
slide plate. Clearance should be max. 1 mm with all slide plates
installed.
Use a spacer plate to adjust the clearance.
7 Install the slide plate’s bracket and guide bolt.
Lubrication
004875

ing paste.
9 Run out spreading in and out fully approx. 10 times and check the
spreading function.
slide surfaces.
11 Try to lift a container and then check the extension beams’ clear-
ance again on the attachment’s main beam.

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

page
–
See Main beam attachment, description page 69.
7.5.10 Position sensor, spreading

Position sensor spreading, description
page
–
The spreading position sensors indicate the position of the spreader

1 2 3 4 5
beams. The position sensors are used to control spreading so that the
twistlocks fit the container. The position sensors are located on the top
of the protective plate on the left side of the attachment’s main beam.
The sensor for end-position (B769) indicate the end-position for a
20-foot and 40-foot container. The sensor detects the end-positions of
the spreader beams through two indicator plates on the top of the
spreader beam. The sensor is used to activate damping.
With the 30-foot stop option, one extra sensor are mounted, sensor
position (B779), along with two additional indicator plates. The sensor
is used to activate the 30-foot stop.
The sensors are supplied power by and send as 24 V signal to the at-
tachment control unit (D791-1) when the indicator plates pass the sen-
sor. Indicator plates on the spreader units are mounted so that the
sensors generate a signal when the spreader unit passes the sensor.
The indicator plates and the position of the sensors are designed so
that the distance between the spreaders becomes 20' (30') and 40'.
003165
1. Indicator plate 20'

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

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

page
–
See Relief valve attachment, description page 69.

page
–

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

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

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

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

D1
1
2
D790-1
D797-R D791-1
3 7
D8
D4
8
C6
P1 A
11, 12
4 T1 B
9 10
C6 5
006410
1 The control lever (S815-P3) sends Counter-clockwise: Section 9 Frame, body, cab and accesso-
the cab control unit (D790-1) a volt- US815/P3 = 0.5-2.0 V ries, group 9.1 Controls and instruments
age signal proportional to lever D1: Diagnostic menu, see section 8 Control
Zero position:
movement. system, group 8.4.9.1 ATTACH, menu 1
US815/P3 = 2.0-3.0 V
Clockwise:
US815/P3 = 3.0-4.5 V
0.5 V and 4.5 V, respectively,

is the highest rotation speed.
Lower voltage than 0.5 V and
higher voltages than 4.5 V
are used to detect malfunc-
tions in cabling and controls.

96 7 Load handling – 7.6 Rotation

clockwise rotation or anticlockwise error shown with error code. group 11.5.3.1 Control unit, cab
rotation on the CAN-bus.
3 Control unit, frame rear (D797-R) U = 24 V Section 11 Common electrics,
activates Solenoid valve, engage- group 11.5.3.3 Control unit frame rear
ment of hydraulics for top lift D4: Diagnostic menu, see section 8 Control
(Y6003). system, group 8.4.5.6 HYD, menu 6
4 Solenoid valve, engagement of hy- - Valve block, top lift hydraulics, description
draulics for top lift (Y6003) opens page 58
and pressurises valve block, lift cyl- D4: Diagnostic menu, see section 8 Control
inder and sends a load signal to the system, group 8.4.5.6 HYD, menu 6
hydraulic oil pumps.
5 The shuttle valve forwards the - Section 10 Common hydraulics,
strongest load signal to hydraulic oil group 10.5.3 Shuttle valve
pump 2 if several functions are acti-
vated simultaneously.
6 Hydraulic oil pump 2 pumps oil from See the pressure plate on the Section 10 Common hydraulics,
the hydraulic oil tank. left-hand frame beam. group 10.4.2 Axial piston pump with
variable displacement
7 Control unit, attachment (D791-1) I = 435–650 mA Section 11 Common electrics,
activates Servo valve, rotation group 11.5.3.5 Control unit, attachment
clockwise or Servo valve, rotation D8: Diagnostic menu, see section 8 Control
counter-clockwise. system, group 8.4.9.11 ATTACH, menu 11
8 Servo valve, rotation clockwise - Attachment control valve, description
(Y6008), or Servo valve, rotation page 99
counter-clockwise (Y6009), pressu- D8: Diagnostic menu, see section 8 Control
rises the rotation slide in the attach- system, group 8.4.9.11 ATTACH, menu 11
ment control valve. and 8.4.9.12 ATTACH, menu 12
9 The rotation slide in Control valve, - Attachment control valve, description
attachment changes position and page 99
controls the pressure to the Valve
block hydraulic motor.
10 Valve block hydraulic motor con- - Valve block rotation motor, description
trols the pressure to both motors. page 100
11 The hydraulic motors’ disc brakes - Rotation motor unit, description page 101
are disengaged.
12 The hydraulic motors rotate the at- - Rotation motor unit, description page 101
tachment.

levelling

7 Load handling – 7.6 Rotation 97
Rotation stop, function description

page
–
Rotation stop is used to avoid rotating the attachment into the boom in
the raised position.

1 D1
2
3 7
D2 D790-1 D795
D791-1 D5
6
D6
006411
5

1 Switch, rotation stop (S1014) Switch in on position: Section 9 Frame, body, cab and accessories,
sends a voltage signal to Control US1014/1 = 0 V group 9.1 Controls and instruments
unit, cab (D790-1). D1: Diagnostic menu, see section 8 Control
US1014/5 U = 24 V
US1014/1 = 24 V
US1014/5 U = 24 V
2 The control lever (S815-P3) Counter-clockwise: Section 9 Frame, body, cab and accessories,
sends the cab control unit US815/P3 = 0.5-2.0 V group 9.1 Controls and instruments
(D790-1) a voltage signal propor- D2: Diagnostic menu, see section 8 Control
Zero position:
tional to lever movement. system, group 8.4.9.1 ATTACH, menu 1
US815/P3 = 2.0-3.0 V
Clockwise:
US815/P3 = 3.0-4.5 V
0.5 V is the slowest rotation

speed and 4.5 V is the fastest
rotation speed. Lower voltage
than 0.5 V and higher voltages
than 4.5 V are used to detect
malfunctions in cabling and
controls.


3 Control unit, cab (D790-1) trans- Checked by control system, er- Section 11 Common electrics,
mits clockwise rotation to stop or ror shown with error code. group 11.5.3.1 Control unit, cab
counter-clockwise rotation to
stop on the CAN-bus.
4 Rotation is activated in the same - Rotation, function description page 95

way as the normal rotation steps
3–12.
5 Sensor rotation stop (B7225) Sensor directly opposite indica- Sensor rotation stop, description page 109
sends voltage signal to attach- tor plate: U = 24 V D5: Diagnostic menu, see section 8 Control
ment control unit (D791-1). system, group 8.4.9.21 ATTACH, menu 21
6 The rotation is stopped by the at- - Attachment control valve, description

tachment control unit (D791-1) page 99
cutting the current to the servo D6: Diagnostic menu, see section 8 Control
valve, rotation clockwise (Y6008) system, group 8.4.9.11 ATTACH, menu 11
or servo valve, rotation and 8.4.9.12 ATTACH, menu 12
counter-clockwise (Y6009).
7 When the rotation stop has been - Section 11 Common electrics,

achieved the KID control unit group 11.5.3.12 Control unit, KID
(D795) activates the event menu
for rotation stop.

levelling

page
–


page
–


page
–
Rotation is controlled by a separate section in the attachment’s control

valve. For a more detailed description of the valve and component po-
sitions, see Attachment control valve, description page 59.
Rotation slide
The valve slide controls the direction and speed of rotation. The valve
slide is controlled by servo valve, rotation clockwise and servo valve,
rotation counter-clockwise.
Servo valve, rotation clockwise

Servo valve, rotation clockwise controls pressure to the rotation slide
so that the rotation slide opens and pressurises the rotation motors.
Servo valve, rotation clockwise is controlled electrically by solenoid
valve, rotation clockwise (Y6008), which is activated by the attach-
ment control unit (D791-1). The servo valve directs servo pressure to
the rotation slide in proportion to the control current to the solenoid
valve.
Servo valve, spreading counter-clockwise

Servo valve, rotation counter-clockwise controls pressure to the rota-
tion slide so that the rotation slide opens and pressurises the rotation
motors.
Servo valve, rotation counter-clockwise is controlled electrically by so-
lenoid valve, rotation counter-clockwise (Y6009), which is activated by
the attachment control unit (D791-1). The servo valve directs servo
pressure to the rotation slide in proportion to the control current to the
solenoid valve.

page
–
7.6.4 Shuttle valve

page
–

100 7 Load handling – 7.6.5 Valve block rotation motor
7.6.5 Valve block rotation motor

Valve block rotation motor, description
page
–
Valve block, rotation motor controls pressure to the rotation motors.

The valve block is located on one of the rotation motors.
The valve block provides a controlled rotation by preventing the load
from pulling away and provides faster rotation than that provided by
the hydraulic motor. The valve block contains shuttle valve and over-
centre valves.
1
1
2
2
3 3
4 4
6 5
7
000530
1. Hydraulic motor rotation

2.Disc brake
3.Planetary gear
4.Gear
5.Rotation yoke
6.Ring gear
7.Sideshift frame

7 Load handling – 7.6.6 Rotation motor unit 101
7.6.6 Rotation motor unit

Rotation motor unit, description
page
–
The rotation motors rotate the attachment in relation to the boom. The
motors are located along the front pf the attachment’s rotation yoke.
The motors work against the ring gear between the rotation yoke and
the side shift frame. The rotation motor unit consists of hydraulic
motor, disc brake and planetary gear which are built together into
one unit.
The hydraulic motor is located on the disc brake housing. There is a
gear between the motor and the discs.
The disc brake prevents accidental rotation. The disc brake is applied
1 with springs and is disengaged when the hydraulic pressure is built up
1
to rotate the yoke.
2
2 The planetary gear amplifies the output in the motor and disc brake.
3 The planetary gear reduces the motor speed so that motor power is
3
greater.
4 4
6 5
7
000530

2.Disc brake
3.Planetary gear
4.Gear
5.Rotation yoke
6.Ring gear
7.Sideshift frame

102 7 Load handling – 7.6.6 Rotation motor unit
Rotation motor unit, changing

page
–
NOTE
section B Safety.
section B Safety.
3 Mark up and disconnect the hydraulic hoses from motor.
NOTE
4 Remove the hydraulic motor’s attaching bolts.
5 Lift away the rotation motor unit. Position the motor unit so that
the pinion and planetary gear are not damaged.
6 Clean the contact surfaces on the motor unit and rotation yoke.
7 Lift the new motor unit into place.
8 Install the motor unit. Tighten the bolts crosswise in steps with in-
creasing torque to 117 Nm.

7 Load handling – 7.6.6 Rotation motor unit 103
9 Connect the hydraulic hoses to the motor and brake according to

the marking.
NOTE
NOTE
CAUTION

010475

the engine.

13 Check that the hydraulic connections are sealed tightly.
14 Check that the rotation works.

104 7 Load handling – 7.6.7 Rotation yoke
CAUTION
Do not overfill!

7.6.7 Rotation yoke

Rotation yoke, description
page
–
The rotation yoke is a part of the attachment which connects the at-
1 2 3 4 5 6 tachment to the boom. The rotation yoke is secured on the inner boom
with two shafts which run in bearing equipped attaching lugs. In the
bottom of the rotation yoke is the ring gear with through-bolts.
Using the rotation motors, which act on the ring gear, the remaining
parts of the attachment can be rotated in relation to the lift boom.
The rotation yoke’s mounting in the lift boom facilitates longitudinal
motion (so-called tilt). The oscillating motion is dampened by two hy-
draulic cylinders which are secured between the upper yoke and the
upper edge on the inner boom.
000526
1. Main beam
2. Ring gear
4. Rotation yoke
6. Sideshift frame

7 Load handling – 7.6.7 Rotation yoke 105
Rotation yoke, changing

page
–
1 Clean the attachment and boom nose.

2 Disconnect the attachment from the boom.
3 Remove the rotation motors from the rotation yoke.
4 Install the lifting equipment on the rotation yoke.
5 Remove the pipes for ring gear lubrication.
The illustration shows removed rotation yoke and

ring gear.
6 Remove the rotation yoke’s attaching bolts.
7 Lift away the rotation yoke.
8 Clean the contact surfaces on the ring gear.
9 Remove the plastic plugs and clean the threads and holes on
the new rotation yoke, clean the contact surface against the
ring gear.
10 Transfer parts to the new rotation yoke.
• Grease cups
• Mounting pins
11 Transfer the lifting equipment to the new rotation yoke.
12 Lift the new rotation yoke into place.
NOTE
Align the position against that of the ring gear so that the lu-
brication lines can be installed.
13 Brush the rotation yoke’s mounting pins with grease and install
them in the rotation yoke.

106 7 Load handling – 7.6.7 Rotation yoke
14 Tighten the rotation yoke’s attaching bolts to a torque of 331 Nm.
15 Install the pipes for the ring gear’s lubrication lines.

16 Lubricate the ring gear with grease.
Rotate the yoke during lubrication it so that the grease is distrib-
uted evenly.
17 Rotate the yoke so that it is aligned straight.
18 Install the rotation motors, see Rotation yoke, description
page 104.
NOTE
If necessary, rotate the rotation yoke slightly so that the ro-
tation motor’s gear wheel aligns against the ring gear.
19 Connect the attachment to the boom.
20 Start the motor and check that the rotation works.
21 Clean the attachment.
oil level should be at the top of the level glass. Top up as needed.
CAUTION
Do not overfill!


7 Load handling – 7.6.8 Ring gear 107
7.6.8 Ring gear

Ring gear, description
page
–
The ring gear is the joint between the rotation yoke and the sideshift
frame. The ring gear consists of gear, bearings, and mounting parts.
The unit is bolted to the rotation yoke and sideshift frame.
1
1
2
2
3 3
4 4
6 5
7
000530

2.Disc brake
3.Planetary gear
4.Gear
5.Rotation yoke
6.Ring gear
7.Sideshift frame

Ring gear, changing

page
–
1 Remove the rotation yoke, see Rotation yoke, changing

page 105.
2 Remove the lubricating pipes from the ring gear.
NOTE
Note the locations of the lubricating pipes to facilitate rein-
stalling.
The illustration shows removed rotation yoke and 3 Remove the attaching bolts between the ring gear and the side-
ring gear. shift frame.
4 Lift away the ring gear.
5 Clean the contact surfaces on the sideshift frame and ring gear.
6 Lift the new ring gear into place.
NOTE
Rotate it so that the connections for the lubricating pipes are
in the same positions as before.
7 Lubricate the inner attaching bolts with grease and install them.
Tighten the bolts crosswise in turns to a torque of 331 Nm.
8 Install the rotation yoke, see Rotation yoke, changing page 105.
9 Install the lubricating pipes for the ring gear.
10 Lubricate the ring gear with grease.
11 Start the motor and check the function of the rotation.
The illustration shows removed rotation yoke and

ring gear.
oil level should be at the top of the level glass. Top up as needed.
CAUTION
Do not overfill!


page
–
See Side shift frame, description page 65.

7 Load handling – 7.6.10 Sensor rotation stop 109
7.6.10 Sensor rotation stop

Sensor rotation stop, description
page
–
Sensor rotation stop (B7225) indicates when rotation is 25 from the
centre position and is used to activate rotation stop. The sensor is lo-
cated on a bracket on the left side of the rotation yoke and detects 25
towards the rotation yoke’s mechanical stop.
The sensors are supplied with power by and send a 24 V signal to
Control unit, attachment (D791-1) when the ’flares’ pass the sensor.

page
–

page
–

page
–

110 7 Load handling – 7.7 Tilt
7.7 Tilt
Tilt damping, function description
page
–
2
C1-
A C2+
C
B C1+
C2- 3
1
000461
1 Hydraulic oil pump 2 pumps oil. See the pressure plate Section 10 Common hydraulics,
on the left-hand frame group 10.4.2 Axial piston pump with varia-
beam. ble displacement
2 The tilt damping block distributes oil to the - Damping block tilt, description page 116
tilt cylinders.
3 The tilt cylinders dampen the attachment’s - Tilt cylinder, description page 120
movements.

7 Load handling – 7.7 Tilt 111
Tilt lock, function description

page
–
1 D1
2
D790-1
D797-R D791-1
3 7
D3 8 D7
C1-
A C2+
10
4
B C1+
C2-
5 9
C6
6
006412
1 The control lever (S815-T3.1) sends a US815/T3.1 = 24 V Section 9 Frame, body, cab and accessories,
voltage signal to the Cab control unit group 9.1 Controls and instruments
(D790-1). D1: Diagnostic menu, see section 8 Control
2 Control unit, cab (D790-1) sends tilt lock Checked by control sys- Section 11 Common electrics,
on the CAN-bus. tem, error shown with group 11.5.3.1 Control unit, cab
error code.
3 Control unit, frame rear (D797-R) acti- U = 24 V Valve block, top lift hydraulics, description
vates Solenoid valve, engagement of page 58
lics for top lift (Y6003) opens and pres- page 58
surises valve block, lift cylinder and D3: Diagnostic menu, see section 8 Control
sends a load signal to the hydraulic oil system, group 8.4.5.6 HYD, menu 6
pumps.

load signal if several hydraulic oil pumps group 10.5.3 Shuttle valve
are activated at the same time.


6 Hydraulic oil pump 2 pumps oil from the See the pressure plate Section 10 Common hydraulics, group 10.4.2
hydraulic oil tank. on the left-hand frame Axial piston pump with variable displacement
beam.
7 The attachment control unit (D791-1) ac- Float mode: U = 24 V Section 11 Common electrics,
tivates the Servo valve, tilt lock (Y6012). Lock position: U = 0 V group 11.5.3.5 Control unit, attachment
8 Servo valve, tilt lock (Y6012) pressuris- - Lock valve tilt, description page 118
es the lock valve in the attachment’s D7: Diagnostic menu, see section 8 Control
control valve. system, group 8.4.9.15 ATTACH, menu 15
9 The lock valve changes position and - Lock valve tilt, description page 118
blocks the connections to the tilt
cylinders.
10 The tilt cylinders lock the attachment’s - Tilt cylinder, description page 120
inclination.
11 When tilt lock is activated, the KID con- - Section 11 Common electrics,
trol unit (D795) shows the tilt lock event group 11.5.3.12 Control unit, KID
menu.
When tilt lock is activated, the machine’s
speed is limited to max. 5 km/h.

levelling

7 Load handling – 7.7 Tilt 113
Tilt control, function description

page
–

D1
1
2
D790-1
D797-F D791-2 D791-1

3 7 10
D7
D3
8 11 D10
C6
C1-
P1 A A C2+
13
4
T1 B B C1+
C2-
C6 9 12
5
6
013027
1 The control lever (S815-P4) sends Tilt out: US815/P4 = 0.5-2.0 V Section 9 Frame, body, cab and accessories,
the cab control unit (D790-1) a group 9.1 Controls and instruments
Zero position:
voltage signal proportional to lever D1: Diagnostic menu, see section 8 Control
US815/P4 = 2.0-3.0 V
movement. system, group 8.4.9.1 ATTACH, menu 1
Tilt in: US815/P4 = 3.0-4.5 V
2 The cab control unit (D790-1) Checked by control system, Section 11 Common electrics,
transmits tilt in or tilt out on the error shown with error code. group 11.5.3.1 Control unit, cab
CAN bus.
3 Control unit, frame rear (D797-R) U = 24 V Section 11 Common electrics,

activates Solenoid valve, engage- group 11.5.3.3 Control unit frame rear
ment of hydraulics for top lift D3: Diagnostic menu, see section 8 Control
(Y6003). system, group 8.4.5.6 HYD, menu 6


4 Solenoid valve, engagement of - Valve block, top lift hydraulics, description
hydraulics for top lift (Y6003) page 58
opens and pressurises valve D3: Diagnostic menu, see section 8 Control
block, lift cylinder and sends a system, group 8.4.5.6 HYD, menu 6
load signal to the hydraulic oil
pumps.
5 The shuttle valve sends on the - Section 10 Common hydraulics,

strongest load signal if several hy- group 10.5.3 Shuttle valve
draulic oil pumps are activated at
the same time.
6 Hydraulic oil pump 2 pumps oil See the pressure plate on the Section 10 Common hydraulics, group 10.4.2
from the hydraulic oil tank. left-hand frame beam. Axial piston pump with variable displacement
7 The attachment control unit option I = 400–650 mA Section 11 Common electrics, group 11.5.3.6
(D791-2) activates Servo valve, tilt Control unit, attachment option or section 11
out (6010) or Servo valve, tilt in Common electrics, group 11.5.3.8 Control
(Y6011). unit, attachment right jack pair
Machine with lifting jacks
The attachment control unit right and 8.4.9.17 ATTACH, menu 17
jack pair (D791-4) activates Servo
valve, tilt out (6010) or Servo
valve, tilt in (Y6011).
8 The servo valve, tilt out (Y6010) or - Attachment control valve, description
the servo valve, tilt in (Y6011) page 119
pressurises the tilt slide in the at- D7: Diagnostic menu, see section 8 Control
tachment’s control valve. system, group 8.4.9.16 ATTACH, menu 16
9 The control valve’s tilt slide chang- - Attachment control valve, description
es position and pressurises the page 119
damping valve.
10 The attachment control unit Float mode: U = 24 V Section 11 Common electrics,

(D791-1) activates the Servo Lock position: U = 0 V group 11.5.3.5 Control unit, attachment
valve, tilt lock (Y6012). D10: Diagnostic menu, see section 8 Control
11 Servo valve, tilt lock (Y6012) pres- - Lock valve tilt, description page 118
surises the lock valve in the at- D10: Diagnostic menu, see section 8 Control
tachment’s control valve. system, group 8.4.9.15 ATTACH, menu 15
12 The lock valve changes position - Damping block tilt, description page 116
and directs oil crosswise to the tilt
cylinders.
13 The tilt cylinders change the at- - Tilt cylinder, description page 120
tachment’s inclination.


levelling
Tilt damping, adjusting

page
–
NOTE
section B Safety.
NOTE
Tilt damping may need to be adjusted after running-in due to me-
chanical tolerances.
1 The engine running at idle.
2 Raise the boom without a load and check that the attachment is
suspended horizontally throughout the lifting movement.
3 Adjust tilt damping as required by adjusting the screws on the
damping block. Adjust both screws by the same amount.
1 Clockwise: increase damping.
Counter-clockwise: decrease damping.
4 Lift a loaded container, test-drive, and brake, check that the con-
tainer does not swing uncontrollably. If necessary, adjust the
damping according to Step 3.
5 Start the machine and check that the function is working
satisfactorily.
005350
1. Adjusting screws

page
–


page
–

116 7 Load handling – 7.7.3 Damping block tilt
7.7.3 Damping block tilt

Damping block tilt, description
page
–
The damping block contains restrictions which create resistance to the

1
tilt cylinder’s movements, which in turn dampen the attachment’s os-
cillations. The damping block is located on the boom nose.
The damping block is supplied with oil via the return from the attach-
ment’s control valve. The feed means that the cylinders are always
filled with oil. Precisely adjusted restrictions mean that the feed does
2 2
not affect the tilting. The constant feed means that the tilt cylinders do
not need bleeding after work on the tilt.
The damping block contains two shock valves which protect the valve
against pressure shocks.
000535
1. Damping block
2. Tilt cylinder
Damping block tilt, changing

page
–
NOTE
section B Safety.
section B Safety.
3 Mark up and detach the hydraulic hoses from the valve block.
NOTE
4 Remove the valve block from the boom.

7 Load handling – 7.7.3 Damping block tilt 117
5 Transfer the connection adapters to the new valve. Transfer one

adapter at a time so that the marking is not mixed up.
NOTE
6 Install a new valve block on the boom nose.
The illustration shows damping block with

controllable tilt.
7 Connect the hydraulic hoses to the damping block according to
the marking.
NOTE
NOTE
CAUTION

010475

the engine.

118 7 Load handling – 7.7.4 Lock valve tilt
10 Start the machine and check sealing and function.

Check both tilt and attachment functions.
CAUTION
Do not overfill!

7.7.4 Lock valve tilt

Lock valve tilt, description
page
–
On machines with tilt lock, there are two solenoid valves on the damp-
ing block’s return lines. When the solenoid valves are activated the
connection between the cylinders is blocked and locks the tilt position.
The lock valves are located on the damping block.
Solenoid valve tilt (Y6012) is supplied with voltage by Control unit, at-
tachment option (D791-2) when tilt lock is not activated.


page
–
Controllable tilt is controlled by a separate section in the attachment’s

control valve. For a more detailed description of the valve and compo-
nent positions, see Attachment control valve, description page 59.
Tilt slide
The valve slide controls the direction and speed of attachment tilt.
The valve slide is controlled by servo valve, tilt in and servo valve, tilt
out.
Servo valve, tilt out

Servo valve tilt out controls pressure to the tilt slide so that the tilt slide
opens and pressurises the tilt cylinders.
Servo valve tilt out is controlled electrically with solenoid valve tilt out
(Y6010) and is activated by the attachment control unit option (D791-
2). The servo valve triggers servo pressure to the tilt slide in proportion
to the control current to the solenoid valve.
Servo valve, tilt in

Servo valve tilt in controls pressure to the tilt slide so that the tilt slide
opens and pressurises the tilt cylinders.
Servo valve tilt in is controlled electrically with solenoid valve tilt in
(Y6011) and is activated by the attachment control unit option
(D791-2). The servo valve triggers servo pressure to the tilt slide in
proportion to the control current to the solenoid valve.

page
–
7.7.6 Shuttle valve

page
–

120 7 Load handling – 7.7.7 Tilt cylinder
7.7.7 Tilt cylinder

Tilt cylinder, description
page
–
The tilt cylinders are located between the inner boom’s front edge and
1
the rotation yoke’s upper section. The two cylinders are positioned di-
agonally and can therefore effectively dampen or control tilt motion.
The piston rod bracket is welded to the piston rod, which is threaded
in the piston head and locked with a lock bolt. The cylinder head is
threaded in the cylinder barrel.
2 2
000535
1. Damping block
2. Tilt cylinder

page
–
7.7.8 Lift boom

Lift boom, general
page
–
See Lift boom, description page 35.
7.7.9 Rotation yoke

Rotation yoke, general
page
–
See group 7.6.7 Rotation yoke.

page
–

page
–

7 Load handling – 7.8 Levelling 121
7.8 Levelling
Hydraulic levelling, function description
page
–

D1
1
2
+ D790-1
D791-2
D797-R
3 D791-3 7 9
D8
D9
D4
10 8
C6 14
P1 A
4 T1 B
11 12 13
5
C6
006888

1 Control lever (S815-P3) sends a voltage Levelling right: Section 9 Frame, body, cab and accessories,
signal proportional to lever movement US815/P3 = 0.5-2.0 V group 9.1 Controls and instruments
while control lever S815-T4 sends voltage D1: Diagnostic menu, see section 8 Control
Zero position:
to the cab control unit (D790-1). system, group 8.4.9.1 ATTACH, menu 1
US815/P3 = 2.0-3.0 V
Levelling left:
US815/P3 = 3.0-4.5 V
US815/T4 = 24 V
2 Control unit, cab (D790-1) sends levelling Checked by control Section 11 Common electrics,
left or levelling right on the CAN-bus. system, error shown group 11.5.3.1 Control unit, cab
with error code.

122 7 Load handling – 7.8 Levelling

vates Solenoid valve, engagement of hy- group 11.5.3.3 Control unit frame rear
draulics for top lift (Y6003). D4: Diagnostic menu, see section 8 Control
4 Solenoid valve, engagement of hydraulics - Valve block, top lift hydraulics, description
for top lift (Y6003) opens the connection page 58
between the pumps and the attachment’s D4: Diagnostic menu, see section 8 Control
control valve. system, group 8.4.5.6 HYD, menu 6

6 Hydraulic oil pump 2 pumps oil from the See the pressure Section 10 Common hydraulics, group 10.4.2
hydraulic oil tank. plate on the left-hand Axial piston pump with variable displacement
frame beam.
7 Control unit, attachment option (D791-2) U = 24 V Section 11 Common electrics, group 11.5.3.6
or activates Solenoid valve, levelling Control unit, attachment option or section 11
(Y6034). Common electrics, group 11.5.3.7 Control
unit, attachment left jack pair
Machine with combi attachment
Control unit, attachment left jack pair system, group 8.4.9.18 ATTACH, menu 18
(D791-3) activates Solenoid valve,
levelling (Y6034).
8 The levelling solenoid valve opens a con- - Levelling cylinders’ valve block, description
nection to the levelling cylinders in Valve page 127
block levelling cylinders.
9 Control unit, attachment option (D791-2) I = 400–650 mA Section 11 Common electrics, group 11.5.3.6
or control unit attachment, left jack pair Control unit, attachment option or section 11
(D791-3) activates servo valve levelling Common electrics, group 11.5.3.7 Control
right (Y6035) or servo valve levelling left unit, attachment left jack pair
10 The servo valve for levelling right (Y6035) - Attachment control valve, description
or levelling left (Y6036) actuates the level- page 126
ling slide in the attachment control valve. D9: Diagnostic menu, see section 8 Control
11 The control valve’s levelling slide changes - Attachment control valve, description
position and pressurises the levelling page 126
overcentre valve.
12 The overcentre valve opens and directs - Overcentre valve, levelling, description
pressure to the levelling cylinders’ valve page 127
block.

7 Load handling – 7.8 Levelling 123

13 The levelling cylinders’ valve block directs - Levelling cylinders’ valve block, description
pressure on to the levelling cylinders. page 127
14 The levelling cylinders lock the attach- - Levelling cylinders, description page 128
ment’s inclination.

levelling

124 7 Load handling – 7.8 Levelling
Levelling lock, function description

page
–

D1
1 2 10
D790-1 D795
D791-2
D797-F
3 D791-3 7 D8
D4
8
C6
P1 A
9
4 T1 B
5
C6
Pos Explanation Signal description Reference 006889
1 The control lever (S815-T3.1) sends a US815/T3.1 = 24 V Section 9 Frame, body, cab and accessories,
voltage signal to the Cab control unit group 9.1 Controls and instruments
2 Control unit, cab (D790-1) sends level- Checked by control sys- Section 11 Common electrics,
ling lock on the CAN-bus. tem, error shown with group 11.5.3.1 Control unit, cab
error code.
3 Control unit, frame rear (D797-R) acti- U = 24 V Valve block, top lift hydraulics, description
vates Solenoid valve, engagement of page 58


lics for top lift (Y6003) opens the connec- page 58
tion between the pumps and the D4: Diagnostic menu, see section 8 Control
attachment’s control valve. system, group 8.4.5.6 HYD, menu 6

6 The hydraulic oil pumps pump oil from See the pressure plate Section 10 Common hydraulics, group 10.4.2
the hydraulic oil tank. on the left-hand frame Axial piston pump with variable displacement
beam.
7 Control unit, attachment option (D791-2) U=0V Levelling cylinders’ valve block, description
stops activation solenoid valve, levelling page 127
Machine with combi attachment.
Control unit, attachment left jack pair
(D791-3) stops activation solenoid
valve, levelling (Y6034).
8 The levelling control valve (Y6034) - Levelling cylinders’ valve block, description
blocks the connections to the levelling page 127
cylinders in the levelling cylinders’ valve D8: Diagnostic menu, see section 8 Control
block. system, group 8.4.9.18 ATTACH, menu 18
9 The levelling cylinders change the at- - Levelling cylinders, description page 128
tachment’s inclination.
10 When tilt lock is activated, the event - Section 11 Common electrics,

menu shows tilt lock. group 11.5.3.12 Control unit, KID
When levelling lock is activated, the ma-
chine’s speed is limited to max. 5 km/h.

levelling

page
–


page
–


page
–
Hydraulic levelling is controlled by a separate section in the attach-

ment control valve. For a general description of the valve and compo-
nent locations, see Attachment control valve, description page 59.
Levelling slide
The valve slide controls the direction and speed of attachment
levelling.
The valve slide is controlled by the for servo valve levelling right
(Y6035) and servo valve levelling left (Y6034).
Servo valve, levelling right

The servo valve for levelling right controls pressure to the levelling
slide so that it opens and pressurises the levelling cylinders.
Servo valve levelling right is controlled electrically with solenoid valve
levelling right (Y6035) and is activated by the attachment control unit
option (D791-2). The servo valve triggers servo pressure to the tilt
Servo valve, levelling left

The servo valve for levelling left controls pressure to the levelling slide
so that it opens and pressurises the levelling cylinders.
Servo valve levelling left is controlled electrically with solenoid valve
levelling left (Y6036) and is activated by the attachment control unit
option (D791-2). The servo valve triggers servo pressure to the tilt
Passive levelling
The servo valves open a connection to the tank, in addition, hydraulic
oil can flow between right and left side levelling cylinders, from piston
sides to rod sides, according to the inclination.
Active levelling
Levelling is monitored by the sequence valves in the valve block lev-
elling cylinder, which close when the feed pressure is high enough to
set all cylinders in bottom position. Then hydraulic oil is fed to the rod
sides on one side’s cylinders and the side lifts. When levelling, the oth-
er side will thus always be in its lowest position. This always gives
maximal levelling travel.

page
–

7 Load handling – 7.8.4 Shuttle valve 127
7.8.4 Shuttle valve

page
–
7.8.5 Overcentre valve levelling

Overcentre valve, levelling, description
page
–
The overcentre valve ensures that the levelling cylinders are com-
pletely extended. The valve is located to the right of the attachment
control valve on the rear edge of the sideshift frame under the levelling
cylinders’ valve block.
Passive levelling
The overcentre valves allow the flow of hydraulic oil between right and
left levelling cylinders, from piston sides to rod sides, according to the
inclination.
Active levelling
The over-centre valves close when the feed pressure is high enough
to put all levelling cylinders in bottom position. Then, hydraulic oil is
supplied through the levelling cylinder valve block to the rod sides on
one side’s (right or left) cylinders and the side lifts. When levelling, the
other side will thus always be in its lowest position. This always gives
maximal levelling travel.
001062
7.8.6 Valve block levelling cylinders

Levelling cylinders’ valve block, description
page
–
The levelling cylinders’ valve block directs pressure from the attach-
ment control valve to the levelling cylinders. The valve block contains
lock valves that block the levelling when the levelling lock is activated
or if the machine is without power. The valve is located to the right of
the attachment control valve on the rear edge of the sideshift frame
above the overcentre valve for levelling.
Lock valve
The lock valve is opened by Solenoid valve levelling (Y6034). When
the lock valve is closed the oil is blocked to and from the levelling cyl-
inders, and levelling is blocked. Solenoid valve levelling (Y6034) is
supplied with voltage by Control unit, attachment option (D791-2) or
Control unit, attachment right jack pair (D791-4).
001061

128 7 Load handling – 7.8.7 Levelling cylinders
7.8.7 Levelling cylinders

Levelling cylinders, description
page
–
On machines with hydraulic levelling there are four hydraulic cylinders

between the sideshift frame’s parts, see Side shift frame, description
page 128.
001860

page
–

page
–
The sideshift frame is available in two different versions, see Side shift
1 2 3 4
frame, description page 65.
Mechanical levelling
The sideshift frame is larger than the attachment’s main beam. The
main beam can move freely between the slide plates. This allows ap-
prox. 5  levelling.
001932
5 Hydraulic levelling
1. Main beam, attachment The sideshift frame is split in two. There are four levelling cylinders be-
2. Sideshift frame upper section tween the two sections, see Levelling cylinders, description page 128.
3. Levelling cylinder The outer section is secured in the rotation yoke via the ring gear. The
4. Sideshift frame lower section inner part holds the attachment’s main beam. The main beam slides
5. Sideshift cylinder on slide plates. The hydraulic cylinders’ stroke makes levelling of the
main beam possible, approx. 5 . With hydraulically controlled level-
ling, the angle of the main beam attachment can be controlled with the
control lever.

page
–

page
–

7 Load handling – 7.9 Load carrier 129
7.9 Load carrier

7.9.1 Twistlocks
Twistlocks, function description
page
–

Control breaker Disengaged Section 11 Common electrics, group 11.5.1.4 Emergency stop switch
voltage
Alignment Full alignment or by- Section 9 Frame, body, cab and accessories, group 9.1 Controls and
pass activated instruments
Section 8 Control system, group 8.2.2 Bypass
D1
2 1
D18
8 7, 20
5, 21
D790-1 D790-2 D795
D2
D797-R D791-1
4, 6, 13,18, 19
9
D13
D8 D3
14 3
17
C12
D17
P1 A
10 16
T1 B
C12 15
11
12
006890

1 The switch for locking the twistlocks U = 24 V Section 9 Frame, body, cab and accessories,
(S1003) (automatic mode) sends a volt- group 9.1 Controls and instruments
age signal to the cab control unit (D790-1). D1: Diagnostic menu, see section 8 Control

130 7 Load handling – 7.9.1 Twistlocks

2 The control lever (S815-T2) sends a volt- US815/T2 = 24 V Section 9 Frame, body, cab and accessories,
age signal to the cab control unit (D790-1) group 9.1 Controls and instruments
for twistlock opening. D2: Diagnostic menu, see section 8 Control
If Switch, lock twistlocks (S1003) is in system, group 8.4.9.3 ATTACH, menu 3
manual position then no signal is required
from the control lever to open twistlocks.
3 Sensor, alignment left front (7202L), Sen- Sensor directly oppo- Sensor, alignment, description page 139
sor, alignment right front (7202R), Sensor, site indicator plate: D3: Diagnostic menu, see section 8 Control
alignment left rear (Y7203L) and Sensor, U = 24 V system, group 8.4.9.6 ATTACH, menu 6
alignment right rear (Y7203R) send a volt-
age signal to Control unit, attachment
(D791).
4 Control unit, attachment (D791) sends Checked by control Section 11 Common electrics,
alignment on the CAN-bus. system, error shown group 11.5.3.5 Control unit, attachment
with error code.
5 Control unit KID (D795) activates the - Section 11 Common electrics,

event menu for alignment. group 11.5.3.12 Control unit, KID
6 Control unit attachment (D791) activates U = 24 V D18: Diagnostic menu, see section 8 Control
the indicator light for alignment on the system, group 8.4.9.10 ATTACH, menu 10
boom’s light panel.
7 Control unit KID (D790-2) activates the in- - Section 11 Common electrics,
dicator light for alignment on the cab’s group 11.5.3.11 Control unit, KIT
light panel.
8 Control unit, cab (D790-1) transmits "open Checked by control Section 11 Common electrics,
twistlocks" or "lock twistlocks" on the system, error shown group 11.5.3.1 Control unit, cab
CAN bus. with error code.

10 Solenoid valve, engagement of hydraulics - Valve block, top lift hydraulics, description
for top lift (Y6003) opens and pressurises page 58
valve block, lift cylinder and sends a load D8: Diagnostic menu, see section 8 Control
signal to hydraulic oil pump 2. system, group 8.4.5.6 HYD, menu 6

12 Hydraulic oil pump 2 pumps oil from the See the pressure Section 10 Common hydraulics, group 10.4.2
hydraulic oil tank. plate on the left-hand Axial piston pump with variable displacement
frame beam.
13 The attachment control unit (D791) acti- U = 24 V Section 11 Common electrics,

vates servo valve "open twistlocks" group 11.5.3.5 Control unit, attachment
(Y6039) servo valve "lock twistlocks" D12: Diagnostic menu, see section 8 Control
(Y6040). system, group 8.4.9.9 ATTACH, menu 9

7 Load handling – 7.9.1 Twistlocks 131

14 The servo valve "open twistlocks" (Y6039) - Attachment control valve, description
or servo valve "lock twistlocks" (Y6040) page 134
pressurises the twistlock slide with servo D12: Diagnostic menu, see section 8 Control
pressure. system, group 8.4.9.9 ATTACH, menu 9
15 The control valve’s twistlock slide valve - Attachment control valve, description
changes position and pressurises the lock page 134
cylinders.
16 The lock cylinders rotate the twistlocks. - Lock cylinder, description page 135
17 Sensor "unlocked twistlocks" (B7204) or Sensor directly oppo- Sensor, twistlocks, description page 140
Sensor "locked twistlocks" (B7205) sends site indicator plate: D16: Diagnostic menu, see section 8 Control
a signal to Control unit, attachment U = 24 V system, group 8.4.9.7 ATTACH, menu 7
(D791).
18 Control unit, attachment (D791) supplies U = 24 V D18: Diagnostic menu, see section 8 Control
voltage to Indicator light "unlocked twist- system, group 8.4.9.10 ATTACH, menu 10
locks" (H562) or Indicator light "locked
twistlocks" (H563) on the boom’s light
panel.
19 Control unit, attachment (D791) transmits Checked by control Section 11 Common electrics,
"twistlocks unlocked" or "twistlocks system, error shown group 11.5.3.5 Control unit, attachment
locked" on the CAN-bus. with error code.
20 Control unit KIT (D790-2) supplies voltage - Section 11 Common electrics,

to Indicator light "unlocked twistlocks" or group 11.5.3.11 Control unit, KIT
Indicator light "locked twistlocks" on the
cab lamp panel.
21 Control unit KID (D795) activates event - Section 11 Common electrics,

menu twistlocks. group 11.5.3.12 Control unit, KID

levelling

132 7 Load handling – 7.9.1 Twistlocks
Overheight jacks, function description

page
–

Control breaker Not activated Section 11 Common electrics, group 11.5.1.4 Emergency stop switch voltage
Overload system Passive Section 8 Control system, group 8.2.1.1 Mechanical overload system
Twistlocks Open Twistlocks, function description page 129
13
1
2
D790-1
D797-R D791-2 7
3
8 12
D3
C6
P1
A
4 B 11
T1
10
9
C6 5
6
008218

1. The overheight jacks switch (S1031) sends U = 24 V Section 9 Frame, body, cab and accesso-
a voltage signal to the cab control unit ries, group 9.1 Controls and instruments
(D790-1).
2. Control unit cab (D790-1) sends a message Checked by control Section 11 Common electrics,
to lower overheight jacks on the CAN-bus. system, error shown group 11.5.3.1 Control unit, cab
with error code.
3. Control unit, frame rear (D797-R) activates U = 24 V Valve block, top lift hydraulics, description
Solenoid valve, engagement of hydraulics page 58
for top lift (Y6003). D3: Diagnostic menu, see section 8 Con-
trol system, group 8.4.5.6 HYD, menu 6

7 Load handling – 7.9.1.1 Hydraulic oil pump 133

4. Solenoid valve, engagement of hydraulics - Valve block, top lift hydraulics, description
for top lift (Y6003) opens and pressurises page 58
valve block, top lift hydraulics and sends a
load signal to hydraulic oil pump 2.
5. The shuttle valve sends on the strongest - Section 10 Common hydraulics,

load signal to hydraulic oil pump 2 if several group 10.5.3 Shuttle valve
functions are activated at the same time.
6. Hydraulic oil pump 2 pumps oil from the hy- See the pressure plate Section 10 Common hydraulics,
draulic oil tank. on the left-hand frame group 10.4.2 Axial piston pump with varia-
beam. ble displacement
7. Control unit, attachment option (D791-2) ac- U = 24 V Attachment control valve, description
tivates the servo valve overheight jacks up page 134
(Y6070) or servo valve overheight jacks
down (Y6071).
8. Servo valve overheight jacks up (Y6070) or U = 24 V Attachment control valve, description

servo valve overheight jack down (Y6071) page 134
pressurises the overcentre valve for over-
height jacks.
9. Overcentre valve opens and pressurises hy- - Overcentre valve (product alternative
draulic cylinder overheight jacks. Overheight jacks) page 141
10. Hydraulic cylinder overheight jacks lowers - Hydraulic cylinder, overheight jacks
the overheight jacks. page 141
11. Sensor overheight jacks up left (B7231-L) or Sensor directly oppo- Sensor, overheight-jacks page 142
sensor overheight jacks up right (B7231-R) site indicator plate:
sends a voltage signal to Control unit, at- U = 24 V
tachment option (D791-2).
12. Control unit, attachment option (D791-2) ac- Overheight jacks up: Section 11 Common electrics,
tivates the indicator light for overheight jacks U = 24 V group 11.5.3.6 Control attachment option
up (H5001). Overheight jacks
down: U = 0 V
13 Indicator light, overheight jacks up (H5001) Overheight jacks up: Section 9 Frame, body, cab and accesso-
illuminates when the jacks are completely U = 24 V ries, group 9.1 Controls and instruments
raised. Overheight jacks
down: U = 0 V
7.9.1.1 Hydraulic oil pump

page
–

7.9.1.2 Valve block top lift hydraulics

page
–

134 7 Load handling – 7.9.1.3 Control valve, attachment
7.9.1.3 Control valve, attachment

page
–
Twistlocks are controlled by a separate section in the attachment’s

control valve. For a general description of the valve and component lo-
cations, see Attachment control valve, description page 59.
Twistlocks slide, description

The valve slide controls the direction and the lock cylinder.
The valve slide is controlled by two servo valves, lock twistlocks and
open twistlocks.
Servo valve lock twistlocks, description

Servo valve "lock twistlocks" solenoid valve directs pressure to the
twistlock slide so that the slide and pressurises the lock cylinders.
The servo valve lock twistlocks is controlled electrically by the solenoid
valve for lock twistlocks (Y6040), which is activated by Control unit, at-
tachment (D791-1). The servo valve directs servo pressure to the
twistlocks slide in proportion to the control current to the solenoid
valve.
Servo valve open twistlocks, description

Servo valve "open twistlocks" solenoid valve directs pressure to the
twistlock slide so that the slide and pressurises the lock cylinders.
The servo valve open twistlocks is controlled electrically by the sole-
noid valve for open twistlocks (Y6041), which is activated by Control
unit, attachment (D791-1). The servo valve directs servo pressure to
the twistlocks slide in proportion to the control current to the solenoid
valve.

page
–
7.9.1.4 Shuttle valve

page
–

7 Load handling – 7.9.1.5 Lock cylinder 135
7.9.1.5 Lock cylinder

Lock cylinder, description
page
–
The lock cylinder pulls the lock mechanism so that the twistlocks are
rotated. Two lock cylinders - one in the right and one in the left spread-
er beam - pull the lock mechanism. The lock cylinders are located in
the centre of the spreader beam’s longitudinal section.
000539
page
–
7.9.1.6 Lock mechanism

Lock mechanism, description
page
–
The lock mechanism transfers the force of the lock cylinders to the
twistlocks. Two lock mechanisms - one in the right and one in the left
spreader beam - actuate the twistlocks. The lock mechanism operates
in the spreader beam’s longitudinal part between the twistlocks.
The lock mechanism consists of a rod with two spherical plain bear-
ings in the end. The rod is fastened in levers that rotate the twistlocks.
An attaching eye for the lock cylinder is located in the centre of the rod.
001863

136 7 Load handling – 7.9.1.7 Twistlocks
7.9.1.7 Twistlocks
Twistlocks, description
page
–
1
WARNING
Dropped load.
2 Extreme danger!
Twistlocks hold the load during load handling and

5 therefore it is of the utmost importance that twist-
locks are checked according to instructions and are
replaced at the slightest sign of damage or wear.
4 3 Twistlocks secure the load and are located out in the corners of the
spreader beam’s longitudinal section.
Twistlocks are manufactured from high-strength steel according to in-
ternational standards. The lift pins are marked with serial numbers.
Twistlocks are connected in pairs via a linkage system to a hydraulic
cylinder which in turn is controlled via a section in the attachment’s
control valve. Inductive sensors send signals when the twistlocks are
000536
locked and unlocked, respectively.
1. Lock mechanism
2.Sensor alignment
3.Alignment pin
4.Lift pin
5.Lock guide

7 Load handling – 7.9.1.7 Twistlocks 137
Twistlock, changing
page
–

section B Safety.
3 Clean the twistlocks and the surrounding area.
4 Loosen the centre nut for the twistlocks.
5 Tap on the nut so that the lift pin releases from the wedge.
6 Hold the lift pin while removing the centre nut.
WARNING
Dropped component.
Risk of pinch injury or product damage.
Twistlock weighs approx. 30 kg.
7 Remove the centre nut and lift away the twistlock.

8 Grease a new lift pin and place it in the guide pin.
9 Place the lift pin and guide pin in the extension beam. Place the
guide pin so that the grease cup is accessible through the holes
in the extension beam.
NOTE
Do not forget the washer between the extension beam and
guide pin.
10 Position the wedge, bearing, lever, new lock washers and new
lock nuts on the lock pin.
Brush grease to the parts before installing.
11 Check the positions of the parts and that the twistlock can move.
12 Tighten the lock nut to torque 300 Nm.
13 Grease the guide pin, lever, and bearing.
14 Check that the twistlock mechanism can move.
15 Turn on the main electric power and start the machine.
16 Check that the twistlock works.

138 7 Load handling – 7.9.1.7 Twistlocks
Twistlock, changing (product alternative Collet type)

page
–
1 Machine in service position, see section B Safety in Workshop

manual.
2 Depressurise the hydraulic systems, See section B Safety in
Workshop manual.
3 Clean the twistlocks and the surrounding area.
4 Slacken the screws on the clamp holding the twistlocks in place.
5 Hold the twistlock while removing the clamp halves.
WARNING
Dropped component.
Risk of pinch injury or product damage.
Twistlock weighs approx. 30 kg.

009958
6 Remove the clamp halves and lift away the twistlock.

7 Install a new twistlock and secure it with the clamp halves.
NOTE
Remember the washer.
8 Check the positions of the parts and that the twistlock can move.
9 Tighten the screws of the clamp halves.
10 Grease the twistlock and lock mechanism.
11 Check that the twistlock mechanism can move.
12 Turn on the main electric power and start the machine.
13 Check that the twistlock works.
009958

7 Load handling – 7.9.1.8 Sensor, alignment 139
7.9.1.8 Sensor, alignment

Sensor, alignment, description
page
–
The alignment sensors detect when the attachment has contact with
the container. Four inductive sensors - one at each twistlock at the far
corner of the longitudinal section of the spreader beam - are used to
indicate alignment.
The sensor senses the position of a spring pin which is pressed in
when the attachment has contact up against the container. The sensor
is located over 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 at-
tachment and the container’s corner boxes means the sensors stop
sending signals when the attachment is lifted.
The sensors are supplied with power and send a 24 V signal to the at-
tachment control unit (D791) when the indicator pin is pressed in.
001451
Sensor alignment, checking

page
–

2 Check that the indicator pins in the corner boxes can freely move
up and down. The indicator pins must spring down when they are
not loaded.
3 Check that the sensor is free of damage and dirt.
4 Start the machine.
5 Lower the attachment to a container and check that all twistlocks

indicate alignment, filled circles in the event menu for alignment,
and that the indicator light for alignment illuminates.
6 Lift the attachment slightly so that alignment is just off (unfilled cir-
cles in the event menu for contact or the indicator light for align-
000360
ment goes out).

Event menu, alignment 7 Check how much indicator pin movement is required to detect
alignment. The movement should be 3–4 mm.
8 Adjust sensor position if necessary, see Position sensor, check-
ing and adjustment page 5.

page
–

140 7 Load handling – 7.9.1.9 Sensor twistlocks
7.9.1.9 Sensor twistlocks

Sensor, twistlocks, description
page
–
Twistlocks sensors detect when the twistlocks are locked or unlocked.

Four inductive position sensors - two in each spreader beam - detect
the position of the lock mechanism. The sensors are located at the
lock cylinder in the centre of the longitudinal section of the spreader
beam.
Both sides function the same way independently of one another. An
indicator plate sits on the lock mechanism at the lock cylinder. When
the lock mechanism is in the position that locks the twistlocks, one of
the sensors sends a signal to the attachment control unit (D791).
When the lock mechanism is in the position that unlocks the twistlocks,
001452
the other sensor sends a signal to the attachment control unit (D791).
No signals are sent if the lock mechanism stops midway.
The sensors are supplied power by and send a 24 V signal to Control
unit, attachment (D791-1) when the indicator plate is in front of the
sensor.

page
–
7.9.1.10 Relief valve, attachment

page
–
7.9.1.11 Pipes and hoses

page
–

7 Load handling – 7.9.1.12 Overcentre valve 141
7.9.1.12 Overcentre valve

Overcentre valve (product alternative Overheight jacks)
page
–
1
The overcentre valve prevents the overheight jacks from lowering un-
2 der their own weight.
008219
1. Hydraulic cylinder, overheight jacks

2. Overcentre valve, overheight jacks
3. Sensor, overheight jacks up (B7231-L and
B7231-R)
7.9.1.13 Hydraulic cylinder, overheight jacks

Hydraulic cylinder, overheight jacks
page
–
1
The hydraulic cylinder lowers the overheight jacks. The hydraulic cyl-
2 inder is controlled by a separate section in the attachment control
valve, see Attachment control valve, description page 78.
3
008219

B7231-R)

page
–

142 7 Load handling – 7.9.1.14 Sensor, overheight-jacks
7.9.1.14 Sensor, overheight-jacks

Sensor, overheight-jacks
page
–
1
Sensor, overheight jacks up, detects when the jacks are completely
2 raised.
Sensor, overheight jacks up left (B7231-L) detects the position of the
3 left jack pair and sends a voltage signal to Control unit, attachment op-
tion (D791-2) when the jack pair is fully raised.
Sensor, overheight jacks up right (B7231-R) detects the position of the
left jack pair and sends a voltage signal to Control unit, attachment op-
008219 tion (D791-2) when the jack pair is fully raised.

B7231-R)

page
–

7 Load handling – 7.9.2 Lift jacks 143
7.9.2 Lift jacks

Raising/lowering front lifting jacks, function
page
–
description

20
25
1, 29 D1 21, 22
D21
26, 27
A B A B A B A B A B
T1 D26
P1
19 24
2
D28 3, 18, 23
D790-1 D791-4 D18 D23
D797-R D791-3 D8 D13

3, 8, 13, 28
4
9 14
P1
T1
A B A B A B A B A B
D16
D4
D11 16, 17
5
15
6 11, 12
C7
7 10
013028

1 The switch for lowering the front jacks U = 24 V Section 9 Frame, body, cab and accesso-
(S1006) sends a voltage signal to the ries, group 9.1 Controls and instruments
cab control unit (D790-1). D1: Diagnostic menu, see section 8 Control
system, group 8.4.11.1 COMBI, menu 1

144 7 Load handling – 7.9.2 Lift jacks

2 Control unit cab (D790-1) sends front Checked by control sys- Section 11 Common electrics,
lifting jacks down or up on the CAN-bus. tem, error shown with er- group 11.5.3.1 Control unit, cab
ror code.
3 Control unit, attachment left jack pair Checked by control sys- Section 11 Common electrics, group
(D791-3) and Control unit, attachment tem, error shown with er- 11.5.3.7 Control unit, attachment left jack
right jack pair (D791-4) send activate ror code. pair and section 11 Common electrics, group
top hydraulics on the CAN-bus. 11.5.3.8 Control unit, attachment right jack
pair
lics for top lift (Y6003) opens and pres- page 58
surises valve block, lift cylinder and D4: Diagnostic menu, see section 8 Control
sends a load signal to hydraulic oil system, group 8.4.5.6 HYD, menu 6
pump 2.
7 Hydraulic oil pump 2 pumps oil from the See the pressure plate on Section 10 Common hydraulics,
hydraulic oil tank. the left-hand frame beam. group 10.4.2 Axial piston pump with variable
displacement
8 Control unit, attachment left jack pair U = 24 V Section 11 Common electrics,
(D791-3) activates solenoid valve front group 11.5.3.7 Control unit, attachment
knee out left (Y6056L). left jack pair
9 Solenoid valve front knee out left - Control valve, lifting jacks, description
(Y6056L) pressurises hydraulic cylinder page 159
knee left front. D8: Diagnostic menu, see section 8 Control
10 Hydraulic cylinder knee left front lowers - Hydraulic cylinder knee/clamp, description
knee left front. page 164
11 Sensor front knee left (B7217L) sends a U = 24 V Sensor knee, description page 165
voltage signal to Control unit, attach- D11: Diagnostic menu, see section 8 Control
ment left jack pair (D791-3) when the system, group 8.4.11.1 COMBI, menu 4
knee is lowered.
12 Sensor front knee left (B7217L) stops U=0V Sensor knee, description page 165
sending a signal to Control unit, attach- D12: Diagnostic menu, see section 8 Control
ment left jack pair (D791-3). system, group 8.4.11.1 COMBI, menu 4


13 Control unit, attachment left jack pair U = 24 V Section 11 Common electrics,
(D791-3) activates solenoid valve front group 11.5.3.7 Control unit, attachment
jack down left (Y6013L) when sensor left jack pair
front knee left (B7217L) stops sending a D13: Diagnostic menu, see section 8 Control
signal. system, group 8.4.11.1 COMBI, menu 10
14 Solenoid valve front jack down left - Control valve, lifting jacks, description
(Y6013L) pressurises Hydraulic cylinder page 159
jack left front. D13: Diagnostic menu, see section 8 Control
15 Hydraulic cylinder jack left front lowers - Hydraulic cylinder, jack, description
jack left front. page 167
16 Sensor front jack left (B7219L) sends a U = 24 V Sensor, lifting jack, description page 167
signal to Control unit, attachment left D16: Diagnostic menu, see section 8 Control
jack pair (D791-3) when the jack is system, group 8.4.11.1 COMBI, menu 4
lowered.
17 Sensor front jack left (B7219L) stops U=0V Sensor, lifting jack, description page 167
ment left jack pair (D791-3). system, group 8.4.11.1 COMBI, menu 4
18 Control unit, attachment right jack pair U = 24 V Section 11 Common electrics, group
(D791-4) activates solenoid valve front 11.5.3.8 Control unit, attachment right
knee out right (Y6056R) when sensor jack pair
front jack left (B7219L) stops sending a D18: Diagnostic menu, see section 8 Control
signal. system, group 8.4.11.1 COMBI, menu 10
19 Solenoid valve front knee out right - Control valve, lifting jacks, description
(Y6056R) pressurises hydraulic cylinder page 159
knee right front. D18: Diagnostic menu, see section 8 Control
20 Hydraulic cylinder knee right front low- - Hydraulic cylinder knee/clamp, description
ers knee right front. page 164
21 Sensor front knee right (B7217R) sends U = 24 V Sensor knee, description page 165
a voltage signal to Control unit, attach- D21: Diagnostic menu, see section 8 Control
ment right jack pair (D791-4) when the system, group 8.4.11.1 COMBI, menu 4
knee is lowered.
22 Sensor front knee right (B7217R) stops U=0V Sensor knee, description page 165
ment right jack pair (D791-4). system, group 8.4.11.1 COMBI, menu 4
(D791-4) activates solenoid valve front 11.5.3.8 Control unit, attachment right jack
jack down right (Y6013R) when sensor pair
front knee right (B7217R) stops sending D23: Diagnostic menu, see section 8 Control
a signal. system, group 8.4.11.1 COMBI, menu 10
24 Solenoid valve front jack down right - Control valve, lifting jacks, description
(Y6013R) pressurises Hydraulic cylin- page 159
der jack right front.


25 Hydraulic cylinder jack right front lowers - Hydraulic cylinder, jack, description
jack right front. page 167
26 Sensor front jack right (B7219R) sends U = 24 V Sensor, lifting jack, description page 167
a signal to Control unit, attachment right D26: Diagnostic menu, see section 8 Control
jack pair (D791-4) when the jack is system, group 8.4.11.1 COMBI, menu 4
lowered.
27 Sensor front jack right (B7219R) stops U=0V Sensor, lifting jack, description page 167
ment right jack pair (D791-4) when the system, group 8.4.11.1 COMBI, menu 4
jack has reached the end-position.
(D791-4) activates indicator light front 11.5.3.8 Control unit, attachment right jack
jack down (H580). pair
29 When the switch is released, activation of all solenoid valves is cut off. Solenoid valves remain activated even after
the movement has been completed in order for it to be possible to complete the movement if the button is released
when the lifting jack is in an intermediate position.

Raising/lowering rear lifting jacks, function

page
–
description

D32 32
20
31
21
1, 33 D1 D21 22
D26 25
26 30 D30
27
A B A B A B A B A B
P1
T1
D23
24 19 29
2
3, 18, 23, 28 D18
D790-1 D791-4
D29
D797-R D791-3 3, 8, 13, 28 D8
4
D5 14 9 29
D13
P1
T1 A B A B A B A B A B
5 D16 16
17 30
15
C 6
11
D11 12
7 31
10 32
D32
013029


1 The rear jacks switch (S1007) sends a U = 24 V Section 9 Frame, body, cab and accesso-
voltage signal to the cab control unit ries, group 9.1 Controls and instruments
(D790-1). D1: Diagnostic menu, see section 8 Con-
trol system, group 8.4.11.1 COMBI,
menu 1
2 Control unit cab (D790-1) sends rear lift- Checked by control sys- Section 11 Common electrics,
ing jacks down or up on the CAN-bus. tem, error shown with er- group 11.5.3.1 Control unit, cab
ror code.
3 Control unit, attachment left jack pair Checked by control sys- Section 11 Common electrics, group
(D791-3) and Control unit, attachment tem, error shown with er- 11.5.3.7 Control unit, attachment left jack
right jack pair (D791-4) send activate top ror code. pair and section 11 Common electrics,
hydraulics on the CAN-bus. group 11.5.3.8 Control unit, attachment
right jack pair

draulics for top lift (Y6003). D5: Diagnostic menu, see section 8 Con-
trol system, group 8.4.5.6 HYD, menu 6
lics for top lift (Y6003) opens and pressu- page 58
rises valve block, lift cylinder and sends a D5: Diagnostic menu, see section 8 Con-
load signal to hydraulic oil pump 2. trol system, group 8.4.5.6 HYD, menu 6

7 Hydraulic oil pump 2 pumps oil from the See the pressure plate on Section 10 Common hydraulics, group
hydraulic oil tank. the left-hand frame beam. 10.4.2 Axial piston pump with variable dis-
placement
8 Control unit, attachment left jack pair U = 24 V Section 11 Common electrics, group
(D791-3) activates solenoid valve rear 11.5.3.7 Control unit, attachment left jack
knee out left (Y6058L). pair
menu 12
9 Solenoid valve rear knee out left - Control valve, lifting jacks, description
(Y6058L) pressurises hydraulic cylinder page 159
knee left rear. D8: Diagnostic menu, see section 8 Con-
menu 12
10 Hydraulic cylinder knee left rear lowers - Hydraulic cylinder knee/clamp, description
knee left rear. page 164


11 Sensor rear knee left (B7218L) sends a U = 24 V Sensor knee, description page 165
voltage signal to Control unit, attachment D11: Diagnostic menu, see section 8 Con-
left jack pair (D791-3) when the knee is trol system, group 8.4.11.1 COMBI,
lowered. menu 5
12 Sensor rear knee left (B7218L) stops U=0V Sensor knee, description page 165
sending a signal to Control unit, attach- D11: Diagnostic menu, see section 8 Con-
ment left jack pair (D791-3). trol system, group 8.4.11.1 COMBI,
menu 5
13 Control unit, attachment left jack pair U = 24 V Section 11 Common electrics, group
(D791-3) activates solenoid valve rear 11.5.3.7 Control unit, attachment left jack
jack down left (Y6014L), sensor rear knee pair
left (B7218L) stops sending a signal. D13: Diagnostic menu, see section 8 Con-
menu 12
14 Solenoid valve rear jack down left - Control valve, lifting jacks, description
(Y6014L) pressurises Hydraulic cylinder page 159
jack left rear. D13: Diagnostic menu, see section 8 Con-
menu 12
15 Hydraulic cylinder jack left rear lowers - Hydraulic cylinder, jack, description
jack left rear. page 167
16 Sensor rear jack left (B7220L) sends a U = 24 V Sensor, lifting jack, description page 167
signal to Control unit, attachment left jack D16: Diagnostic menu, see section 8 Con-
pair (D791-3) when the jack is lowered. trol system, group 8.4.11.1 COMBI,
menu 5
17 Sensor rear jack left (B7220L) stops U=0V Sensor, lifting jack, description page 167
ment left jack pair (D791-3) when sensor trol system, group 8.4.11.1 COMBI,
rear jack left (B7220L) stops sending a menu 5
signal.
(D791-4) activates solenoid valve rear 11.5.3.8 Control unit, attachment right jack
knee out right (Y6058R). pair
menu 12
19 Solenoid valve rear knee out right - Control valve, lifting jacks, description
(Y6058R) pressurises hydraulic cylinder page 159
knee right rear. D18: Diagnostic menu, see section 8 Con-
menu 12
20 Hydraulic cylinder knee/right rear lowers - Hydraulic cylinder knee/clamp, description

knee right rear. page 164


21 Sensor rear knee right (B7218R) sends a U = 24 V Sensor knee, description page 165
voltage signal to Control unit, attachment D21: Diagnostic menu, see section 8 Con-
right jack pair (D791-4) when the knee is trol system, group 8.4.11.1 COMBI,
lowered. menu 5
22 Sensor rear knee right (B7218R) stops U=0V Sensor knee, description page 165
ment right jack pair (D791-4) when the trol system, group 8.4.11.1 COMBI,
knee reaches the end-position. menu 5
(D791-4) activates solenoid valve rear 11.5.3.8 Control unit, attachment right jack
jack down right (Y6014R) when sensor pair
rear knee right (B7218R) stops sending a D23: Diagnostic menu, see section 8 Con-
signal. trol system, group 8.4.11.1 COMBI,
menu 12
24 Solenoid valve rear jack down right - Control valve, lifting jacks, description
(Y6014R) pressurises Hydraulic cylinder page 159
jack right rear. D23: Diagnostic menu, see section 8 Con-
menu 12
25 Hydraulic cylinder jack right rear lowers - Hydraulic cylinder, jack, description
jack right rear. page 167
26 Sensor rear jack right (B7220R) sends a U = 24 V Sensor, lifting jack, description page 167
signal to Control unit, attachment right D26: Diagnostic menu, see section 8 Con-
jack pair (D791-4) when the jack is low- trol system, group 8.4.11.1 COMBI,
ered. menu 5
27 Sensor rear jack right (B7220R) stops U=0V Sensor, lifting jack, description page 167
ment right jack pair (D791-4). trol system, group 8.4.11.1 COMBI,
menu 5
28 When both rear lifting jacks are complete- U = 24 V Section 11 Common electrics, group
ly lowered Control unit, attachment left 11.5.3.7 Control unit, attachment left jack
jack pair (D791-3) activates solenoid pair and section 11 Common electrics,
valve operating position left (Y6053L) and group 11.5.3.8 Control unit, attachment
solenoid valve clamping left (Y6054L). right jack pair
At the same time Control unit, attachment D29: Diagnostic menu, see section 8 Con-
right jack pair (D791-4) activates Solenoid trol system, group 8.4.11.1 COMBI,
valve operating position right (Y6053R) menu 15 and 8.4.11.1 COMBI, menu 16
and Solenoid valve clamping right
(Y6054R).


29 Solenoid valve operating position left - Control valve, lifting jacks, description
(Y6053L) closes the connection between page 159
control valve and hydraulic cylinder D29: Diagnostic menu, see section 8 Con-
clamping left front. trol system, group 8.4.11.1 COMBI,
Solenoid valve operating position right menu 15 and 8.4.11.1 COMBI, menu 16
(Y6053R) closes the connection between
control valve and hydraulic cylinder
clamping right front.
30 Solenoid valve clamping left (Y6054L) - Control valve, lifting jacks, description
pressurises hydraulic cylinder clamp left page 159
rear. D30: Diagnostic menu, see section 8 Con-
Solenoid valve clamping right (Y6054R) trol system, group 8.4.11.1 COMBI,
pressurises hydraulic cylinder clamp right menu 15
rear.
31 Hydraulic cylinder clamp presses knee - Hydraulic cylinder knee/clamp, description

down and thus presses the rear lifting page 164
jacks forward.
32 Sensor operating position left (B7212L) Sensor directly opposite Sensor operating position, description
sends a voltage signal to Control unit, at- indicator plate: U = 24 V page 164
tachment left jack pair (D791-3) and sen- D32: Diagnostic menu, see section 8 Con-
sor operating position right (B7212R) trol system, group 8.4.11.1 COMBI,
sends a voltage signal to Control unit at- menu 6
tachment right jack pair (D791-4) when
the jack pair is in the operating position.
33 When the switch is released, activation of all solenoid valves is cut off. Solenoid valves remain activated even after
the movement has been completed in order for it to be possible to complete the movement if the button is released
when any lifting jack is in an intermediate position.

Clamping with lift jacks, function description

page
–

Lift jacks Lowered Raising/lowering front lifting jacks, function description page 143
Raising/lowering rear lifting jacks, function description page 147
22 20 15 14
17 22
D1
1
D22 D20 D17
P1 B A B A B A B A B A
D22
T1
D21
D12
13
2, 25 3, 12, 18, 21
D790-1 D791-4
D797-R D791-3 D795

4 3, 8, 23 24
9
D23 D4 D8
P1
T1
A B A B A B A B A B
D22
5
D22 D16
D19
6
7 22 19 16 22
006894
11 10

1 The switch for clamp/release jacks U = 24 V Section 9 Frame, body, cab and accessories,
(S1008) sends a voltage signal to the cab group 9.1 Controls and instruments
control unit (D790-1). D1: Diagnostic menu, see section 8 Control
2 The cab control unit (D790-1) sends Checked by control Section 11 Common electrics,
clamp or release jacks on the CAN-bus. system, error shown group 11.5.3.1 Control unit, cab
with error code.


3 Control unit, attachment left jack pair Checked by control Section 11 Common electrics, group 11.5.3.7
(D791-3) and Control unit, attachment system, error shown Control unit, attachment left jack pair and sec-
right jack pair (D791-4) send activate top with error code. tion 11 Common electrics, group 11.5.3.8
hydraulics on the CAN-bus. Control unit, attachment right jack pair

lics for top lift (Y6003) opens and pressu- page 58
rises valve block, lift cylinder and sends a D4: Diagnostic menu, see section 8 Control
load signal to hydraulic oil pump 2. system, group 8.4.5.6 HYD, menu 6

7 Hydraulic oil pump 2 pumps oil from the See the pressure plate Section 10 Common hydraulics, group 10.4.2
hydraulic oil tank. on the left-hand frame Axial piston pump with variable displacement
beam.
8 Control unit, attachment left jack pair U = 24 V Section 11 Common electrics, group 11.5.3.7
(D791-3) activates solenoid valve clamp Control unit, attachment left jack pair
left (Y6054L) or solenoid valve clamp re- D8: Diagnostic menu, see section 8 Control
lease left (Y6055L). system, group 8.4.11.1 COMBI, menu 15
9 Solenoid valve clamp left (Y6054L) or so- - Control valve, lifting jacks, description
lenoid valve clamp release left (Y6055L) page 159
pressurises hydraulic cylinder clamp left D8: Diagnostic menu, see section 8 Control
front and hydraulic cylinder clamp left system, group 8.4.11.1 COMBI, menu 15
rear.
10 Hydraulic cylinder knee and clamp left - Hydraulic cylinder knee/clamp, description
front act on knee left front so that left lifting page 164
jacks clamp or release.
11 Hydraulic cylinder knee and clamp left - Hydraulic cylinder knee/clamp, description
rear act on knee left rear so that left lifting page 164
12 Control unit, attachment right jack pair U = 24 V Section 11 Common electrics, group 11.5.3.8
(D791-4) activates solenoid valve clamp Control unit, attachment right jack pair
right (Y6054R) or solenoid valve clamp D12: Diagnostic menu, see section 8 Control
release right (Y6055R). system, group 8.4.11.1 COMBI, menu 15
13 Solenoid valve clamp left (Y6054L) or so- - Control valve, lifting jacks, description
lenoid valve clamp release left (Y6055L) page 159
pressurises hydraulic cylinder clamp left D12: Diagnostic menu, see section 8 Control
front and hydraulic cylinder clamp left system, group 8.4.11.1 COMBI, menu 15
rear.


14 Hydraulic cylinder knee and clamp right - Hydraulic cylinder knee/clamp, description
front act on knee left front so that left lifting page 164
15 Hydraulic cylinder knee and clamp right - Hydraulic cylinder knee/clamp, description
rear act on knee left rear so that left lifting page 164
16 Sensor clamping position front jack left U = 24 V Sensor, clamping position, description
(B7215L) sends a voltage signal to page 170
Control unit, attachment left jack pair D16: Diagnostic menu, see section 8 Control
(D791-3). system, group 8.4.11.1 COMBI, menu 2
17 Sensor clamping position front jack right U = 24 V Sensor, clamping position, description
(B7215R) sends a voltage signal to page 170
Control unit, attachment right jack pair D17: Diagnostic menu, see section 8 Control
(D791-4) activates indicator light clamp- Control unit, attachment right jack pair
ing position front jack (H578). D21: Diagnostic menu, see section 8 Control
19 Sensor clamping position rear jack left U = 24 V Sensor, clamping position, description
(B7216L) sends a voltage signal to page 170
Control unit, attachment left jack pair D19: Diagnostic menu, see section 8 Control
20 Sensor clamping position rear jack right U = 24 V Sensor, clamping position, description
(B7216R) sends a voltage signal to page 170
Control unit, attachment right jack pair D20: Diagnostic menu, see section 8 Control
(D791-4) activates indicator light clamp- Control unit, attachment right jack pair
ing position rear jack (H579). D21: Diagnostic menu, see section 8 Control
22 When lifting is started, Sensor alignment U = 24 V Section 9 Frame, body, cab and accessories,
front jack left (B7213L) and Sensor align- group 9.1 Controls and instruments
ment rear jack left (B7214L) send a signal D22: Diagnostic menu, see section 8 Control
to Control unit, attachment left jack pair system, group 8.4.11.1 COMBI, menu 3
(D791-3). Sensor alignment front jack
right (B7213R) and Sensor alignment rear
jack right (B7214R) send a signal to
Control unit, attachment right jack pair
(D791-4).
If it takes longer than 4 seconds between
the first sensor’s signal until all sensors
send signals, the lift function is blocked.


23 Control unit, attachment left jack pair U = 24 V Section 11 Common electrics, group 11.5.3.7
(D791-3) activates the alignment indica- Control unit, attachment left jack pair
tor light for each lifting jack. D23: Diagnostic menu, see section 8 Control

event menu alignment bottom lift. group 11.5.3.12 Control unit, KID
25 When more than two sensors indicate Checked by control Section 8 Control system, group 8.2.5 Speed
alignment or clamping position, speed system, error shown limitation
limitation is activated. with error code.
Lift jacks, checking and adjusting

page
–
If necessary, the lifting jacks can be operated manually, step by step

with the diagnosis menu Extra\\Combi menu 17, see section 8 Control
system, group 8.4.11.1 COMBI.
1 Start key in position I.

2 Check that all sensors have voltage. The LED on the sensor
should turn on when the sensor indicates.
3 Check the distance between all sensors and their target surface,
the distance will be 41 mm when the sensor is directly opposite
the lug.
Sensor knee and Sensor jack should only be active during the
movement, not in the two end-positions.
4 Check that the attachment hangs horizontally, adjust the tilt func-
tion if necessary.
5 Lower all jacks completely.
6 Check that the jacks are vertical in the lateral direction.
7 If necessary, adjust the position on the lowering cylinder’s rod
mounting by turning the piston rod.
After adjustment, the target surfaces for the jack sensors may
need to be precisely adjusted.
NOTE
Loosen the lock nuts on the piston head before adjustment.
8 Check the c-c measurement between right and left lift jacks, the
90˚ 90˚ measurement should be approximately 4876 mm at the bottom of
the jacks.
c-c = 4876 mm
008205
Attachment, seen from the front

9 Operate the lifting jacks to clamping position.

10 Check that the lifting jacks are tilted 8.0 toward each other in the
longitudinal direction.
11 If necessary, adjust the position on the clamping cylinder’s rod
mounting by turning the piston rod.
After adjustment, the target surfaces for the knee sensors may
need to be precisely adjusted.
NOTE
Loosen the lock bolts in the piston head before adjustment.
8,0˚ 8,0˚
007458
Clamping position, max. retracted jacks

12 Run apart the lifting jacks from clamping position.
13 Check that the rear lifting jacks are tilted 1.5 out (backward).
14 Check that the front lifting jacks are tilted 9.0 out (forward).
9,0˚ 1,5˚
007459
Clamping position, max. extended jacks.

15 Press the top of the rear lowering button, the rear lifting jacks
should move to operating position. (Operate clamping position
apart to return to end-position in order to test the operating posi-
tion again.)
16 Check that the lifting jacks stop at 1.0 inward (forward).
1,0˚
007460
Operating position, rear jacks

17 Adjust the position by moving the sensor clamping position
laterally.
001856
Sensor, operating position

18 Press in the alignment lug on one lifting jack at a time and check
that each alignment indicator light works.
If the light does not illuminate when the lug is pressed in, check
the light and alignment sensor, see Sensor, alignment, descrip-
tion page 169.
008200
Indicator lights, alignment

158 7 Load handling – 7.9.2.1 Hydraulic oil pump
19 Press in the contact surfaces on the front and rear lifting jacks
and check that the indicator light for clamping position alignment
for each jack pair works.
When both contact surfaces are pressed in the indicator light for
clamping position front and rear should turn on.
If the light does not turn on when the contact surfaces are
pressed in, check the light and clamping position sensor, see
Sensor, clamping position, description page 170.
008201
Indicator lights, clamping position
20 Check that the indicator light for front jacks lowered is on when
the front lifting jacks are lowered.
008202
Indicator light, front jacks down

21 Operate the front lifting jacks up and check the indicator light for
front jacks lowered is off when the jacks are raised, and that the
indicator light for front jacks raised is on when the front lifting
jacks are completely raised.
22 Check that the work lights on the attachment changes between
lighting the twistlocks and lighting the lifting jacks on the right and
left side when the rear lifting jacks on each side are raised and
lowered.
008204
Indicator light, front jacks up

page
–

7.9.2.2 Valve block top lift hydraulics

page
–

7 Load handling – 7.9.2.3 Control valve, lifting jacks 159
7.9.2.3 Control valve, lifting jacks

Control valve, lifting jacks, description
page
–
The lifting jacks are controlled by two control valves: one for the left
1 2 3 4 5 6 7 8 9 10 jack pair and one for the right jack pair. The control valves are control-
led by separate control units: Control unit, attachment left jack pair
23 (D791-3) and Control unit, attachment right jack pair (D791-4). The
11 control valves are installed crosswise (left front and right rear, respec-
22
tively) on the bracket for the knee on the attachment’s main beam.
12
21 The control valves are identical and have five sections each:
20 13 • Raising/lowering of front knee

• Raising/lowering of front jacks
19 14
• Raising/lowering of rear knee
18
15 • Raising/lowering of rear jacks
17 • Clamping position
16
The servo pressure controls the spring-centred valve slides, which
simultaneously.
000467
Valve slide front knee

1. Solenoid valve, rear knee out (Y6058) The valve slide controls the direction and speed of front knee lowering
2. Solenoid valve, rear knee in (Y6059) by controlling the hydraulic pressure to hydraulic cylinder knee and
3. Solenoid valve, clamp (Y6054) clamp.
4. Solenoid valve, clamp release (Y6055)
The valve slide is controlled by servo valve, front knee out and servo
5. Solenoid valve, front knee in (Y6057)
valve, front knee in.
6. Solenoid valve, front jack up (Y6060)
7. Solenoid valve, front jack down (Y6013)
Servo valve front knee out
8. Solenoid valve, front knee out (Y6056)
9. Drain to tank Servo valve front knee out, controls servo pressure to valve slide front
10. Connection, hydraulic cylinder for front jack knee so that it controls oil pressure for front knee out.
11. Connection, hydraulic cylinder for front knee Servo valve front knee is controlled electrically with Solenoid valve
12. Connection, hydraulic cylinder for front jack front knee out (Y6056) which is activated by Control unit,
13.Connection, hydraulic cylinder for front knee attachment left jack pair (D791-3) or Control unit, attachment right
14. Connection, hydraulic cylinder for clamping jack pair (D791-4), depending on if it is the right or left jack.
15. Connection, hydraulic cylinder for rear knee The signal can be checked via the diagnostic menu. See
16. Connection, hydraulic cylinder for rear jack section 8 Control system, group 8.4.11.1 COMBI, menu 10.
17. Feed from hydraulic oil pumps
18. Tank return (through filter) Servo valve front knee in
19. Connection, hydraulic cylinder for rear jack
Servo valve front knee in, controls servo pressure to valve slide front
20. Connection, hydraulic cylinder for rear knee
knee so that it controls oil pressure for front knee in.
21. Connection, hydraulic cylinder for clamping
22. Solenoid valve, rear jack down (Y6014) Servo valve front knee is controlled electrically with Solenoid valve
23. Solenoid valve, rear jack up (Y6061) front knee in (Y6057) which is activated by Control unit, attachment left
jack pair (D791-3) or Control unit, attachment right jack pair (D791-4),
depending on if it is the right or left jack.
section 8 Control system, group 8.4.11.1 COMBI, menu 11.

160 7 Load handling – 7.9.2.3 Control valve, lifting jacks
Valve slide front jack

The valve slide controls the direction and speed of front jack lowering
by controlling the hydraulic pressure to hydraulic cylinder jack.
The valve slide is controlled by servo valve front jack down and servo
valve front jack out.
Servo valve front jack down

Servo valve front jack down, controls servo pressure to valve slide
front jack so that it controls oil pressure for lowering of jack.
Servo valve front jack is controlled electrically with Solenoid valve front
jack down (Y6013) which is activated by Control unit, attachment left
Servo valve front jack up

Servo valve front jack up, controls servo pressure to valve slide front
jack so that it controls oil pressure for raising of jack.
Servo valve front jack is controlled electrically with Solenoid valve front
jack up (Y6060) which is activated by Control unit, attachment left jack
pair (D791-3) or Control unit, attachment right jack pair (D791-4), de-
pending on if it is the right or left jack.
Valve slide clamp

Valve slide clamp controls the direction and speed of clamping with the
jack pair by controlling the hydraulic pressure to hydraulic cylinder
knee and clamp.
The valve slide is controlled by servo valve clamp and servo valve
clamp release.
Servo valve clamp

Servo valve clamp, controls servo pressure to valve slide clamp so
that it controls oil pressure for clamping.
Servo valve clamp is controlled electrically with Solenoid valve clamp
in (Y6054) which is activated by Control unit, attachment left jack pair
(D791-3) or Control unit, attachment right jack pair (D791-4), depend-
ing on if it is the right or left jack pair.

7 Load handling – 7.9.2.3 Control valve, lifting jacks 161
Servo valve clamp release

Servo valve clamp release, controls servo pressure to valve slide
clamping position so that it controls oil pressure for clamp release.
Servo valve clamp release is controlled electrically with Solenoid valve
clamp release in (Y6055) which is activated by Control unit, attach-
ment left jack pair (D791-3) or Control unit, attachment right jack pair
(D791-4), depending on if it is the right or left jack pair.
Valve slide rear knee

The valve slide controls the direction and speed of rear knee lowering
by controlling the hydraulic pressure to hydraulic cylinder knee and
clamp.
The valve slide is controlled by servo valve, rear knee out and servo
valve, rear knee in.
Servo valve rear knee out

Servo valve rear knee out, controls servo pressure to valve slide rear
knee so that it controls oil pressure for knee out.
Servo valve rear knee out is controlled electrically with Solenoid valve
rear knee out (Y6058) which is activated by Control unit, attachment
left jack pair (D791-3) or Control unit, attachment right jack pair
(D791-4), depending on whether it is the right or left knee.
Servo valve rear knee in

Servo valve rear knee in, controls servo pressure to valve slide knee
so that it controls oil pressure for knee in.
Servo valve rear knee in is controlled electrically with Solenoid valve
rear knee in (Y6059) which is activated by Control unit, attachment left
depending on if it is the right or left knee.
Valve slide rear jack

The valve slide controls the direction and speed of rear jack lowering
by controlling the hydraulic pressure to hydraulic cylinder jack.
The valve slide is controlled by servo valve rear jack down and servo
valve rear jack out.

162 7 Load handling – 7.9.2.4 Shuttle valve
Servo valve rear jack down

Servo valve rear jack down, controls servo pressure to valve slide front
jack so that it controls oil pressure for jack lowering.
Servo valve rear jack down is controlled electrically with Solenoid
valve rear jack down (Y6014) which is activated by Control unit, at-
tachment left jack pair (D791-3) or Control unit, attachment right jack
pair (D791-4), depending on if it is the right or left jack.
Servo valve rear jack up

Servo valve rear jack up, controls servo pressure to valve slide rear
jack so that it controls oil pressure for jack raising.
Servo valve rear jack up is controlled electrically with Solenoid valve
rear jack up (Y6061) which is activated by Control unit, attachment left

page
–
7.9.2.4 Shuttle valve

page
–

7 Load handling – 7.9.2.5 Valve, operating position 163
7.9.2.5 Valve, operating position

Valve operating position, description
page
–
The valve for operating position cuts off the pressure to the front hy-
draulic cylinder for clamping. The valve is located on the attachment’s
main beam by the hydraulic cylinder knee and clamp.
When the valve is activated, it cuts the hydraulic connection between
Control valve, attachment lifting jacks and hydraulic cylinder knee and
clamp front. This results in only the rear lifting jack being angled
forward.
Solenoid valve operating position (Y6053L/R) is activated by Control
unit, attachment left jack pair (D791-3) or Control unit, attachment right
jack pair (D791-4), depending on if it is the right or left jack.
001849
7.9.2.6 Main beam attachment

page
–
The brackets for knee and hydraulic cylinder knee and clamp are lo-
cated on the attachment’s main beam.
7.9.2.7 Knee
Knee, description
page
–
The knee is located between the attachment’s main beam and lifting
jack. There are four knees, one at each lifting jack. The knee enables
folding in and clamping with the jacks. The knee is controlled by hy-
draulic cylinder knee and clamp.
Located on the knee joint is an indicator ring which is turned with the
lifting jack. The indicator ring is used together with Sensor, knee, to de-
termine if the jack is raised, in intermediate position or lowered.
001851

164 7 Load handling – 7.9.2.8 Hydraulic cylinder knee and clamp
7.9.2.8 Hydraulic cylinder knee and clamp

Hydraulic cylinder knee/clamp, description
page
–
Hydraulic cylinder knee and clamp has two pistons in separate cylin-
1 2
ders. There are four hydraulic cylinders, one at each lifting jack. The
hydraulic cylinder is located between attachment and knee. One of the
hydraulic cylinder’s pistons folds the knee joint out. The other piston
clamps with the lifting jacks by angling the knee joint further.
001852
1. Hydraulic cylinder, clamp

2. Hydraulic cylinder, knee

page
–
7.9.2.9 Sensor, operating position

Sensor operating position, description
page
–
The sensor for operating position senses the position of the rear lifting
jacks’ hydraulic cylinder for knee and clamp. This is used to indicate
operating position for the rear lifting jacks. There are two sensors, one
on each side (right and left).
Sensor, operating position left (B7212L/R) provides a voltage signal
when the rear hydraulic cylinder lowering knee/clamp is in its inner end
position. The signal is used to stop activation of the solenoid valve for
operating position when the rear lifting jack is lowered.
001856

page
–

7 Load handling – 7.9.2.10 Sensor knee 165
7.9.2.10 Sensor knee

Sensor knee, description
page
–
Sensor knee senses the position of the knee joint, this is used to con-
trol lowering of the jacks. There are four sensors, one by each knee.
Sensor front knee (B7217) and Sensor rear knee (B7218) give voltage
signals when the knee is between either end-position. The signal goes
to 0 V when end-position is reached. This applies both when retracting
and extending. The signal is used to activate the next step in the se-
quence. If the signal does not go to 0 V, the jack is not lowered.
section 8 Control system, group 8.4.11.1 COMBI, menu 4–5.
001853

page
–

166 7 Load handling – 7.9.2.11 Lift jacks
7.9.2.11 Lift jacks

Lifting jacks, description
page
–
The lifting jacks grip around/under the load. In the lower end of the
jacks there are lifting shoes. The lifting jacks are raised and lowered
with the hydraulic cylinder for lifting jacks.
Located on the lifting jack’s joint is an indicator ring which is turned
with the lifting jack. The indicator ring is used together with Sensor,
jack, to determine if the jack is raised, in intermediate position or
lowered.
001866

7 Load handling – 7.9.2.12 Hydraulic cylinder, jack 167
7.9.2.12 Hydraulic cylinder, jack

Hydraulic cylinder, jack, description
page
–
Hydraulic cylinder lifting jack is located between knee and lifting jack.
The hydraulic cylinder raises and lowers the lifting jacks.
001855

page
–
7.9.2.13 Sensor lift jacks

Sensor, lifting jack, description
page
–
Sensor, lifting jacks, senses the position of the lifting jacks, this is used
to control lowering of the jacks. There are four sensors, one by each
lifting jack.
Sensor front jack (B7219) and Sensor rear lifting jack (B7220) give
voltage signals when the lifting jacks are between either end-position.
The signal goes down to 0 V when end-position is reached. This ap-
plies both when raising and lowering. The signal is used to activate the
next step in the sequence. If the signal does not go to 0 V, the knees
are not lowered.
section 8 Control system, group 8.4.11.1 COMBI, menu 4–5.
001859

page
–

168 7 Load handling – 7.9.2.14 Lifting shoe
7.9.2.14 Lifting shoe

Lifting shoe, description
page
–
The lifting shoe is located at the lower end of the lifting jacks. The lifting
shoe grips under the load. At each lifting shoe there are two sensors.
Sensor alignment senses when the lifting shoe has contact with the
load from above, see Sensor, alignment, description page 169. Sen-
sor clamping position senses when the lifting shoe has horizontal con-
tact with the load, see Sensor, clamping position, description
page 170.
3
001857
1. Indicator pin, clamping position sensor

2. Indicator pin, alignment sensor
3. Lifting shoe

7 Load handling – 7.9.2.15 Sensor, alignment 169
7.9.2.15 Sensor, alignment

Sensor, alignment, description
page
–
The sensor for alignment (B7213L/R or B7214L/R) senses when the

lifting shoe has contact with the load from above. The sensor is located
behind the lifting shoe and senses the position on a linkage. The link-
age is affected by a pin in the middle of the lifting shoe which is
1 pressed down when the load is positioned correctly in the lifting shoe.
001858
1. Sensor clamping position (B7215L/R or B7216L/R)

2. Sensor alignment (B7213L/R or B7214L/R)

page
–

170 7 Load handling – 7.9.2.16 Sensor clamping position
7.9.2.16 Sensor clamping position

Sensor, clamping position, description
page
–
The sensor for clamping position (B7215L/R or B7216L/R) senses

when the lifting shoe has horizontal contact with the load. The sensor
is located behind the lifting shoe and is activated by a bolt mounted on
a spring-loaded plate on the lifting shoe.
1
2
001858
1. Sensor clamping position (B7215L/R or B7216L/R)

2. Sensor alignment (B7213L/R or B7214L/R)

page
–
7.9.2.17 Relief valve, attachment

page
–

page
–

7 Load handling – 7.10 Other functions 171
7.10 Other functions

7.10.1 Support jacks
Support jacks, function description
page
–

Control breaker Disengaged Section 10 Common hydraulics, group 10.4.2 Axial piston pump with varia-
ble displacement
Parking brake Released Section 4 Brakes, group 4.5 Parking brake system
Transmission Neutral position Section 2 Transmission
Machine stationary Speed = 0 km/h -
D1 D13
1
2, 13
D790-1 11
D795
D794 D797-O
4
D4 12
C8 D3
5
10 3
P
B
LS
7 T
C8 T1 A
8 6 9
013030

1 Switch, support jacks (S1013) sends a volt- U = 24 V Section 9 Frame, body, cab and accesso-
age signal to Control unit, cab (D790-1). ries, group 9.1 Controls and instruments
system, group 8.4.11.3, SUPPORT-JACKS
menu 1
2 The cab control unit (D790-1) sends sup- Checked by control Section 11 Common electrics,
port jacks down or up on the CAN-bus. system, error shown group 11.5.3.1 Control unit, cab
with error code.

172 7 Load handling – 7.10.1 Support jacks

3 Sensor support jacks up (B7222) or Sensor Support jacks up or Sensor, support jacks up, description
support jacks down (B7021) sends a volt- down: U = 24 V page 178
age signal to Control unit, frame option Support jacks in inter- Sensor, support jacks down, description
(D797-O). mediate position: page 179
U=0V D3: Diagnostic menu, see section 8 Control
system, group 8.4.11.3, SUPPORT-JACKS
menu 2
4 Control unit, frame option (D797-O) acti- U = 24 V Section 11 Common electrics, group
vates the Solenoid valve support jacks 11.5.3.4 Control unit frame option
down (Y6064) or Solenoid valve support D4: Diagnostic menu, see section 8 Control
jacks up (Y6063) and sends the status for system, group 8.4.11.3, SUPPORT-JACKS
the support jacks’ position on the CAN-bus. menu 3
5 Solenoid valve support jacks down (Y6064) - Control valve, option frame, description
or Solenoid valve support jacks up (Y6063) page 173
pressurises the support jacks slide in Con- D4: Diagnostic menu, see section 8 Control
trol valve, option frame. system, group 8.4.11.3, SUPPORT-JACKS
menu 3
6 Control valve, option frame sends a load - Control valve, option frame, description
signal to shuttle valve, option frame and page 173
pressurises valve block, support jacks cylin-
der.
7 The shuttle valve sends pressure signal on - Section 10 Common hydraulics,

to hydraulic oil pumps 1 & 2. group 10.5.3 Shuttle valve
8 Hydraulic oil pump 1 & 2 pump oil from the See the pressure Section 10 Common hydraulics, group
hydraulic oil tank. plate on the left-hand 10.4.2 Axial piston pump with variable
frame beam. displacement
9 Valve block support jacks pressurises hy- - Valve block, support jacks, description
draulic cylinder support jacks. page 179
10 The hydraulic cylinder lowers or raises the - Hydraulic cylinder, support jacks, description
support jack. page 177
11 Control unit KID (D795) activates the event - Section 11 Common electrics,
menu for support jacks and blocks shifting group 11.5.3.12 Control unit, KID
from neutral position.
12 Control unit, engine (D794) sends engine Checked by control Section 11 Common electrics,
speed on the CAN-bus. If the engine speed system, error shown group 11.5.3.10 Control unit, engine
is higher than 1000 rpm then the cab control with error code.
unit (D790-1) activates automatic lowering
of support jacks.

7 Load handling – 7.10.1.1 Hydraulic oil pump 173

13 The cab control unit (D790-1) activates the U = 24 V Section 11 Common electrics,
indicator light for support jacks down. group 11.5.3.1 Control unit, cab
When support jacks are lowered the cab D13: Diagnostic menu, see section 8 Control
control unit (D790-1) changes the load system, group 8.4.11.3, SUPPORT-JACKS
curve (limit for overload protection menu 4
systems).
When support jacks are raised the cab con-
trol unit (D790-1) allows shifting from neu-
tral position.

page
–

7.10.1.2 Control valve option frame

Control valve, option frame, description
page
–
1
On machines with support jacks, lowering/raising of support jacks is
controlled by a separate section in the control valve frame option. The
6 2
control valve is installed on a bracket at the front end in the engine
compartment.
5 3
The control valve is controlled by Control unit, frame option (D797-O).
Control valve, option frame is made up of several sections, each sec-
4 tion controls one function. The following functions are controlled by
control valve, option frame.
• Support jacks
• Sliding cab/Cab lift
• Cab tilt
000624

The servo pressure controls the spring-centred valve slides, which
1. Load signal (LS)
3. Tank return (T1)
simultaneously.
4. Connection, steering cylinder (B)
5. Tank return (TP)
Valve slide, support jacks
6. Connection, steering cylinder (A)
The valve slide controls the direction and speed of support jack lower-
ing by controlling the hydraulic pressure to hydraulic cylinder, support
jacks.
The valve slide is controlled by servo valve, support jacks up and ser-
vo valve, support jacks down.

174 7 Load handling – 7.10.1.2 Control valve option frame
Servo valve, support jacks down

Servo valve, support jacks up controls servo pressure to valve slide
support jacks so that it controls oil pressure for support jacks up.
Servo valve support jacks down regulates electrically with the solenoid
valve support jacks down (Y6064), which is activated by Control unit,
frame option (D797-O).
section 8 Control system, group 8.4.11.3 SUPPORT-JACKS, menu 3.
Servo valve, support jacks up

Servo valve, support jacks down controls servo pressure to valve slide
support jacks so that it controls oil pressure for support jacks down.
Servo valve support jacks up regulates electrically with the solenoid
valve support jacks up (Y6063), which is activated by Control unit,
section 8 Control system, group 8.4.11.3 SUPPORT-JACKS, menu 3.

7 Load handling – 7.10.1.2 Control valve option frame 175
Control valve, option frame, changing

page
–
NOTE
section B Safety.
section B Safety.
1
NOTE
4
NOTE
NOTE
000624

1. Load signal (LS)
mixed up.
3. Tank return (T1) 7 Mark up the servo valves on the new control valve.
4. Connection, hydraulic cylinder (B) 8 Fit the valve.
5. Tank return (TP)
6. Connection, hydraulic cylinder (A)
marking.
the marking.
NOTE

176 7 Load handling – 7.10.1.2 Control valve option frame
NOTE
CAUTION

010475

the engine.

CAUTION
product damage.

cavitation.

7 Load handling – 7.10.1.3 Hydraulic cylinder support jacks 177
CAUTION
Do not overfill!

7.10.1.3 Hydraulic cylinder support jacks

Hydraulic cylinder, support jacks, description
page
–
Hydraulic cylinder support jacks lowers the support jack up and down.
1 The hydraulic cylinder is located between support jacks and frame.
5
001870
7 6
1. Hydraulic cylinder, support jacks
2. Sensor, support jacks up (B7222)
3. Upper bracket
4. Support jacks
5. Support foot
6. Lower bracket
7. Sensor, support jacks down (B7221)

178 7 Load handling – 7.10.1.4 Support jacks
7.10.1.4 Support jacks

Support jacks, description
page
–
The support jack consists of linkage and support. The linkage is de-
1 signed so that it locks automatically when it is loaded from below in its
lowered position.
2 The support jack is secured in the frame and in the drive axle’s attach-
ing bolts.
5
001870
7 6
3. Upper bracket
4. Support jacks
5. Support foot
6. Lower bracket
7.10.1.5 Sensor, raised support jacks

Sensor, support jacks up, description
page
–
Sensor, support jacks up (B7222) is located under hydraulic cylinder,

1 support jacks and senses when the support jack is raised. There is a
sensor for each support jack. The sensor indicates when the support
jack is fully raised. This is used to control the support jacks event
2 menu.
3 section 8 Control system, group 8.4.11.3 SUPPORT-JACKS, menu 2.
Sensor, support jacks up (B7222) sends a voltage signal to Control
unit, frame option (D797-O) when the support jack is completely
4
raised.
5
001870
7 6
3. Upper bracket
4. Support jacks
5. Support foot
6. Lower bracket

7 Load handling – 7.10.1.6 Sensor, lowered support jacks 179

page
–
7.10.1.6 Sensor, lowered support jacks

Sensor, support jacks down, description
page
–
Sensor, support jacks down (B7221) is located under the support

1 jack’s upper mounting and detects when the support jack is lowered.
A sensor is installed on each support jack. This is used to control the
support jacks and the activation of the indicator light for support jacks
2 down.
3 section 8 Control system, group 8.4.11.3 SUPPORT-JACKS, menu 2.
Sensor, support jacks down (B7221) sends a voltage signal to Control
unit, frame option (D797-O) when the support jack is completely
4
lowered.
5
001870
7 6
3. Upper bracket
4. Support jacks
5. Support foot
6. Lower bracket

page
–

page
–
7.10.1.8 Shuttle valve option

Shuttle valve, option, description
page
–
See section 10 Common hydraulics , group 10.5.3. Shuttle valve .
7.10.1.9 Valve block support jacks

Valve block, support jacks, description
page
–
Valve block, support jacks is located by the hydraulic cylinders and

contains a blocking valve which protects against accidental raising
and lowering of the support jacks.

180 7 Load handling – 7.10.2 Weight indicator
7.10.2 Weight indicator

Weight indicator, description
page
–
The weight indicator uses Sensor hydraulic pressure lift cylinder

(B768) and sensor boom angle to calculate the load. For more
information about sensors, see section 8 Control system,
group 8.2.1 Overload system.
The pressure sensors signal can be checked via the diagnostic menu.
See section 8 Control system, group 8.4.5.3 HYD, menu 3.
Fixed scale (only model year -2008)

The fixed scale weighs the load in a preset position on the boom by
measuring the pressure on the piston side in the lift cylinders. The
boom angle for the measuring position is indicated by a rod and mark-
ing on the left lift cylinder. The boom length for the measuring position
is indicated with an extra Sensor boom length (Position sensor boom
length 60 cm).
Dynamic scale
The dynamic scale weighs the load regardless of boom position. The
weight is calculated as a function of boom angle, boom length and the
pressure in the lift cylinders. The dynamic scale uses Sensor, hydrau-
lic pressure lift cylinder, Sensor, boom angle (analogue sensor) and
Sensor, boom length (analogue sensor).

7 Load handling – 7.10.2 Weight indicator 181
Weight indicator, function description (product

page
–
alternative fixed scale) (only model year -2008)

1 D1
3, 4
2 7, 12
D790-1 D795
D797-R 11 D797-F D791-1

6 9
D5 D10 D10 D8
10
006896
5 >˚ Pa Pa 8

1 The pistol trigger on the control lever US815/T4 = 24 V Section 9 Frame, body, cab and accesso-
sends a voltage signal to the cab control ries, group 9.1 Controls and instruments
2 Control unit, cab (D790-1) sends weigh- Checked by control sys- Section 11 Common electrics,
ing activated on the CAN-bus. tem, error shown with group 11.5.3.1 Control unit, cab
error code.
3 Boom lowered to measuring position - Lifting/lowering, function description

(when the boom is in measuring page 11
position boom lowering is interrupted
automatically).
4 The boom is operated to 60 cm extension - Extension, function description (Rexroth)

(when the boom is in measuring page 37
position boom extension is interrupted
automatically).
5 Sensor, boom angle (B771) sends a volt- U = 0.5-4.5 V Section 8 Control system,
age signal proportional to boom angle to group 8.2.1.5 Sensor, boom angle
Control unit, frame rear (D797-R). D5: Diagnostic menu, see section 8 Control
system, group 8.4.10.4 OP, menu
sends boom angle on the CAN-bus. tem, error shown with group 11.5.3.3 Control unit frame rear
error code. D5: Diagnostic menu, see section 8 Control
system, group 8.4.10.4 OP, menu


7 The KID control unit (D795) activates the - Section 11 Common electrics,
event menu fixed scale (flashing). group 11.5.3.12 Control unit, KID
8 Sensor, boom length 60 cm (B7224) U = 24 V Section 8 Control system,

sends a signal to the attachment control group 8.2.1.6 Sensor, boom length
9 Control unit, attachment (D791-1) sends Checked by control sys- Section 11 Common electrics,
Boom length 60 cm on the CAN-bus. tem, error shown with group 11.5.3.5 Control unit, attachment
error code. D8: Diagnostic menu, see section 8 Control
10 Sensor, hydraulic pressure lift cylinder U = 0.5 - 4.5 V Sensor hydraulic pressure lift cylinder, de-
piston side left (B768-L1) and Sensor hy- scription page 32
draulic pressure lift cylinder piston side D10: Diagnostic menu, see section 8 Control
right (B768-R1) send a voltage signal to system, group 8.4.10.3 OP, menu 3
Control unit, frame front (D797-F).
weight information on the CAN-bus. tem, error shown with group 11.5.3.2 Control unit, frame front
error code.
12 The KID control unit (D795) updates the - Section 11 Common electrics,
weight information in the display group 11.5.3.12 Control unit, KID
(fixed glow).

7 Load handling – 7.10.2 Weight indicator 183
Weight indicator, function description

page
–
(product alternative dynamic scale)

8
D790-1 D795
D797-F D797-R
7 3,5
D6
D2 D4
6
006897
Pa Pa Pa Pa 2 m <˚ 4

1 Operating menu dynamic scale is select- - Section 9 Frame, body, cab and accesso-
ed in the display. ries, group 9.1 Controls and instruments
2 Sensor, boom length (B777) sends a volt- U = 0.5-4.5 V Section 8 Control system,
age signal proportional to boom length to group 8.2.1.6 Sensor, boom length
system, group 8.4.10.4 OP, menu 4
3 Control unit, frame rear (D797-R) trans- Checked by control sys- Section 11 Common electrics,
mits boom length information on the tem, error shown with group 11.5.3.3 Control unit frame rear
4 Sensor, boom angle (B771) sends a volt- U = 0.5-4.5 V Section 8 Control system,
age signal proportional to boom angle to group 8.2.1.5 Sensor, boom angle
5 Control unit, frame rear (D797-R) sends Checked by control sys- Section 11 Common electrics,
boom angle information on the CAN-bus. tem, error shown with group 11.5.3.3 Control unit frame rear
error code.


6 Sensor hydraulic pressure lift cylinder U = 0.5-4.5 V Sensor hydraulic pressure lift cylinder, de-
piston side left (B768-L12), Sensor hy- scription page 32
draulic pressure lift cylinder rod side left D6: Diagnostic menu, see section 8 Control
(B768-L11), Sensor hydraulic pressure system, group 8.4.10.3 OP, menu 3
lift cylinder piston side right (B768-R10)
and Sensor hydraulic pressure lift cylin-
der rod side right (B768-R13) send volt-
age signals proportional to the hydraulic
pressure in the lift cylinders to Control
7 Control unit, frame front (D797-F) calcu- Checked by control sys- Section 11 Common electrics,
lates and sends the weight on the CAN- tem, error shown with group 11.5.3.2 Control unit, frame front
bus. The weight is calculated by a ma- error code.
chine-unique load curve based on sensor
values for boom angle, boom length and
pressure in the lift cylinders.
NOTE
The load curve is unique for each
machine.
8 Control unit KID (D795) shows weight in- - Section 11 Common electrics,
formation in the display. group 11.5.3.12 Control unit, KID
Printer, description
page
–
Printer is an option for the dynamic scale function that makes it possi-
ble to save weights and print lists of saved weights.
The printer is connected to the KID control unit (D795) and is mounted
on the instrument panel to the right of the steering wheel.
The printer is controlled by the printer operating menu in the display,
where the operator selects the weights to be saved and what should
be printed.
004907
Printer location

7 Load handling – 7.10.2.1 Sensor hydraulic pressure lift cylinder 185
7.10.2.1 Sensor hydraulic pressure lift cylinder

Sensor hydraulic pressure lift cylinder, general
page
–
See Sensor hydraulic pressure lift cylinder, description page 32.
7.10.2.2 Sensor boom angle

Sensor boom angle, general
page
–
See section 8 Control system, group 8.2.1.2 Sensor, boom angle.
7.10.2.3 Sensor boom length

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

186 7 Load handling – 7.10.3 Container counter
7.10.3 Container counter

Container counter, description
page
–
The container counter counts the number of lifted containers. The

counter has two counters that can be reset separately. The container
counter counts in different ways depending on whether the top lift
(twistlocks) or bottom lift (lifting jacks) is used.
Top lift
The container counter counts lifting when alignment is broken with
locked twistlocks and twistlocks are not opened within 8 seconds.
Bottom lift
The container counter counts lifting when the clamp function is activat-
ed and lifting is started and unloading clamping position is not activat-
ed within 10 seconds.

7 Load handling – 7.10.3 Container counter 187
Container counter, function description

page
–
(product alternative top lift)

1, 4, 7
D1
10
D790-1 D795
D797-R D791-1
3, 6, 9
D5
D2
2, 8 5
006898
1 The attachment is positioned over a - Lifting/lowering, function description page 11
container with the functions 7.2 Lifting/ Extension, function description (Rexroth)
lowering, 7.3 Sideshift. page 37
system, group 8.4.8.1 BOOM, menu 1
2 Sensor, alignment left front (7202L), Sensor directly oppo- Sensor, alignment, description page 139
Sensor, alignment right front (7202R), site indicator plate: D2: Diagnostic menu, see section 8 Control
Sensor, alignment left rear (Y7203L) U = 24 V system, group 8.4.9.6 ATTACH, menu 6
and Sensor, alignment right rear
(Y7203R) send a voltage signal to Con-
trol unit, attachment (D791-1).
3 Control unit, attachment (D791-1) sends Checked by control Section 11 Common electrics,
alignment on the CAN bus. system, error shown group 11.5.3.5 Control unit, attachment
with error code.
4 Twistlocks are rotated to the locked po- - Twistlocks, function description page 129
sition and are closed with the 7.9.1
Twistlocks function.
5 The sensor for locked twistlocks left Sensor directly oppo- Sensor, twistlocks, description page 140
(B7205L) and sensor for locked twist- site indicator plate: D5: Diagnostic menu, see section 8 Control
locks right (B7205R) send a voltage U = 24 V system, group 8.4.9.7 ATTACH, menu 7
(D791-1).


locked twistlocks on the CAN bus. system, error shown group 11.5.3.5 Control unit, attachment
with error code.
7 The container is lifted with the function - Lifting/lowering, function description page 11
7.2 Lifting/lowering.
8 Sensor, alignment left front (7202L), U=0V Sensor, alignment, description page 139
Sensor, alignment right front (7202R), D2: Diagnostic menu, see section 8 Control
Sensor, alignment left rear (Y7203L) system, group 8.4.9.6 ATTACH, menu 6
and Sensor, alignment right rear
(Y7203R) stop sending a voltage signal
to Control unit, attachment (D791-1).
no alignment on the CAN bus. system, error shown group 11.5.3.5 Control unit, attachment
with error code.
10 If the twistlocks remain locked for 8 sec- - Section 11 Common electrics,

onds then Control unit, cab (D790-1) group 11.5.3.1 Control unit, cab
adds one lift to the container counter.

7 Load handling – 7.10.3 Container counter 189
Container counter, function description

page
–
(product alternative bottom lift)

value
Control breaker Disengaged Section 11 Common electrics, group 11.5.1.4 Emergency stop switch voltage (15E)
1 3 4
2, 7
D4
D3
D1
D2
10
D790-1 D795
6, 9 D791-3 D791-4 6, 9
D5 D8 D5
5 8 5 8 D8
006899
1 The attachment’s rear lifting jacks fold are - Raising/lowering rear lifting jacks, function
lowered to operating position with the func- description page 147
tion 7.9.2 Lifting jacks. D1: Diagnostic menu, see section 8 Control
2 The attachment is positioned over a con- - Lifting/lowering, function description page 11

tainer with the functions 7.2 Lifting/lower- Extension, function description (Rexroth)
ing, 7.3 Sideshift. page 37
system, group 8.4.8.1 BOOM, menu 1
3 The front lifting jacks are lowered with the - Raising/lowering front lifting jacks, function
function 7.9.2 Lifting jacks. description page 143
4 The lifting jacks clamp around the contain- - Clamping with lift jacks, function description
er with the function 7.9.2 Lifting jacks. page 152


5 Sensor clamping position front jack left Sensor directly oppo- Sensor, clamping position, description
(B7215L) and sensor clamping position site indicator plate: page 170
rear jack left (B7216L) send a voltage sig- U = 24 V D5: Diagnostic menu, see section 8 Control
nal to Control unit, attachment left jack pair system, group 8.4.11.1 COMBI, menu 2
(D791-3).
Sensor clamping position front jack right
(B7215R) and sensor clamping position
rear jack right (B7216R) send a voltage
signal to Control unit, attachment right jack
pair (D791-4).
6 Control unit, attachment left jack pair Checked by control Section 11 Common electrics, group 11.5.3.7
(D791-3) and Control unit, attachment right system, error shown Control unit, attachment left jack pair
jack pair (D791-4) send clamping position, with error code. Section 11 Common electrics, group 11.5.3.8
lifting jacks on the CAN bus. Control unit, attachment right jack pair
7 The container is lifted with the function 7.2 - Lifting/lowering, function description page 11
Lifting/lowering.
8 Sensor alignment front jack left (B7213L) Sensor directly oppo- Sensor, alignment, description page 169
and sensor alignment rear jack left site indicator plate: U D8: Diagnostic menu, see section 8 Control
(B7214L) send a voltage signal to Control = 24 V system, group 8.4.11.1 COMBI, menu 3
unit, attachment left jack pair (D791-3).
Sensor alignment front jack right (B7213R)
and sensor alignment rear jack right
(B7214R) send a voltage signal to Control
unit, attachment right jack pair (D791-4).
alignment on the CAN bus. system, error shown group 11.5.3.5 Control unit, attachment
with error code.
10 If clamping position remains active - Section 9 Frame, body, cab and accessories,
for 10 seconds then Control unit, cab group 9.1 Controls and instruments
(D790-1) adds one bottom lift to the
container counter.

7 Load handling – 7.10.4 Synchronised lift 191
7.10.4 Synchronised lift

Synchronized lift, function description
page
–

switch voltage
Height limitation
D1
+
2, 6
D790-1 D795
5 D797-R D797-F
D3 D4
006900
3 m <˚ 4

1 The control lever sends for lift or low- Lower: US815/P1 = 0.5-2.0 V Section 9 Frame, body, cab and accessories,
er and pistol trigger voltage signal to group 9.1 Controls and instruments
Lift: US815/P1 = 3.0-4.5 V
Control unit, cab (D790-1). D1: Diagnostic menu, see section 8 Control
Pistol trigger:
system, group 8.4.8.1 BOOM, menu 1 and
US815-T4 = 24 V
8.4.9.2 ATTACH, menu 2
2 Control unit, cab (D790-1) sends Checked by control system, Section 11 Common electrics,
synchronized lift on the CAN-bus. error shown with error code. group 11.5.3.1 Control unit, cab
3 Sensor, boom angle (B771) sends a U = 0.5-4.5 V Section 8 Control system,

voltage signal to Control unit, frame group 8.2.1.5 Sensor, boom angle
rear (D797-R). D3: Diagnostic menu, see section 8 Control
4 Sensor, boom length (B777) sends a U = 0.5-4.5 V Section 8 Control system, group 8.2.1.6 Sen-
voltage signal to Control unit, frame sor, boom length
rear (D797-R). D4: Diagnostic menu, see section 8 Control
5 Control unit, frame rear (D797-R) Checked by control system, Section 11 Common electrics,
transmits length and angle informa- error shown with error code. group 11.5.3.3 Control unit frame rear
tion on the CAN bus.

192 7 Load handling – 7.10.4 Synchronised lift

6 Control unit, cab (D790-1) controls - Lifting/lowering, function description page 11
the functions 7.2 Lift/lower and 7.3 Extension, function description (Rexroth)
Extension at the same time so that page 37
the lifting movement is vertical.

8 Control system 1
8 Control system
Table of Contents 8 Control system

mm mm mm mm mm mm
8 Control system ............................................................................................... 3

8.1.4 Switch to bypass load centre and height limitations .............................. 4
8.1.10 Error code menu .................................................................................... 4
8.2 Monitoring ................................................................................................... 7
8.2.1 Overload system .................................................................................... 7
8.2.2 Bypass ................................................................................................. 15
8.2.3 Load centre limitation ........................................................................... 16
8.2.4 Height limitation ................................................................................... 16
8.2.5 Speed limitation ................................................................................... 17
8.2.6 Service indicator .................................................................................. 17
8.4 Diagnostics ............................................................................................... 18
8.4.1 CAN/POWER ....................................................................................... 20
8.4.2 LIGHTS ................................................................................................ 40
8.4.3 CAB ..................................................................................................... 53
8.4.4 CLIMATE ............................................................................................. 62
8.4.5 HYD ..................................................................................................... 70
8.4.6 ENGINE ............................................................................................... 75
8.4.7 TRANSM, Dana TE32FF ..................................................................... 82
8.4.7 TRANSM, ZF 5WG261 ........................................................................ 95
8.4.8 BOOM ................................................................................................ 101
8.4.9 ATTACH ............................................................................................ 109
8.4.10 OP ...................................................................................................... 132
8.4.11 EXTRA ............................................................................................... 137
8.4.13 RMI .................................................................................................... 165
8.5 Setup ...................................................................................................... 168
8.5.1 Initiation ............................................................................................. 168
8.5.2 Calibration .......................................................................................... 196

2 8 Control system

8 Control system 3
8 Control system
mm mm mm mm mm mm
Control system, general

page
–
In many cases the machine’s functions are controlled electrically. The

signals that control the machine are monitored to warn the operator or
limit the machine’s functions in the event of certain dangerous situa-
tions or if there are malfunctions in the machine.
The control system function is divided into the following functions:
• Monitoring
• Error codes
• Diagnostics
• Setup
• Software
Monitoring functions describe the machine’s monitoring functions that
warn the operator or limit the machine’s functions in the event of any
dangerous situations.
Error codes notify operators and mechanics when malfunctions have
been detected.
Diagnostic test is tool for performing service and troubleshooting with
menus in the machine’s display.
Settings is the tool for setting and adapting the machine’s functions.
The software creates the functions in the control system.

4 8 Control system – 8.1 Controls and instruments

8.1.4 Switch to bypass load centre and
height limitations
Switch to bypass height limitation, description
page
–
Switch to bypass height limitation (S1015) bypasses the height limita-

tion and makes it possible to raise the boom over the limit for the
height limitation. See Height limitation, description page 16.
The switch is supplied with voltage from and sends a voltage signal to
the cab control unit (D790-1), when the switch is activated.
008216
8.1.10 Error code menu

Error code menu, description
page
–
The control and monitoring system’s display is divided into four fields
C where the information is shown (see figure to the left).
D E • Field B: Error code level is shown with a symbol.

• 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 affect operator safety or
cause machine breakdown. The error code must be taken care of
D E
immediately. Stop working with the machine and contact service
immediately.
000350
The error code is shown automatically on the display.
• Warning
C Indicates machine malfunction that should be taken care of as
soon as possible. After finished work shift with the machine, con-
D E
tact service as soon as possible.
000351

8 Control system – 8.1.10 Error code menu 5
• Information
C Information to the operator that something should be taken care
of as soon as possible, e.g., defective light bulb. Take action to fix
D E the cause of the error code as soon as possible.
The error code is stored in the error code list under operating
000352
menu for service.
Field C: Error code number

The control 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:
XXX/YY Shown with error code number XXX/YY on display.
D
NOTE
B If several error codes come from the engine, the error code
013390
level is shown for the most serious error code.
• Transmission:
XX/YY Shown with error code number XX/YY on display.
B
013391
Field D: Type of error

1. Temperature too high/too low.
1 2 3
2. Incorrect signal to solenoid valve.
3. Incorrect hydraulic pressure.
4. Incorrect sensor signal.
4 5 6 5. Incorrect signal from control.

6. Incorrect signal to bulb.
7. Incorrect signal, for example, open circuit.
7
000396

6 8 Control system – 8.1.10 Error code menu
Field E: Affected function

1. Attachment
1 2 3
2. Rotation of attachment
3. Sideshift attachment
4. Length adjustment attachment
4 5 6 5. Levelling attachment
6. Twistlocks
7. Tilt attachment
7 8 9 8. Bottom lift attachment
9. Bottom lift attachment, clamping position
10. Bottom lift attachment, jacks up/down
10 11 12 11. Boom up/down

12. Boom in/out
13. Pressure sensor lift cylinder (overload system, OP)
14. Overload system
13 14 15
15. Support jacks up/down
16. Hydraulic functions
17. Brake system
16 17 18
18. Steering
19. Engine
20. Transmission
19 20 21 21. Central lubrication
22. Control unit
23. Hardware-related error
22 23 24 24. Cab
25. Air conditioning
26. Fuel system
25 26 27 27. Headlights
28. Windscreen wipers
29. Battery voltage
28 29 30 30. Bulb for lighting

000397

8 Control system – 8.2 Monitoring 7
8.2 Monitoring
8.2.1 Overload system
8.2.1.1 Mechanical overload system
Mechanical overload system, function description
page
–
(model year -2008)
3, 10
D795
4 2, 5, 7, 9 D797-R D793
8
D6
1 D1
006413
D4 >˚ 6

1 Sensor steering axle load (B7221) Normal: U = 24 V Sensor, steering axle load, description
sends a voltage signal to Control unit Overload: U = 0 V page 11
frame rear (D797-R) if the load on the D1: Diagnostic menu, see section 8 Control
steering axle is low. system, group 8.4.10.1 OP, menu 1
2 Control unit frame rear (D797-R) sends Checked by the control Section 11 Common electrics,
"Overload forward" on the CAN-bus. system, error indicated group 11.5.3.3 Control unit frame rear
with error code.
3 Control unit KID (D795) shows Event - Section 11 Common electrics,

menu overload forward. group 11.5.3.12 Control unit, KID
4 Position sensor boom length 1.5 m Extension less than Sensor boom length, description (position
(B777) sends voltage signal to Control 1.5 m: U = 24 V sensor) page 13
unit frame rear (D797-R) that boom ex- Extension more than D4: Diagnostic menu, see section 8 Control
tension is shorter than 1.5 m. 1.5 m: U = 0 V system, group 8.4.10.1 OP, menu 1
5 Control unit, frame rear (D797-R) sends Checked by the control Section 11 Common electrics,
"boom length under 1.5 m" on the system, error indicated group 11.5.3.3 Control unit frame rear
CAN-bus. with error code.
6 Sensor boom angle (B771) sends a volt- UB771/1 = 5 V Sensor boom angle, description (angle sen-
age signal proportional to boom angle to sor) page 12
UB771/2 = 0 V
UB771/3 = 0.5 - 4.5 V
7 The frame control unit rear (D797-R) Checked by the control Section 11 Common electrics,
sends "boom angle" on the CAN-bus. system, error indicated group 11.5.3.3 Control unit frame rear
with error code.
8 The transmission control unit (D793) Checked by the control Section 11 Common electrics,
sends speed information on the system, error indicated group 11.5.3.9 Control unit, transmission

8 8 Control system – 8.2.1.2 Mechanical overload system with analogue position sensors

9 If both Position sensors boom length Checked by the control Section 11 Common electrics,
1.5 m (B777) send voltage signal and system, error indicated group 11.5.3.3 Control unit frame rear
boom angle exceeds 35 at the same with error code.
time as the machine is operated faster
than 10 km/h, Control unit frame rear
(D797-R) sends "Overload on steering
axle" on the CAN-bus.
10 The KID control unit (D795) activates - Section 11 Common electrics,

Event menu overload on steering axle. group 11.5.3.12 Control unit, KID
8.2.1.2 Mechanical overload system with

analogue position sensors
Mechanical overload system with analogue position
page
–
sensors, function description (model year -2008)
3, 8
D795
D797-R D793
D4 2, 7 6
4
m
D5
1 D1
006414
<˚ 5

1 Sensor steering axle load (B7221) Normal: U = 24 V Sensor, steering axle load, description
sends a voltage signal to Control unit Overload: U = 0 V page 11
frame rear (D797-R) if the load on the D1: Diagnostic menu, see section 8 Control
steering axle is low. system, group 8.4.10.1 OP, menu 1
2 Control unit frame rear (D797-R) sends Checked by the control Section 11 Common electrics,
"Overload forward" on the CAN-bus. system, error indicated group 11.5.3.3 Control unit frame rear
with error code.
3 Control unit KID (D795) activates Event - Section 11 Common electrics,

menu overload forward. group 11.5.3.12 Control unit, KID
4 Sensor, boom length (R777) sends a UB777/1 = 5 V Sensor boom length, description (analogue
voltage signal proportional to the sensor) page 14
UB777/2 = 0 V
boom length to Control unit, frame rear D4: Diagnostic menu, see section 8 Control
(D797-R). UB777/3 = 0.5 - 4.5 V

8 Control system – 8.2.1.3 Electric overload system 9

5 Sensor, boom angle (R771) sends a UB771/1 = 5 V Sensor boom angle, description (angle sen-
voltage signal proportional to the sor) page 12
UB771/2 = 0 V
boom angle to Control unit, frame rear D6: Diagnostic menu, see section 8 Control
(D797-R). UB771/3 = 0.5 - 4.5 V
7 If boom length is less than 1.5 m and Checked by the control Section 11 Common electrics,
boom angle is more than 35 at the system, error indicated group 11.5.3.3 Control unit frame rear
same time as the machine is operated with error code.
faster than 10 km/h, Control unit frame
rear (D797-R) sends "Overload on
steering axle" on the CAN-bus.
8 The KID control unit (D795) activates - Section 11 Common electrics,

Event menu overload on steering axle. group 11.5.3.12 Control unit, KID
8.2.1.3 Electric overload system

Electric overload system, function description
page
–
(model year 2009-)
6
D795
D797-R D797-F D793

4 5, 8 2 7
m
D4 3 D3 D1 1
006415
<˚ Pa Pa

1 Sensor, hydraulic pressure lifting cylin- UB768-XX/1 = 5 V Section 8 Control system,
der left (B768-L1 and B768-L2) sends a group 8.2.1.7 Sensor, hydraulic pressure
UB768-XX/2 = 0 V
voltage signal proportional to the pres- lift cylinder
sure in the left lift cylinder to Control unit, UB768-XX/3 = 0.5 - 4.5 V
frame front (D797-F). system, group 8.4.10.3 OP, menu 3
Sensor, hydraulic pressure lifting cylin-
der right (B768-R1 and B768-R2) sends
a voltage signal proportional to the pres-
sure in the right lift cylinder to Control

10 8 Control system – 8.2.1.3 Electric overload system

2 Control unit, frame front (D797-F) sends Checked by the control Section 11 Common electrics,
pressure information on the CAN-bus. system, error indicated group 11.5.3.2 Control unit, frame front
with error code.
3 Sensor, boom length (B777) sends a UB777/1 = 5 V Section 8 Control system,

voltage signal proportional to the group 8.2.1.6 Sensor, boom length
UB777/2 = 0 V
boom length to Control unit, frame rear D3: Diagnostic menu, see section 8 Control
(D797-R). UB777/3 = 0.5 - 4.5 V
Alternatively, Sensor, boom length
(B777) may have a position sensor for
none or maximum boom extension.
4 Sensor, boom angle (BR771) sends a UB771/1 = 5 V Section 8 Control system,

voltage signal proportional to the group 8.2.1.5 Sensor, boom angle
UB771/2 = 0 V
boom angle to Control unit, frame rear D4: Diagnostic menu, see section 8 Control
(D797-R). UB771/3 = 0.5 - 4.5 V
5 Control unit, frame front (D797-F) calcu- Checked by the control Section 11 Common electrics,
lates and sends the weight, which is cal- system, error indicated group 11.5.3.2 Control unit, frame front
culated and compared with a machine with error code.
unique load curve based on the sensor
values for boom angle, boom length,
and pressure in the lift cylinders.
NOTE
The load curve is unique for each
machine.
If the load is high then Control unit,
frame front (D797-F) sends Overload
forward on the CAN bus.

event menu for overload, depending on group 11.5.3.12 Control unit, KID
the load situation.
8 In the event of overload on the steering Checked by the control

axle the speed is limited gradually with system, error indicated
the increasing load. with error code

8 Control system – 8.2.1.4 Sensor, steering axle load 11
8.2.1.4 Sensor, steering axle load

Sensor, steering axle load, description
page
–
Sensor, steering axle load (B7221L and B7221R) sense when the
steering axle’s rear suspension bottoms out. The sensors are located
on both sides of the steering axle’s rear suspension.
Sensors, steering axle load are inductive position sensors that are
supplied with voltage by and send voltage signal to Control unit
The sensors’ signals can be checked via the diagnostic menu. See
005122
Position, Sensor steering axle load

(B7221L and B7221R)

page
–
Sensor, steering axle load, changing

page
–

2 Replace the sensor.
3 Adjust sensor’s position, see section 7 Load handling.
4 Turn on the main electric power and turn the start key to
position I.
5 Check the overload system, see section 8 Control system,
group 8.2.1 Overload system.
005122

12 8 Control system – 8.2.1.5 Sensor boom angle
8.2.1.5 Sensor boom angle

Sensor boom angle, description (angle sensor)
page
–
The boom’s angle is measured by a sensor that senses the boom’s an-
gle in relation to the frame. The sensor consists of a sensor housing,
potentiometer, and arm. The sensor housing is mounted on the boom.
The arm is connected to the frame and turns the potentiometer when
the boom is angled.
The sensor is supplied with voltage by and sends a signal proportional
to the angle to Control unit, frame rear (D797-R).
001093
Sensor boom angle (B771)
Sensor boom angle, changing (angle sensor)

page
–

position I.
4 Calibrate Sensor, boom angle, see Weight indicator, calibration
(product alternative fixed scale) (only model year -2008)
page 198 or Weight indicator, calibration (product alternative dy-
namic scale) page 200.
5 Check that the end-position damping works in both outer and in-
ner end-positions.

8 Control system – 8.2.1.6 Sensor boom length 13
8.2.1.6 Sensor boom length

Sensor boom length, description (position sensor)
page
–
Sensor boom length indicates boom extension and is available in two

versions, position sensors or analogue sensors. Standard is three in-
ductive position sensors. As an option there are position sensors for
fixed scale (60 cm extension).
Two inductive sensors, Sensor damping boom in (B769-3) and Sensor
damping boom out (769-4), are used to control damping of boom in
and boom out. The sensors are located on the right side of the lift
boom’s outer part.
The sensors are supplied with voltage and send a negative signal
(ground connection) to Control unit frame rear (D797-R) when the
boom’s indicator plate passes the sensor. Each sensor has an LED
that turns on when sensors sense the indicator plate. The LEDs can
1
be used to check the sensor’s function.
2 Position sensor damping extension gives a signal when the boom is

near outer and inner end-position, this is used to activate damping,
3 see section 7 Load handling, group 7.3 Extension. The signal can be
checked with diagnostic menu, see section 8 Control system,
001203
4 group 8.4.8.8 BOOM, menu 8.

1. Position sensor damping boom in (B769-3) Position sensor boom length 1.5 m (B777) gives a signal when the
2. Position sensor 1.5 m (B777) boom’s extension is 1.5 m, this is used for overload system on steering
3. Position sensor damping boom out (B769-4) axle. The can be checked with diagnostic menu, see section 8 Control
4. Position sensor boom length 60 cm (B7224) system, group 8.4.10.1 OP, menu 1.
Position sensor boom length 60 cm (B7224) gives a signal when the
boom’s extension is in position for weighing on machines with fixed
scale, see section 7 Load handling, group 7.10.2 Weight indicator. The
signal can be checked with diagnostic menu, see section 8 Control
system, group 8.4.9.5 ATTACH, menu 5.

page
–
Sensor boom length (position sensor), changing

page
–

3 Adjust sensor’s position, see section 7 Load handling.
ner end-positions.

14 8 Control system – 8.2.1.7 Sensor hydraulic pressure lift cylinder
Sensor boom length, description (analogue sensor)

page
–
Sensor, boom length (R777) senses the lift boom’s extension and is
located in the rear edge of the boom on the left side.
The sensor is made up of a spring-loaded line connected to a rotary
potentiometer via a gearbox. The line is connected to the inner boom.
When the boom is extended the line acts on the potentiometer and the
signal changes.
The sensor is supplied with voltage by and sends a voltage signal pro-
portional to the length to Control unit, frame rear (D797-R).
000471 section 8 Control system, group 8.4.10.4 OP, menu 4.
Sensor, boom length (R777)
Sensor boom length, (analogue sensor), changing

page
–

position I.
4 Calibrate the sensor, see Weight indicator, calibration (product
alternative dynamic scale) page 200.
ner end-positions.
8.2.1.7 Sensor hydraulic pressure lift cylinder

Sensor hydraulic pressure lift cylinder, general
page
–
See section 7 Load handling, group 7.2.9 Sensor, hydraulic pressure

lift cylinder.

8 Control system – 8.2.2 Bypass 15
8.2.2 Bypass
Bypass, description
page
–
When the overload system engages and turns off the hydraulic con-
trols, it may take place in a situation where it is necessary to bypass
the safety system.
Bypassing is activated with switches, the machine is equipped with
one to three switches depending on the installed equipment:
• Switch, bypass
• Switch bypass height limitation
• Switch rotation stop

By-passing the safety system allows:
• lowering of load in case of overload
• locking and opening of twistlocks without complete alignment
• 20’-40’ spreading with locked twistlocks
• bottom lift without full alignment
• manual control of the recirculation damper for ECC or EHC
• release of parking brake in case of malfunction of Switch, parking
brake or Sensor, operator-in-seat
• lifting above height limitation
• rotation past rotation stop
• load manoeuvring past limit for load centre limitation.
• lift, lower, and extension with active error in the overload system
• selection of travel direction in case of malfunction of Sensor, op-
erator-in-seat, speed is limited to 10 km/h
DANGER
Bypassing the safety systems results in a risk of tip-
ping. Use at your own risk.

16 8 Control system – 8.2.3 Load centre limitation
8.2.3 Load centre limitation

Load centre limitation, description
page
–
Load centre limitation prevents the load from being brought to close to
the machine. Load centre limitation is controlled by the control system
with signals from Sensor boom angle, see Sensor boom angle, de-
000358
scription (angle sensor) page 12 and Sensor boom length, see Sensor
boom length, description (analogue sensor) page 14. This is used,
Event menu load centre limitation.
e.g., in connection with cab lift to prevent the container from damaging
the cab.
For details of the lifting and lowering or extension, see section 7 Load
handling, group 7.2 Lifting/lowering and section 7 Load handling,
group 7.3 Extension.
Synchronized lift is activated when the load centre limitation reaches
its limit (see section 7 Load handling, group 7.10.4 Synchronized lift)
this function can be temporarily disabled with the Switch, bypass (see
Bypass, description page 15).
The load centre limitation values can be checked via the diagnostic
menu. see 8 Control system, group 8.4.10.5 OP, menu 5.
8.2.4 Height limitation

Height limitation, description
page
–
Height limitation is part of the control system and prevents the ma-
chine lifting higher than a preset height without the operator being
informed.
Height limitation is controlled by the control system with signals from
Sensor boom angle and Sensor boom length. When boom angle and
extension indicate that permitted height is reached, lift and extension
are blocked, and display information Height limitation is activated.
For details of the lifting and lowering or extension, see section 7 Load
handling, group 7.2 Lifting/lowering and section 7 Load handling,
group 7.3 Extension.
Height limitation may be temporarily disabled with the Switch, bypass
of the load centre and height limitation (S1015), see Switch to bypass
height limitation, description page 4.
The height limitation values can be checked via the diagnostic menu,
see 8 Control system, group 8.4.10.6 OP, menu 6.

8 Control system – 8.2.5 Speed limitation 17
8.2.5 Speed limitation

Speed limitation, description
page
–
Speed limitation prevents the machine’s speed from exceeding the

preset value by limiting gear position and engine speed.
Speed limitation is set via the initiation menu, see section 8 Control
system, group 8.5.1.5 INIT DRIVETRAIN, menu 9.
8.2.6 Service indicator

Service indicator, resetting
page
–

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 (Serv-

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

18 8 Control system – 8.4 Diagnostics
8.4 Diagnostics
Diagnostic test, general
page
–
The machine has built-in functions for troubleshooting called diagnos-

DIAGNOSIS tic test. The diagnostic test consists of several menus shown on the
CAN/POWER LIGHTS CAB
display. The menus are grouped for faster access. The following pag-
CLIMATE HYD ENGINE
es describe the menu figures content and which functions that can be
TRANSM BOOM ATTACH
controlled.
009268
OP EXTRA RMI
The diagnostic test is divided into the following groups:
• Voltage feed and communication for the Control system,
CAN/POWER, description page 20.
• Lighting, LIGHTS, description page 40.
• Cab functions, CAB, description page 53.
• Air conditioning, CLIMATE, description page 62.
• Hydraulic functions, HYD, description page 70.
• Engine, ENGINE, description page 75.
• Transmission, TRANSM, description page 82.
• Boom functions, BOOM, description page 101.
• Attachment functions, ATTACH, description page 109.
• Overload system, OP, description page 132.
• Optional functions, EXTRA, description page 137.
– Bottom lift, COMBI, menu 1 page 137.
– Hydraulic sliding/vertically adjustable cab, SLIDING-CAB,
menu 1 page 154.
– Support jacks, SUPPORT-JACKS, menu 1 page 157.
– Mini-wheel or joystick steering, EL-STEERING, menu 1
page 160
• RMI (Remote Machine Interface), RMI, description page 165
Diagnostic menu, description

page
–
Diagnostic tests show how the control units interpret input signals as
1 2 3 4
well as which signals that the control units send.
7 DIAG CAB 2(10)

FRONT WIPER
SWITCH (1-3) 2
6 OUTPUT 11 5
004856
FEEDBACK 0
1. DIAG = Diagnostic menus
2. Menu group
3.Menu number
4.Total number of menus in loop
5.Signal value
6.Variable
7. Menu heading

8 Control system – 8.4 Diagnostics 19
DIAG Indicates that diagnostic tests are selected.
Menu group Indicates which menu group is selected, these groups are:
CAN/POWER, description page 20.
LIGHTS, description page 40.
CAB, description page 53.
CLIMATE, description page 62.
HYD, description page 70.
ENGINE, description page 75.
TRANSM, description page 82.
BOOM, description page 101.
ATTACH, description page 109.
EXTRA, description page 137.
Menu number Number of current menu. Every menu group consists of several menus in a loop.
Number of Total number of menus in the group.

menus
Variable The signal that is measured. Different signals are designated in different ways:
SWITCH: a digital input signal, e.g. a switch.
OUTPUT: a digital output signal, e.g. feed to a motor.
INPUT: an analogue input signal, e.g. from a sensor.
REFERENCE: status for an analogue output signal.
REQUIRED: triggered output signal for a control current
FEEDBACK: either feedback signal from a motor or measured current on the minus side for an analogue
output signal.
Signal value Measurement value or status for signal for variable. On the same row there are different types that are
interpreted in different ways.
SWITCH: 1 or 0 where 1 means closed circuit.
OUTPUT: two characters where the first number is 1 if the output signal is active. The second number is
status for the circuit, 1=circuit OK, 0=open circuit or short-circuiting.
INPUT: numerical value corresponding to the signal.
REFERENCE: two characters where the first number is 1 if the input signal is active. The second number
is status for the circuit, 1=circuit OK, 0=open circuit or short-circuiting.
REQUIRED: numerical value corresponding to the signal.
FEEDBACK: numerical value corresponding to the signal.
Menu heading Description of the function for which the menu reads signals.

20 8 Control system – 8.4.1 CAN/POWER
8.4.1 CAN/POWER
CAN/POWER, description
page
–
This group handles redundant voltage feed to control units and CAN
DIAGNOSIS bus communication.
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE Confirm selections with function key for Enter.
TRANSM BOOM ATTACH
009268
OP EXTRA RMI
8.4.1.1 CAN/POWER, menu 1

PRESENT REDCAN STATUS, COMMUNICATION MODE
page
–
Description: Indicates communication status for the redundant

DIAG CAN/POWER 1(20) CAN-bus.
PRESENT REDCAN STATUS
COMMUNICATION MODE X Circuit diagram: -
NUMBERS OF UNITS X Contact: -
003177
SEGMENT ERROR X
Function: 11.6.2 Redundant CAN bus
Signal value:
3 OK.
2 Segment check.
0 Error.
PRESENT REDCAN STATUS, NUMBER OF UNITS

page
–
Description: Indicates the number of nodes on the redundant CAN bus

DIAG CAN/POWER 1(20) that should be on the machine in question, excluding Control unit, cab
PRESENT REDCAN STATUS (D790-1) and Control unit KID (D795). (Control unit, transmission
COMMUNICATION MODE X (D793) and Control unit, engine (D794) are connected to a separate
NUMBERS OF UNITS X
CAN bus and are therefore not counted).
003177
SEGMENT ERROR X
Circuit diagram: Circuit CAN BUS opt. frame KDU group 11.6, Circuit
CAN BUS ATT group, 11.6
Contact: -
Signal value:
X Number of nodes that should be in the machine. Number of

nodes dependent on installed options.

8 Control system – 8.4.1.2 CAN/POWER, menu 2 21
PRESENT REDCAN STATUS, SEGMENT ERROR

page
–
Description: Indicates if there is open circuit on the redundant CAN

DIAG CAN/POWER 1(20) bus, and if there is, where the first open circuit is. If there is open cir-
PRESENT REDCAN STATUS cuit, it is indicated with a number that corresponds to the incorrect seg-
COMMUNICATION MODE X ment on the redundant CAN bus.
NUMBERS OF UNITS X
003177
SEGMENT ERROR X Circuit diagram: Circuit CAN BUS opt. frame KDU group 11.6, Circuit
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 incorrect,
that is, that contact between first and second control unit is
cut off.
To see which control units are installed on the machine along
with their order, use diagnostic menu CAN/POWER, menu 2,
see PRESENT REDCAN STATUS, RED.CON.CITIES
page 21.

PRESENT REDCAN STATUS, RED.CON.CITIES
page
–
Description: Indicates which control units have contact with Control

DIAG CAN/POWER 2(20) unit, cab (D790-1) via the redundant CAN bus. Note that certain con-
PRESENT REDCAN STATUS trol units are optional and may not be installed on the machine.
RED.CON.CITIES
XYXYXYXY Circuit diagram: Circuit CAN BUS opt. frame KDU group 11.6, Circuit
000087
1234ROFD CAN BUS ATT group, 11.6

Contact:
D790-1: K13:4, K13:5, K13:7, and K13:8
D795: K1:10, K1:11, K1:12 and K1:13
D797-F, D797-R, D797-O, D791-1, D791-2, D791-2, D791-3,
D797-4: K2:2, K2:3, K2:4, and K2:5
Function: 11.5.3.1 Control unit cab, 11.5.3.2 Control unit frame front,
11.5.3.3 Control unit frame rear, 11.5.3.4 Control unit frame option,
11.5.3.5 Control unit attachment, 11.5.3.6 Control unit attachment op-
tion, 11.5.3.7 Control unit attachment left jack pair, 11.5.3.8 Control
unit attachment right jack pair, 11.5.3.12 Control unit KID, 11.6.2 Re-
dundant CAN-bus

22 8 Control system – 8.4.1.3 CAN/POWER, menu 3
Signal value:
1 Communication with the node is OK.
0 No communication and/or there is some node error.
Position 1: Control unit, attachment (D791-1)
Position 2: Control unit, attachment option (D791-2)
Position 3: Control unit, attachment left jack pair (D791-3)
Position 4: Control unit, attachment right jack pair (D791-4)

Position R: Control unit, frame rear (D797-R)
Position O: Control unit frame option (D797-O)

Position F: Control unit, frame front (D797-F)
Position D: Control unit KID (D795)

PRESENT DRIVE-TRAIN CAN BUS STATUS, ENGINE
page
–
Description: Indicates status for engine in the drivetrain’s CAN bus.

DIAG CAN/POWER 3(20) Circuit diagram: Circuit CAN-BUS opt. frame KDU group 11.6, Circuit
PRESENT DRIVE-TRAIN
CAN BUS STATUS Engine Volvo 1240&1250, group 1.0, Circuit Engine Cummins
ENGINE X group 1.0
000088
TRANSMISSION X Contact:
Volvo TWD1240VE: CAN J1939 from D790-1/K13:1 and K13:2 to
D794/1 and 2
Volvo TWDTAD1250VE: CAN J1939 from D790-1/K13:1 and
K13:2 to D794/1 and 2
Cummins QSM11: CAN J1939 from D790-1/K13:1 and K13:2 to
D794/46 and 37
Function: 11.6.3 CAN bus drive-train
Signal value:
NOTE
The cable harness for CAN bus drivetrain is common to the en-
gine and transmission from the cab electronic box to the frame
electronic box. The cable branches in the frame electronic box. If
communication with both the engine and transmission is cut off,
start troubleshooting at the cable harness between the cab elec-
tronic box and the frame electronic box. If there is communication
with either engine or transmission, then this rules out a fault in the
cable harness between the cab electronic box and the frame
electronic box.

PRESENT DRIVE-TRAIN CAN BUS STATUS,

page
–
TRANSMISSION
Description: Indicates status for transmission in the drivetrain’s
DIAG CAN/POWER 3(20) CAN bus.
PRESENT DRIVE-TRAIN
CAN BUS STATUS Circuit diagram: Circuit CAN-BUS opt. frame KDU group 11.6, Circuit
ENGINE X Dana TE32 FF group 2.0, Circuit shifting ZF group 2.0
000088
TRANSMISSION X Connection for Dana: CAN J1939 from D790-1/K13:1 and K13:2 to
D793/L2 and M2
Connection for ZF: CAN J1939 from D790-1/K13:1 and K13:2 to
D7930-2/25 and 26
Function: 11.6.3 CAN bus drive-train
Signal value:
NOTE
The cable harness for CAN bus drivetrain is common to the en-
gine and transmission from the cab electronic box to the frame
electronic box. The cable branches in the frame electronic box. If
communication with both the engine and transmission is cut off,
start troubleshooting at the cable harness between the cab elec-
tronic box and the frame electronic box. If there is communication
with either engine or transmission, then this rules out a fault in the
cable harness between the cab electronic box and the frame
electronic box.

IGNITION, KEY IN
page
–
Description: Indicates if ignition is turned on (key in ignition).

DIAG CAN/POWER 4(X)
Circuit diagram: Circuit Power group 11.5
INGNITION
KEY IN X Connection: signal from S150/15 to D790-1/K11:1
RELAY K315-1 XY
Function: 11.5.1.3 Ignition voltage
006859
RELAY K315-2 XY
Signal value:
1 Input signal active.
0 No signal.

IGNITION, RELAY K315-1

page
–
Description: Control current to Relay, ignition voltage (K315-1),

DIAG CAN/POWER 4(X) 15-voltage.
INGNITION
KEY IN X Circuit diagram: Circuit Power group 11.5
RELAY K315-1 XY Connection: signal from D790-1/K10:10 to K315-1/86
006859
RELAY K315-2 XY
Function: 11.5.1.3 Ignition voltage (15)
Signal value:
00 No output signal and open circuit in the circuit.
01 Normal mode function off.

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

page
–
Description: Control current to Relay, ignition voltage (K315-2)

DIAG CAN/POWER 4(X) (15-voltage).
INGNITION
KEY IN X Circuit diagram: Circuit Power group 11.5
RELAY K315-1 XY Connection: signal from D790-1/K10:16 to K315-2/86
006859
RELAY K315-2 XY
Signal value:


is missing.


EMERGENCY STOP, SW
page
–
Description: Indicates if switch, emergency stop switch, is activated.

DIAG CAN/POWER 5(X)
EMERGENCY STOP, SW X
RELAY K3009-1 XY Connection: signal from S250/12 to D790-1/K8:4
FEEDBACK X
Function: 11.5.1.4 Emergency stop switch voltage (15E)
006860
RELAY K3009-2 XY
Signal value:
0 No signal.
EMERGENCY STOP, RELAY K3009-1

page
–
Description: Status for control current to Relay K2, for emergency stop
DIAG CAN/POWER 5(X) switch voltage (K3009-1), 15E voltage.
RELAY K3009-1 XY Circuit diagram: Circuit Power group 11.5
FEEDBACK X Connection: signal from D790-1/K10:11 to K3009-1/86
006860
RELAY K3009-2 XY
Signal value:


is missing.
EMERGENCY STOP, FEEDBACK

page
–
Description: Feedback signal from control breaker voltage (K3009-1),

DIAG CAN/POWER 5(X) indicates that relay is working normally.
FEEDBACK X Connection: signal from K3009-1/87 via F58-3/8 to digital in D790-1/
006860
RELAY K3009-2 XY K11:13

Signal value:
0 No signal.

EMERGENCY STOP, RELAY K3009-2

page
–
Description: Status for control current to Relay control breaker voltage

DIAG CAN/POWER 5(X) (K3009-2), 15E voltage.
FEEDBACK X Connection: signal from D790-1/K10:12 to K3009-2/86
006860
RELAY K3009-2 XY
Signal value:


is missing.

790-1 CAB, POWER
page
–
Description: Ignition voltage (15) to Control unit, cab (D790-1).

DIAG CAN/POWER 6(20)
790-1 CAB
POWER XX.XXV Connection: 15 voltage from K315-1/87 via F54/4 and F58-5/1 to
5V REF X.XXV D790-1/K1:2, D790-1/K1:3 and D790-1/K1:4
000091
Function: 11.5.1 Voltage feed

Signal value: XX.XXV = voltage on the connection. The signal value
should be 22-30 V (battery voltage).
790-1 CAB, 5V REF

page
–
Description: Reference voltage 5 V to controls in cab.

Circuit diagram: Circuit Climate system group 9.4 (contact 1, 2), Circuit
790-1 CAB
POWER XX.XXV Drive-train group 1.1 (contact 3), Circuit Joystick group 7.1 (contact 4)
5V REF X.XXV Contact:
000091
1. signal from digital out D790-1/K4:5 to Y672/10 and Y673/10

2. signal from digital out D790-1/K5:11 to S118/1, S139/1 and
S117/1
3. signal from digital out D790-1/K5:13 to Y690/1 and Y697/1
4. signal from digital out D790-1/K7:2 to S815/9
Function: 9.4 Heating, ventilation and air conditioning (contact 1 and
2); 1 Engine and 2 Transmission (contact 3); 7 Load handling
(contact 4)
Signal value: X.XXV = 5.00 V, Important that the signal value is stable
(not varying).


790-1 CAB, 24V SENSOR SUPPLY
page
–
Description: 24 V voltage feed to components in cab.

Circuit diagram:
790-1 CAB
24V SENSOR SUPPLY XY 1. Circuit Wiper group 9.5
24V SUPPLY,RPM>500 XY
2. Circuit Extra equipment group 9.1, Circuit Drivetrain group 2.1,
003178
Circuit Cab operator’s seat group 9.3, Circuit Lighting group 9.6,
Circuit Work lights group 9.6 and Circuit Extra Sensor Instr.
group 9.1
3. Circuit Joystick group 7.1
4. Circuit Power group 11.5, Circuit Brake system group 4.0, Circuit
Bypassing group 8.2, Circuit Sliding/Vertically adjustable Cab
group 9.10, Circuit Hyd Support jacks group 7.10, Circuit Twist-
lock group 7.9, Circuit Spreading Sensor group 7.5, Circuit Op-
tional equipment group 9.1
5. Circuit Combi Att group 7.9
6. -
7. Circuit Sliding/Vertically adjustable cab group 9.10
8. Circuit alarm, audible signals group 9.7
9. Circuit Wiper group 9.5
10. Circuit Wiper group 9.5
Contact:
1. signal from digital out D790-1/K4:14 to M650-1/53a
2. signal from digital out D790-1/K5:1 to S199-1/5, S199-3/5, S199-
4/5, S220-2/1, S143/5, S100/5, S110/5, S105-3/5, S105-2/5,
S105-1/5
4. signal from digital out D790-1/K8:16 to S250/11, S107/5, S1005/
5, S1015/5, S1014/5, S177/3, S1013/3, S1003/3, S1003/4,
S1004/5, S199-2/5
5. signal from digital out D790-1/K9:1 to S1006/3, S1007/3, S1008/3
6. signal from digital out D790-1/K9:7 not connected
7. signal from digital out D790-1/K10:1 to B769-2/1

Function:
1. 9.5.5 Wiper motor front
2. 2.0 Transmission, 9.3 Seat, 9.6 Lighting
3. 7.1.1 Control lever
4. 11.5.1.4 Control breaker voltage, 4.5 Parking brake system,
8.2.2 Bypass, 9.10.4 Sliding cab, 9.10.5 Vertically adjustable cab,
7.10.1 Support jacks, 7.9.1 Twistlocks
5. 7.9.2 Lift jacks
6. -
7. 9.10.4 Sliding cab, 9.10.5 Vertically adjustable cab
8. 9.3.10 Sensor operator in seat
9. 9.5.7 Wiper motor rear
10. 9.5.6 Wiper motor roof
Signal value:

No output signal. It can also be a short circuit in the circuit as
errors can only be detected when the output signal is active.
10 Output signal active, short-circuiting. 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

page
–
Description: Voltage feed when engine speed is higher than 500 rpm.
Circuit diagram: Circuit Sensor Instr. group 9.1
790-1 CAB
24V SENSOR SUPPLY XY Connection: signal from digital out D790-1/K10:9 to P708/+ and
24V SUPPLY,RPM>500 XY K358/86
003178
Function: 9.3.6 Compressor air-suspension seat, 11.1.1 Hour meter

Signal value:


is missing.


797-F FRAME, POWER
page
–
Description: Ignition voltage (15) to Control unit, frame front (D797-F).

797-F FRAME
RED.POWER Le X Ri X D797-F/K2:1, D797-F/K2:9 and D797-F/K2:10
000093
EME STOP POWER X
797-F FRAME, RED. POWER

page
–
Description: Redundant voltage to Control unit, frame front (D797-F).

Circuit diagram: Circuit CAN BUS opt. frame KDU group 11.6
797-F FRAME
POWER XX.XXV Contact:
RED.POWER Le X Ri X
Le: redundant feed to D797-F/K2:7
000093
EME STOP POWER X

Ri: redundant feed to D797-F/K2:8
Function: 11.5.1.2 Redundant voltage feed of control units
Signal value:
1 Feed active.
0 No feed.
797-F FRAME, EME STOP POWER

page
–
Description: Control breaker voltage to Control unit, frame front

DIAG CAN/POWER 8(20) (D797-F).
797-F FRAME
POWER XX.XXV Circuit diagram: Circuit Power group 11.5
RED.POWER Le X Ri X Connection: 15E-voltage from K3009-1787 via K3009-2/87 and
000093
EME STOP POWER X F58-3/2 to D797-F/K2:11

Signal value:
1 Feed active.
0 No feed.


797-F FRAME, 24V SENSOR SUPPLY
page
–
Description: Voltage feed 24 V to sensors connected to Control unit,

DIAG CAN/POWER 9(20) frame front (D797-F) (pressure monitors).
797-F FRAME
24V SENSOR SUPPLY XY Circuit diagram: Circuit Brake system group 4.0, Circuit Drivetrain
5V REF X.XXV group 2.1, Circuit Lighting group 9.6
000094
Connection: signal from digital out D797-F/K1:39 to S, 200, S204,
S216 and S220
Function: 9.6.4 Brake lights, 2.2.6 Make-contact (closing switch) de-
clutch, 4.3.7 Make-contact (closing switch) brake pressure,
4.3.8 Make-contact (closing switch) brake lights 4.5.5 Make-contact
(closing switch) parking brake
Signal value:


is missing.
797-F FRAME, 5V REF

page
–
Description: Reference voltage 5 v to sensors connected to Control

DIAG CAN/POWER 9(20) unit, frame front (D797-F) (voltage feed to pressure sensors).
797-F FRAME
24V SENSOR SUPPLY XY Circuit diagram: Circuit OP + Scale group 8.2
5V REF X.XXV Connection: digital out from 797-F/K1:8 to B768-R1, B768-R2, B768-
000094
L1 and B768-L2
Function: 7.2.9 Sensor hydraulic pressure lift cylinder
(not varying).

797-R FRAME, POWER
page
–
Description: Ignition voltage (15) to Control unit, frame rear (D797-R).

Circuit: Circuit Power group 11.5
797-R FRAME
RED.POWER Le X Ri X D797-R/K2:1, and D797-R/K2:9
000095


797-R FRAME, RED. POWER

page
–
Description: Redundant voltage to Control unit, frame rear (D797-R).

797-R FRAME
POWER XX.XXV Contact:
RED.POWER Le X Ri X
Le: redundant feed to D797-R/K2:7
000095
Ri: redundant feed to D797-R/K2:8
Signal value:
1 Feed active.
0 No feed.

797-R FRAME, 24V SENSOR SUPPLY
page
–
Description: Voltage feed 24 V to sensors connected to Control unit,

DIAG CAN/POWER 11(20) frame rear (D797-R).
797-R FRAME
5V REF X.XXV Connection: digital out from D797-R/K1:2 to B7221
000096
Function: 8.2.1.1 Sensor steering axle load

Signal value:


is missing.
797-R FRAME, 5V REF

page
–
Description: Reference voltage 5 V to sensors connected to Control

DIAG CAN/POWER 11(20) unit, frame rear (D797-R).
797-R FRAME
5V REF X.XXV Connection: digital out from 797-R/K1:8 to B771/1 and B777/1
000096
Function: 8.2.1.2 Sensor, boom angle (angle sensor), 8.2.1.3 Sensor,

boom length (analogue sensor)
(not varying).


797-O FRAME, POWER
page
–

797-O FRAME Description: Ignition voltage (15) to Control unit, frame option
POWER XX.XXV (D797-O).
RED.POWER Le X Ri X
000097
EME STOP POWER X
Connection: 15-voltage from K315-1/30 via F54/4 and F58-2/4 to
D797-O/K2:10
797-O FRAME, RED. POWER

page
–

797-O FRAME Description: Redundant voltage to Control unit, frame option
POWER XX.XXV (D797-O).
RED.POWER Le X Ri X
000097
EME STOP POWER X

Contact:
Le: redundant feed to D797-O/K2:7
Ri: redundant feed to D797-O/K2:8
Signal value:
1 Feed active.
0 No feed.
797-O FRAME, EME STOP POWER

page
–

797-O FRAME Description: Control breaker voltage (15E) to Control unit, frame
POWER XX.XXV option (D797-O).
RED.POWER Le X Ri X
000097
EME STOP POWER X

Connection: 15E-voltage from K3009-1/87 via K3009-2/87 and F58-3/
4 to D797-O/K2:11
Signal value:
1 Feed active.
0 No feed.


797-O FRAME, 24V SENSOR SUPPLY
page
–

797-O FRAME Description: Battery voltage to sensor.
24V SENSOR SUPPLY XY Circuit diagram: Circuit Hyd Support jacks group 7.10, Circuit Tiltable
5V REF X.XXV
cab group 9.10
000098
Connection: digital out D797-O/K1:9 to B7222L, B7222R, B7223L,
B7223R
Function: 7.10.1.5 Sensor raised support jacks, 7.10.1.6 Sensor low-
ered support jacks
Signal value:


is missing.
790-O FRAME, 5V REF

page
–

797-O FRAME Description: not connected
24V SENSOR SUPPLY XY Circuit diagram: -
5V REF X.XXV
000098
Connection: digital out from D797-O/K1:8, not connected

Function: -
Signal value: -

795 DISPLAY, RED. POWER
page
–
Description: Redundant voltage to Control unit KID (D795).

795 DISPLAY
Contact:
RED.POWER Le X Ri X
Le: redundant feed to D790/K1:8
000099
Ri: redundant feed to D790/K1:7

Signal value:
1 Feed active.
0 No feed.


793 TRANSMISSION, POWER
page
–
Description: Battery voltage (30) to Control unit, transmission (D793).

Circuit diagram: Circuit Current group 11.5, Circuit Dana TE 32000
793 TRANSMISSION
POWER XX.XXV group 2.0, Circuit Dana TE32 FF group 2.0
IGNITION POWER XX.XXV Connection: 30-voltage from F54/2 via F58-1/5 to D793/A1
000100
SENSOR SUPPLY XX.XXV
Function: 11.5.1.1 Battery voltage (30)
793 TRANSMISSION, IGNITION POWER

page
–
Description: Ignition voltage (15) to Control unit, transmission (D793).

Circuit diagram: Circuit Current group 11.5, Circuit Dana TE 32000
793 TRANSMISSION
POWER XX.XXV group 2.0, Circuit Dana TE32 FF group 2.0
IGNITION POWER XX.XXV Connection: 15E-voltage from K315/87 via F54/4 and F58-2/5 till
000100
SENSOR SUPPLY XX.XXV D793/S2

793 TRANSMISSION, SENSOR SUPPLY

page
–
Description: Voltage feed to sensors on transmission, reference volt-

DIAG CAN/POWER 15(20) age of 5 V.
793 TRANSMISSION
POWER XX.XXV Circuit diagram: Circuit Dana TE 32000 group 2.0, Circuit Dana TE32
IGNITION POWER XX.XXV FF group 2.0
000100
SENSOR SUPPLY XX.XXV Contact:

Dana: 5V analogue Ref from D793/M1 to S221/1
Dana full-flow: 5V analogue Ref from D793/M1 to S2210/1
Function: 2.9 Control system, transmission
Signal value: XX.XXV = voltage on connection. The signal value
should be 8 V, stable (not vary).

791-1 ATTACHMENT, POWER
page
–
Description: Battery voltage to Control unit, attachment (D791-1).

791-1 ATTACHMENT
POWER XX.XXV Connection: 15E voltage from K3009-1/87 via K3009-2/87, F58-3/1
RED.POWER Le X Ri X
00003179
and F52-1 to D791-1/K2:1, K2:9, K2:10, K2:11


791-1 ATTACHMENT, RED. POWER

page
–
Description: Redundant voltage feed to Control unit, attachment

DIAG CAN/POWER 16(20) (D791-1).
791-1 ATTACHMENT
POWER XX.XXV Circuit diagram: Circuit CAN BUS opt. frame KDU group 11.6, Circuit
RED.POWER Le X Ri X CAN BUS ATT group, 11.6
00003179
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.

page
–

791-2 ATTACHMENT Description: Battery voltage to Control unit, attachment option
POWER XX.XXV (D791-2).
RED.POWER Le X Ri X
Circuit diagram: Circuit Power group 11.5, Circuit Power att.
000102
group 11.5
Connection: 15E voltage from K3009-1/87 via K3009-2/87, F58-3/1
and F52-1 to D791-2/K2:1, K2:11

page
–

791-2 ATTACHMENT Description: Redundant voltage to Control unit, attachment option
RED.POWER Le X Ri X
000102

Contact:
Le: redundant feed to D791-2/K2:7
Ri: redundant feed to D791-2/K2:8
Signal value:
1 Feed active.
0 No feed.


page
–

Description: Battery voltage to Control unit, attachment left jack pair
791-3 ATTACHMENT
RED.POWER Le X Ri X Circuit diagram: Circuit Power group 11.5, Circuit Combi Att group 7.9
000103
and F52-2 to D791-3/K2:1, K2:11
should be 22-30V (battery voltage).

page
–

Description: Redundant voltage to Control unit, attachment left jack
791-3 ATTACHMENT
POWER XX.XXV pair (D791-3).
RED.POWER Le X Ri X Circuit diagram: Circuit CAN BUS opt. frame KDU group 11.6, Circuit
000103

Contact:
Signal value:
1 Feed active.
0 No feed.

page
–

791-4 ATTACHMENT Description: Battery voltage to Control unit, attachment right jack pair
RED.POWER Le X Ri X
Circuit diagram: Circuit Power group 11.5, Circuit Combi Att group 7.9
000104

and F52-2 to D791-4/K2:1, K2:11
should be 22 - 30V (battery voltage).


page
–

791-4 ATTACHMENT Description: Redundant voltage to Control unit, attachment right jack
POWER XX.XXV pair (D791-4).
RED.POWER Le X Ri X
000104
Contact:
Signal value:
1 Feed active.
0 No feed.

24V SENS. SUP 791-1
page
–
Description: Voltage feed to position sensors connected to the attach-

DIAG CAN/POWER 20(20) ment control unit (D791-1).
24V SENS.SUP 791-1 XY
24V SENS.SUP 791-2 XY Circuit diagram: Circuit Spreading Valves group 7.5
24V SENS.SUP 791-3 XY Connection: digital out from D791/K1:10 to B769, B777-3, B7224,
003180
24V SENS.SUP 791-4 XY B7225, B7202L, B7202R, B7203L, B7203R, B7204L, B7204R,
B7205L and B7205R
Function: 7.5.10 Position sensor spreading, 7.6.10 Sensor rotation
stop, 7.9.1.8 Sensor alignment, 7.9.1.9 Sensor twistlocks, 8.2.1.6
Sensor boom length
Signal value:


is missing.

24V SENS. SUP 791-2

page
–

24V SENS.SUP 791-1 XY Description: Voltage feed to position sensors connected to the attach-
24V SENS.SUP 791-2 XY ment control unit (D791-2).
Circuit diagram: Circuit Over Height group 7.9
003180
Connection: digital out from D791/K1:10 to B7231L and B7231R
Function: 7.9.1 Twistlocks
Signal value:


is missing.
24V SENS. SUP 791-3

page
–

24V SENS.SUP 791-1 XY Description: Battery voltage to position sensor for the left jack pair on
24V SENS.SUP 791-2 XY the Combi attachment.
Circuit diagram: Circuit Combi Att group 7.9
003180

Connection: digital out from D791-3/K1:26 to B7212L, B7213L,
B7214L, B7215L, B7216L, B7217L, B7218L, B7219L and B7220L
Function: 7.9.2.9 Sensor, operating position, 7.9.2.10 Sensor knee,
7.9.2.13 Sensor lifting jacks, 7.9.2.15 Sensor alignment, 7.9.16 Sen-
sor clamping position
Signal value:


is missing.

24V SENS. SUP 791-4

page
–

24V SENS.SUP 791-1 XY Description: Battery voltage to position sensor for the right jack pair on
24V SENS.SUP 791-2 XY the combi attachment.
003180
Connection: digital out from D791-4/K1:26 to B7212R, B7213R,
B7214R, B7215R, B7216R, B7217R, B7218R, B7219R and B7220R
Function: 7.9.2.9 Sensor, operating position, 7.9.2.10 Sensor knee,
7.9.2.13 Sensor lifting jacks, 7.9.2.15 Sensor alignment, 7.9.16 Sen-
sor clamping position
Signal value:


Output signal active, circuit OK. It can also be an open circuit
as this can only be detected when the output signal is
missing.

REDCAN STATUS CHECK
page
–
Description: Control function from the redundant CAN bus. The control
DIAG CAN/POWER 21(X) unit attachment (D791-1) creates a virtual error in the redundant
REDCAN STATUS CHECK CAN-bus to check that all control units have contact and are connect-
PRESS ENTER ed in the right order. The control system indicates the fault by number-
ing the cables between the control units (segments) from 1 onwards.
006861
SEGMENT ERROR X
Segment 1 is always between the cab control unit (D790-1) and the
control unit attachment (D791-1). The last segment is always between
the KID control unit (D795) and the cab control unit (D790-1). The seg-
ments in between vary depending on machine configuration.
D791-4 D791-3 D791-2 D791-1
CAN R CAN L CAN R CAN L CAN R CAN L CAN R CAN L Contact:
4 3 2
D790-1 D790-2 D795 Signal value:

5
CAN RCAN L CAN R CAN L
1 9 8
0 No errors.
6 7
CAN L CAN R CAN L CAN R CAN L CAN R
>0 X > 0, the number indicates incorrect segment. Use circuit di-
006883
D797-R D797-O D797-F

agram to find the incorrect segment.
Segment numbering with maximum number of control
units. Control units marked with dashes are optional.

40 8 Control system – 8.4.2 LIGHTS
8.4.2 LIGHTS
LIGHTS, description
page
–
This group covers lighting.

DIAGNOSIS
CAN/POWER LIGHTS CAB Confirm selections with function key for Enter.
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
012083
OP EXTRA RMI
8.4.2.1 LIGHTS, menu 1

WORKING LIGHT CAB, SWITCH
page
–
Description: Signal from switch, work lights cab roof.

DIAG LIGHTS 1(13)
Circuit diagram: Circuit Work lights group 9.6
WORKING LIGHT CAB
SWITCH X Connection: from S105-1/1 to digital in D790-1/K6:10
OUTPUT LE XY RI XY
Function: 9.6 Lighting system
000107
Signal value:
0 No signal.
WORKING LIGHT CAB, OUTPUT

page
–
Description: Voltage feed to work lights cab roof.

DIAG LIGHTS 1(13)
WORKING LIGHT CAB
SWITCH X Contact:
OUTPUT LE XY RI XY
LE: digital out from D790-1/K2:7 to E404-1L
000107
RI: digital out from D790-1/K2:6 to E404-1R

Function: 9.6.9 Work light cab
Signal value:

No output signal. It can also be an error 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.

8 Control system – 8.4.2.2 LIGHTS, menu 2 41

WORKING LIGHT ATTACH, SWITCH
page
–
Description: Signal from switch, work lights attachment.

DIAG LIGHTS 2(13)
WORKING LIGHT ATTACH
SWITCH X Connection: signal from S105-2/1 to digital in D790-1/K6:2
OUTPUT LE XY RI XY
012084
OPT OUTPUT (2X) XY
Signal value:
0 No signal.
WORKING LIGHT ATTACH, OUTPUT

page
–
Description: Voltage feed to work lights, attachment, feed.

DIAG LIGHTS 2(13)
WORKING LIGHT ATTACH
SWITCH X Contact:
OUTPUT LE XY RI XY
LE: digital out from D791/K1:15 to E404-2L
012084
OPT OUTPUT (2X) XY

RI: digital out from D791/K1:1 to E404-2R
Function: 9.6.11 Work light attachment
Signal value:


is missing.

42 8 Control system – 8.4.2.3 LIGHTS, menu 3
WORK LIGHT ATTACH, OPT OUTPUT (2X)

page
–
DIAG LIGHTS 2(13)

WORKING LIGHT ATTACH Description: Voltage feed to the extra work lights on the attachment.
SWITCH X
Circuit diagram: Circuit Extra Work.li. Att group 9.6
OUTPUT LE XY RI XY
012084
OPT OUTPUT (2X) XY Connection: digital out from D791/K1:42 to E404-4R and E404-4L
Function: 9.6.11 Work light attachment
Signal value:


is missing.

WORK LIGHT BOOM, SWITCH
page
–
Description: Signal from switch, work lights boom.

DIAG LIGHTS 3(13)
WORKING LIGHT BOOM
SWITCH X Connection: from S105-3/1 to digital in D790-1/K6:3
OUTPUT LE XY RI XY
000109
OPTIONAL OUTPUT XX
Signal value:
0 No signal.

WORK LIGHT BOOM, OUTPUT

page
–
Description: Voltage feed to work lights boom.

DIAG LIGHTS 3(13)
WORKING LIGHT BOOM
SWITCH X Contact:
OUTPUT LE XY RI XY
LE: digital out from D797-R/K1:1 to E404-3L
000109
OPTIONAL OUTPUT XX
RI: digital out from D797-R/K1:15 to E404-3R
Function: 9.6.10 Work light boom
Signal value:


is missing.
WORK LIGHT BOOM, OPTIONAL OUTPUT

page
–
DIAG LIGHTS 3(13)

WORKING LIGHT BOOM Description: Voltage feed to extra work lights on the boom.
SWITCH X Circuit diagram: Circuit Extra Work.li. Boom group 9.6
OUTPUT LE XY RI XY
000109
OPTIONAL OUTPUT XX Connection: digital out from D790-1/K10:8, via relay K304/87 to
H404-5L and H404-5R
Function: 9.6.10 Work light boom
Signal value:


is missing.


MAIN LIGHT, SWITCH
page
–
Description: Signal from switch, headlights.

DIAG LIGHTS 4(13)
Circuit diagram: Circuit Lighting group 9.6
MAIN LIGHT
SWITCH X Connection: from S100/1 to digital in D790-1/K6:5
000110
Signal value:
0 No signal.

PRESENT OUTPUT SIGNAL, SIDE-F
page
–
Description: Voltage feed to side lights front.

DIAG LIGHTS 5(13)
PRESENT OUTPUT SIGNAL
SIDE-F LE XY RI XY Contact:
SIDE-R LE XY RI XY
LE: digital out from D797-F/K1:25 to H416-1
000111
REAR LE XY RI XY
RI: digital out from D797-F/K1:29 to H417-1
Function: 9.6.2 Running lights
Signal value:


is missing.

PRESENT OUTPUT SIGNAL, SIDE-R

page
–
Description: Voltage feed to side lights rear.

DIAG LIGHTS 5(13)
SIDE-R LE XY RI XY
LE: digital out from D797-R/K1:7 to H416-2
000111
REAR LE XY RI XY
RI: digital out from D797-R/K1:9 to H417-2
Function: 9.6.2 Running lights
Signal value:


is missing.
PRESENT OUTPUT SIGNAL, REAR

page
–
Description: Voltage feed to tail lights.

DIAG LIGHTS 5(13)
SIDE-R LE XY RI XY
LE: digital out from D797-R/K1:10 to H412L
000111
REAR LE XY RI XY
RI: digital out from D797-R/K1:25 to H412R
Function: 9.6.3 Tail lights
Signal value:


is missing.


HEAD LIGHTS, SWITCH
page
–
Description: Lighting headlights front, switch.

DIAG LIGHTS 6(13)
HEAD LIGHTS
SWITCH X Connection: from S162/56A to digital in D790-2/K3:9
HEAD LE XY RI XY
000112
DIMMED XY
Signal value:
0 No signal.
HEADLIGHTS, HEAD
page
–
Description: Power supply to headlights, high beams. If the machine is

DIAG LIGHTS 6(13) equipped with optional work lights front, this is connected in parallel
HEAD LIGHTS with the high beams.
SWITCH X
HEAD LE XY RI XY Circuit diagram: Circuit Lighting group 9.6 and Circuit Optional Work
000112
DIMMED XY lights Frame group 9.6

Contact:
LE: digital out from D797-F/K1:1 to E402L ( E404-7L and

E404-8L)
RI: digital out from D797-F/K1:15 to E402R ( E404-7R and

E404-8R)
Function: 9.6.1 Headlights
Signal value:


is missing.

HEADLIGHTS, LOW BEAM

page
–
Description: Voltage feed to headlights, low beam.

DIAG LIGHTS 6(13)
HEAD LIGHTS
SWITCH X Connection: digital out from D797-F/K1:42 to E400L and E400R
HEAD LE XY RI XY
Function: 9.6.1 Headlights
000112
DIMMED XY
Signal value:


is missing.

PRESENT INPUT SIGNAL, HAZARD SWITCH
page
–
Description: Signal from switch, flashing hazard lights (Hazard).

DIAG LIGHTS 7(13)
Circuit diagram: Circuit Direction indicators, Hazard flashers,
HAZARD SWITCH X group 9.7
FLASH.SW. LE X RI X Connection: from S109/1 to digital in D790-1/K5:6
000113
Function: 9.7 Signalling system

Signal value:
0 No signal.
PRESENT INPUT SIGNAL, FLASH.SW.

page
–
Description: Signal from switch, direction indicators.

DIAG LIGHTS 7(13)
HAZARD SWITCH X group 9.7
FLASH.SW. LE X RI X Contact:
000113
LE: from S161/1 to digital in D790-2/K8:9

RI: from S161/6 to digital in D790-2/K8:8
Signal value:
0 No signal.


PRESENT OUTPUT SIGNAL HAZARD/FLASHER, FRONT
page
–
Description: Voltage feed to direction indicators front.

DIAG LIGHTS 8(13)
HAZARD/FLASHER group 9.7
FRONT LE XY RI XY Contact:
000114
REAR LE XY RI XY
LE: digital out from D797-F/K1:9 to H422
RI: digital out from D797-F/K1:10 to H423
Function: 9.6.6 Direction indicators, 9.6.7 Flashing hazard lights
(Hazard)
Signal value:


is missing.
PRESENT OUTPUT SIGNAL HAZARD/FLASHER, REAR

page
–
Description: Voltage feed to direction indicators rear.

DIAG LIGHTS 8(13)
HAZARD/FLASHER group 9.7
FRONT LE XY RI XY Contact:
000114
REAR LE XY RI XY
LE: digital out from D797-R/K1:29 to H426
RI: digital out from D797-R/K1:39 to H427
Function: 9.6.6 Direction indicators, 9.6.7 Flashing hazard lights
(Hazard)
Signal value:


is missing.


ROTATION BEACON, SWITCH
page
–
Description: Signal from switch, rotating beacon.

DIAG LIGHTS 9(13)
ROTATION BEACON
SWITCH X Connection: from S110/1 to digital in D790-1/K6:4
OUTPUT XY
000115
Signal value:
0 No signal.
ROTATION BEACON, OUTPUT

page
–
Description: Voltage feed to rotating beacon.

DIAG LIGHTS 9(13)
ROTATION BEACON
SWITCH X Connection: digital out D790-1/K2:5 to H428
OUTPUT XY
Function: 9.6.8 Revolving beacon
000115
Signal value:



PRESENT INPUT SIGNAL, BRAKE LIGHT SWITCH
page
–
Description: Signal from make-contact (closing switch) brake lights.

DIAG LIGHTS 10(13)
BRAKE LIGHT SWITCH X Connection: from S216/2 to digital in D797-E/K1:13
REVERSE LIGHT SIGNAL X
Function: 4.3.8 Make-contact (closing switch) brake lights
013260
Signal value:
0 No signal.

PRESENT INPUT SIGNAL, REVERSE LIGHT SIGNAL

page
–
Description: Signal from Control unit, transmission (D793) when re-

DIAG LIGHTS 10(13) verse gear is activated.
BRAKE LIGHT SWITCH X Circuit diagram: Circuit Lighting group 9.6
REVERSE LIGHT SIGNAL X Contact: -
013260
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 LIGHT
page
–
Description: Voltage feed to brake lights.

DIAG LIGHTS 11(13)
BRAKE LIGHT LEXY RIXY Contact:
REVERSE LGT LEXY RIXY
000117
REVERSE ALARM XY
Function: 9.6.4 Brake lights
Signal value:


is missing.

PRESENT OUTPUT SIGNAL, REVERSE LGT

page
–
Description: Voltage feed to brake lights.

DIAG LIGHTS 11(13)
BRAKE LIGHT LEXY RIXY Contact:
000117
REVERSE ALARM XY
Function: 9.6.5 Back-up lights
Signal value:


is missing.
PRESENT OUTPUT SIGNAL, REVERSE ALARM

page
–
Description: Voltage feed to back-up alarm.

DIAG LIGHTS 11(13)
Circuit diagram: Circuit Back-up alarm group 9.7
BRAKE LIGHT LEXY RIXY Connection: digital out from D797-R/K1:30 to H965
Function: 9.7.5 Reverse alarm
000117
REVERSE ALARM XY
Signal value:


is missing.


CAB LIGHT, MANUAL SWITCH
page
–
Description: Signal from switch, lighting cab.

DIAG LIGHTS 12(13)
CAB LIGHT
MANUAL SWITCH X Connection: from KIT, D790-2/K8:11 to digital in D790-1/K11:2
DOOR SWITCH X
000118
OUTPUT XXX
Signal value:
0 No signal.
CAB LIGHT, DOOR SWITCH

page
–
Description: Signal from break-contact (opening switch) door.

DIAG LIGHTS 12(13)
CAB LIGHT
MANUAL SWITCH X Connection: from S266LE or S266RE (connected in parallel) to digital
DOOR SWITCH X in D790-1/K11:3
000118
OUTPUT XXX
Function: 9.10.2 Doors
Signal value:
0 No signal.
CAB LIGHT, OUTPUT

page
–
Description: Voltage feed to interior lighting cab.

DIAG LIGHTS 12(13)
CAB LIGHT
MANUAL SWITCH X Connection: from D790-1/K11:6 to E434
DOOR SWITCH X
Function: 9.6.12 Interior lighting cab
000118
OUTPUT XXX
Signal value: XXX = 0-255 = 0-24 V (255 means 24 V which corre-
sponds to battery voltage).

SWITCH LIGHTS, OUTPUT
page
–
Description: Voltage feed to background lighting in switches, panels

DIAG LIGHTS 13(13) and keys.
SWITCH LIGHTS Circuit diagram: -
OUTPUT XXX Contact: -

000119
Function: 9.6.12 Interior lighting cab

Signal value:
50 Means 4-5 V.
170 Means 15-16 V.

8 Control system – 8.4.3 CAB 53
8.4.3 CAB
CAB, description
page
–
This group covers functions in the cab.

DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
012086
OP EXTRA RMI
8.4.3.1 CAB, menu 1

WASHER, SWITCH
page
–
Description: Signal from gearshift lever and multi-function lever switch

DIAG CAB 1(X) washer.
WASHER
SWITCH X Circuit diagram: Circuit Wiper group 9.5
OUTPUT FRONT XY Connection: signal from S162/53C to digital in D790-2/K3:4
012087
OUTPUT REAR/ROOF XY
Function: 9.5 Wiper and washer system
Signal value:
0 No signal.
WASHER, OUTPUT
page
–
Description: Voltage feed to motor, windshield washer.

DIAG CAB 1(X)
Circuit diagram: Circuit Wiper group 9.5
WASHER
SWITCH X Connection: digital out D790-1/K10:13 to M651-1 and M651-2
OUTPUT FRONT XY
Function: 9.5.4 Washer motor and reservoir
012087
OUTPUT REAR/ROOF XY
Signal value:



54 8 Control system – 8.4.3.2 CAB, menu 2
WASHER, OUTPUT REAR/ROOF

page
–
Description: Grounding of motor washer roof and rear window. The

DIAG CAB 1(X) motor is supplied with voltage parallel with Motor windshield washing,
WASHER activation is controlled by controlling grounding of the motor. The mo-
SWITCH X tor is grounded at windshield washing if the wiper motor roof or rear
OUTPUT FRONT XY
window is activated.
012087
OUTPUT REAR/ROOF XY
Connection: PWM out D790-1/K5:4 to M651-2
Function: 9.5.4 Washer motor and reservoir
Signal value:


is missing.
8.4.3.2 CAB, menu 2

FRONT WIPER, SWITCH (1-3)
page
–
Description: Signal from multi-function lever, switch wiper function.

DIAG CAB 2(10)
FRONT WIPER
SWITCH (1-3) X Contact:
OUTPUT XY
X = 1 Interval slow: signal from S162/J1 to digital in D790-2/K3:6
000122
FEEDBACK X
X = 2 Interval less slow: signal from S162/J2, digital in D790-2/
K3:7
X = 3 Interval continuous: signal from S162/53, digital in D790-2/
K3:8
Signal value:
1 Long interval.
2 Normal interval.
3 Continuous operation.

8 Control system – 8.4.3.3 CAB, menu 3 55
FRONT WIPER, OUTPUT

page
–
Description: Voltage feed to wiper front.

DIAG CAB 2(10)
FRONT WIPER
SWITCH (1-3) X Connection: digital out D790-1/K2:1 to M650-1/53
OUTPUT XY
Function: 9.5.5 Wiper motor front
000122
FEEDBACK X
Signal value:


FRONT WIPER, FEEDBACK

page
–
Description: Signal from motor wiper front, indicates when the wiper
DIAG CAB 2(10) sweep is completed.
FRONT WIPER
SWITCH (1-3) X Circuit diagram: Circuit Wiper group 9.5
OUTPUT XY Connection: from M650-1/31b to digital in D790-1/K4:13
000122
FEEDBACK X
Function: 9.5.5 Wiper motor front
Signal value:
1 Input signal active (wiper sweep).
0 No signal (home position).
8.4.3.3 CAB, menu 3

REAR WIPER, SWITCH
page
–
Description: Status of rear window wiper switch on Control unit KIT

DIAG CAB 3(10) (D790-2).
REAR WIPER
SWITCH X Circuit diagram: -
OUTPUT XY Contact: -
000123
FEEDBACK X
Signal value:
1 Input signal active. Key for continuous/interval pressed down.
0 No signal.

REAR WIPER, OUTPUT

page
–
Description: Voltage feed to windshield wiper rear.

DIAG CAB 3(10)
REAR WIPER
SWITCH X Connection: digital out from D790-1/K2:4 to M650-2/53
OUTPUT XY
Function: 9.5.7 Wiper motor rear
000123
FEEDBACK X
Signal value:


REAR WIPER, FEEDBACK

page
–
Description: Signal from motor windshield wiper rear, indicates when

DIAG CAB 3(10) the wiper sweep is completed.
REAR WIPER
000123
FEEDBACK X
Function: 9.5.7 Wiper motor rear
Signal value:
8.4.3.4 CAB, menu 4

ROOF WIPER, SWITCH
page
–
Description: Signal from switch, wiper roof.

DIAG CAB 4(10)
Circuit diagram: -
ROOF WIPER
SWITCH X Contact: -
OUTPUT XY
000124
FEEDBACK X
Signal value:
1 Input signal active. Key for continuous/interval pressed down.
0 No signal.

ROOF WIPER, OUTPUT

page
–
Description: Voltage feed to wiper roof.

DIAG CAB 4(10)
ROOF WIPER
SWITCH X Connection: digital out D790-1/K10:14 to M650-3/53
OUTPUT XY
Function: 9.5.6 Wiper motor roof
000124
FEEDBACK X
Signal value:


is missing.
ROOF WIPER, FEEDBACK

page
–
Description: Signal from motor wiper roof, indicates when the wiper
DIAG CAB 4(10) sweep is completed.
ROOF WIPER
000124
FEEDBACK X
Function: 9.5.6 Wiper motor roof
Signal value:

8.4.3.5 CAB, menu 5

HORN, SWITCH
page
–
Description: Signal from switch, horn.

DIAG CAB 5(10)
Circuit diagram: Circuit alarm, audible signals group 9.7
HORN
SWITCH X Connection: signal from S162/H to digital in D790-2/K3:2
OUTPUT XY
013382
SWITCH JOYSTICK X
Signal value:
0 No signal.
HORN, OUTPUT
page
–
Description: Voltage feed to horn.

DIAG CAB 5(10)
HORN
SWITCH X
Connection: digital out D790-1/K11:11 to H850/8 ( for compressor
OUTPUT XY
horn, signal to relay K3016/86)
013382
SWITCH JOYSTICK X
Function: 9.7.1 Horn
Signal value:


SWITCH JOYSTICK
page
–
Description: Signal from switch open twistlocks on the joystick. The

DIAG CAB 5(10) signal is used to activate the horn when there is no alignment.
HORN
SWITCH X Circuit diagram: Circuit Joystick group 7.1
OUTPUT XY Connection: signal from S815/20 to digital in D790-1/K7:15
013382
SWITCH JOYSTICK X
Signal value:
0 No signal.

8.4.3.6 CAB, menu 6

BUZZER
page
–
Description: Voltage feed to buzzer for alarm indication panel, feed.

DIAG CAB 6(10)
BUZZER XY
SWITCH SEAT X Connection: digital out D790-1/K11:5 to H853/1
ALARM X
Function: 9.3 Seats, 1 Engine, 8.2.1 Overload system
000126
OP X
Signal value:


is missing.
SWITCH SEAT
page
–
Description: Signal from Sensor, operator-in-seat.

DIAG CAB 6(10)
BUZZER XY
SWITCH SEAT X Connection: signal from S230/1 to D790-1/K11:14
ALARM X
Function: 9.3.9 Sensor operator in seat
000126
OP X
Signal value:
1 Input signal active. Operator in seat.
0 No signal. No operator in seat.
ALARM
page
–
Description: Status for alarm indication panel, warning from control

DIAG CAB 6(10) system.
BUZZER XY
SWITCH SEAT X Circuit diagram: -
ALARM X Contact: -
000126
OP X
Function: 8.1.2 Information display
Signal value:
1 Conditions for activation of buzzer from seat switch and park-

ing brake are fulfilled
0 Conditions for activation of buzzer are not fulfilled.

OP
page
–
Description: Status for overload warning from the control system.

DIAG CAB 6(10)
Circuit diagram: Circuit OP + Scale group 8.2
BUZZER XY
SWITCH SEAT X Contact: -
ALARM X
Function: 8.2.1 Overload system
000126
OP X
Signal value:
1 Conditions for activation of the buzzer are fulfilled, that is,

overload system is indicating.
0 Conditions for activation of the buzzer are not fulfilled.
8.4.3.7 CAB, menu 7

FUEL, SENSOR VALUE
page
–
Description: Signal from sensor fuel level.

DIAG CAB 7(10)
FUEL
SENSOR VALUE XXXOHM Connection: analogue rheostat signal from B757/1 signal to D797-R/
PROC XXX K2:15
000127
Function: 1.2.2 Sensor fuel level

Signal value: XXXOHM = Current resistance value from sensor fuel
level in ohm.
FUEL, PROC
page
–
Description: The control system’s interpretation of the signal from sen-

DIAG CAB 7(10) sor, fuel tank.
FUEL
SENSOR VALUE XXXOHM Circuit diagram: Circuit Sensor Instr. group 9.1
PROC XXX Contact: -
000127
Function: 1.2.2 Sensor fuel level

Signal value: XXX = 0-100 = 0-100% = Fuel volume in tank.
8.4.3.8 CAB, menu 8

SEAT HEATER, SWITCH
page
–
DIAG CAB 8(10)

SEAT HEATER Description: Signal from switch, seat heat.
SWITCH X Circuit diagram: Circuit Cab operator’s seat group 9.3
OUTPUT XY
000128
Connection: signal from S143/1 to digital in D790-1/K6:6

Function: 9.3 Seat
Signal value:
0 No signal.

SEAT HEATER, OUTPUT

page
–
DIAG CAB 8(10)

SEAT HEATER Description: Control voltage to seat heating relay.
SWITCH X Circuit diagram: Circuit Cab operator’s seat group 9.3
OUTPUT XY
000128
Connection: digital out D790-1/K10:7 to K383/86
Function: 9.3.3 Heating coil
Signal value:


is missing.
8.4.3.9 CAB, menu 9

AUT. LUBRICATION CHASSIS, OUTPUT
page
–
DIAG CAB 9(X)

AUT LUBRICATION Description: Voltage feed to Central lubrication chassis. Central lubri-
CHASSI cation is only supplied with voltage when machine is in operation.
Circuit diagram: Circuit Central lubrication group 9.14
006863
OUTPUT XY
Connection: digital out D797-F/K1:28 to K693-1
Function: 9.14 Central lubrication
Signal value:


is missing.

8.4.3.10 CAB, menu 10

AUT. LUBRICATION ATTACHMENT, OUTPUT
page
–
DIAG CAB 10(X)

AUT LUBRICATION Description: Central lubrication, attachment, feed. Central lubrication
ATTACHMENT is only supplied with voltage when machine is in operation.
Circuit diagram: Circuit Central lubrication group 9.14
006864
OUTPUT XY
Connection: digital out D791/K1:14 to M693-2
Function: 9.14 Central lubrication
Signal value:


8.4.4 CLIMATE
CLIMATE, description
page
–
This group covers the cab’s air conditioning.

DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
012088
OP EXTRA RMI
8.4.4.1 CLIMATE, menu 1

PRESENT INPUT SIGNAL, REQUIRED TEMP
page
–
Description: Set value for desired temperature.

DIAG CLIMATE 1(8)
Circuit diagram: Circuit Climate system group 9.4
REQUIRED TEMP XXX Connection: signal from S139/3 to analogue in D790-1/K5:8
PRESENT TEMP XXX
Function: 9.4 Heating, ventilation and air conditioning
000132
WATER VALVE FEEDB. XXX

Signal value: XXX = 160-280 = 16-28 C Preset temperature
shown in tenths of degrees and adjusted in increments of half degrees
(200 = 20 C). Test by increasing or decreasing temperature with the
temperature switch on the panel.

8 Control system – 8.4.4.2 CLIMATE, menu 2 63
PRESENT INPUT SIGNAL, PRESENT TEMP

page
–
Description: Signal from sensor cab temperature.

DIAG CLIMATE 1(8)
REQUIRED TEMP XXX Connection: signal from B775-1/2 to input D790-1/K4:8
PRESENT TEMP XXX
Function: 9.4.17 Sensor cab temperature
000132
Signal value: XXX = Cab’s interior temperature in tenths of degrees
(200 = 20 C).
PRESENT INPUT SIGNAL, WATER VALVE FEEDB.

page
–
Description: Water valve’s position (opening in percent).

DIAG CLIMATE 1(8)
REQUIRED TEMP XXX Connection: signal from Y673/9 to analogue in D790-1/K10:4
PRESENT TEMP XXX
Function: 9.4.5 Water valve
000132

Signal value: XXX = 0-100 = 0-100% = Water valve’s opening in %.
0 = Closed. 100 = Fully open.

TEMP COIL
page
–
Description: Temperature of the air out from the fan. The sensor is lo-
DIAG CLIMATE 2(8) cated in the air distributor.
TEMP COIL XXX
TEMP COOLANT XXX Circuit diagram: Circuit Climate system group 9.4
TEMP AMBIENT XXX Connection: signal from B775-2/2 to input D790-1/K4:10
000133
TEMP DE-ICE XXX

Function: 9.4.16 Sensor, temperature outlet fan
Signal value: XXX = Temperature of the air blown into the cab in tenths
of degrees (200 = 20 C).
TEMP COOLANT
page
–
Description: Coolant temperature, temperature of the engine’s cool-

DIAG CLIMATE 2(8) ant. Signal is retrieved from the engine via CAN bus drivetrain.
TEMP COIL XXX
TEMP COOLANT XXX Circuit diagram: Circuit Climate system group 9.4
TEMP AMBIENT XXX Connection: from engine via CAN bus, see PRESENT INPUT SIG-
000133
TEMP DE-ICE XXX NAL, COOLANT TEMP page 80.

Function: 1.7.9 Sensor coolant temperature
Signal value: XXX = Engine temperature in tenths of degrees
(200 = 20 C).
TEMP AMBIENT
page
–
Description: Outdoor temperature. Heat radiation from engine and sun

DIAG CLIMATE 2(8) may affect the value since the sensor is installed on the rear of the cab
TEMP COIL XXX roof.
TEMP COOLANT XXX
TEMP AMBIENT XXX Circuit diagram: Circuit Climate system group 9.4
000133
TEMP DE-ICE XXX Connection: signal from B774/2 to input D790-1/K7:9

Function: 9.4.18 Sensor ambient temperature
Signal value: XXX = Outdoor temperature in tenths of degrees
(200 = 20 C).

64 8 Control system – 8.4.4.3 CLIMATE, menu 3
TEMP DE-ICE
page
–
Description: Temperature in refrigerant circuit.

DIAG CLIMATE 2(8)
TEMP COIL XXX
TEMP COOLANT XXX Connection: signal from B775-3/2 to input D790-1/K4:11
TEMP AMBIENT XXX
Function: 9.4.12 Sensor temperature refrigerant
000133
TEMP DE-ICE XXX
Signal value: XXX = Refrigerant temperature in tenths of degrees
(200 = 20 C).

PRESENT INPUT SIGNAL, PRESSURE SWITCH
page
–
Description: Signal from refrigerant pressure monitor.

DIAG CLIMATE 3(X)
PRESSURE SWITCH X Connection: signal from S246/2 to digital in D797-R/K1:37
OPT DOOR SWITCH X
Function: 9.4.10 Pressure switch
006865
Signal value:
1 Input signal active. Press Ok.
0 No signal, too high or too low pressure.
PRESENT INPUT SIGNAL, OPT DOOR SWITCH

page
–
DIAG CLIMATE 3(X)

PRESENT INPUT SIGNAL Description: Signal from switch operator’s door. On machines with the
PRESSURE SWITCH X option of automatic shutdown of AC with open door this signal is used
OPT DOOR SWITCH X to control the shutdown.
006865

Connection: signal from S266-LE or S266-RI to digital in D790-1/
K11:3
Signal value:
1 Input signal active. Door open.
0 No signal. Doors closed.


PRESENT INPUT SIGNAL, WATER VALVE
page
–
Description: Signal from water valve, the voltage is a measure of the

DIAG CLIMATE 4(8) position.
WATER VALVE XX.XXV Circuit diagram: Circuit Climate system group 9.4
DRAUGHT VALVE XX.XXV Connection: signal from Y673/9 to analogue in D790-1/K10:4
000135
Signal value: XX.XXV = 0.50 - 4.50 V
PRESENT INPUT SIGNAL, DRAUGHT VALVE

page
–
Description: Signal from the engine to the air distributor. Voltage is a

DIAG CLIMATE 4(8) measure of the valve’s position.
WATER VALVE XX.XXV Circuit diagram: Circuit Climate system group 9.4
DRAUGHT VALVE XX.XXV Connection: signal from Y672/9 to analogue in D790-1/K4:7
000135
Function: 9.4.14 Air distributor

Signal value: XX.XXV = 0.50 - 4.50 V

PRESENT INPUT SIGNAL, REQUIRED TEMP
page
–
Description: Signal from switch temperature. Voltage when switch is

DIAG CLIMATE 5(8) pressed in voltage level indicates increase or decrease of the
PRESENT INPUT SIGNAL temperature.
REQUIRED TEMP XX.XXV
REQ. DRAUGHT XX.XXV Circuit diagram: Circuit Climate system group 9.4
000136
REQ. FAN SPEED XX.XXV Connection: signal from S139/3 to analogue in D790-1/K5:8
Signal value: XX.XXV  2.4 / 0 / 5.0 V = Increase / - / decrease.
PRESENT INPUT SIGNAL, REQ. DRAUGHT

page
–
Description: Signal from switch air distribution, voltage when switch is

DIAG CLIMATE 5(8) pressed in. The voltage level indicates change of air control against
PRESENT INPUT SIGNAL windshield (up) or floor (down). The valve’s position changes in steps
REQUIRED TEMP XX.XXV between windshield - floor.
REQ. DRAUGHT XX.XXV
000136
REQ. FAN SPEED XX.XXV Circuit diagram: Circuit Climate system group 9.4
Connection: signal from S117/3 to analogue in D790-1/K5:9
Signal value: XX.XXV  2.4 / 0 / 5.0 V = Up / - / down.
PRESENT INPUT SIGNAL, FAN SPEED

page
–
Description: Signal from switch fan speed, switch controls increase or

DIAG CLIMATE 5(8) decrease of fan speed. Speed is endless adjustable. The voltage level
PRESENT INPUT SIGNAL indicates if the speed should be increased or decreased.
REQUIRED TEMP XX.XXV
REQ. DRAUGHT XX.XXV Circuit diagram: Circuit Climate system group 9.4
000136
REQ. FAN SPEED XX.XXV Connection: signal from S118/2 to analogue in D790-1/K5:7
Signal value: XX.XXV  2.4 / 0 / 5.0 V = Increase / - / decrease.


PRESENT OUTPUT SIGNAL, FAN SPEED
page
–
Description: Current control of fan motor, speed is controlled with

DIAG CLIMATE 6(8) PWM-control of grounding (of fan motor).
FAN SPEED XXX Circuit diagram: Circuit Climate system group 9.4
RECIRKULATION XY Connection: analogue out from D790-1/K2:2 to M657/31
000137
COMPRESSOR XY
Function: 9.4.3 cab fan.
Signal value: XXX = 0-255 = Fan speed (255 = max. fan speed).
PRESENT OUTPUT SIGNAL, RECIRCULATION

page
–
Description: Control voltage feed to motor for fresh air and recircula-
DIAG CLIMATE 6(8) tion damper.
FAN SPEED XXX Circuit diagram: Circuit Climate system group 9.4
RECIRKULATION XY Connection: digital out from D790-1/K2:3 to M612
000137
COMPRESSOR XY
Function: 9.4.2 Fresh air and recirculation damper
Signal value:


PRESENT OUTPUT SIGNAL, COMPRESSOR

page
–
Description: voltage feed of AC compressor’s electromagnetic clutch.

DIAG CLIMATE 6(8) Controls cut-in and cut-out of the compressor. Two outputs are con-
PRESENT OUTPUT SIGNAL nected in parallel to handle the current.
FAN SPEED XXX
RECIRKULATION XY Circuit diagram: Circuit Climate system group 9.4
000137
COMPRESSOR XY Connection: digital out from D797-R/K1:34 and K1:35 to M645/1

Function: 9.4.7 Compressor
Signal value:


is missing.


OUTPUT WATER VALVE, CLOCKWISE
page
–
Description: voltage feed to water valve, for opening. The valve is con-
DIAG CLIMATE 7(8) nected to an H-bridge. The signal can only be diagnosed when the
OUTPUT WATER VALVE valve’s position changes. The valve’s opening and closing are control-
CLOCKWISE XY XY led by the climate control unit’s software depending on desired tem-
ANTI-CLOCKWISE XY XY perature, outside temperature, cab temperature and coolant
temperature, therefore it may be difficult to determine if the valve is
working as it should.
24V
Connection: digital out from D790-1/K4:1 via R3 to Y673/5 and from
D790-1/K4:2 via R4 to Y673/6
M Signal value: motor runs clockwise row 1: 11 11 row 2: 00 11

000138
0V
H-bridge this is only detected when the output signal is active.

is missing.

OUTPUT WATER VALVE, ANTI-CLOCKWISE

page
–
Description: voltage feed to water valve, for closing. The valve is con-
DIAG CLIMATE 7(8) nected to an H-bridge. The signal can only be diagnosed when the
OUTPUT WATER VALVE valve’s position changes. The valve’s opening and closing are control-
CLOCKWISE XY XY led by the climate control unit’s software depending on desired tem-
ANTI-CLOCKWISE XY XY perature, outside temperature, cab temperature and coolant
temperature, therefore it may be difficult to determine if the valve is
working as it should.
24V
D790-1/K4:2 via R4 to Y673/6
M Signal value: motor runs anticlockwise row 1: 00 11, row 2: 11 11

000138
0V
H-bridge this is only detected when the output signal is active.

is missing.

OUTPUT DRAUGHT VALVE, CLOCKWISE
page
–
Description: Voltage feed to motor for the air distributor, rotation clock-
DIAG CLIMATE 8(8) wise. Is connected to an H-bridge. Signal can only be diagnosed when
OUTPUT DRAUGHT VALVE the air distributor’s position changes.
CLOCKWISE XY XY
ANTI-CLOCKWISE XY XY Circuit diagram: Circuit Climate system group 9.4
D790-1/K4:4 via R6 to Y672/6
24V
Signal value: motor runs clockwise row 1: 11 11, row 2: 00 11
M 01 Normal mode function off.


000139
0V 11 Normal mode function on.

H-bridge
is missing.

OUTPUT DRAUGHT VALVE, ANTI-CLOCKWISE

page
–
Description: Voltage feed to motor for the air distributor, rotation coun-
DIAG CLIMATE 8(8) ter-clockwise. The motor is connected to an H-bridge. Signal can only
OUTPUT DRAUGHT VALVE be diagnosed when the air distributor’s position changes.
CLOCKWISE XY XY
ANTI-CLOCKWISE XY XY Circuit diagram: Circuit Climate system group 9.4
D790-1/K4:4 via R6 to Y672/6
24V
Signal value: motor runs anticlockwise row 1: 00 11, row 2: 11 11
M 01 Normal mode function off.


000139
0V 11 Normal mode function on.

H-bridge
is missing.

70 8 Control system – 8.4.5 HYD
8.4.5 HYD
HYD, description
page
–
This group covers the hydraulic functions.

DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
009272
OP EXTRA RMI
8.4.5.1 HYD, menu 1

HYDRAULIC OIL, TEMP
page
–
Description: Signal from sensor hydraulic oil temperature.

DIAG HYD 1(6)
Circuit diagram: Circuit Hydraulics group 10.0
HYDRAULIC OIL
TEMP XXX Connection: signal from B776/1 for input D797-R/K2:13
FAN XY
Function: 10.6.3 Sensor hydraulic oil temperature
000141
Signal value: XXX = Temperature in tenths of degrees (200 = 20 C).
HYDRAULIC OIL, FAN

page
–
Description: Voltage feed cooling fan hydraulic oil.

DIAG HYD 1(6)
Circuit diagram: Circuit Hydraulics group 10.0
HYDRAULIC OIL
TEMP XXX Connection: digital out from D797-R/K1:14 to M668/1
FAN XY
Function: 10.6.4 Cooling fan
000141
Signal value:



8 Control system – 8.4.5.2 HYD, menu 2 71
8.4.5.2 HYD, menu 2

BRAKE COOLANT OIL, TEMP
page
–
Description: Signal from sensor for oil temperature, brake system.

DIAG HYD 2(6)
Circuit diagram: Circuit Brake system group 4.0
BRAKE COOLANT OIL
TEMP XXX Connection: signal from B762/1 for input D797-F/K2:13
FAN XY
Function: 4.8.10 Sensor oil temperature, brake system
000142
Signal value: XXX = Temperature in tenths of degrees (200 = 20 C).
BRAKE COOLING OIL, FAN

page
–
Description: Voltage feed to cooling fan for brake system oil.

DIAG HYD 2(6)
BRAKE COOLANT OIL
TEMP XXX Connection: digital out from D797-F/K1:14 to M674/1
FAN XY
Function: 4.8.8 Cooling fan
000142
Signal value:


8.4.5.3 HYD, menu 3

PRESSURE LIFTING CYL, C-
page
–
DIAG HYD 3(6)

PRESSURE LIFTING CYL Description: Pressure on the lift cylinders’ rod side (C-). For voltage
Le Ri value, see OP, description page 132.
C- XXX XXX
C+ XXX XXX Circuit diagram: Circuit OP + Scale group 8.2
Connection: See PRESENT INPUT SIGNAL LIFT CYL LE RI, C-
page 134
C- Signal value: XXX = 0-250 = Hydraulic pressure 0 - 25 MPa.
(255 = incorrect signal.)
NOTE
You can test the sensors quickly by lifting max. and overflowing
C+
the lift function. All 4 sensors (C+ and C-) should then show the
same pressure 0.1 MPa.
000143

72 8 Control system – 8.4.5.4 HYD, menu 4
PRESSURE LIFTING CYL, C+

page
–
Description: Pressure on the lift cylinders’ piston side (C+). For voltage
DIAG HYD 3(6) value, see OP, description page 132. Sensor on right lift cylinder is op-
PRESSURE LIFTING CYL
Le Ri tional .
C- XXX XXX Circuit diagram: Circuit OP + Scale group 8.2
C+ XXX XXX
Connection: See PRESENT INPUT SIGNAL LIFT CYL LE RI, C+
page 134
C- Signal value: XXX = 0-250 = Hydraulic pressure 0 - 25 MPa.

(255 = incorrect signal.)
NOTE
You can test the sensors quickly by lifting max. and overflowing
C+ the lift function. All 4 sensors (C+ and C-) should then show the
same pressure 0.1 MPa.
000143
8.4.5.4 HYD, menu 4

PRESSURE SWITCHES, BRAKE PRESSURE
page
–
Description: Signal from break-contact (opening switch) for oil pres-

DIAG HYDRAULIC 4(X) sure, brake system.
PRESSURE SWITCHES
BRAKE PRESSURE X Circuit diagram: Circuit Brake system group 4.0
BRAKE LIGHT PRESS. X Connection: signal from S204/2 to analogue in D797-E/K1:20
012403
DECLUTCH PRESSURE X
Function: 4.3.7 Break-contact (opening switch) oil pressure, brake
system
Signal value:
0 No signal.
PRESSURE SWITCHES, BRAKE LIGHT PRESS.

page
–
Description: Signal from make-contact (closing switch) brake lights.

DIAG HYDRAULIC 4(X)
PRESSURE SWITCHES
BRAKE PRESSURE X Connection: from S216/2 to analogue in D797-E/K1:13
BRAKE LIGHT PRESS. X
Function: 4.3.8 Make-contact (closing switch) brake lights
012403
DECLUTCH PRESSURE X
Signal value:
0 No signal.

8 Control system – 8.4.5.5 HYD, menu 5 73
PRESSURE SWITCHES, DECLUTCH PRESSURE

page
–
Description: Signal from make-contact declutch.

DIAG HYDRAULIC 4(X)
Circuit diagram: Circuit Drivetrain group 2.1
PRESSURE SWITCHES
BRAKE PRESSURE X Connection: from S220-2/2 to analogue in D797-F/K1:41
BRAKE LIGHT PRESS. X
Function: 2.8.2 Make-contact (closing switch), declutch
012403
DECLUTCH PRESSURE X
Signal value:
0 No signal.
8.4.5.5 HYD, menu 5

P-BRAKE, SWITCH
page
–
Description: Signals from switch parking brake. Two signals, one for
DIAG HYDRAULIC 5(X) released parking brake and one for applied parking brake. Both sig-
P-BRAKE nals must be valid to enable release of parking brake.
SWITCH X/Y
FEEDBACK SWITCH X Circuit diagram: Circuit Brake system group 4.0
012404
VALVE XY Connection: signal from S107/1 to digital in D790-1/K8:13 and from

S107/7 to digital in D790-1/K8:5
Function: 4.1.2 Switch parking brake
Signal value:
1/0 Open, parking brake released.
0/1 On, parking brake applied.
P-BRAKE, FEEDBACK SWITCH

page
–
Description: Signal from break-contact (opening switch) parking

DIAG HYDRAULIC 5(X) brake.
P-BRAKE
SWITCH X/Y Circuit diagram: Circuit Brake system group 4.0
FEEDBACK SWITCH X Connection: signal from S200/2 analogue in D797-E/K1:27
012404
VALVE XY
Function: 4.5.5 Break-contact (opening switch), parking brake
Signal value:
0 No signal.

74 8 Control system – 8.4.5.6 HYD, menu 6
P-BRAKE, VALVE
page
–
Description: Voltage feed to Solenoid valve parking brake.

DIAG HYDRAULIC 5(X)
P-BRAKE
SWITCH X/Y Connection: digital out D797-F/K1:7 to Y642-1
FEEDBACK SWITCH X
Function: 4.5.3 Solenoid valve parking brake
012404
VALVE XY
Signal value:


is missing.
8.4.5.6 HYD, menu 6

PRESENT OUTPUT SIGNAL, PRESSURE TO ATTACHM.
page
–
VALVE
Description: Voltage feed to Solenoid valve, engagement of hydraulics
DIAG HYD 6(6) for top lift.
PRESSURE TO ATTACHM. Circuit diagram: Circuit Rotation, group 7.6
VALVE XY Connection: digital out D797-R/K1:31 to Y6003/1
000146
Function: 7.4 Sideshift, 7.5 Spreading, 7.6 Rotation, 7.7 Tilt, 7.8 Lev-
elling 7.9.1 Twistlock, 7.9.2 Lifting jacks
Signal value:


is missing.

8 Control system – 8.4.6 ENGINE 75
8.4.6 ENGINE
ENGINE, description
page
–
This group handles engine functions.

DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
012093
OP EXTRA RMI

PRESENT INPUT SIGNAL, ACCELERATOR
page
–
Description: Signal from accelerator pedal.

DIAG ENGINE 1(X)
ACCELERATOR X.XXV Connection: signal from R690/2 to analogue in D790-1/K6:11
REQUIRED SPD PROC XXX
Function: 1 Engine
006866
REQUIRED SPD RPM XXXX

Signal value: X.XXV = 0.50-4.50 V
PRESENT INPUT SIGNAL, REQUIRED SPD PROC

page
–
Description: Required engine speed (in percent) which is sent from

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 TCU

page
–
Description: Required engine speed in rpm which is sent from Control

DIAG ENGINE 1(X) unit, transmission(D793) 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

76 8 Control system – 8.4.6.2 ENGINE, menu 2

PRESENT INPUT SIGNAL, ENGINE SPEED EDC
page
–
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: -
009281
Contact: -
Function: 1.9.2 Sensor engine rpm
Signal value: XXXX = Active speed in rpm.
PRESENT INPUT SIGNAL, ENGINE SPEED TCU

page
–
Description: Engine speed from Control unit, transmission (D793) to

DIAG ENGINE 2(X) Control unit, cab (D790-1) via CAN bus drive-train. Actual value for en-
PRESENT INPUT SIGNAL gine speed engine.
ENGINE SPEED EDC XXXX
ENGINE SPEED TCU XXXX Circuit diagram: -
009281
Contact: -
Function: 2.2.5 Sensor engine speed and oil temperature transmission
Signal value: XXXX = Active speed in rpm.

PRESENT INPUT SIGNAL, PRESENT TORQUE
page
–
Description: Current torque from engine control unit (D794). Percent-

DIAG ENGINE 3(X) age torque use of engine’s capacity.
PRESENT TORQUE XXX Circuit diagram: -
PRESENT TORQUE XXX Contact: -
006867
PRES TORQUE @ RPM XXX

Signal value: XXX = 0-100%
PRESENT INPUT SIGNAL, REQUIRED TORQUE

page
–
Description: Requested torque from cab control unit (D790-1) to en-

DIAG ENGINE 3(X) gine control unit (D794).
PRESENT TORQUE XXX Circuit diagram: -
006867

PRESENT INPUT SIGNAL, PRES TORQUE @ RPM

page
–
Description: Available torque at current engine speed.

DIAG ENGINE 3(X)
Circuit diagram: -
PRESENT TORQUE XXX
006867


8 Control system – 8.4.6.4 ENGINE, menu 4 77

PRESENT INPUT SIGNAL, PREHEAT SWITCH
page
–
DIAG ENGINE 4(10)

PRESENT INPUT SIGNAL Description: Signal from ignition, preheating position. Only used on
PREHEAT SWITCH X machines with Volvo engines.
CRANK ENGINE SWITCH X
000151
D+ X
Function: 1 Engine, 1.10.1 Preheating
Signal value:
0 No signal.
PRESENT INPUT SIGNAL, CRANK ENGINE SWITCH

page
–
Description: Signal from ignition, start position.

DIAG ENGINE 4(10)
PREHEAT SWITCH X Connection: signal from S150/50 to digital in D790-2/K2:1
CRANK ENGINE SWITCH X
Function: 1 Engine, 1.11 Start and stop
000151
D+ X
Signal value:
0 No signal.
PRESENT INPUT SIGNAL, D+

page
–
Description: Signal from alternator, indicates if alternator supplies

DIAG ENGINE 4(10) current.
PREHEAT SWITCH X Circuit diagram: Circuit Power group 11.5
CRANK ENGINE SWITCH X Connection: from G660/D+ to digital in D797-R/K2:16
000151
D+ X
Function: 11.4.1 Alternator
Signal value:
0 No signal.


PRESENT OUTPUT SIGNAL, PREHEAT
page
–
Description: Status for preheating of induction air.

DIAG ENGINE 5(10)
Circuit diagram: -
PREHEAT X Contact:
CRANK ENGINE X
Volvo: software signals on CAN-bus drivetrain
000152
Cummins: controlled by engine’s control system
Function: 1.10.1 Preheating
Signal value:
1 Output signal active.
0 No output signal.
PRESENT OUTPUT SIGNAL, CRANK ENGINE

page
–
Description: Status for Voltage feed starter motor.

DIAG ENGINE 5(10)
PREHEAT X Contact:
CRANK ENGINE X
Volvo: software signals on CAN-bus drivetrain
000152
Cummins: digital out D797-R/K1:36 to K360/86

Function: 1.11 Start and stop
Signal value:


is missing.


PRESENT INPUT SIGNAL, OIL PRESSURE
page
–
Description: Engine oil pressure. CAN-bus message from Control unit,

DIAG ENGINE 6(X) engine (D794) to Control unit, cab (D790-1).
OIL PRESSURE XXX Circuit diagram: see supplier documentation, engine
BOOST PRESSURE XXX Contact:
006868
OIL LEVEL XXX
Volvo TWD1240VE: signal from "43 Sensor oil temperature / pres-
sure" to Control unit engine (D794) "black connector" socket 14
Volvo TAD1250VE: signal from "28 Sensor oil temperature and oil
pressure" to engine control unit (D794) "Connector B" socket 11
Cummins QSM11: signal from "Oil pressure/temperature sensor"
to Control unit, engine (D794) "Sensor connector" socket 44
Function: 1.8.3 Sensor oil pressure engine
Signal value: XXX = 10 corresponds to 100 kPa.
PRESENT INPUT SIGNAL, BOOST PRESSURE

page
–
Description: Boost pressure. CAN-bus message from Control unit, en-

DIAG ENGINE 6(X) gine (D794) to Control unit, cab (D790-1).
OIL PRESSURE XXX Circuit diagram: see supplier documentation, engine
BOOST PRESSURE XXX Contact:
006868
OIL LEVEL XXX

Volvo TWD1240VE: signal from "36 Sensor boost pressure /
charge-air temp" to Control unit engine (D794) "black connector"
socket 2
Volvo TAD1250VE: signal from "23 Sensor boost pressure /
charge-air temp" to Control unit engine (D794) "connector A"
socket 22
Cummins QSM11: signal from "Intake manifold (boost) pressure
sensor" to Control unit, engine (D794) "Sensor connector"
socket 39
Function: 1.6.5 Sensor boost pressure
Signal value: XXX = 10 corresponds to 100 kPa.
PRESENT INPUT SIGNAL, OIL LEVEL

page
–
DIAG ENGINE 6(X)

PRESENT INPUT SIGNAL Only on engine alternative Volvo TAD1250VE
OIL PRESSURE XXX Description: Oil level engine. CAN-bus message from Control unit, en-
BOOST PRESSURE XXX
gine (D794) to Control unit, cab (D790-1).
006868
OIL LEVEL XXX

Circuit diagram: see supplier documentation, engine
Connection: Volvo TAD1250VE: signal from "15 Sensor oil level" to
Control unit engine (D794) "connector A" socket 3
Function:
Signal value: XXX = 0-100 = 0-100% = Oil level in percent.


PRESENT INPUT SIGNAL, OIL TEMP
page
–
Description: Temperature engine oil. 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 Contact:
009284
INTAKE MAIN.TEMP XXX
Volvo TWD1240VE: signal from "43 Sensor oil temperature / pres-
sure" to Control unit engine (D794) "black connector" socket 1
Volvo TAD1250VE: signal from "28 Sensor oil temperature and oil
pressure" to engine control unit (D794) "connector A" socket 31
Cummins QSM11: signal from "Oil pressure/temperature sensor"
socket 4 to Control unit, engine (D794) "Sensor connector"
socket 42
Function: 1.8.7 Sensor oil temperature
Signal value: XXX = 200 corresponds to 20 C.
PRESENT INPUT SIGNAL, COOLANT TEMP

page
–
Description: Temperature coolant. CAN-bus message from Control

009284

Volvo TWD1240VE: signal from "35 Sensor coolant temperature /
pressure" to Control unit engine (D794) "black connector"
socket 25
Volvo TWD1250VE: signal from "16 Sensor coolant temperature /
pressure" to Control unit engine (D794) "connector B" socket 27
Cummins QSM11: signal from "Coolant temperature sensor" to
Control unit, engine (D794) "Sensor connector" socket 02
Function: 1.7.9 Sensor coolant temperature

PRESENT INPUT SIGNAL, INTAKE MAIN.TEMP

page
–
Description: Temperature charge-air. CAN-bus message from Control

009284
Volvo TWD1240VE: signal from "36 Sensor boost pressure /
charge-air temp." to Control unit engine (D794) "black connector"
socket 2
Volvo TAD1250VE: signal from "23 Sensor boost pressure /
charge-air temp." to Control unit engine (D794) "connector A"
socket 47
Cummins QSM11: signal from "Intake manifold /(Boost) tempera-
ture sensor" to Control unit, engine (D794) "Sensor connector"
sleeve 38
Function: 1.6.6 Sensor charge-air temperature

PRESENT EDC ERROR, NO. OF ACT ERROR
page
–
Description: Number of active error codes from Control unit, engine

DIAG ENGINE 8(X) (D794).
PRESENT EDC ERROR
NR OF ACT ERROR XX Circuit diagram: -
SPN XXXX Contact: -
009279
FMI XX
Function: 1.9 Control system
Signal value: XX = number of active error codes.
PRESENT EDC ERROR, SPN

page
–
Description: SPN number for the first error code from Control unit, en-
DIAG ENGINE 8(X) gine (D794). SPN indicates the malfunction area, i.e., what component
PRESENT EDC ERROR or signal is defective. Error codes are shown using SPN/FMI in the er-
NR OF ACT ERROR XX ror 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

page
–
Description: FMI number for the first error code from the engine control
DIAG ENGINE 8(X) unit (D794). FMI indicates error type, e.g., short circuit or low value. Er-
PRESENT EDC ERROR ror codes are shown with SPN/FMI in error code menus.
NR OF ACT ERROR XX
SPN XXXX Circuit diagram: -
009279
FMI XX Contact: -
Function: 8.3 Error codes
Signal value: XX = fault type number. Use the error code list; see sec-
tion D Error codes.


FUEL CONSUMPTION, MOMENTARILY l/h
page
–
Description: Current fuel consumption in litres/hour.

DIAG ENGINE 9(X)
Circuit diagram: -
FUEL CONSUMTION
MOMENTARILY l/h XXX Contact: -
Function: 1.2 Fuel system
009280
Signal value: XXX = fuel consumption in l/h.
8.4.7 TRANSM, Dana TE32FF

TRANSM, description
page
–
This group handles transmission functions.

DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
009274
OP EXTRA RMI
8.4.7.1 TRANSM, menu 1

PRESENT INPUT SIGNAL, BRAKE PEDAL
page
–
DIAG TRANSM. 1(15)

PRESENT INPUT SIGNAL Description: Not used.
BRAKE PEDAL X.XXV Circuit diagram: Circuit Drivetrain group 2.1
DECLUTCH SWITCH X
000159
DECLUTCH PRESS SW. X Connection: signal from R697/3 to analogue on D790-1/K6:12

Function: -
PRESENT INPUT SIGNAL, DECLUTCH SWITCH

page
–
Description: Signal from declutch pedal.

DIAG TRANSM. 1(15)
BRAKE PEDAL X.XXV Connection: signal from S220-1/2 to digital in D790-1/K6:14
DECLUTCH SWITCH X
Function: 2.1.2 Declutch pedal
000159
DECLUTCH PRESS SW. X

Signal value:
1 Input signal active. Declutch pedal pressed down.
0 No signal.

8 Control system – 8.4.7.2 TRANSM, menu 2 83
PRESENT INPUT SIGNAL, DECLUTCH PRESS SW.

page
–
Description: Signal from make-contact declutch (pressure monitor).

DIAG TRANSM. 1(15)
BRAKE PEDAL X.XXV Connection: signal from S220-2/2 to digital in D797-E/K1:41
DECLUTCH SWITCH X
000159
Signal value:
0 No signal.

SWITCHES, FORWARD
page
–
Description: Signal from gearshift lever and multi-function lever

DIAG TRANSM. 2(15) (forward).
SWITCHES
FORWARD X Circuit diagram: Circuit Drivetrain group 2.1
REVERSE X Connection: from S162/F to digital in D790-2/K3:11
000160
SHIFT MODE X
Function: 2 Transmission
Signal value:
1 Input signal active. Travel direction forward selected.
0 No signal.
SWITCHES, REVERSE
page
–

DIAG TRANSM. 2(15) (reverse).
SWITCHES
REVERSE X Connection: from S162/R to digital in D790-2/K3:12
000160
SHIFT MODE X
Signal value:
1 Input signal active. Travel direction reverse selected.
0 No signal.

84 8 Control system – 8.4.7.3 TRANSM, menu 3
SWITCHES, SHIFT MODE

page
–
Description: Signal from shifting program switch. Status on CAN bus

DIAG TRANSM. 2(15) from KIT control unit (D790-2). The switches are integrated in the KIT
SWITCHES control unit (D790-2).
FORWARD X
REVERSE X Circuit diagram: -
000160
SHIFT MODE X Contact: -
Signal value:
1 Shifting program 1 selected.
4 Automatic shifting selected.

PRESENT VALUE, FORWARD
page
–
Description: Status for forward direction of travel from transmission

DIAG TRANSM. 3(15) control unit (D793). Indicates if forward drive is activated in the
PRESENT VALUE transmission.
FORWARD X
000161
GEAR X Contact: -
Signal value:
1 Output signal for travel direction forward active.
0 No output signal.
PRESENT VALUE, REVERSE

page
–
Description: Status for rearward direction of travel from transmission

DIAG TRANSM. 3(15) control unit (D793). Indicates if rearward drive is activated in the
FORWARD X
000161
GEAR X Contact: -
Signal value:
1 Output signal for travel direction reverse active.
0 No output signal.

PRESENT VALUE, GEAR

page
–
Description: Current gear, status from transmission control unit

DIAG TRANSM. 3(15) (D793). Shows which gear is activated in the transmission.
PRESENT VALUE
FORWARD X Circuit diagram: -
REVERSE X Function: 2.8 Control system, transmission
000161
GEAR X
Contact: -
Signal value: X = current gear.

OPERATING STATE, AUT/MAN MODE
page
–
Description: Shows which shifting program is selected automatic or

DIAG TRANSM. 4(15) manual.
OPERATING STATE
AUT/MAN MODE X Circuit diagram: -
WARNING X Contact: -
000162
OPERATING MODE X
Signal value:
1 Automatic.
0 Manual.
OPERATING STATE, WARNING

page
–
Description: Warning for serious malfunction in transmission from

DIAG TRANSM. 4(15) Control unit, transmission (D793).
OPERATING STATE
000162
OPERATING MODE X
Signal value:
1 Active error.
0 No errors.

OPERATING STATE, OPERATING MODE

page
–
Description: Operating mode status for Control unit, transmission

DIAG TRANSM. 4(15) (D793), also shown in control unit display.
OPERATING STATE
000162
OPERATING MODE X
Signal value:
0 Not used.
1 Manual or automatic shifting, standard mode shown during

operation.
2 Not used.
3 Not used.
4 Limp-home, reduced capacity due to malfunction in transmis-

sion.
5 Shutdown, serious transmission malfunction control unit

shuts down, likely that malfunction cannot be shown as
CAN-bus.
6 Calibration of transmission in progress.

OPERATING STATE, SHIFT IN PROGRESS
page
–
Description: Status for transmission function during operation, shifting

DIAG TRANSM. 5(15) in progress. Active during shifting.
OPERATING STATE
SHIFT IN PROGRESS X Circuit diagram: -
FAULT X Contact: -
000163
OLD FAULT X
Signal value:
1 Shifting in progress.
0 No activity.
OPERATING STATE, FAULT

page
–
Description: Status for transmission’s function during operation, active

DIAG TRANSM. 5(15) error codes present.
OPERATING STATE
FAULT X Contact: -
000163
OLD FAULT X
Signal value:
1 Active error code.
0 No error codes.

OPERATING STATE, OLD FAULT

page
–
Description: Status for transmission’s function during operation, there

DIAG TRANSM. 5(15) are inactive error codes that have not been acknowledged.
OPERATING STATE
FAULT X Contact: -
000163
OLD FAULT X
Signal value:
1 There are inactive error codes that have not been

acknowledged.
0 No unacknowledged error codes.

ENGINE SPEED
page
–
Description: Rpm signal from sensor rpm engine speed (position 3).
DIAG TRANSM. 6(15)
Circuit diagram: Circuit Dana TE32 FF group 2.0
ENGINE SPEED XXXXrpm
TURBINE SPEED XXXXrpm Connection: signal from B7530 to D793/F3 and D793/K3
DRUM SPEED XXXXrpm
OUTPUT SPEED XXXXrpm
Signal value: XXXXrpm = rpm.
1 2 3
5
013149
4
1. Sensor, drum rpm (B7520)
2.Temperature switch, torque converter (S2210)
3.Sensor rpm output shaft (B7530)
4.Sensor speed turbine transmission (B7510)
6.Sensor oil temperature (B7660)

TURBINE SPEED
page
–
Description: signal from sensor rpm turbine transmission (position 4).

DIAG TRANSM. 6(15)
TURBINE SPEED XXXXrpm Connection: signal from B7510 to D793/G3 and D793/K3
DRUM SPEED XXXXrpm
Function: 2.3.6 Sensor rpm turbine
1 2 3
5
013149
4
DRUM SPEED
page
–
Description: Signal from sensor rpm drum (position 1).

DIAG TRANSM. 6(15)
TURBINE SPEED XXXXrpm Connection: signal from B7520 till D793/B3 and D793/C3
DRUM SPEED XXXXrpm
Function: 2.3.7 Sensor rpm drum
1 2 3
5
013149
4

OUTPUT SPEED
page
–
Description: Signal from sensor rpm output shaft (propeller shaft)

DIAG TRANSM. 6(15) (position 5).
TURBINE SPEED XXXXrpm Circuit diagram: Circuit Dana TE32 FF group 2.0
DRUM SPEED XXXXrpm Connection: signal from B7580 till D793/ D3 and D793/ E3
Function: 2.3.9 Sensor rpm output shaft
1 2 3
5
013149
4

FWD SELECTION
page
–
Description: Status of feed to solenoid valve FWD selection.

DIAG TRANSM. 7(15)
FWD SELECTION X
REV SELECTION X Connection: signal from D793/K1 and D793/S3 to Y6066F
2/4 SELECTION X
013178
1/3 SELECTION X
1 Activated.
0 No signal.
REV SELECTION
page
–
Description: Status of feed to solenoid valve FWD selection.

DIAG TRANSM. 7(15)
FWD SELECTION X
REV SELECTION X Connection: signal from D793/E2 and D793/S3 to Y6066R
2/4 SELECTION X
013178
1/3 SELECTION X
Signal value:
1 Activated.
0 No signal.

2/4 SELECTION
page
–
Description: Status of feed to solenoid valve 2ND/4TH SELECTION.

DIAG TRANSM. 7(15)
FWD SELECTION X
REV SELECTION X Connection: signal from D793/K2 and D793/R2 to Y6074
2/4 SELECTION X
013178
1/3 SELECTION X
Signal value:
1 Activated.
0 No signal.
1/3 SELECTION
page
–
Description: Status of feed to solenoid valve 1ST/3RD SELECTION.

DIAG TRANSM. 7(15)
FWD SELECTION X
REV SELECTION X Connection: signal from D793/F2 and D793/S3 to Y60675
2/4 SELECTION X
013178
1/3 SELECTION X
Signal value:
1 Activated.
0 No signal.

2/4 SUPPLY
page
–
Description: Status for control current to clutch pack 2/4.

DIAG TRANSM. 8(15)
SUPPLY
FWD/REV SUPPLY X Connection: signal from D793/F1 and D793/G1 to Y6069
2/4 SUPPLY X
Function: 2.3.5 Valve block, transmission control, 2.8 Control system,
013252
1/3 SUPPLY X
transmission
Signal value:
1 Activated.
0 No signal.
1/3 SUPPLY
page
–
Description: Status for control current to clutch pack 1/3.

DIAG TRANSM. 8(15)
SUPPLY
FWD/REV SUPPLY X Connection: digital out from D793/ D1 and D793/ E1 to Y6067
2/4 SUPPLY X
013252
1/3 SUPPLY X
transmission
Signal value:
1 Activated.
0 No signal.


ANALOG OUTPUTS, FWD/REV FEEDBACK
page
–
Description: Present control current to solenoid valve clutch pack for-

DIAG TRANSM. 9(X) ward and reverse.
ANALOG OUTPUTS
FWD/REV F.B XXXXmA Circuit diagram: Circuit Dana TE32 FF group 2.0
2/4 FEEDBACK XXXXmA Connection: signal from D793/B1 and D793/C1 to Y6300
1/3 FEEDBACK XXXXmA
013408
transmission
Signal value: XXXX = Measured current value in mA.
ANALOG OUTPUTS, 2/4 FEEDBACK

page
–
Description: Present control current to solenoid valve clutch pack 2/4.

DIAG TRANSM. 9(X) Circuit diagram: Circuit Dana TE32 FF group 2.0
ANALOG OUTPUTS
FWD/REV F.B XXXXmA Connection: signal from D793/F1 and D793/G1 to Y6069
2/4 FEEDBACK XXXXmA
1/3 FEEDBACK XXXXmA
013408
transmission
ANALOG OUTPUTS, 1/3 FEEDBACK

page
–
Description: Present control current to solenoid valve clutch pack 1/3.

ANALOG OUTPUTS
FWD/REV F.B XXXXmA Connection: digital out from D793/ D1 and D793/ E1 to Y6067
2/4 FEEDBACK XXXXmA
1/3 FEEDBACK XXXXmA
013408
transmission

2/4 PRESSx10
page
–
Description: Signal from sensor oil pressure in transmission.

2/4 PRESSx10 XXXXBar
1/3 PRESSx10 XXXXBar Connection: signal from B6069 to D793/S1
TRANSM.TEMP XXXXmV
Function: 2.6.2 Sensor oil pressure
CONV OUT TEMP XXXXmV
013410
Signal value:
0-5 bar Short-circuiting to ground.
8-15 bar Oil pressure is correct.
15-25 bar Oil pressure is high.
Over 25 bar Open circuit or short-circuiting to voltage.

1/3 PRESSx10
page
–
Description: Signal from sensor oil pressure in transmission.

1/3 PRESSx10 XXXXBar Connection: signal from B6067 to D793/A2
TRANSM.TEMP XXXXmV
Function: 2.6.2 Sensor oil pressure
013410
Signal value:
0-5 bar Short-circuiting to ground.
8-15 bar Oil pressure is correct.
15-25 bar Oil pressure is high.
Over 25 bar Open circuit or short-circuiting to voltage.
TRANSM.TEMP
page
–
Description: Signal from sensor transmission oil temperature.

1/3 PRESSx10 XXXXBar Connection: signal from B7660 to D793/H3
TRANSM.TEMP XXXXmV
013410
Signal value: XXXX mV = signal voltage in mV (0-5000 mV).
CONV OUT TEMP

page
–
Description: Signal from sensor oil temperature in cooler transmission.

DIAG TRANSM. 10(X) The transmission uses a temperature-sensitive make-contact and two
2/4 PRESSx10 XXXXBar resistors in the cable harness to generate different voltage levels.
TRANSM.TEMP XXXXmV Circuit diagram: Circuit Dana TE32 FF group 2.0
013410
Connection: signal from S2210 to D793/J3

Function: 2.7.4 Sensor oil temperature oil cooler
Signal value:
0 mV Transmission oil has operating temperature.
2500 mV Transmission oil temperature is low.

AXLE RATIOx1024
page
–
Description: Drive axle gear ratio.

DIAG TRANSM. 11(X) Circuit diagram: -
PRESENT VALUE
AXLE RATIOx1024 XXXXX Contact: -
RADIUS XXXX Function: 2.8 Control system, transmission
SPEED LIMIT XXXX
013431
Signal value: XXXXX = drive axle’s total gear ratio

RADIUS
page
–
Description: Drive wheels’ radius

PRESENT VALUE
SPEED LIMIT XXXX
013431
Signal value: XXXX = Drive wheels’ radius in mm.
SPEED LIMIT (transmission alternative Dana full-flow)

page
–
Description: Speed limitation.

PRESENT VALUE
SPEED LIMIT XXXX
013431
Signal value: XXX = Speed limitation in km/h.

NOT USED
page
–
This menu is not used.

DIAG TRANSM. 12(X)
NOT USED
006872

ACT ERROR AREA
page
–
Description: Indicates malfunction area active error, first part of the er-
DIAG TRANSM. 13(15) ror code. In case of several error codes, the most serious error code
ACT ERROR AREA XXX is shown.
TYPE XXX
NUMBER OF OCCU. XXXXX Circuit diagram: -
000171
TIME AGO XXXXX Contact: -

Signal value: XXX = First part of error code; see section D Error codes.
TYPE
page
–
Description: Indicates type of active error.

DIAG TRANSM. 13(15)
Circuit diagram: -
ACT ERROR AREA XXX
TYPE XXX Contact: -
NUMBER OF OCCU. XXXXX
000171
TIME AGO XXXXX

Signal value: XXX = Second part of error code.

NUMBER OF OCCU.
page
–
Description: Number of times active errors have occurred.

DIAG TRANSM. 13(15)
Circuit diagram: -
ACT ERROR AREA XXX
TYPE XXX Contact: -
000171
TIME AGO XXXXX
Signal value: XXXXX = Number of times active errors have occurred.
TIME AGO
page
–
Description: When latest active error occurred.

DIAG TRANSM. 13(15)
Circuit diagram: -
ACT ERROR AREA XXX
TYPE XXX Contact: -
000171
TIME AGO XXXXX

Signal value: XXXXX = Operating time in hours since latest error.

CONVERTER STATUS (Nm), TORQUE IMPELLER
page
–
Description: Torque transmitted by from engine to impeller in torque

DIAG TRANSM. 14(X) converter. The torque absorbed by the transmission.
CONVERTER STATUS (Nm)
TORQUE IMPELLER XXXX Circuit diagram: -
TORQUE TURBINE XXXX Contact: -
006873

Signal value: XXXX = Torque in Nm.
CONVERTER STATUS (Nm), TORQUE TURBINE

page
–
Description: Current torque transmitted by torque converter to the

DIAG TRANSM. 14(X) gearbox.
CONVERTER STATUS (Nm)
TORQUE IMPELLER XXXX Circuit diagram: -
TORQUE TURBINE XXXX Contact: -
006873

Signal value: XXXX = Torque in Nm.

8 Control system – 8.4.7 TRANSM, ZF 5WG261 95
8.4.7 TRANSM, ZF 5WG261

PRESENT INPUT SIGNAL, BRAKE PEDAL
page
–
DIAG TRANSM. 1(X)

PRESENT INPUT SIGNAL Description: Not used.
BRAKE PEDAL X.XXV
DECLUTCH SWITCH X
015635
DECLUTCH PRESS SW. X Connection: signal from R697/3 to analogue on D790-1/K6:12
Function: -
PRESENT INPUT SIGNAL, DECLUTCH SWITCH

page
–
Description: Signal from declutch pedal.

DIAG TRANSM. 1(X)
BRAKE PEDAL X.XXV Connection: signal from S220-1/2 to digital in D790-1/K6:14
DECLUTCH SWITCH X
Function: 2.1.2 Declutch pedal
015635

Signal value:
1 Input signal active. Declutch pedal pressed down.
0 No signal.
PRESENT INPUT SIGNAL, DECLUTCH PRESS SW.

page
–
Description: Signal from make-contact declutch (pressure monitor).

DIAG TRANSM. 1(X)
BRAKE PEDAL X.XXV Connection: signal from S220-2/2 to digital in D797-E/K1:41
DECLUTCH SWITCH X
015635

Signal value:
0 No signal.

SWITCHES, FORWARD
page
–

DIAG TRANSM. 2(X) (forward).
SWITCHES
REVERSE X Connection: from S162/F to digital in D790-2/K3:11
015636
SHIFT MODE X
Signal value:
1 Input signal active. Travel direction forward selected.
0 No signal.

SWITCHES, REVERSE
page
–

DIAG TRANSM. 2(X) (reverse).
SWITCHES
REVERSE X Connection: from S162/R to digital in D790-2/K3:12
015636
SHIFT MODE X
Signal value:
1 Input signal active. Travel direction reverse selected.
0 No signal.
SWITCHES, SHIFT MODE

page
–
Description: Signal from shifting program switch. Status on CAN bus

DIAG TRANSM. 2(X) from KIT control unit (D790-2). The switches are integrated in the KIT
SWITCHES control unit (D790-2).
FORWARD X
015636
SHIFT MODE X Contact: -

Signal value:
4 Automatic shifting selected.

PRESENT VALUE, FORWARD
page
–
Description: Status for forward direction of travel from transmission

DIAG TRANSM. 3(X) control unit (D793). Indicates if forward drive is activated in the
FORWARD X
015637
GEAR X Contact: -
Signal value:
1 Output signal for travel direction forward active.
0 No output signal.

PRESENT VALUE, REVERSE

page
–
Description: Status for rearward direction of travel from transmission

DIAG TRANSM. 3(X) control unit (D793). Indicates if rearward drive is activated in the
FORWARD X
015637
GEAR X Contact: -
Signal value:
1 Output signal for travel direction reverse active.
0 No output signal.
PRESENT VALUE, GEAR

page
–
Description: Current gear, status from transmission control unit

DIAG TRANSM. 3(X) (D793). Shows which gear is activated in the transmission.
PRESENT VALUE
FORWARD X Circuit diagram: -
REVERSE X Function: 2.8 Control system, transmission
015637
GEAR X
Contact: -
Signal value: X = current gear.

NOT USED
page
–

DIAG TRANSM. 4(X)
NOT USED
015638

OPERATING STATE, SHIFT IN PROGRESS
page
–
Description: Status for transmission function during operation, shifting

DIAG TRANSM. 5(X) in progress. Active during shifting.
OPERATING STATE
OPERATING MODE X Contact: -
013383
ENGAGED X
Signal value:
1 Shifting in progress.
0 No activity.


page
–
Description: Status for operating position for Control unit transmission

DIAG TRANSM.
TRANSM. 5(X)
5(X) (D7930-2).
OPERATING STATE
OPERATING STATE
SHIFT IN Circuit diagram: -
SHIFT IN PROGRESS
PROGRESS XX
OPERATING
OPERATING MODE
MODE XX Contact: -
013383
ENGAGED X
013383
ENGAGED X Function: 2.8 Control system, transmission
Signal value:
0 Normal operation.
1 Substitute clutch control, harsh shifting due to malfunction in

control. Control of clutches takes place in simpler form.
2 Limp-home, transmission shifts to neutral position, reduced

capacity due to defect in transmission. To operate machine,
select travel direction again.
3 Shutdown, transmission locked in neutral.
4 Serious malfunction of transmission’s control system. Control

unit transmission (D7930-2) shuts down, likely then that mal-
function cannot be shown on CAN-bus.

page
–
Description: Status for drive position for Control unit transmission

DIAG TRANSM. 5(X) (D7930-2).
OPERATING STATE
OPERATING MODE X Contact: -
013383
ENGAGED X
Signal value:
1 Drive engaged.
0 Neutral position.

PRESENT VALUE, OUTPUT SPEED
page
–
Description: Signal from sensor rpm output shaft (propeller shaft).

DIAG TRANSM. 6(X)
Circuit diagram: Circuit Shifting ZF group 2.0
PRESENT VALUE
OUTPUT SPEED XXXXrpm Connection: signal from B7580 to D7930-2/64
013384
Signal value: XXXXX rpm = output shaft speed.
PRESENT VALUE, ENGINE SPEED

page
–
Description: Rpm signal from sensor rpm engine speed.

DIAG TRANSM. 6(X)
PRESENT VALUE
OUTPUT SPEED XXXXrpm Connection: signal from B7530 to D7930-2/19
013384
Signal value: XXXX rpm = engine speed 0-2010 rpm.


NOT USED
page
–

DIAG TRANSM. 7(X)
NOT USED
015639
NOT USED
page
–

DIAG
DIAG TRANSM.
TRANSM. 8(X)
12(X)
NOT
NOT USED
USED
006872
015640

NOT USED
page
–

DIAG
DIAG TRANSM.
TRANSM. 9(X)
12(X)
NOT
NOT USED
USED
015641
006872

PRESENT SENSOR INPUT, TRANSM.TEMP
page
–
Description: Signal from sensor for oil temperature sump.

DIAG TRANSM. 10(X)
PRESENT SENSOR INPUT
Connection: signal from B7660 to D7930-2/49
TRANSM.TEMP XXX
013385
CONV. TEMP XXX

Signal value: XXX = Oil temperature in °C.
PRESENT SENSOR INPUT, CONV.TEMP

page
–
Description: Signal from sensor for oil temperature converter.

DIAG TRANSM. 10(X)
PRESENT SENSOR INPUT
Connection: signal from A3/8 to D7930-2/39
TRANSM.TEMP XXX
013385
CONV. TEMP XXX

Signal value: XXX = Oil temperature in °C.


AXLE RATIOx1000
page
–
Description: Drive axle gear ratio.

DIAG TRANSM. 11(X)
Circuit diagram: -
PRESENT VALUE
RADIUS XXXX
013386
SPEED LIMIT XXXX
Signal value: XXXXX = drive axle’s total gear ratio x 1000.
RADIUS
page
–
Description: Drive wheels’ radius

DIAG TRANSM. 11(X)
Circuit diagram: -
PRESENT VALUE
RADIUS XXXX
013386
SPEED LIMIT XXXX

Signal value: XXXX = Drive wheels’ radius in mm.
SPEED LIMIT
page
–
Description: Speed limitation.

DIAG TRANSM. 11(X)
Circuit diagram: -
PRESENT VALUE
RADIUS XXXX
013386
SPEED LIMIT XXXX

Signal value: XXX = Speed limitation in km/h.

NOT USED
page
–

DIAG
DIAG TRANSM.
TRANSM. 12(X)
12(X)
NOT
NOT USED
USED
006872
06872

ACT ERROR
page
–
Description: States up to six active error codes, the most severe error
DIAG TRANSM. 13(X) codes are displayed.
ACTIVE ERROR
ERROR 1 XX ERROR 4 XX Circuit diagram: -
ERROR 2 XX ERROR 5 XX Contact: -
013387
ERROR 3 XX ERROR 6 XX
Signal value: XX = Error code number, ZF-code, see section D Error
codes.

8 Control system – 8.4.8 BOOM 101
8.4.8 BOOM
BOOM, description
page
–
This group handles boom functions.

DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
009275
OP EXTRA RMI

PRESENT INPUT SIGNALS, BOOM UP/DOWN
page
–
Description: Signal from control lever (boom up/down).

DIAG BOOM 1(8)
Circuit diagram: Circuit Joystick group 7.1
PRESENT INPUT SIGNALS
BOOM UP/DOWN XX.XXV Connection: signal from S815/8 to analogue in D790-1/K7:3
BOOM IN/OUT XX.XXV
Function: 7.1.1 Control lever
000175
Signal value: XX.XXV = 0.50 - 4.50 V. 2.5 V in zero position.
PRESENT INPUT SIGNALS, BOOM IN/OUT

page
–
Description: Signal from control lever (boom in/out).

DIAG BOOM 1(8)
Circuit diagram: Circuit Joystick group 7.1
BOOM UP/DOWN XX.XXV Connection: signal from S815/4 to analogue in D790-1/K7:4
BOOM IN/OUT XX.XXV
Function: 7.1.1 Control lever
000175
Signal value: XX.XXV = 0.50 - 4.50 V. 2.5 V in zero position.

BLOCK VALVES, UP/DOWN
page
–
Description: Voltage feed to solenoid valve blocking, lower.

DIAG BOOM 2(8)
Circuit diagram: Circuit Boom up/down group 7.2
BLOCK VALVES
UP/DOWN LE XY RI XY Contact:
IN XY
LE: digital out from D797-F/K1:30 to Y6002/1
012097
RELIEVE PRESS. IN XY
RI: digital out from D797-F/K1:31 to Y6001/1
Function: 7.2.7 Valve block lift cylinder
Signal value:


missing.

102 8 Control system – 8.4.8.2 BOOM, menu 2
BLOCK VALVES, IN/OUT

page
–
Description: Voltage feed to solenoid valve blocking boom in.

DIAG BOOM 2(8)
Circuit diagram: Circuit Boom in/out group 7.3
BLOCK VALVES
UP/DOWN LE XY RI XY Connection: digital out from D797-R/K1:5 to Y6050/1
IN XY
Function: 7.3.7 Valve block extension cylinder
012097
Signal value:


missing.
BLOCK VALVES, RELIEVE PRESS. IN

page
–
Description: Voltage feed to solenoid valve pump unloading.

DIAG BOOM 2(8)
BLOCK VALVES
UP/DOWN LE XY RI XY Connection: digital out from D797-R/K1:40 to Y6062/1
IN XY
Function: 7.3.9 Valve block pump unloading.
012097
Signal value:


missing.

8 Control system – 8.4.8.3 BOOM, menu 3 103

BOOM HIGH SPEED, UP
page
–
Description: Voltage feed to solenoid valve, regeneration boom up.

DIAG BOOM 3(8)
Circuit diagram: Circuit Boom up/down group 7.2
BOOM HIGH SPEED
UP LE XY RI XY Contact:
OUT XY
LE: digital out from D797-F/K1:33 to Y6052/1
000177
RE: digital out from D797-F/K1:32 to Y6051/1
Function: 7.2.7 Valve block lift cylinder
Signal value:


missing.
BOOM HIGH SPEED, OUT

page
–
Description: Voltage feed to solenoid valve, regeneration, extension.

DIAG BOOM 3(8)
BOOM HIGH SPEED
UP LE XY RI XY Connection: digital out from D797-R/K1:4 to Y6046/1
OUT XY
Function: 7.3.7 Valve block extension cylinder
000177
Signal value:


missing.


OUTPUT BOOM UP, REFERENCE
page
–
Description: Status for control current to control valve lift, lower and ex-
DIAG BOOM 4(8) tension (solenoid valve lift).
OUTPUT BOOM UP
REFERENCE XY Circuit diagram: Circuit Boom up/down group 7.2
REQUIRED VALUE XXX Connection: digital out from D797-F/K1:2 to M6005/1
000178
FEEDBACK XXX
Function: 7.2.5 Control valve lift, lower and extension
Signal value:


missing.
OUTPUT BOOM UP, REQUIRED VALUE

page
–
Description: Reference value for control current to control valve lift,

DIAG BOOM 4(8) lower and extension (solenoid valve lift).
OUTPUT BOOM UP
REQUIRED VALUE XXX Connection: output signal reference value out from D797-F/K1:16 to
000178
FEEDBACK XXX Y6005/2

Signal value: XXX = Current value in mA for controlling solenoid valve.
OUTPUT BOOM UP, FEEDBACK

page
–
Description: Current control current to control valve lift, lower and ex-
DIAG BOOM 4(8) tension (solenoid valve lift).
OUTPUT BOOM UP
REQUIRED VALUE XXX Connection: output signal actual value out from D797-F/K1:16 to
000178

Signal value: XXX = Measured current value in mA.


OUTPUT BOOM DOWN, REFERENCE
page
–
DIAG BOOM 5(8) tension (solenoid valve lower).
OUTPUT BOOM DOWN
000179
FEEDBACK XXX
Signal value:


missing.
OUTPUT BOOM DOWN, REQUIRED VALUE

page
–

DIAG BOOM 5(8) lower and extension (solenoid valve lower).
OUTPUT BOOM DOWN
000179

OUTPUT BOOM DOWN, FEEDBACK

page
–
DIAG BOOM 5(8) tension (solenoid valve lower).
OUTPUT BOOM DOWN
000179



OUTPUT BOOM IN, REFERENCE
page
–
DIAG BOOM 6(8) tension (solenoid valve extension in).
OUTPUT BOOM IN
REFERENCE XY Circuit diagram: Circuit Boom in/out group 7.3
000180
FEEDBACK XXX
Signal value:


missing.
OUTPUT BOOM IN, REQUIRED VALUE

page
–

DIAG BOOM 6(8) lower and extension (extension in).
OUTPUT BOOM IN
000180

OUTPUT BOOM IN, FEEDBACK

page
–
Description: Current for control current to control valve lift, lower and
DIAG BOOM 6(8) extension (solenoid valve extension in).
OUTPUT BOOM IN
000180



OUTPUT BOOM OUT, REFERENCE
page
–
DIAG BOOM 7(8) tension (solenoid valve extension out).
OUTPUT BOOM OUT
000181
FEEDBACK XXX
Signal value:


missing.
OUTPUT BOOM OUT, REQUIRED VALUE

page
–

DIAG BOOM 7(8) lower and extension (extension out).
OUTPUT BOOM OUT
000181

OUTPUT BOOM OUT, FEEDBACK

page
–
DIAG BOOM 7(8) tension (solenoid valve extension out).
OUTPUT BOOM OUT
000181



PRESENT INPUT SIGNAL BOOM LOW SPEED, UP/DOWN
page
–
Description: Signal from sensor boom angle, to activate damping

DIAG BOOM 8(8) when lifting and lowering.
BOOM LOW SPEED Circuit diagram: Circuit OP + Scale group 8.2
UP/DOWN X Connection: signal in from B771 to analogue in D797-R/K1:21
000182
IN/OUT X/X
Function: 7.2.11 Sensor, boom angle (position sensor)
Signal value:
0 No signal.
PRESENT INPUT SIGNAL BOOM LOW SPEED, IN/OUT

page
–
Description: Signal from sensor boom length to activate damping for

DIAG BOOM 8(8) extension.
BOOM LOW SPEED Circuit diagram: Circuit OP + Scale group 8.2 (Mechanical overload
UP/DOWN X system with analogue position sensors or Electrical overload system),
000182
IN/OUT X/X Circuit Boom in/out group 7.3 (Mechanical overload system)
Contact:
Mechanical overload system with analogue position sensors or
Electric overload system:
Analogue signal in from B777/3 to analogue in D797-R/K1:22
Mechanical overload system:
Boom in: digital in from B769-3/C to digital in D797-R/K1:26
Boom out: digital in from B769-4/C to analogue in D797-R/K1:23
(software generated signal from overload system)
Function: 7.3.11 Sensor, boom length
Signal value:
0 No signal.

8 Control system – 8.4.9 ATTACH 109
8.4.9 ATTACH
ATTACH, description
page
–
This group covers attachment functions.

DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
009276
OP EXTRA RMI

PRESENT INPUT SIGNALS, ROT CW/CCW
page
–
Description: Signals from control lever for rotating the attachment

DIAG ATTACHMENT 1(21) Circuit diagram: Circuit Joystick group 7.1
ROT CW/CCW XX.XXV Connection: signal from S815/11 to analogue in D790-1/K7:5
TILT IN/OUT XX.XXV Function: 7.6 Rotation
000184
Signal value: XX.XXV = 0.50 - 4.50 V. 2.5 V in control lever zero

position.
PRESENT INPUT SIGNALS, TILT IN/OUT

page
–
DIAG ATTACHMENT 1(21)

PRESENT INPUT SIGNALS Description: Signals from control lever for tilting the attachment
ROT CW/CCW XX.XXV Circuit diagram: Circuit Joystick group 7.1
TILT IN/OUT XX.XXV
000184
Connection: signal from S815/1 to analogue in D790-1/K7:6

Function: 7.7 Tilt
Signal value: XX.XXV = 0.50 - 4.50 V. 2.5 V in control lever middle
position.

PRESENT INPUT SIGNALS, SIDESHIFT
page
–
Description: Signals from control lever for sideshift of attachment. If

DIAG ATTACHMENT 2(21) the pistol trigger is pressed at the same time as the sideshift, then
PRESENT INPUT SIGNALS spreading is activated. Text in brackets describes spreading.
SIDE SHIFT LE X RI X
PISTOL X Circuit diagram: Circuit Joystick group 7.1
000185
30/35 STOP X Contact:

LE: Signal from S815/14 to digital in D790-1/K7:14 (spreading in)
RI: Signal from S815/16 to digital in D790-1/K7:13 (spreading out)
Function: 7.4 Sideshift
Signal value:
0 No signal.

110 8 Control system – 8.4.9.3 ATTACH, menu 3
PRESENT INPUT SIGNALS, PISTOL

page
–
Description: Signals from control lever for pistol trigger.

SIDE SHIFT LE X RI X Connection: from S815/19 to digital in D790-1/K7:16
PISTOL X Function: 7.5 Spreading, 7.10.2 Weight Indicator, 7.10.4 Synchro-
000185
30/35 STOP X
nized lift
Signal value:
0 No signal.
PRESENT INPUT SIGNALS, 30/35 STOP

page
–

PRESENT INPUT SIGNALS Description: Signal from switch for stop at 30’/35’.
SIDE SHIFT LE X RI X Circuit diagram: Circuit Spreading Sensors group 7.5
PISTOL X
000185
30/35 STOP X Connection: from S1004/1 to digital in D790-1/K8:10

Function: 7.5 Spreading
Signal value:
0 No signal.

PRESENT INPUT SIGNALS, LOCK TW
page
–
Description: Signal from switch, lock twistlock.

DIAG ATTACHMENT 3(21) Circuit diagram: Circuit Twistlock group 7.9
LOCK TW X Connection: from S1003/7 and S1007/2 to digital in D790-1/K8:12
UNLOCK TW X Function: 7.9.1 Twistlocks
000186
BY-PASS HEIGHT X
Signal value:
0 No signal.
PRESENT INPUT SIGNALS, UNLOCK TW

page
–
Description: Signal from control lever to unlock twistlock.

LOCK TW X Connection: from S815/20 to digital in D790-1/K7:15
UNLOCK TW X Function: 7.9.1 Twistlocks
000186
BY-PASS HEIGHT X
Signal value:
0 No signal.

8 Control system – 8.4.9.4 ATTACH, menu 4 111
PRESENT INPUT SIGNALS, BY-PASS HEIGHT

page
–

PRESENT INPUT SIGNALS Description: Signal from switch bypassing load centre limitation and
LOCK TW X height limitation if machine is equipped with these options.
UNLOCK TW X
Circuit diagram: Circuit Bypassing group 8.2
000186
BY-PASS HEIGHT X
Connection: from S1014/1015/1 to digital in D790-1/K8:14
Function: 8.2.2 Bypassing
Signal value:
0 No signal.

PRESENT INPUT SIGNALS, TILT LOCK
page
–
DIAG ATTACHMENT 4(X)

PRESENT INPUT SIGNALS Description: Signal from control lever for tilt lock.
TILT LOCKING X Circuit diagram: Circuit Joystick group 7.1
LEVELLING LOCKING X
006874
AUTO 20'-40' X Connection: from S815/18 to digital in D790-1/K8:2

Function: 7.7 Tilt
Signal value:
0 No signal.
PRESENT INPUT SIGNALS, LEVELLING LOCK

page
–

PRESENT INPUT SIGNALS Description: Signal from control lever for levelling lock.
TILT LOCKING X Circuit diagram: Circuit Joystick group 7.1
LEVELLING LOCKING X
006874
AUTO 20'-40' X Connection: from S815/17 to digital in D790-1/K8:1

Function: 7.8 Levelling
Signal value:
0 No signal.

PRESENT INPUT SIGNALS, AUTO 20'-40'

page
–

PRESENT INPUT SIGNALS Description: Signal from switch automatic spreading 20'-40'.
TILT LOCKING X Circuit diagram: Circuit Extra equipment group 9.1
LEVELLING LOCKING X
006874
AUTO 20'-40' X Connection: from S199-2 to digital in D790-1/K8:11
Signal value:
0 No signal.

PRESENT INPUT SIGNALS, LOW SPEED 20/40
page
–
Description: Signal from position sensor spreading for end position

DIAG ATTACHMENT 5(21) damping 20’/40’. On machines with 30’ stop the sensor also gives the
PRESENT INPUT SIGNALS signal to control the stop point for the 30’ position.
LOW SPEED 20/40 X
30/35 STOP X Circuit diagram: Circuit Spreading Sensors group 7.5
000188
EXTENSION 60CM X Connection: from inductive sensor B769/C to digital in D791-1/K1:12

Function: 7.5.10 Position sensor spreading
Signal value:
0 No signal.
PRESENT INPUT SIGNALS, 30/35 STOP

page
–

PRESENT INPUT SIGNALS Description: Signal from position sensor spreading for stop at 30’/35’.
LOW SPEED 20/40 X The sensor gives the signal for damping at the 30’ position and for stop
30/35 STOP X at the 20’ and 40’ position.
000188
EXTENSION 60CM X
Circuit diagram: Circuit Spreading Sensors group 7.5
Connection: from inductive sensor B777-3 to digital in D791-1/K1:20
Function: 7.5.10 Position sensor spreading
Signal value:
0 No signal.

PRESENT INPUT SIGNALS, EXTENSION 60CM

page
–
(model year -2008)

PRESENT INPUT SIGNALS Description: Signal from position sensor extension 60 cm, for fixed
LOW SPEED 20/40 X scale.
30/35 STOP X
000188
EXTENSION 60CM X
Connection: from inductive sensor B7224/C to digital in D791-1/K1:21
Function: 7.10.2 Weight indicator
Signal value:
0 No signal.

PRESENT INPUT SIGNALS ALIGNMENT, FRONT
page
–
Description: Signals from sensors, alignment, right front and left front.
Circuit diagram: Circuit Twistlock group 7.9
ALIGNMENT LE RI Contact:
FRONT X X
LE: signal from B7202L/C to analogue in (used as digital)
000202
REAR X X
D791-1/K1:13
RI: signal from B7202R/C to digital in D791-1/K1:40
Function: 7.9.1.8 Alignment sensor
Signal value:
0 No signal.
PRESENT INPUT SIGNALS ALIGNMENT, REAR

page
–
Description: Signals from sensors, alignment, right rear and left rear.
ALIGNMENT LE RI Contact:
FRONT X X
000202
REAR X X
D791-1/K1:27
Signal value:
0 No signal.


PRESENT INPUT SIGNAL, LOCKED TW
page
–
Description: Signals from sensors locked twistlock right and left.

LE RI Contact:
LOCKED TW X X
001633
UNLOCKED TW X X
D791-1/K1:23
RI: signal from B7205R/C to analogue in (used as digital)
D791-1/K1:24
Function: 7.9.1.9 Sensor twistlock
Signal value:
0 No signal.
PRESENT OUTPUT SIGNAL, UNLOCKED TW

page
–
Description: Signals from sensors open twistlock right and left.

LE RI Contact:
LOCKED TW X X
001633
UNLOCKED TW X X
D791-1/K1:22
RI: signal from B7204R/C to analogue in (used as digital)
D791-1/K1:41
Function: 7.9.1.9 Sensor twistlock
Signal value:
1 Output signal active.
0 No signal.


PRESENT OUTPUT SIGNAL, SIDESHIFT LEFT
page
–
Description: Voltage feed to control valve attachment, sideshift left.

DIAG ATTACHMENT 8(21) Circuit diagram: Circuit Spreading Valves group 7.5
SIDE SHIFT LEFT XY Connection: digital out from D791-1/K1:31 to Y6020/1
SIDE SHIFT RIGHT XY Function: 7.4.3 Control valve attachment
000189
Signal value:


missing.
PRESENT OUTPUT SIGNAL, SIDESHIFT RIGHT

page
–
Description: Voltage feed to control valve attachment, sideshift right.

DIAG ATTACHMENT 8(21) Circuit diagram: Circuit Spreading Valves group 7.5
SIDE SHIFT LEFT XY Connection: digital out from D791-1/K1:30 to Y6021/1
SIDE SHIFT RIGHT XY Function: 7.4.3 Control valve attachment
000189
Signal value:


missing.


PRESENT OUTPUT SIGNAL, LOCK TW
page
–
Description: Voltage feed to control valve attachment, lock twistlock.

LOCK TW XY Contact: digital output from D791-1/K1:32 to Y6040/1
UNLOCK TW XY
Function: 7.9.1.3 Attachment control valve
000190
Signal value:


missing.
PRESENT OUTPUT SIGNAL, UNLOCK TW

page
–
Description: Voltage feed to control valve attachment, open twistlock.

LOCK TW XY Contact: digital output from D791-1/K1:33 to Y6039/1
UNLOCK TW XY
Function: 7.9.1.3 Attachment control valve
000190
Signal value:


missing.


PRESENT OUTPUT SIGNAL, IND. LOCKED TW
page
–
Description: Voltage feed indicator light locked twistlock.

IND. LOCKED TW XY Connection: digital out from D791-1/K1:39 to H563/1
IND. UNLOCKED TW XY
000191
IND. ALIGNMENT XY
Signal value:


missing.
PRESENT OUTPUT SIGNAL, IND. UNLOCKED TW

page
–
Description: Voltage feed indicator light open twistlock.

IND. UNLOCKED TW XY
000191
IND. ALIGNMENT XY
Signal value:


missing.

PRESENT OUTPUT SIGNAL, ALIGNMENT

page
–
Description: Voltage feed indicator light alignment.

IND. UNLOCKED TW XY
000191
IND. ALIGNMENT XY
Signal value:


missing.

OUTPUT ROTATION C.W., REFERENCE
page
–
Description: Status control current to control valve attachment for ro-

DIAG ATTACHMENT 11(21) tation clockwise.
OUTPUT ROTATION C.W.
REFERENCE XY Circuit diagram: Circuit Rotation, group 7.6
RQUIRED VALUE XXX Connection: digital out from D791-1/K1:2 to solenoid valve Y6008/1
000192
FEEDBACK XXX
Function: 7.6.3 Control valve attachment
Signal value:


missing.

OUTPUT ROTATION C.W., REQUIRED VALUE

page
–
Description: Reference value for control current to control valve at-

DIAG ATTACHMENT 11(21) tachment for rotation clockwise.
RQUIRED VALUE XXX Connection: output signal reference value out from D791-1/K1:16 to
000192
OUTPUT ROTATION C.W., FEEDBACK

page
–
Description: Current control current to control valve attachment for ro-

RQUIRED VALUE XXX Connection: output signal actual value out from D791-1/K1:16 to
000192


OUTPUT ROTATION C.C.W., REFERENCE
page
–
Description: Status control current to control valve attachment for ro-

DIAG ATTACHMENT 12(21) tation counter-clockwise.
OUTPUT ROTATION C.C.W.
REQUIRED VALUE XXX Connection: digital out from D791-1/K1:3 to solenoid valve Y6009/1
000193
FEEDBACK XXX
Signal value:


missing.
OUTPUT ROTATION C.C.W., REQUIRED VALUE

page
–

DIAG ATTACHMENT 12(21) tachment for rotation counter-clockwise.
REQUIRED VALUE XXX Connection: output signal reference value out from D791-1/K1:17 to
000193


OUTPUT ROTATION C.C.W., FEEDBACK

page
–
Description: Current control current to control valve attachment for ro-

REQUIRED VALUE XXX Connection: output signal actual value out from D791-1/K1:17 to
000193

OUTPUT SPREADER OUT, REFERENCE
page
–
Description: Status control current to control valve attachment for

DIAG ATTACHMENT 13(21) spreader out.
OUTPUT SPREADER OUT
REFERENCE XY Circuit diagram: Circuit Spreading Valves group 7.5
REQUIRED VALUE XXX Connection: digital out from D791-1/K1:4 to Y6018/1
000194
FEEDBACK XXX
Signal value:


missing.
OUTPUT SPREADER OUT, REQUIRED VALUE

page
–

DIAG ATTACHMENT 13(21) tachment for output signal, spreading out.
OUTPUT SPREADER OUT
REQUIRED VALUE XXX Connection: output signal reference value out from D791-1/K1:18 to
000194

OUTPUT SPREADER OUT, FEEDBACK

page
–
Description: Current control current to control valve attachment for

DIAG ATTACHMENT 13(21) spreader out.
OUTPUT SPREADER OUT
REQUIRED VALUE XXX Connection: output signal actual value out from D791-1/K1:18 to
000194



OUTPUT SPREADER IN, REFERENCE
page
–
Description: Status control current to control valve attachment for

DIAG ATTACHMENT 14(21) spreader in.
OUTPUT SPREADER IN Circuit diagram: Circuit Spreading Valves group 7.5
REFERENCE XY
RQUIRED VALUE XXX Connection: digital out from D791-1/K1:5 to Y6019/1
000195
FEEDBACK XXX
Signal value:


missing.
OUTPUT SPREADER IN, REQUIRED VALUE

page
–

DIAG ATTACHMENT 14(21) tachment for spreader in.
REFERENCE XY
RQUIRED VALUE XXX Connection: output signal reference value out from D791-1/K1:19 to
000195

OUTPUT SPREADER IN, FEEDBACK

page
–
Description: Current control current to control valve attachment for

DIAG ATTACHMENT 14(21) spreader in.
REFERENCE XY
RQUIRED VALUE XXX Connection: output signal actual value out from D791-1/K1:19 to
000195



PRESENT OUTPUT SIGNAL, TILT LOCK 1
page
–

PRESENT OUTPUT SIGNAL Description: Voltage feed to lock valve, tilt.
TILT LOCKING 1 XY Circuit diagram: Circuit Tilt lock group 7.7
TILT LOCKING 2 XY
006875
BUZZER AUTO 20-40 XY Contact: digital output from D791-1/K1:7 to Y6012-1/1
Function: 7.7.4 Lock valve tilt
Signal value:


missing.
PRESENT OUTPUT SIGNAL, TILT LOCK 2

page
–

PRESENT OUTPUT SIGNAL Description: Voltage feed to lock valve, tilt.
TILT LOCKING 1 XY Circuit diagram: Circuit Tilt lock group 7.7
TILT LOCKING 2 XY
006875
BUZZER AUTO 20-40 XY Contact: digital output from D791-1/K1:9 to Y6012-2/1

Function: 7.7.4 Lock valve tilt
Signal value:


missing.

PRESENT OUTPUT SIGNAL, BUZZER AUTO 20-40

page
–

PRESENT OUTPUT SIGNAL Description: Voltage feed to buzzer, automatic spreading 20'-40'.
TILT LOCKING 1 XY Circuit diagram: Circuit Spreading Auto group 7.5
TILT LOCKING 2 XY
006875
BUZZER AUTO 20-40 XY Connection: digital out from D791-1/K1:28 to H9003/1
Signal value:


missing.

OUTPUT TILT OUT, REFERENCE
page
–

OUTPUT TILT OUT Description: Status control current to control valve attachment for
REFERENCE XY tilt out.
REQUIRED VALUE XXX
Circuit diagram: Circuit Tilt + Levelling group 7.7
000197
FEEDBACK XXX
Contact:
Top lift attachment: digital out from D791-2/K1:4 to Y6010/1
Combi attachment: digital out from D791-4/K1:2 to Y6010/1
Signal value:


missing.

OUTPUT TILT OUT, REQUIRED VALUE

page
–

OUTPUT TILT OUT Description: Reference value for control current to control valve at-
REFERENCE XY tachment for tilt out.
REQUIRED VALUE XXX
000197
FEEDBACK XXX
Contact:
Top lift attachment: output signal reference value out from
D791-2/K1:18 to Y6010/2
Combi attachment: output signal reference value out from
D791-4/K1:16 to Y6010/2
OUTPUT TILT OUT, FEEDBACK

page
–

OUTPUT TILT OUT Description: Current control current to control valve attachment for
REFERENCE XY tilt out.
REQUIRED VALUE XXX
000197
FEEDBACK XXX
Contact:
Top lift attachment: output signal actual value out from D791-2/
K1:18 to Y6010/2
Combi attachment: output signal actual value out from D791-4/
K1:16 to Y6010/2


OUTPUT TILT IN, REFERENCE
page
–

OUTPUT TILT IN Description: Status control current to control valve attachment for
REFERENCE XY tilt in.
REQUIRED VALUE XXX
000198
FEEDBACK XXX
Contact:
Signal value:


missing.
OUTPUT TILT IN, REQUIRED VALUE

page
–

OUTPUT TILT IN Description: Reference value for control current to control valve at-
REFERENCE XY tachment for tilt in.
REQUIRED VALUE XXX
000198
FEEDBACK XXX
Contact:
D791-2/K1:19 to Y6011/2
D791-4/K1:17 to Y6011/2

OUTPUT TILT IN, FEEDBACK

page
–

OUTPUT TILT IN Description: Current control current to control valve attachment for
REFERENCE XY tilt in.
REQUIRED VALUE XXX
000198
FEEDBACK XXX
Contact:
Top lift attachment: output signal actual value out from
D791-2/K1:19 to Y6011/2
Combi attachment: output signal actual value out from
D791-4/K1:17 to Y6011/2

PRESENT OUTPUT SIGNAL, LOCK LEVELLING 1
page
–

PRESENT OUTPUT SIGNAL Description: Voltage feed to lock valve, levelling.
LOCK LEVELLING 1 XY Circuit diagram: Circuit Tilt + Levelling group 7.7
LOCK LEVELLING 2 XY
000199
Contact:
Top lift attachment: digital out from D791-2/K1:30 to Y6034-1/1
Combi attachment: digital output from D791-3/K1:15 to Y6034-1/
1 and Y6034-2/1
Function: 7.8.6 Valve block, levelling cylinders
Signal value:


missing.

PRESENT OUTPUT SIGNAL, LOCK LEVELLING 2

page
–

PRESENT OUTPUT SIGNAL Description: Voltage feed to lock valve, levelling.
LOCK LEVELLING 1 XY Connection: Circuit Tilt + Levelling group 7.7
LOCK LEVELLING 2 XY
000199
Top lift attachment: digital out from D791-2/K1:31 to Y6034-2/1
Combi attachment: digital output from D791-3/K1:15 to Y6034-1/
1 and Y6034-2/1
Function: 7.8.6 Valve block, levelling cylinders
Signal value:


missing.

OUTPUT LEVELLING RI, REFERENCE
page
–

OUTPUT LEVELLING RI Description: Status control current to control valve attachment for lev-
REFERENCE XY elling right.
RQUIRED VALUE XXX
000200
FEEDBACK XXX
Contact:
Signal value:


missing.

OUTPUT LEVELLING RI, REQUIRED VALUE

page
–

OUTPUT LEVELLING RI Description: Reference value for control current to control valve at-
REFERENCE XY tachment for levelling right.
RQUIRED VALUE XXX
000200
FEEDBACK XXX
Contact:
D791-2/K1:16 to Y6035/2
D791-3/K1:16 to Y6035/2
OUTPUT LEVELLING RI, FEEDBACK

page
–

OUTPUT LEVELLING RI Description: Current control current to control valve attachment for lev-
REFERENCE XY elling right.
RQUIRED VALUE XXX
000200
FEEDBACK XXX
Contact:
K1:16 to Y6035/2
K1:16 to Y6035/2


OUTPUT LEVELLING LE, REFERENCE
page
–

OUTPUT LEVELLING LE Description: Status control current to control valve attachment for lev-
REFERENCE XY elling left.
REQUIRED VALUE XXX
006876
FEEDBACK XXX
Contact:
Signal value:


missing.
OUTPUT LEVELLING LE, REQUIRED VALUE

page
–

OUTPUT LEVELLING LE Description: Reference value for control current to control valve at-
REFERENCE XY tachment for levelling left.
REQUIRED VALUE XXX
006876
FEEDBACK XXX
Contact:
D791-2/K1:17 to Y6036/2
D791-3/K1:17 to Y6036/2

OUTPUT LEVELLING LE, FEEDBACK

page
–

OUTPUT LEVELLING LE Description: Current control current to control valve attachment for lev-
REFERENCE XY elling left.
REQUIRED VALUE XXX
006876
FEEDBACK XXX
Contact:
K1:17 to Y6036/2
K1:17 to Y6036/2

ROTATION STOP, SWITCH
page
–

PRESENT INPUT SIGNALS Description: Signal from switch rotation stop.
ROTATION STOP Circuit diagram: Circuit Bypassing group 8.2
SWITCH X
006877
SENSOR STOP X Connection: signal from S1014-1015/3 to digital in D790-1/K8:14

Function: 7.6 Rotation
Signal value:
0 No signal.
ROTATION STOP, SENSOR STOP

page
–

PRESENT INPUT SIGNALS Description: Signal from sensor rotation stop, when rotating 25.
ROTATION STOP Circuit diagram: Circuit Rotation, group 7.6
SWITCH X
006877
SENSOR STOP X Connection: signal from B7225/C to digital in D791-1/K1:11

Function: 7.6.10 Sensor rotation stop
Signal value:
0 No signal.


PRESENT INPUT SIGNAL, LENGTH TO CONTAINER
page
–

PRESENT INPUT SIGNAL Description: Current distance from attachment to container.
LENGTH TO Circuit diagram: Circuit diagram sensor ultrasonic
CONTAINER (cm) XXXX
006878
DAMP DOWN X Connection: signal from B769/4 to analogue in D791-1/K1:21
Function: 7.2 Lift and lower
Signal value: XXXX = distance to container in cm.
PRESENT INPUT SIGNAL, DAMP DOWN

page
–

PRESENT INPUT SIGNAL Description: Status damping lower boom.
LENGTH TO Circuit diagram:
CONTAINER (cm) XXXX
006878
DAMP DOWN X Contact: -

Signal value:
1 Damping active.
0 No damping.

132 8 Control system – 8.4.10 OP
8.4.10 OP
OP, description
page
–
This group handles the overload system’s functions.

DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
009277
OP EXTRA RMI
8.4.10.1 OP, menu 1

PRESENT INPUT SIGNAL, STEERING AXLE
page
–
(model year -2008)

Description: Signal from sensor steering axle load right and left (me-
DIAG OP 1(X) chanical overload system). It is enough for one sensor to give signal
PRESENT INPUT SIGNAL to activate the warning for overload.
STEERING AXLE X X
BOOM ANGLE X Circuit diagram: Circuit OP + Scale group 8.2
008203
EXTENSION X Connection: signal from B7221R/C to digital in D797-R/K1:12 and

B7221L/C digital in D797-R/K1:11
Function: 8.2.1.1 Sensor steering axle load
Signal value:
11 Input signal active left and right.
10 No signal left, input signal active right.
01 Input signal active left, no signal right.
00 No signal right and left.
PRESENT INPUT SIGNAL, BOOM ANGLE

page
–
(model year -2008)
DIAG OP 1(X)
PRESENT INPUT SIGNAL Description: Status for boom angle for overload system indicates
STEERING AXLE X X when boom angle exceeds 35.
BOOM ANGLE X
008203
EXTENSION X
Connection: signal from B771/3 to analogue in D797-R/K1:21
Function: 8.2.1.2 Sensor, boom angle
Signal value:
1 Input signal active. Boom angle exceeds 35.
0 No signal. Boom angle less than 35.

8 Control system – 8.4.10.2 OP, menu 2 133
PRESENT INPUT SIGNAL, EXTENSION (model year -2008)

page
–
DIAG OP 1(X)
PRESENT INPUT SIGNAL Description: Signal from sensor boom length (position sensor boom
STEERING AXLE X X length 1.5 m). On machines with mechanical overload system with an-
BOOM ANGLE X alogue position sensors or electrical overload system, the menu is
008203
EXTENSION X used to show status for boom extension for the overload system.
Connection: signal from B777/C to analogue in (used as digital)
D797-R/K1:22
Function: 8.2.1.3 Sensor, boom length
Signal value:
1 Input signal active. Boom extension exceeds 1.5 m.
0 No signal. Boom extension less than 1.5 m.
8.4.10.2 OP, menu 2

PRESENT INPUT SIGNAL, BY-PASS
page
–
Description: Signal from switch, bypass.

DIAG OP 2(5)
Circuit diagram: Circuit Bypassing group 8.2
BY-PASS X
Function: 7.1.3 Bypass switch
000206
Signal value:
1 Input signal active. The signal is only active for max.

60 seconds.
0 No signal.

134 8 Control system – 8.4.10.3 OP, menu 3
8.4.10.3 OP, menu 3

PRESENT INPUT SIGNAL LIFT CYL LE RI, C-
page
–
DIAG OP 3(5)
PRESENT INPUT SIGNAL Description: Signal from hydraulic pressure sensor, lift cylinder (C-,
LIFT CYL LE RI rod side). See also PRESSURE LIFTING CYL, C- page 71 (for pres-
C- X.XXV X.XXV sure information).
C+ X.XXV X.XXV
Contact:
LE: signal from B768-L2/3 to analogue in D797-F/K1:22
RI: signal from B768-R2/3 to analogue in D797-F/K1:24

1 Signal value: X.XXV = 0.50-4.50 V = Hydraulic oil pressure, 0.50 V
corresponds to 0 MPa, 4.50 V corresponds to 25 MPa.
2
000207
1. Pressure C-
2. Pressure C+
PRESENT INPUT SIGNAL LIFT CYL LE RI, C+

page
–
DIAG OP 3(5)
PRESENT INPUT SIGNAL Description: Signal from hydraulic pressure sensor, lift cylinder
LIFT CYL LE RI (C+, piston side). See also PRESSURE LIFTING CYL, C+ page 72
C- X.XXV X.XXV (for pressure).
C+ X.XXV X.XXV
Contact:
LE: signal from B768-L1 to analogue in D797-F/K1:21
RI: signal from B768-R1 to analogue in D797-F/K1:23

Signal value: X.XXV = 0.50-4.50 V = Hydraulic oil pressure, 0.50 V
1
corresponds to 0 MPa, 4.50 V corresponds to 25 MPa.
2
000207
1. Pressure C-
2. Pressure C+

8 Control system – 8.4.10.4 OP, menu 4 135
8.4.10.4 OP, menu 4

PRESENT INPUT SIGNAL, BOOM ANGLE
page
–
(Standard model year 2009-)

DIAG OP 4(5)
PRESENT INPUT SIGNAL Description: Signal from sensor boom angle.
BOOM ANGLE X.XXV Circuit diagram: Circuit OP + Scale group 8.2
BOOM EXTENSION X.XXV
000208
Function: 7.2.11 Sensor, boom angle
Signal value: X.XXV = 0.50 - 4.50 V
PRESENT INPUT SIGNAL, BOOM EXTENSION

page
–
(Standard model year 2009-)

DIAG OP 4(5)
PRESENT INPUT SIGNAL Description: Signal from sensor boom length (analogue sensor).
BOOM ANGLE X.XXV Circuit diagram: Circuit OP + Scale group 8.2
BOOM EXTENSION X.XXV
000208

Function: 7.3.11 Sensor, boom length
8.4.10.5 OP, menu 5

ALLOWED LOAD
page
–
Description: Permitted load at the current load centre.

DIAG OP 5(X)
Circuit diagram: -
ALLOWED LOAD XXXXXkg
PRESENT LOAD XXXXXkg Contact: -
LOAD STR.AXLE XXXXXkg
006879
LOAD-CENTER XX.XXm
Signal value: XXXXkg = Weight in kg.
PRESENT LOAD
page
–
Description: Calculated load.

DIAG OP 5(X)
Circuit diagram: -
006879
LOAD-CENTER XX.XXm
LOAD STR.AXLE
page
–
Description: Estimated load on the steering axle.

DIAG OP 5(X)
Circuit diagram: -
006879
LOAD-CENTER XX.XXm

136 8 Control system – 8.4.10.6 OP, menu 6
LOAD-CENTER
page
–
Description: Horizontal distance between centre drive axle and load

DIAG OP 5(X) centre.
PRESENT LOAD XXXXXkg Circuit diagram: -
LOAD STR.AXLE XXXXXkg Contact: -
006879
LOAD-CENTER XX.XXm
Function: 8.2.1 Overload system, 8.2.3 Load centre limitation
Signal value: XX.XXm = distance in metres
8.4.10.6 OP, menu 6

BOOM ANGLE
page
–
Description: Current boom angle.

DIAG OP 6(X)
Circuit diagram: -
BOOM ANGLE XXX
EXTENSION XXX Contact: -
BOOM HEIGHT XXX
006880
BOOM HEIGHT-NOSE XXX

Signal value: XXX = boom angle in .
BOOM EXTENSION
page
–
Description: Current boom extension.

DIAG OP 6(X)
Circuit diagram: -
BOOM ANGLE XXX
EXTENSION XXX Contact: -
BOOM HEIGHT XXX
006880

Signal value: XXX = boom extension in cm.
BOOM HEIGHT
page
–
Description: Status for boom height at the top edge of the boom, the
DIAG OP 6(X) machine’s total height.
BOOM ANGLE XXX
EXTENSION XXX Circuit diagram: -
BOOM HEIGHT XXX Contact: -
006880

Function: 8.2.4 Height limitation
Signal value: XXX = height above ground in cm.
BOOM HEIGHT-NOSE
page
–
Description: Status of current height for the attachment’s suspension

DIAG OP 6(X) point in the boom suspension. The height is used to calculate the
BOOM ANGLE XXX load’s center of gravity as a part of the overload system.
EXTENSION XXX
BOOM HEIGHT XXX Circuit diagram: -
006880
BOOM HEIGHT-NOSE XXX Contact: -

Signal value: XXX = height above ground in cm.

8 Control system – 8.4.11 EXTRA 137
8.4.11 EXTRA
EXTRA, description
page
–
DIAGNOSIS
CAN/POWER LIGHTS CAB This menu consists of optional functions:
CLIMATE HYD ENGINE
• Bottom lift attachment, COMBI
TRANSM BOOM ATTACH
009278
OP EXTRA RMI • Sliding cab, SLIDING-CAB
• Support jacks, SUPPORT-JACKS
• Joystick control or mini-wheel, EL-STEERING
Confirm selections in the main menu with function key for Enter.
8.4.11.1 COMBI
COMBI, menu 1
page
–
This menu handles the bottom lift attachment functions.

DIAGNOSIS EXTRA
COMBI SLIDING-CAB Confirm selections with function key for Enter.
SUPPORT-JACKS
EL-STEERING
000211
SWITCHES, FRONT LEG UP/DOWN

Description: Signal from switch lowering front jacks (bottom lift).
DIAG COMBI 1(17)
SWITCHES
FRONT LEG UP/DOWN X/Y Contact:
REAR LEG UP/DOWN X/Y
Up: signal from S1006/1 to digital in D790-1/K9:3
CLAMP IN/OUT X/Y
Down: signal from S1006/7 to digital in D790-1/K9:4
Function: 7.9.2 Lifting jacks
Signal value:
1/0 Input signal active, jacks up

1
0/1 Input signal active, jacks down.
0/0 No signal.
2
3
000212
1. Knee
2. Leg
3. Clamping plate

138 8 Control system – 8.4.11.1 COMBI
SWITCHES, REAR LEG UP/DOWN

Description: Signal from switch lowering rear jacks (bottom lift).
DIAG COMBI 1(17)
SWITCHES
Up: signal from S1007/1 to digital in D790-1/K9:5
CLAMP IN/OUT X/Y
Down: signal from S1007/7 to digital in D790-1/K9:10
Signal value:
1/0 Input signal active, jacks up.

1
0/1 Input signal active, jacks down.
0/0 No signal.
2
3
000212
1. Knee
2. Leg
3. Clamping plate
SWITCHES, CLAMP IN/OUT

Description: Signal from switch clamp/loosen legs (bottom lift).
DIAG COMBI 1(17)
SWITCHES
Clamp: signal from S1008/1 to analogue in (used as digital)
CLAMP IN/OUT X/Y
D790-1/K9:8
Open: signal from S1008/7 to analogue in (used as digital)
D790-1/K9:9
Signal value:
1
1/0 Input signal active, jacks up
2 0/1 Input signal active, jacks down.
0/0 No signal.
3
000212
1. Knee
2. Leg
3. Clamping plate

8 Control system – 8.4.11.1 COMBI 139
COMBI, menu 2
page
–
PRESENT INPUT SIGNAL CLAMPING SENSORS, FRONT

LEGS
Description: Signal from sensor clamping position front
DIAG COMBI 2(17) (jacks against load).
CLAMPING SENSORS Circuit diagram: Circuit Combi Att group 7.9
FRONT LEGS LE X RI X Contact:
REAR LEGS LE X RI X
LE: signal from B7215L/C to digital in D791-1/K3:36
Function: 7.9.2.15 Sensor clamping position
Signal value:
0 No signal.
1
000214
1. Sensor clamping position
PRESENT INPUT SIGNAL CLAMPING SENSORS, REAR

LEGS
Description: Signal from sensor clamping position rear
DIAG COMBI 2(17) (jacks against load).
CLAMPING SENSORS Circuit diagram: Circuit Combi Att group 7.9
FRONT LEGS LE X RI X Contact:
REAR LEGS LE X RI X
Function: 7.9.2.15 Sensor clamping position
Signal value:
0 No signal.
1
000214
1. Sensor clamping position

COMBI, menu 3
page
–
PRESENT INPUT SIGNAL ALIGNMENT SENSORS,

FRONT LEGS
Description: Signal from sensor alignment front (load secured).
DIAG COMBI 3(17) Circuit diagram: Circuit Combi Att group 7.9
ALIGNMENT SENSORS Contact:
FRONT LEGS LE X RI X LE: signal from B7213L/C to digital in D791-1/K3:13
REAR LEGS LE X RI X
Signal value:
0 No signal.
1
000216
1. Sensor, alignment
PRESENT INPUT SIGNAL ALIGNMENT SENSORS,

REAR LEGS
Description: Signal from sensor alignment rear (load secured).
DIAG COMBI 3(17) Circuit diagram: Circuit Combi Att group 7.9
ALIGNMENT SENSORS Contact:
FRONT LEGS LE X RI X LE: signal from B7214L/C to digital in D791-1/K3:20
REAR LEGS LE X RI X
Signal value:
0 No signal.
1
000216
1. Sensor, alignment

COMBI, menu 4
page
–
PRESENT INPUT SIGNAL END POS SENSORS FRONT,

KNEE
Description: Signal from sensor knee front.
DIAG COMBI 4(17)
END POS SENSORS FRONT Contact:
KNEE LE X RI X
000217
LEG LE X RI X
Function: 7.9.2.10 Sensor knee
Signal value:
1 Input signal active. Moving.
0 No signal.
PRESENT INPUT SIGNAL END POS SENSORS FRONT,

LEG
Description: Signal from sensor lift leg front.
DIAG COMBI 4(17)
END POS SENSORS FRONT Contact:
KNEE LE X RI X
000217
LEG LE X RI X
Function: 7.9.2.13 Sensor lift legs
Signal value:
0 No signal.
COMBI, menu 5
page
–
PRESENT INPUT SIGNAL END POS SENSORS REAR,

KNEE
Description: Signal from sensor knee rear.
DIAG COMBI 5(17)
Circuit diagram: Circuit Combi Att group 7.9.
END POS SENSORS REAR Contact:
KNEE LE X RI X
000218
LEG LE X RI X
Function: 7.9.2.10 Sensor knee
Signal value:
0 No signal.

PRESENT INPUT SIGNAL END POS SENSORS REAR, LEG

Description: Signal from sensor lift leg rear.
DIAG COMBI 5(17)
END POS SENSORS REAR Contact:
KNEE LE X RI X
000218
LEG LE X RI X
Function: 7.9.2.13 Sensor lift legs
Signal value:
0 No signal.
COMBI, menu 6
page
–
PRESENT INPUT SIGNAL LEGS IN DRIVE, POSITION

Description: Signal from sensor operating position.
DIAG COMBI 6(17)
LEGS IN DRIVE Contact:
POSITION LE X RI X
000219

Function: 7.9.2.9 Sensor operating position
Signal value:
0 No signal.

COMBI, menu 7
page
–
INDICATOR LIGHTS ALIGNMENT, FRONT

Description: Voltage feed to indicator light alignment front.
DIAG COMBI 7(17)
INDICATION LAMPS
ALIGNMENT Contact:
FRONT LE XY RI XY
LE: digital out from D791-3/K1:29 to H566L/1
000220
REAR LE XY RI XY
RI: digital out from D791-3/K1:10 to H566R/1
Signal value:


missing.
INDICATOR LIGHTS ALIGNMENT, REAR

Description: Status of Voltage feed to indicator light alignment rear.
DIAG COMBI 7(17)
INDICATION LAMPS
ALIGNMENT Contact:
FRONT LE XY RI XY
000220
REAR LE XY RI XY
Signal value:


missing.

COMBI, menu 8
page
–
INDICATOR LIGHTS CLAMP, FRONT

Description: Status of Voltage feed to indicator light clamp position
DIAG COMBI 8(17) front.
INDICATION LAMPS
CLAMP Circuit diagram: Circuit Combi Att group 7.9
FRONT XY Connection: digital out from D791-4/K1:29 to H578/1
000221
REAR XY
Signal value:


missing.
INDICATOR LIGHTS CLAMP, REAR

Description: Status of Voltage feed to indicator light clamp position
DIAG COMBI 8(17) rear.
INDICATION LAMPS
FRONT XY Connection: digital out from D791-4/K1:39 to H579/1
000221
REAR XY
Signal value:


missing.

COMBI, menu 9
page
–
INDICATOR LIGHTS, FRONT LEGS UP

Description: Status of Voltage feed to indicator light front legs up.
DIAG COMBI 9(17)
INDICATION LAMPS
Connection: digital out from D791-4/K1:10 to H580/1
FRONT LEGS UP XY
000222
FRONT LEGS DOWN XY
Signal value:


missing.
INDICATOR LIGHTS, FRONT LEGS DOWN

Description: Status of Voltage feed to indicator light front legs down.
DIAG COMBI 9(17)
INDICATION LAMPS
Connection: digital out from D791-4/K1:25 to H581/1
FRONT LEGS UP XY
000222
FRONT LEGS DOWN XY

Signal value:


missing.

COMBI, menu 10
page
–
PRESENT OUTPUT SIGNAL FRONT LEGS DOWN, KNEE

Description: Status of voltage feed to Control valve lift legs, solenoid
DIAG COMBI 10(17) valve front knee out.
FRONT LEGS DOWN Circuit diagram: Circuit Combi Att group 7.9
KNEE LE XY RI XY Contact:
000223
LEGS LE XY RI XY
Function: 7.9.2.3 Control valve, lift legs
Signal value:


missing.
PRESENT OUTPUT SIGNAL FRONT LEGS DOWN, LEGS

DIAG COMBI 10(17) valve front leg down.
FRONT LEGS DOWN Circuit diagram: Circuit Combi Att group 7.9
000223
LEGS LE XY RI XY
Signal value:


missing.

COMBI, menu 11
page
–
PRESENT OUTPUT SIGNAL FRONT LEGS UP, KNEE

DIAG COMBI 11(17) valve front knee in.
FRONT LEGS UP Circuit diagram: Circuit Combi Att group 7.9
000224
LEGS LE XY RI XY
Signal value:


missing.
PRESENT OUTPUT SIGNAL FRONT LEGS UP, LEGS

DIAG COMBI 11(17) valve front leg up.
FRONT LEGS UP Circuit diagram: Circuit Combi Att group 7.9
000224
LEGS LE XY RI XY
Signal value:


missing.

COMBI, menu 12
page
–
PRESENT OUTPUT SIGNAL REAR LEGS DOWN, KNEE

DIAG COMBI 12(17) valve rear knee out.
REAR LEGS DOWN Circuit diagram: Circuit Combi Att group 7.9
000225
LEGS LE XY RI XY
Function: 7.9.2.3 Solenoid valve lift legs
Signal value:


missing.
PRESENT OUTPUT SIGNAL REAR LEGS DOWN, LEGS

DIAG COMBI 12(17) valve rear leg down.
REAR LEGS DOWN Circuit diagram: Circuit Combi Att group 7.9
000225
LEGS LE XY RI XY
Signal value:


missing.

COMBI, menu 13
page
–
PRESENT OUTPUT SIGNAL REAR LEGS UP, KNEE

DIAG COMBI 13(17) valve rear knee in.
REAR LEGS UP Circuit diagram: Circuit Combi Att group 7.9
000226
LEGS LE XY RI XY
Signal value:


missing.
PRESENT OUTPUT SIGNAL REAR LEGS UP, LEGS

DIAG COMBI 13(17) valve rear leg up.
REAR LEGS UP Circuit diagram: Circuit Combi Att group 7.9
000226
LEGS LE XY RI XY
Signal value:


missing.

COMBI, menu 14
page
–
SEQUENCE MODE, FRONT

Description: Present sequence mode for lowering the front legs.
DIAG COMBI 14(17)
SEQUENCE MODE
LE RI Contact: -
FRONT X X
000227
REAR X X
Signal value:
0 Sequence error
1 Leg up (0), knee retracted (0).
2 Leg up (0), knee moving (1).
3 Leg up (0), knee extended (0).
4 Leg moving (1), knee extended (0).
5 Leg down (0), knee out (0). No signal.
SEQUENCE MODE, REAR

Description: Present sequence mode for lowering the rear legs.
DIAG COMBI 14(17)
SEQUENCE MODE
LE RI Contact: -
FRONT X X
000227
REAR X X
Signal value:
0 Sequence error
1 Leg up (0), knee retracted (0).
2 Leg up (0), knee moving (1).
3 Leg up (0), knee extended (0).
4 Leg moving (1), knee extended (0).
5 Leg down (0), knee out (0). No signal.

COMBI, menu 15
page
–
PRESENT OUTPUT SIGNAL CLAMP, OUT

DIAG COMBI 15(X) valve clamps apart.
IN LE XY RI XY Contact:
006881
OUT LE XY RI XY
RI: digital out from D797-4/K1:12 to Y6055R/1
Signal value:


missing.
PRESENT OUTPUT SIGNAL CLAMP, IN

DIAG COMBI 15(X) valve clamps in.
IN LE XY RI XY Contact:
006881
OUT LE XY RI XY
LE: digital out from D791-3/K1:11 to Y6054L/1
RI: digital out from D797-4/K1:11 to Y6054R/1
Signal value:


missing.

COMBI, menu 16
page
–
PRESENT OUTPUT SIGNAL DRIVE POSITION

DIAG COMBI 16(17)
Description: Status of Voltage feed to solenoid valve operating
DRIVE POSITION position.
000229
LE XY RI XY
Contact:
LE: digital out from D791-3/K1:42 to Y6053L
RI: digital out from D797-4/K1:42 to Y6053R
Function: 7.9.2.5 Valve block operating position
Signal value:


missing.

COMBI, menu 17
page
–
FORCE CONTROL (+/-), VALVE

DIAG COMBI 17(17)
Description: Forced operation of solenoid valves that control the lift
FORCE CONTROL (+/-)
legs. Select solenoid valve with +/- keys and activate valve with
"VALVE" Enter key.
000230
0: no valve selected
1: Y6056L (knee out left front)
2: Y6057L (knee in left front)
3: Y6013L (leg down left front)
4: Y6060L (leg up left front)
5: Y6056R (knee out right front)
6: Y6057R (knee in right front)
7: Y6013R (leg down right front)
8: Y6060R (leg up right front)
9: Y6058L (knee out left rear)
10: Y6059L (knee in left rear)
11: Y6014L (leg down left rear)
12: Y6061L (leg up left rear)
13: Y6058R (knee out right rear)
14: Y6059R (knee in right rear)
15: Y6014R (leg down right rear)
16: Y6061R (leg up right rear)
17: Y6054L (clamp together left)
18: Y6055L (clamp apart left)
19: Y6054R (clamp together right)
20: Y6055R (clamp apart right)
Contact: -
Signal value: -

154 8 Control system – 8.4.11.2 SLIDING-CAB
8.4.11.2 SLIDING-CAB
SLIDING-CAB, menu 1
page
–
This group handles hydraulic sliding cab and hydraulic vertically ad-
DIAGNOSIS EXTRA justable cab. The menu texts are created for hydraulic sliding cab.
COMBI SLIDING-CAB
SUPPORT-JACKS Confirm selections function key for Enter.
EL-STEERING
000231
SWITCHES, FORWARD
Description: Signal from switch hydraulic sliding cab (forward) or
DIAG SLID-CAB 1(4) switch hydraulic vertically adjustable (up).
SWITCHES
FORWARD X Circuit diagram: Circuit Sliding/Vertically adjustable cab group 9.10
REVERSE X Connection: from S177/1 to digital in D790-1/K8:7
000215
OPENED DOORS X
Function: 9.10.4 Sliding cab, 9.10.5 Vertically adjustable cab
Signal value:
0 No signal.
SWITCHES, REVERSE
Description: Signal from switch hydraulic sliding cab (backward) or
DIAG SLID-CAB 1(4) switch hydraulic vertically adjustable (down).
SWITCHES
FORWARD X Circuit diagram: Circuit Sliding/Vertically adjustable cab group 9.10
REVERSE X Connection: from S177/7 to digital in D790-1/K8:6
000215
OPENED DOORS X
Function: 9.10.4 Sliding cab, 9.10.5 Vertically adjustable cab
Signal value:
0 No signal.
SWITCHES, OPENED DOORS

Description: Signal from door switches, condition that doors are
DIAG SLID-CAB 1(4) closed.
SWITCHES
FORWARD X Circuit diagram: Circuit Lighting group 9.6
REVERSE X Connection: signal from S266-LE/2 or S266-RI/2 to digital in D790-1/
000215
OPENED DOORS X K11:3

Signal value:
1 Input signal active. Door open.
0 No signal. Doors closed.

8 Control system – 8.4.11.2 SLIDING-CAB 155
SLIDING-CAB, menu 2
page
–
PRESENT INPUT SIGNAL, LOW SPEED

Description: Signal from Sensor end position damping, cab sliding or
DIAG SLID-CAB 2(4) vertically adjustable cab.
LOW SPEED X Circuit diagram: Circuit Sliding/Vertically adjustable cab group 9.10
CAB DOWN (LIFT) X Connection: from S769-2/3 to digital in D790-1/K10:6
000232
Function: 9.10.4.8 Sensor end position damping, 9.10.5.9 Sensor end
position damping
Signal value:
0 No signal.
PRESENT INPUT SIGNAL, CAB SPEED (LIFT)

Description: Signal from Sensor lowered cab (vertically
DIAG SLID-CAB 2(4) adjustable cab).
LOW SPEED X Circuit diagram: Circuit Sliding/Vertically adjustable cab group 9.10
CAB DOWN (LIFT) X Connection: from B777-2/3 to analogue in (used as digital) D797-O/
000232
K1:21
Function: 9.10.5.8 Sensor, lowered cab
Signal value:
0 No signal.
SLIDING-CAB, menu 3
page
–
OUTPUT FORWARD, REFERENCE

Description: Status of control current to control valve option, solenoid
DIAG SLID-CAB 3(4) valve sliding cab forward.
OUTPUT FORWARD
REFERENCE XY Circuit diagram: Circuit Sliding/Vertically adjustable cab group 9.10
REQUIRED VALUE XXX Connection: digital out from D797-O/K1:2 to Y6016/1
000233
FEEDBACK XXX
Function: 9.10.4.4 Control valve option frame
Signal value:


missing.

OUTPUT FORWARD, REQUIRED VALUE

Description: Reference value for control current to control valve op-
DIAG SLID-CAB 3(4) tion, solenoid valve sliding cab forward.
OUTPUT FORWARD
REQUIRED VALUE XXX Connection: output signal reference value out from D797-O/K1:16 to
000233
OUTPUT FORWARD, FEEDBACK

Description: Current control current to control valve option, solenoid
DIAG SLID-CAB 3(4) valve sliding cab forward.
OUTPUT FORWARD
REQUIRED VALUE XXX Connection: output signal actual value out from D797-O/K1:16 to
000233

Signal value: XXX = Measured value in mA.
SLIDING-CAB, menu 4
page
–
OUTPUT REVERSE, REFERENCE

Description: Status of control current to control valve option, solenoid
DIAG SLID-CAB 4(4) valve sliding cab backward.
OUTPUT REVERSE
REQUIRED VALUE XXX Connection: digital out from D797-O/K1:3 to Y6017/1
000234
FEEDBACK XXX
Signal value:


missing.

8 Control system – 8.4.11.3 SUPPORT-JACKS 157
OUTPUT REVERSE, REQUIRED VALUE

Description: Reference value for control current to control valve op-
DIAG SLID-CAB 4(4) tion, solenoid valve sliding cab backward.
OUTPUT REVERSE
REQUIRED VALUE XXX Connection: output signal reference value out from D797-O/K1:17 to
000234
OUTPUT REVERSE, FEEDBACK

Description: Current control current to control valve option, solenoid
DIAG SLID-CAB 4(4) valve sliding cab backward.
OUTPUT REVERSE
REQUIRED VALUE XXX Connection: output signal actual value out from D797-O/K1:17 to
000234

Signal value: XXX = Measured value in mA.
8.4.11.3 SUPPORT-JACKS
SUPPORT-JACKS, menu 1
page
–
This group handles support jack functions.

DIAGNOSIS EXTRA
COMBI SLIDING-CAB Confirm selections function key for Enter.
SUPPORT-JACKS
EL-STEERING
000235
SWITCHES, UP
Description: Signal from switch support jacks (up).
DIAG S-JACKS 1(4) Circuit diagram: Circuit Hyd Support jacks group 7.10
SWITCHES
UP X Connection: from S1013/1 to digital in D790-1/K8:9
DOWN X Function: 7.10.1 Support jacks
000213
Signal value:
0 No signal.

158 8 Control system – 8.4.11.3 SUPPORT-JACKS
SWITCHES, DOWN
Description: Signal from switch support jacks (down).
DIAG S-JACKS 1(4) Circuit diagram: Circuit Hyd Support jacks group 7.10
SWITCHES
UP X Connection: from S1013/7 to digital in D790-1/K8:8
DOWN X Function: 7.10.1 Support jacks
000213
Signal value:
0 No signal.
page
–
PRESENT INPUT SIGNALS, UP

Description: Signal from sensor support jacks (up).
DIAG S-JACKS 2(4)
Circuit diagram: Circuit Hyd Support jacks group 7.10
Contact:
UP LE X RI X
LE: from B7222L/A to digital in D797-O/K1:13
000236
DOWN LE X RI X
RI: from B7222R/A to digital in D797-O/K1:27
Function: 7.10.1.5 Sensor, support jacks up
Signal value:
0 No signal.
PRESENT INPUT SIGNALS, DOWN

Description: Signal from sensor support jacks (down).
DIAG S-JACKS 2(4)
Contact:
UP LE X RI X
• LE: from B7223L/A to digital in D797-O/K1:20
000236
DOWN LE X RI X
• RI: from B7223R/A to digital in D797-O/K1:41
Function: 7.10.1.6 Sensor, support jacks down
Signal value:
0 No signal.

8 Control system – 8.4.11.3 SUPPORT-JACKS 159
page
–
OUTPUT VALVE S-J UP

Description: Voltage feed to control valve option frame, solenoid valve
DIAG S-JACKS 3(4) support jacks up.
OUTPUT VALVE
S-J UP XY Circuit diagram: Circuit Hyd Support jacks group 7.10
S-J DOWN XY Connection: digital out from D797-O/K1:30 to Y6063/1
000237
Signal value:


missing.
OUTPUT VALVE S-J DOWN

Description: Voltage feed to control valve option frame, solenoid valve
DIAG S-JACKS 3(4) support jacks down.
OUTPUT VALVE
S-J UP XY Circuit diagram: Circuit Hyd Support jacks group 7.10
S-J DOWN XY Connection: digital out from D797-O/K1:31 to Y6064/1
000237

Signal value:


missing.

160 8 Control system – 8.4.11.4 EL-STEERING
page
–
INDICATOR LIGHT, DOWN

Description: Status of voltage feed supply to indicator light support
DIAG S-JACKS 4(4) jacks down.
INDICATOR LAMP
DOWN XY Connection: digital out from D790-1/K7:11 to H574/1
000238
Function: 7.10.1 Support jacks
Signal value:


missing.
8.4.11.4 EL-STEERING
EL-STEERING, menu 1
page
–
This group handles functions for joystick steering/mini-wheel steering.

DIAGNOSIS EXTRA
COMBI SLIDING-CAB Confirm selections function key for Enter.
SUPPORT-JACKS
EL-STEERING
000239
PRESENT INPUT SIGNAL, SIGNAL 1

Description: Signal from mini-wheel (signal 1) or joystick.
DIAG STEERING 1(5)
Circuit diagram: Circuit Steering joystick/mini-wheel group 5.2, Circuit
SIGNAL 1 X.XXV Steering joystick/mini-wheel and Combi att. group 5.2
SIGNAL 2 X.XXV Contact:
001972
Top lift attachment from R825/H1 to digital in D790-1/K9:8

Combi attachment from R825/H1 to digital in D790-3/K1:21
Function: 5.2 Power-assisted steering system

8 Control system – 8.4.11.4 EL-STEERING 161
PRESENT INPUT SIGNAL, SIGNAL 2

Description: Signal from mini-wheel (signal 2). (Only applies to
DIAG STEERING 1(5) mini-wheel)
SIGNAL 1 X.XXV Circuit diagram: Circuit Steering joystick/mini-wheel group 5.2, Circuit
SIGNAL 2 X.XXV Steering joystick/mini-wheel and Combi att. group 5.2
001972
Contact:
Top lift attachment from R825/H2 to digital in D790-1/K9:9
Combi attachment from R825/H2 to digital in D790-3/K1:22
EL-STEERING, menu 2
page
–
SWITCHES, ON/OFF
Description: Signal from switch mini-wheel/joystick.
DIAG STEERING 2(5)
SWITCHES
ON/OFF X Steering joystick/mini-wheel and Combi att. group 5.2
FORWARD X Contact:
000240
REVERSE X
Top lift attachment from S113/1 to digital in D790-1/K9:5
Combi attachment from S113/1 to digital in D790-3/K1:27
Signal value:
0 No signal.
SWITCHES, FORWARD
Description: Signal from mini-wheel or joystick (travel direction selec-
DIAG STEERING 2(5) tor forward).
SWITCHES
ON/OFF X Circuit diagram: Circuit Steering joystick/mini-wheel group 5.2, Circuit
FORWARD X Steering joystick/mini-wheel and Combi att. group 5.2
000240
REVERSE X Contact:
Top lift attachment from S160-2/1 to digital in D790-1/K9:4
Combi attachment from S160/-2/1 to digital in D790-3/K1:20
Signal value:
0 No signal.

SWITCHES, REVERSE
Description: Signal from mini-wheel or joystick (travel direction selec-
DIAG STEERING 2(5) tor reverse).
SWITCHES
ON/OFF X Circuit diagram: Circuit Steering joystick/mini-wheel group 5.2, Circuit
FORWARD X Steering joystick/mini-wheel and Combi att. group 5.2
000240
REVERSE X Contact:
Signal value:
0 No signal.
EL-STEERING, menu 3
page
–
PRESENT INPUT SIGNAL, HORN

Description: Signal from mini-wheel or joystick (audible signal).
DIAG S-JACKS 3(X)
HORN X Steering joystick/mini-wheel and Combi att. group 5.2
STEER.WHEEL CUT OFF X Contact:
006882

Signal value:
0 No signal.
PRESENT INPUT SIGNAL, STEER. WHEEL CUT OFF

Description: Signal from sensor steering angle.
DIAG S-JACKS 3(X)
HORN X Steering joystick/mini-wheel and Combi att. group 5.2
STEER.WHEEL CUT OFF X Connection: from S720/2 to digital in D790-2/K8:2
006882
Function: 5.2.12 Sensor steering angle

Signal value:
0 No signal.

8 Control system – 8.4.11.4 EL-STEERING 163
EL-STEERING, menu 4
page
–
OUTPUT STEERING LEFT, REFERENCE

Description: Status for control current to control valve option frame,
DIAG STEERING 4(5) solenoid valve steering left.
OUTPUT STEERING LEFT
REFERENCE XY Circuit diagram: Circuit Steering joystick/mini-wheel group 5.2, Circuit
REQUIRED VALUE XXX Steering joystick/mini-wheel and Combi att. group 5.2
000242
FEEDBACK XXX Connection: output signal reference value out from D797-O/K1:4 to
Y636/1
Function: 5.2.10 Control valve option frame
Signal value:


missing.
OUTPUT STEERING LEFT, REQUIRED VALUE

Description: Reference value for control current to control valve option
DIAG STEERING 4(5) frame, solenoid valve steering left.
000242
Y636/2
OUTPUT STEERING LEFT, FEEDBACK

Description: Current control current to control valve option frame, so-
DIAG STEERING 4(5) lenoid valve steering left.
000242
FEEDBACK XXX Connection: output signal, reference value out from D797-0/K1:18 to
Y636L/2

EL-STEERING, menu 5
page
–
OUTPUT STEERING RIGHT, REFERENCE

Description: Status for control current to control valve option frame,
DIAG STEERING 5(5) solenoid valve steering left.
OUTPUT STEERING RIGHT
000243
Y636R/1
Signal value:


missing.
OUTPUT STEERING RIGHT, REQUIRED VALUE

Description: Reference value for control current to control valve option
DIAG STEERING 5(5) frame, solenoid valve steering left.
000243
Y636R/2
OUTPUT STEERING RIGHT, FEEDBACK

Description: Current control current to control valve option frame, so-
DIAG STEERING 5(5) lenoid valve steering left.
000243
Y636R/2

8 Control system – 8.4.13 RMI 165
8.4.13 RMI
RMI, description
page
–
DIAGNOSIS
CAN/POWER LIGHTS CAB This group handles RMI (Remote Machine Interface) functions.
CLIMATE HYD ENGINE
Confirm selections function key for Enter.
TRANSM BOOM ATTACH
007442
OP EXTRA RMI
8.4.13.1 RMI, menu 1

MIU SW VER
page
–
DIAG RMI 1(3)

MIU SW VER XXXX.XXXX Description: Software version in RMI interface.
MIU TIME XXXX.XX.XX Circuit diagram: -
007439
Contact: -
Function: 11.6.5 RMI (Remote Machine Interface)
Signal value: xxxx.xxxx = software number.
MIU TIME
page
–
DIAG RMI 1(3)

MIU SW VER XXXX.XXXX Description: Date setting in RMI interface.
MIU TIME XXXX.XX.XX Circuit diagram: -
007439
Contact: -
Signal value: xxxx.xx.xx = Date in format YYYY.MM.DD.
8.4.13.2 RMI, menu 2

SIGNAL QUALITY, GSM
page
–
DIAG RMI 2(3)

SIGNAL QUALITY Description: Signal strength of GSM-signal through receiver in the RMI
GSM XXX GPRS XXX interface.
WLAN XXX RADIO XXX
Circuit diagram: Circuit RMI group 8.2
007440
SMS XXX:UNS.DATA XXX

Contact: -
Signal value: XXX = 0-100 = Signal strength, 0-100%.

166 8 Control system – 8.4.13.2 RMI, menu 2
SIGNAL QUALITY, GPRS

page
–
DIAG RMI 2(3)

SIGNAL QUALITY Description: Signal strength of GPRS-signal through receiver in the
GSM XXX GPRS XXX RMI interface.
WLAN XXX RADIO XXX
007440
Contact: -
SIGNAL QUALITY, WLAN

page
–
Description: Signal strength of WLAN-signal through receiver in the

RMI interface.
Contact: -
SIGNAL QUALITY, RADIO

page
–
DIAG RMI 2(3)

SIGNAL QUALITY Description: Signal strength of RADIO-signal through receiver in the
GSM XXX GPRS XXX RMI interface.
WLAN XXX RADIO XXX
007440

Contact: -
SIGNAL QUALITY, SMS

page
–
DIAG RMI 2(3)

SIGNAL QUALITY Description: Signal strength of SMS-signal through receiver in the RMI
WLAN XXX RADIO XXX
007440

Contact: -

8 Control system – 8.4.13.3 RMI, menu 3 167
SIGNAL QUALITY, UNS.DATA

page
–
DIAG RMI 2(3)

SIGNAL QUALITY Description: Amount of unsent data in line in transmitter part in the RMI
WLAN XXX RADIO XXX
007440
Contact: -
Signal value: XXX = 0-100 = Data amount in percent of transmitter
buffer, 0-100%.
8.4.13.3 RMI, menu 3

ERROR
page
–
DIAG RMI 3(3)

ERROR XX.XX.XX.XX Description: Internal error code for the RMI interface
ERR.VALID XX.XX.XX.XX Circuit diagram: Circuit RMI group 8.2
ACT.ERR. XX.XX.XX.XX
007441
Contact:-
Signal value: XX.XX.XX.XX = Error code
ERR.VALID
page
–
DIAG RMI 3(3)

007441
Contact:-
ACT.ERR
page
–
DIAG RMI 3(3)

007441
Contact: -

168 8 Control system – 8.5 Setup
8.5 Setup
Setup, general
page
–
Settings are built-in functions to adapt the functions to the unique ma-
chine individual. Settings are performed via menus in the display. Set-
tings are divided into initiation and calibration.
Initiation
Initiation, which involves setting start and stop currents for the steering
and hydraulic functions, is performed before the machine is used in
work. This is done to compensate for mechanical and electrical toler-
ances (variations between different machines).
Calibration
Calibration is performed after the machine has started to be used for
work, after change of control units, and in certain cases, service or
change of components. Calibration is performed so that certain func-
tions shall function properly and show correct values.
8.5.1 Initiation
Initiation, description
page
–
1 2
DANGER
INIT STEERING 9(10)
START CURRENT The settings influence the functions. Adjustments
STEERING LEFT may impair the function. If in doubt, contact Cargotec
4 STORED VALUE XXXmA
3 Service.
000058
PRESENT VALUE XXXmA

Example of initiation menu, start current for lift
function.
NOTE
1. Menu group Initiation does not need to be performed in one process but each
step can be performed separately, independently of other steps.
2. Menu number (in brackets, total number of menus)
In order that hydraulic functions shall work satisfactorily and safely,
3. Values
certain values must be set to operate the machine, this is known as
4. Current variable
initiation.
Initiation is built up of several menus grouped according to functions.
Each individual menu sets a specific variable. The menus are similar
in construction and use a common terminology explained here:
PRESENT
Displays the stored value when the menu is opened. Adjust the value
with the plus and minus keys. Save the set value with the Enter key.
Go to the next menu with the arrow keys. Go back with the R-key.
STORED
States the stored value for the current variable.

8 Control system – 8.5.1 Initiation 169
START CURRENT
Specifies the start current to the solenoid valve for the selected func-
tion. The start current is the lowest current that can be actuated. In
practice, this controls how slowly a function can be operated. On func-
tions with analogue control activation (variable), e.g. lift, this is the cur-
rent that is triggered when the lever leaves the zero position. On
certain functions with digital activation (off/on) which are soft-started,
this is the current which is triggered immediately the function is
activated.
END CURRENT
Specifies the max. current to the solenoid valve for the selected func-
tion. The max. current is the highest current that can be triggered. In
practice, it controls how quickly a function can be operated. On func-
tions with analogue control activation (controllable), e.g. lift, this is the
current when the lever is in the end position. On certain functions with
digital activation (off/on) which are soft-started, this is the current
which is triggered after the ramp time when the function is activated.
The interval between START CURRENT and END CURRENT is the
active range for controlling the solenoid valve.
PROC DAMPING
Specifies how much the control current shall be reduced during damp-
ing. The interval is specified as 0-100% of the active range between
START CURRENT and END CURRENT.
Overview initiations
Function Menu
INIT DRIVE-TRAIN, menu 9 page 192
1 Engine, speed limitation (limitation of engine speed )
INIT DRIVE-TRAIN, menu 11

1 Engine, automatic engine shut-down on idle
page 192
2 Transmission, starting gear INIT DRIVE-TRAIN, menu 1 page 189
2 Transmission, speed limit shifting forward - reverse INIT DRIVE-TRAIN, menu 2 page 189
2 Transmission, engine speed limit shifting forward - reverse INIT DRIVETRAIN, menu 3 page 190
2 Transmission, engine speed limit shifting neutral - gear INIT DRIVETRAIN, menu 4 page 190
2 Transmission, engine speed limit kickdown to 1st INIT DRIVETRAIN, menu 5 page 191
2 Transmission, speed limit declutch INIT DRIVETRAIN, menu 6 page 191
INIT DRIVETRAIN, menu 10

2 Transmission, speed limitation (gear lock-out)
page 192

2 Transmission, automatic engine speed reduction for shift forward - reverse
page 193
5.2 Power-assisted steering system (product option lever steering or mini-wheel), INIT STEERING, menu 1 page 184
lever response

170 8 Control system – 8.5.1 Initiation
Function Menu
speed dependent INIT STEERING, menu 3 page 185
INIT STEERING, menu 4 page 186
steering angle right INIT STEERING, menu 8 page 187
steering angle left INIT STEERING, menu 10 page 188
7.2 Lift/lower, boom up INIT BOOM, menu 1 page 172

INIT BOOM, menu 2 page 172
7.2 Lift/lower, boom down INIT BOOM, menu 3 page 173

Note: The current value is for unloaded machines. When loaded, the current value INIT BOOM, menu 4 page 173
is controlled by the limited lowering speed.
7.2 Lift/lower, lift speed during operation INIT BOOM, menu 9 page 175
7.2 Lift/lower, damping at container (top lift) INIT ATTACH, menu 15 page 181
7.2 Lift/lower, damping at container (bottom lift) INIT ATTACH, menu 16 page 181
7.3 Extension, boom out INIT BOOM, menu 5 page 173

INIT BOOM, menu 6 page 174
7.3 Extension, boom in INIT BOOM, menu 7 page 174

Note: The current value is for unloaded machines. When loaded, the current value INIT BOOM, menu 8 page 174
is controlled by the limited lowering speed.
7.5 Spreading out INIT ATTACH, menu 9 page 179

INIT ATTACH, menu 10 page 179
7.5 Spreading in INIT ATTACH, menu 12 page 180

7.6 Rotation, clockwise INIT ATTACH, menu 1 page 176

7.6 Rotation, counter-clockwise INIT ATTACH, menu 3 page 177

7.7 Tilt INIT ATTACH, menu 5 page 177

7.8 Levelling INIT ATTACH, menu 7 page 178

8.2.3 Load centre limitation INIT BOOM, menu 10 page 175

8 Control system – 8.5.1 Initiation 171
Function Menu
8.2.4 Height limitation INIT BOOM, menu 11 page 175
9.10.4 Sliding cab, forward INIT SLID-CAB, menu 1 page 182

9.10.5 Vertically adjustable cab, up INIT SLID-CAB, menu 2 page 182
INIT SLID-CAB, menu 3 page 183
9.10.4 Sliding cab, backward INIT SLID-CAB, menu 4 page 183

9.10.5 Vertically adjustable cab, down INIT SLID-CAB, menu 5 page 183
INIT SLID-CAB, menu 6 page 184
Initiate hydraulic function, work instruction

page
–
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
The code determines which service menu is activated (Diag-

nostic test, Initiation or Calibration).
4 Select group by scrolling with the arrow keys (1 and 2) and con-
INITIATION firm with Enter.
BOOM ATTACHMENT Each initiation consists of a sequence of a number of menus. The

SLIDING-CAB STEERING first menu for the selected initiation opens in the display. Select
000057
TIMES RETURN the desired menus with the arrow keys (1 and 2).
5 Change the current value with the plus and minus keys.
INITIATION BOOM 1(8)
START CURRENT
LIFT NOTE
STORED VALUE XXXmA Current values can only be adjusted within specific limits.
PRESENT VALUE XXXmA 6 Use the function key for Enter to store the desired current value
setting, "STORED".
INITIATION BOOM 2(8)

END CURRENT
LIFT
STORED VALUE XXXmA
000061
PRESENT VALUE XXXmA

172 8 Control system – 8.5.1.1 BOOM
8.5.1.1 BOOM
INIT BOOM
page
–
This function menu group handles initiation of the boom functions lift,
INITIATION lower and extension.
BOOM ATTACHMENT
SLIDING-CAB STEERING
DANGER
000651
DRIVE-TRAIN
The settings affect the function of lift, lower and ex-

tension. Adjustments can impair functionality. Con-
tact Cargotec Service in the event of uncertainty.
NOTE
Initiation does not need to be performed in one process but each
INIT BOOM, menu 1

page
–
START CURRENT, LIFT

INIT BOOM 1(11)
Description: Start current for activation of solenoid valve lift (Y6005).
START CURRENT
LIFT PRESENT VALUE: Indicates the current value for the start current.
STORED VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
005042
PRESENT VALUE XXXmA the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE: indicates stored value for start current.
Component: Solenoid valve, lift (Y6005)
Signal value: XXXmA = 0 - 999 mA
INIT BOOM, menu 2

page
–
END CURRENT, LIFT

INIT BOOM 2(11)
Description: Control current on full lever actuation for the activation of
END CURRENT
LIFT the solenoid valve for mast (Y6005).
STORED VALUE XXXmA PRESENT VALUE: Indicates the current value for max. current. Adjust
005043
PRESENT VALUE XXXmA the value with the plus and minus keys. Save the set value with the En-
ter key. Go to the next menu with the arrow keys. Exit initiation with the
R-key.
STORED VALUE: indicates stored value for max. current.
Component: Solenoid valve, lift (Y6005)

8 Control system – 8.5.1.1 BOOM 173
INIT BOOM, menu 3

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START CURRENT, LOWER

INIT BOOM 3(11)
Description: Start current for activation of solenoid valve lower
START CURRENT
LOWER (Y6004).
STORED VALUE XXXmA PRESENT VALUE: Indicates the current value for the start current.
005044
PRESENT VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
Component: Solenoid valve, lower (Y6004)
Signal value: XXXmA = 0-999 mA
INIT BOOM, menu 4

page
–
END CURRENT, LOWER

INIT BOOM 4(11)
END CURRENT
LOWER the solenoid valve lower (Y6004).
005045
R-key.
Component: Solenoid valve, lower (Y6004)
INIT BOOM, menu 5

page
–
START CURRENT, BOOM OUT

INIT BOOM 5(11)
Description: Start current for activation of solenoid valve boom out
START CURRENT
BOOM OUT (Y6006).
005046
with the R-key.
Component: Solenoid valve, boom out (Y6006)

174 8 Control system – 8.5.1.1 BOOM
INIT BOOM, menu 6

page
–
END CURRENT, BOOM OUT

INIT BOOM 6(11)
END CURRENT
BOOM OUT the solenoid valve boom out (Y6006).
005047
R-key.
Component: Solenoid valve, boom out (Y6006)
INIT BOOM, menu 7

page
–
START CURRENT, BOOM IN

INIT BOOM 7(11)
Description: Start current for activation of solenoid valve boom in
START CURRENT
BOOM IN (Y6007).
005048
with the R-key.
Component: Solenoid valve, boom in (Y6007)
INIT BOOM, menu 8

page
–
END CURRENT, BOOM IN

INIT BOOM 8(11)
END CURRENT
BOOM IN the solenoid valve boom in (Y6007).
005049
R-key.
Component: Solenoid valve, boom in (Y6007)

8 Control system – 8.5.1.1 BOOM 175
INIT BOOM, menu 9

page
–
OUTPUT LIFT AT F/R

INIT BOOM 9(11)
Description: Lift speed with gear engaged, as a percentage of max. lift
OUTPUT LIFT AT F/R
(PROC) speed.
STORED VALUE XXX PRESENT VALUE: Indicates the current value for lift speed. Adjust
004930
PRESENT VALUE XXX the value with the plus and minus keys. Save the set value with the En-
R-key.
STORED VALUE: indicates stored value for lift speed.
Component: -
Signal Value: XXX = lift speed as a percentage of max. value.
INIT BOOM, menu 10

page
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OPTION LC-LIMIT
INIT BOOM 10(11)
OPTION LC-LIMIT
Description: Limit value for load centre limitation in metres. Distance
STORED VALUE XX.XX
from drive axle’s centre.
004931
PRESENT VALUE XX.XX
NOTE
On machines with a vertically adjustable cab, load centre less
than the cab’s leading point cannot be selected.
PRESENT VALUE: Indicates the current value for load centre. Adjust
the value with the plus and minus keys. Save the set value with the En-
R-key.
STORED VALUE: indicates stored value for load centre.
Function: 8.2.3 Load centre limitation
Component: -
Signal value: XX.XX = load centre limitation in metres.
INIT BOOM, menu 11

page
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OPTION HEIGHT-LIMIT
INIT BOOM 11(11)
OPTION HEIGHT-LIMIT
Description: Limit value for height limitation in metres. Distance to
STORED VALUE XX.XX
boom’s highest point.
004932
PRESENT VALUE XX.XX

PRESENT VALUE: Indicates the current value for height limitation.
Adjust the value with the plus and minus keys. Save the set value with
with the R-key.
STORED VALUE: indicates stored value for height limitation.
Function: 8.2.4 Height limitation
Component: -
Signal value: XX.XX = height limitation in metres.

176 8 Control system – 8.5.1.2 ATTACHMENT
8.5.1.2 ATTACHMENT
INIT ATTACH
page
–
This function handles initiation of the attachment functions rotation,

INITIATION controllable tilt and controllable levelling.
BOOM ATTACHMENT
SLIDING-CAB STEERING
DANGER
001157
DRIVE-TRAIN
The settings impact the function rotation, adjustable

tilt, and adjustable levelling. Adjustments may impair
the function. If in doubt, contact Cargotec.
NOTE
INIT ATTACH, menu 1

page
–
START CURRENT, ROTATION CW

INIT ATTACH 1(14)
Description: Start current for activation of solenoid valve rotation
START CURRENT
ROTATION CW clockwise (Y6008).
005091
with the R-key.
Component: Solenoid valve rotation clockwise (Y6008)
INIT ATTACH, menu 2

page
–
END CURRENT, ROTATION CW

INIT ATTACH 2(14)
END CURRENT
ROTATION CW the solenoid valve rotation counter-clockwise (Y6009).
005092
R-key.
Component: Solenoid valve, counter-clockwise (Y6009)

8 Control system – 8.5.1.2 ATTACHMENT 177
INIT ATTACH, menu 3

page
–
START CURRENT, ROTATION CCW

INIT ATTACH 3(14)
Description: Start current for activation of solenoid valve rotation coun-
START CURRENT
ROTATION CCW ter-clockwise (Y6009).
005093
with the R-key.
Component: Solenoid valve rotation counter-clockwise (Y6009)
INIT ATTACH, menu 4

page
–
END CURRENT, ROTATION CCW

INIT ATTACH 4(14)
END CURRENT
ROTATION CCW the solenoid valve rotation counter-clockwise (Y6009).
005094
R-key.
Component: Solenoid valve, counter-clockwise (Y6009)
INIT ATTACH, menu 5

page
–
START CURRENT, TILT

INIT ATTACH 5(14)
Description: Start current for activation of the solenoid valve rotation
START CURRENT
TILT tilt in (Y6010) and solenoid valve tilt out (Y6011).
005095
with the R-key.
Component: Solenoid valve rotation tilt in (Y6010), Solenoid valve tilt
out (Y6011)

INIT ATTACH, menu 6

page
–
END CURRENT, TILT

INIT ATTACH 6(14)
Description: Control current at full deflection of the lever to activate So-
END CURRENT
TILT lenoid valve rotation tilt in (Y6010), Solenoid valve tilt out (Y6011).
005096
R-key.
Component: Solenoid valve rotation tilt in (Y6010), Solenoid valve tilt
out (Y6011)
INIT ATTACH, menu 7

page
–
START CURRENT, LEVELLING

INIT ATTACH 7(14)
Description: Start current for activation of the solenoid valve for level-
START CURRENT
LEVELING ling right (Y6035) and a solenoid valve for levelling left (Y6036).
005097
with the R-key.
Component: Solenoid valve for levelling right (Y6035), Solenoid valve
for levelling left (Y6036)
INIT ATTACH, menu 8

page
–
END CURRENT, LEVELLING

INIT ATTACH 8(14)
Description: Control current at full lever stroke activation of the sole-
END CURRENT
LEVELING noid valve for levelling right (Y6035) and a solenoid valve for levelling
STORED VALUE XXXmA left (Y6036).
005098
PRESENT VALUE XXXmA PRESENT VALUE: Indicates the current value for max. current. Adjust
R-key.
Component: Solenoid valve for levelling right (Y6035), Solenoid valve
for levelling left (Y6036)

8 Control system – 8.5.1.2 ATTACHMENT 179
INIT ATTACH, menu 9

page
–
START CURRENT, SPREADER OUT 20'-40'

INIT ATTACH 9(X)
Description: Start current for activation of solenoid valve spreading out
START CURRENT
SPREADER OUT, 20'-40' (Y6018).
I [mA] ter key. Go to the next menu with the arrow keys. Exit initiation with the
R-key.
1
2 Function: 7.5.3 Control valve attachment
3
005517
Component: Solenoid valve for spreading out (6018)
t [s]
Signal value: XXXmA = 0-999 mA.
1. Max. current (END CURRENT)
2. Damping (PROC DAMPING)
3. Start current (START CURRENT)
INIT ATTACH, menu 10

page
–
END CURRENT, SPREADER OUT 20'-40'

INIT ATTACH 10(X)
END CURRENT
SPREADER OUT, 20'-40' solenoid valve spreading out (Y6018).
R-key.
1
3
005518
Component: Solenoid valve, spreading out (Y6018)

t [s]

page
–
DAMP (PROC), SPREADING OUT, 20'-40'

INIT ATTACH 11(X)
Description: Control current to Solenoid valve, spreading out (Y6018)
DAMP (PROC)
SPREADER OUT, 20'-40' during damping, when damping is approaching 40'.
STORED VALUE XX PRESENT VALUE: Indicates the current value for max. current. Adjust
PRESENT VALUE XX the value with the plus and minus keys. Save the set value with the En-
R-key.
1
STORED VALUE: indicates stored value in percent.
3
005519
Component: Solenoid valve, spreading out (Y6018)

t [s]
Signal value: XXX = 0-100%. 100% means no damping i.e. max. cur-
1. Max. current (END CURRENT) rent. 0% means full damping i.e. start current.


page
–
START CURRENT, SPREADER IN 40'-20'

INIT ATTACH 12(X)
Description: Start current for activation of solenoid valve spreading in
START CURRENT
SPREADER IN, 40'-20' (Y6019).
R-key.
1
3 005520
Component: Solenoid valve for spreading in (6019)
t [s]
Signal value: XXXmA = 0-999 mA.

page
–
END CURRENT, SPREADER IN 40'-20'

INIT ATTACH 13(X)
END CURRENT
SPREADER IN, 40'-20' solenoid valve spreading in (Y6019).
R-key.
1
3
005521
Component: Solenoid valve, spreading in (Y6019)

t [s]

page
–
DAMP (PROC), SPREADING IN, 40'-20'

INIT ATTACH 14(X)
Description: Control current to Solenoid valve, spreading in (Y6019)
DAMP (PROC)
SPREADER IN, 40'-20' during damping, when damping is approaching 20’.
STORED VALUE XX PRESENT VALUE: Indicates the current value for max. current. Adjust
PRESENT VALUE XX the value with the plus and minus keys. Save the set value with the En-
R-key.
1
STORED VALUE: indicates stored value in percent.
3
005522
Component: Solenoid valve, spreading in (Y6019)

t [s]
1. Max. current (END CURRENT) rent. 0% means full damping i.e. start current.


page
–
INIT ATTACH 15(X)

OPT DAMP BOOM DOWN
TOP LIFT (cm) OPT DAMP BOOM DOWN, TOP LIFT (cm)
STORED VALUE XXXX Description: Distance setting for activation of damping of lowering
006756
PRESENT VALUE XXXX speed for the top lift, distance between the attachment and container.
PRESENT VALUE: Indicates the current value for the distance. Adjust
R-key.
STORED VALUE: indicates stored value for the distance.
Function:
Component:
Signal value: XXXX = distance in cm.

page
–
OPT DAMP DOWN, BOTTOM LIFT (cm)

INIT ATTACH 16(X)
Description: Distance setting for activation of damping of lowering
OPT DAMP BOOM DOWN
BOTTOM LIFT (cm) speed for the bottom lift, distance between the attachment and trailer.
STORED VALUE XXXX PRESENT VALUE: Indicates the current value for the distance. Adjust
006842
PRESENT VALUE XXXX the value with the plus and minus keys. Save the set value with the En-
R-key.
STORED VALUE: indicates stored value for the distance.
Function:
Component:
Signal value: XXXX = distance in cm
8.5.1.3 SLIDING-CAB
INIT SLIDING-CAB
page
–
This function handles initiation of hydraulic sliding cab or hydraulic

INITIATION cab lift.
BOOM ATTACHMENT The sliding cab is smooth started by means of the control current to
SLIDING-CAB STEERING the solenoid valves being increased from a low start value to a max.
001645
DRIVE-TRAIN level. When the cab reaches an end position the speed is dampened
by means of the control current being reduced.
DANGER
Settings affect the function hydraulic sliding cab, ver-
tically adjustable cab, as well as cab tilt. Adjustments
may impair the function. Contact Cargotec Service if
in doubt.

NOTE
INIT SLID-CAB, menu 1

page
–
START CURRENT, FORWARD

INIT SLID-CAB 1(6)
Description: Start current to solenoid valve sliding cab forward
START CURRENT
FORWARD (Y6016) at activation of sliding cab. The control current controls the
STORED VALUE XXXmA start speed for sliding cab forward.
PRESENT VALUE XXXmA PRESENT VALUE: Indicates the current value for the start current.
I [mA] Adjust the value with the plus and minus keys. Save the set value with
1 with the R-key.
2 STORED VALUE: indicates stored value for start current.
3 Function: 9.10.4.3 Control valve option frame
001698
t [s] Component: Solenoid valve sliding cab forward (Y6016)

1. Max. current (END CURRENT) Signal value: XXXmA = 0 - 999 mA

page
–
END CURRENT, FORWARD

INIT SLID-CAB 2(6)
Description: Control current to solenoid valve for sliding cab forward
END CURRENT
FORWARD (Y6016) after full ramp time at activation of switch for sliding cab. This
STORED VALUE XXXmA current controls maximum speed cab sliding speed forward.
I [mA] the value with the plus and minus keys. Save the set value with the En-
1 R-key.
2 STORED VALUE: indicates stored value for max. current.
001787



page
–
PROC DAMPING, FORWARD

INIT SLID-CAB 3(6)
Description: Percent damping of control current to solenoid
PROC DAMPING
FORWARD valve sliding cab forward (Y6016) when the cab approaches
STORED VALUE XXXmA forward end-position.
PRESENT VALUE XXXmA PRESENT VALUE: Indicates the current value for damping. Adjust
I [mA] the value with the plus and minus keys. Save the set value with the
Enter key. Go to the next menu with the arrow keys. Exit initiation with
1 the R-key.
t [s] 001850 Component: Solenoid valve sliding cab forward (Y6016)
rent. 0% means full damping i.e. start current.

page
–
START CURRENT, REVERSE

INIT SLID-CAB 4(6)
Description: Start current to solenoid valve sliding cab reverse
START CURRENT
REVERSE (Y6017) at activation of sliding cab. The control current controls the
STORED VALUE XXXmA start speed for sliding cab reverse.
PRESENT VALUE XXXmA PRESENT VALUE: Indicates the current value for the start current.
I [mA] Adjust the value with the plus and minus keys. Save the set value with
1 with the R-key.
003001
t [s] Component: Solenoid valve sliding cab reverse (Y6017)


page
–
END CURRENT, REVERSE

INIT SLID-CAB 5(6)
Description: Control current to solenoid valve for sliding cab backward
END CURRENT
REVERSE (Y6017) after full ramp time at activation of switch for sliding cab. This
STORED VALUE XXXmA current controls max. speed sliding cab backward.
I [mA] the value with the plus and minus keys. Save the set value with the En-
1 R-key.
2 STORED VALUE: indicates stored value for max. current.
003022


184 8 Control system – 8.5.1.4 STEERING

page
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PROC DAMPING, REVERSE

INIT SLID-CAB 6(6)
Description: Percent damping of control current to solenoid
PROC DAMPING
REVERSE valve sliding cab reverse (Y6017) when the cab approaches
STORED VALUE XXXmA reverse end-position.
PRESENT VALUE XXXmA PRESENT VALUE: Indicates the current value for damping. Adjust
I [mA] the value with the plus and minus keys. Save the set value with the
Enter key. Go to the next menu with the arrow keys. Exit initiation with
1 the R-key.
3 003093 Function: 9.10.4.3 Control valve option frame
t [s] Component: Solenoid valve sliding cab reverse (Y6017)
rent. 0% means full damping i.e. start current.
8.5.1.4 STEERING
INIT STEERING
page
–
This function covers initiation of joystick control or mini-wheel.

INITIATION
BOOM ATTACHMENT
SLIDING-CAB STEERING DANGER
002954
DRIVE-TRAIN
The settings affect the function of lever steering or
mini-wheel. Adjustments can impair function. Contact
Cargotec Service in the event of uncertainty.
NOTE
INIT STEERING, menu 1

page
–
CHARACTER OF THE STEERING LEVER

INIT STEERING 1(10)
Description: Indicates the sensitivity of the steering lever in accord-
CHARACTER OF THE
STEERING LEVER, 0-31 ance with 32 predefined curves (0-31). 0 means that linear wheel an-
STORED VALUE XX gle is uniform in relation to lever angle during the whole lever
PRESENT VALUE XX movement. 31 means that the wheel angle is small at the beginning of
the lever movement and large at the end.
U [V] 0
PRESENT VALUE: Indicates current curve. Change curve with the
plus and minus keys. Save the set curve with the Enter key. Go to the
next menu with the arrow keys. Exit initiation with the R-key.
31
STORED VALUE: indicates saved curve.
Function: 5.2 Power-assisted steering system (product alternative joy-
003130
stick steering or mini-wheel)

X Component: -
U = Output signal to solenoid valve
Signal value: XX = 0-31.
X = Lever movement

8 Control system – 8.5.1.4 STEERING 185

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–
BREAK POINT BP1

INIT STEERING 2(10)
Description: Speed for cut-off point 1. Cut-off points are used to adapt
BRAKE POINT BP1
(kph) the steering angle to the machine’s speed. This enables both sensitive
STORED VALUE XX.X steering at low speeds and stable steering at higher speeds.
PRESENT VALUE XX.X PRESENT VALUE: indicates present speed setting for cut-off point 1.
I [mA] Change speed with plus or minus keys. Save set speed with the Enter-
100% key. Go to the next menu with arrow keys. Exit initiation with the R-key.
STORED VALUE: indicates saved speed for break point 1.
% BP2 Function: 5.2 Power-assisted steering system (product alternative joy-
% BP3 stick steering or mini-wheel)
003131
V [kph] Component: -
BP1 BP2 BP3
I [mA] = control current to solenoid valve Signal value: XX.X = speed for BP1 in km/h.
V [kph] = machine’s speed in km/h
BP1 = speed setting for break point 1
%BP2 = per cent of control current to solenoid valve
at BP2
at BP3

page
–
BREAK POINT BP2

INIT STEERING 3(10)
BRAKE POINT BP2
003132
V [kph] Component: -
BP1 BP2 BP3
at BP2
at BP3


page
–
BREAK POINT BP3

INIT STEERING 4(10)
BRAKE POINT BP3
V [kph] 003133 Component: -
BP1 BP2 BP3
at BP2
at BP3

page
–
PROC REDUCTION, AT PB2

INIT STEERING 5(10)
Description: Percentage reduction of control current to solenoid valve
PROC REDUCTION
AT BP2 for steering right (Y636R) and solenoid valve for steering left (Y636L)
STORED VALUE XXX at BP2.
PRESENT VALUE XXX PRESENT VALUE: Indicates the current value for the reduction. Ad-
I [mA] just the value with the plus and minus keys. Save the set value with
100% the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
% BP2 STORED VALUE: indicates stored value for the reduction.
003134
V [kph] stick steering or mini-wheel)

BP1 BP2 BP3
Component: -
I [mA] = control current to solenoid valve
V [kph] = machine’s speed in km/h Signal value: XXX = 0-100%. 100% means no damping i.e. max. cur-
BP1 = speed setting for break point 1 rent. 0% means full damping i.e. start current.
at BP2
at BP3

8 Control system – 8.5.1.4 STEERING 187

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PROC REDUCTION, AT PB3

INIT STEERING 6(10)
Description: Percentage reduction of control current to solenoid valve
PROC REDUCTION
AT BP3 for steering right (Y636R) and solenoid valve for steering left (Y636L)
STORED VALUE XXX at BP3.
PRESENT VALUE XXX PRESENT VALUE: Indicates the current value for the reduction. Ad-
I [mA] just the value with the plus and minus keys. Save the set value with
100% the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
% BP2 STORED VALUE: indicates stored value for the reduction.
003135
V [kph] stick steering or mini-wheel)
BP1 BP2 BP3
Component: -
I [mA] = control current to solenoid valve
V [kph] = machine’s speed in km/h Signal value: XXX = 0-100%. 100% means no damping i.e. max. cur-
BP1 = speed setting for break point 1 rent. 0% means full damping i.e. start current.
at BP2
at BP3

page
–
START CURRENT, STEERING RIGHT

INIT STEERING 7(10)
Description: Start current to the solenoid valve for steering right
START CURRENT
STEERING RIGHT (Y636R).
003136
with the R key.
Function: 5.2.10 Control valve, lever steering/mini wheel
Component: Solenoid valve for steering right (Y636R)

page
–
END CURRENT, STEERING RIGHT

INIT STEERING 8(10)
Description: Control current to the solenoid valve for steering right
END CURRENT
STEERING RIGHT (Y636R) at end lever position.
003137
R-key.
Component: Solenoid valve for steering right (Y636R)


page
–
START CURRENT, STEERING LEFT

INIT STEERING 9(10)
Description: Start current to the solenoid valve for steering right
START CURRENT
STEERING LEFT (Y636L).
003138
with the R-key.
Component: Solenoid valve for steering right (Y636L)

page
–
END CURRENT, STEERING LEFT

INIT STEERING 10(10)
Description: Control current to the solenoid valve for steering right
END CURRENT
STEERING LEFT (Y636L) at end lever position.
006704
R-key.
Component: Solenoid valve for steering right (Y636L)

8 Control system – 8.5.1.5 DRIVETRAIN, Dana TE32 FF 189
8.5.1.5 DRIVETRAIN, Dana TE32 FF

INIT DRIVE-TRAIN
page
–
This function handles initialisation of the transmission.

INITIATION
BOOM ATTACHMENT NOTE

SLIDING-CAB STEERING Initiation does not need to be performed in one process but each
003140
DRIVE-TRAIN step can be performed separately, independently of other steps.
The machine must be stationary with parking brake applied in or-
der 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.

page
–
START IN 2ND
INIT DRIVE-TRN 1(6)
Description: Setting to get transmission to start in 2nd gear instead of
START IN 2:ND
0=NO 1=YES in 1st. Kick-down to 1st takes place as needed.
STORED VALUE XXX PRESENT VALUE: Indicates the current setting. Change the value
003151
PRESENT VALUE XXX with the plus and minus keys. Save the set value with the Enter key.
Go to the next menu with the arrow keys. Exit initiation with the R-key.
STORED VALUE: indicates saved setting.
Component: -
Signal value: XXX = 1= yes, XXX = 0 = no

page
–
VEHICLE SPEED F-R

INIT DRIVE-TRN 2(12)
Description: Setting of highest permitted speed for shifting between
VEHICLE SPEED F-R
forward and reverse.
005051
Component: -
Signal value: XXX = speed in km/h

190 8 Control system – 8.5.1.5 DRIVETRAIN, Dana TE32 FF

page
–
ENGINE SPEED F-R

Description: Setting of highest engine speed for shifting between for-
ENGINE SPEED F-R
ward and reverse.
STORED VALUE XXX
005052
PRESENT VALUE XXX NOTE
If the rpm is set lower than the engine’s idle rpm, shifting will not
be allowed.
PRESENT VALUE: Indicates the current setting. Change the value
Component: -
Signal value: XXX rpm = engine speed (rpm)

page
–
ENGINE SPEED N-DIR

Description: Setting of highest permitted engine speed for shifting from
ENGINE SPEED N-DIR
neutral to gear.
STORED VALUE XXX
005053

This setting takes priority over the setting in INIT DRIVETRAIN,
menu 3 page 190. If the engine speed is set lower in this menu
that in menu 3, this engine speed will also apply to switching di-
rection of travel. This occurs because the transmission must shift
into neutral when changing direction of travel.
Component: -
Signal value: XXX = engine speed (rpm)

8 Control system – 8.5.1.5 DRIVETRAIN, Dana TE32 FF 191

page
–
ENGINE SPEED, KICKDOWN 1ST

Description: Setting of the lowest engine rpm when conditions for kick-
ENGINE SPEED
KICK DOWN 1:ST down to 1st gear are to be checked.
STORED VALUE XXX
005054
If the rpm is set too low, kickdown may take place before the ma-
chine has used the engagement on the selected gear.
If the rpm is set too high, kickdown takes place slowly or not at all.
Component: -
Signal value: XXX = speed (km/h)

page
–
VEHICLE SPEED, DECLUTCH

Description: Setting of highest permitted speed for disengaging the
VEHICLE SPEED
DECLUTCH transmission.
005055
Component: -

page
–
Not used.

page
–
Not used.

192 8 Control system – 8.5.1.5 DRIVETRAIN, Dana TE32 FF

page
–
OPTION SPEED LIMIT

OPTION SPEED LIMIT
(KM/H)
Description: Setting of speed limitation.
STORED VALUE XXX
004935
PRESENT VALUE XXX PRESENT VALUE: Indicates the current setting. Change the value
Component: -

page
–
OPTION HIGHEST GEAR AT SPEED LIMIT

OPTION HIGHETS GEAR
AT SPEED LIMIT
Description: Setting of highest permissible gear (speed limitation
STORED VALUE XXX
004936
PRESENT VALUE XXX through blocked gears).

Component: -
Signal value: XXX = gear

page
–
OPTION ENGINE SHUT DOWN

OPTION ENGINE SHUT
DOWN AT IDLE (sec)
Description: Setting of idle time prior to automatic engine shutdown.
STORED VALUE XXX
004937
Function: 1 Engine
Component: -
Signal value: XXX = time in seconds before engine shutdown.

8 Control system – 8.5.1.5 DRIVETRAIN, ZF 5WG261 193

page
–
F-R WITHOUT ENGINE SPEED REDUCTION

F-R WITHOUT ENGINE
SPEED REDUCTION
Description: activation or deactivation of automatic engine speed re-
STORED VALUE XXX
004938
PRESENT VALUE XXX duction when changing travel direction forward - reverse. This makes
it possible to change travel direction without releasing the accelerator
pedal. Engine speed drops to that set in menu 3 (see INIT DRIVE-
TRAIN, menu 3 page 190). If no value is set in menu 3, engine speed
is reduced to idling speed.
Component: -
Signal value:
X = 1, activated
X = 0, deactivated
8.5.1.5 DRIVETRAIN, ZF 5WG261

INIT DRIVE-TRAIN
page
–
This function handles initialisation of the transmission.

INITIATION
BOOM ATTACHMENT NOTE

SLIDING-CAB STEERING Initiation does not need to be performed in one process but each
003140
DRIVE-TRAIN step can be performed separately, independently of other steps.

The machine must be stationary with parking brake applied in or-
der 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.

page
–
START IN 2ND
INIT DRIVE-TRN 1(6)
Description: Setting to get transmission to start in 2nd gear instead of
START IN 2:ND
0=NO 1=YES in 1st. Kick-down to 1st takes place as needed.
003151
Component: -
Signal value: XXX = 1= yes, XXX = 0 = no

page
–
Not used.

194 8 Control system – 8.5.1.5 DRIVETRAIN, ZF 5WG261

page
–
ENGINE SPEED F-R

Description: Setting of highest engine speed for shifting between for-
ENGINE SPEED F-R
ward and reverse.
STORED VALUE XXX
005052
If the rpm is set lower than the engine’s idle rpm, shifting will not
be allowed.
Component: -
Signal value: XXX rpm = engine speed (rpm)

page
–
Not used.

page
–
Not used.

page
–
Not used.

page
–
Not used.

page
–
Not used.

page
–
OPTION SPEED LIMIT

OPTION SPEED LIMIT
(KM/H)
Description: Setting of speed limitation.
STORED VALUE XXX
004935
Component: -

8 Control system – 8.5.1.5 DRIVETRAIN, ZF 5WG261 195

page
–
OPTION HIGHEST GEAR AT SPEED LIMIT

OPTION HIGHETS GEAR
AT SPEED LIMIT
Description: Setting of highest permissible gear (speed limitation
STORED VALUE XXX
004936
PRESENT VALUE XXX through blocked gears).
Component: -
Signal value: XXX = gear

page
–
OPTION ENGINE SHUT DOWN

OPTION ENGINE SHUT
DOWN AT IDLE (sec)
Description: Setting of idle time prior to automatic engine shutdown.
STORED VALUE XXX
004937
Function: 1 Engine
Component: -
Signal value: XXX = time in seconds before engine shutdown.

page
–
F-R WITHOUT ENGINE SPEED REDUCTION

F-R WITHOUT ENGINE
SPEED REDUCTION
Description: activation or deactivation of automatic engine speed re-
STORED VALUE XXX
004938
PRESENT VALUE XXX duction when changing travel direction forward - reverse. This makes
it possible to change travel direction without releasing the accelerator
pedal. Engine speed drops to that set in menu 3 (see INIT DRIVE-
TRAIN, menu 3 page 190). If no value is set in menu 3, engine speed
is reduced to idling speed.
Component: -
Signal value:
X = 1, activated
X = 0, deactivated

196 8 Control system – 8.5.2 Calibration
8.5.2 Calibration
Calibration, description
page
–
Certain functions require calibration in order to operate correctly. The

control system has integrated calibrations for these functions.
SCALE
This menu handles calibration of sensors for weight indication.
CALIBRATION
There are two versions of weight indicator, fixed or dynamic scale, see
SCALE STEERING section 7 Load handling, group 7.10.2 Weight indicator. The installed
DRIVE-TRAIN RETURN 000062 alternative on the machine is programmed and does not have to be se-
lected, see:
Weight indicator, calibration (product alternative fixed scale) (only
model year -2008) page 198
Weight indicator, calibration (product alternative dynamic scale)
page 200
EL-STEERING
This menu handles calibration of the joystick for joystick steering/
CALIBRATION control, see:
SCALE STEERING Joystick steering, calibration page 202

DRIVE-TRAIN RETURN
000074
NOTE
Calibration does not need to be performed in one process but
each step can be performed separately, independently of other
steps.
DRIVE-TRAIN
This function handles calibrations for engine and transmission. The
CALIBRATION menu loop contains two different calibrations which are not connected
to each other, see:
SCALE STEERING
DRIVE-TRAIN RETURN Accelerator pedal, calibration page 203
000078
Section 2 Transmission, group 2.8 Control system transmission
NOTE
steps.

8 Control system – 8.5.2 Calibration 197
Calibration menu, explanation

The figure shows an example of a menu, here for calibrating boom ex-
1 2
tension inner position. The table indicates what a description contains
CALIBR SCALE 3(7) (which follows in the next section):
5
BOOM FULLY RETRACTED
Designation: Example Description
STORED VALUE X.XXV
4 3
000063
PRESENT VALUE X.XXV Variable (position 4): BOOM Name of the input signal/control
FULLY RETRACTED signal affected.
1. Menu group
2. Sequence number (total number of sequences Description: Setting sensor A short description of what is
within brackets) boom length (R777) for boom ex- calibrated and the meaning of
3. Signal value tension in the innermost position. the variables.
4. STORED indicates stored value, PRESENT
CALIBR VALUE: indicates
indicates current value of the signal to be calibrated
stored signal value from boom
5. Heading of menu figure
length (R777) for boom exten-
sion in the innermost position.
PRESENT VALUE: indicates the
current signal value from sensor
boom length (R777).
Function: 7.3.11 Sensor, boom Name of current function.

length
Component: Sensor, boom Indicates the component

angle (R777) whose signal is the basis for
calibration.
Calibration, work instructions

page
–
Calibration consists of a number of menus (the number of menus de-

pends on the function). All menus are similar in construction and there-
fore the descriptions are similar.
To select a function to calibrate, proceed as follows:
1 Navigate to the service menu.

2 Press Enter.
000056
3 Enter the code for calibration.

1 23
4 5 NOTE
000060

CALIBRATION firm with Enter.
SCALE STEERING Each calibration consists of a sequence of a number of menus.

DRIVE-TRAIN RETURN The first menu for the selected calibration appears in the display.
000062
Select the next menu with key 1 and 2 (arrow function).

198 8 Control system – 8.5.2.1 Calibrate SCALE
8.5.2.1 Calibrate SCALE

Weight indicator, calibration (product alternative fixed
page
–
scale) (only model year -2008)
NOTE
It is very important for accuracy that all steps are performed in the
given order.
1 Park the machine on level ground without load and centre the
attachment.
2 Navigate to the service menu and press ENTER.
000056

1 23
4 5 NOTE
000060

4 Scroll to SCALE with the arrow keys and press ENTER.
CALIBRATION
Each calibration consists of a sequence of menus. Scroll be-
SCALE STEERING tween menus with the arrow keys.
DRIVE-TRAIN RETURN
000062
5 Lower the boom to the lowest position (0).

CALIBR SCALE 1(X)
6 CALIBR SCALE, menu 1 save the setting with ENTER.
MINIMUM BOOM ANGLE
CALIBR VALUE X.XXV
006798
PRESENT VALUE X.XXV
7 Lift the boom to its highest angle.

CALIBR SCALE 2(x)
8 Scroll to CALIBR SCALE, menu 2 and save the setting with
MAXIMUM BOOM ANGLE
ENTER.
CALIBR VALUE X.XXV
006799
PRESENT VALUE X.XXV

8 Control system – 8.5.2.1 Calibrate SCALE 199
9 Scroll to CALIBR SCALE, menu 8.

CALIBR SCALE 8(X) 10 Place the boom in measuring position, see section 7 Load han-
BOOM IN MEAS. POS X X
WITHOUT LOAD dling, group 7.10.2 Weight indicator.
LE XX.XV RI XX.XV "BOOM IN MEAS. POS" should show " '1' '1' ", this indicates that
006805
STORED SUM XX.XV measuring position is reached for " 'Extension' 'Lift' ".
11 Wait approximately five seconds to stabilise the pressure.
12 Save the setting with ENTER.
NOTE
New values can only be saved when the boom is in measur-
ing position.
Negative values indicate switched connectors on the pres-
sure sensors.
Large variations between right and left indicate errors in the
sensors’ signals.
CALIBR SCALE 9(X) 14 Lift a known reference load and place the boom in measuring
BOOM IN MEAS. POS X X
WITH LOAD XX.XT position.
LE XX.XV RI XX.XV "BOOM IN MEAS. POS" should show " '1' '1' ", this indicates that
006806
STORED SUM XX.XV measuring position is reached for " 'Extension' 'Lift' ".
16 Enter the weight of the reference load with the + and - keys. Save
the setting with ENTER.
NOTE
New values can only be saved when the boom is in measur-
ing position.
IMPORTANT
Check that correct weight for the reference load is
shown in the menu before saving the setting. Incor-
rectly entered weight will result in the scale showing
wrong weight.
Checking the calibration

CALIBR SCALE 10(X) 18 Lift a reference weight and check that the control system calcu-
PRESS BUTTON
lates the correct weight of the load that the machine is lifting,
LOAD XX.XT LOAD.
006806
Weight is stated in tons, to one decimal.

If the weight is not correct, repeat steps 13-16.
19 Operate the machine without a load, stop the machine and check
that LOAD = 00.0  0.5 ton.

200 8 Control system – 8.5.2.1 Calibrate SCALE
NOTE
Check when stationary. (Operating generates dynamic
forces.)
20 Exit calibration with the R-key.
Weight indicator, calibration

page
–
(product alternative dynamic scale)
NOTE
It is very important for accuracy that all steps are performed in the
given order.
1 Warm up the hydraulic oil to operating temperature, min. 40 C.
2 Park the machine on level ground without load and centre the
attachment.
3 Navigate to the service menu and press ENTER.
000056

1 23
4 5 NOTE
000060

5 Scroll to SCALE with the arrow keys and press ENTER.
CALIBRATION
Each calibration consists of a sequence of menus. Scroll be-
SCALE STEERING tween menus with the arrow keys.
DRIVE-TRAIN RETURN
000062
NOTE
Some options, such as height limitation and load centre lim-
itation, mean that bypass must be used to reach the boom’s
end-positions.
6 CALIBR SCALE, menu 1.
CALIBR SCALE 1(X)
7 Lower the boom to the lowest position (0).
MINIMUM BOOM ANGLE
8 Save the setting with ENTER
STORED VALUE X.XXV
011329
PRESENT VALUE X.XXV

CALIBR SCALE 2(x)
10 Lift the boom to its highest angle.
MAXIMUM BOOM ANGLE
STORED VALUE X.XXV
011330
PRESENT VALUE X.XXV

8 Control system – 8.5.2.1 Calibrate SCALE 201

CALIBR SCALE 3(X)
13 Retract the boom completely.
BOOM FULLY RETRACTED
STORED VALUE X.XXV
011331
PRESENT VALUE X.XXV

CALIBR SCALE 4(X)
16 Extend the boom completely.
BOOM FULLY EXTENDED
STORED VALUE X.XXV
011332
PRESENT VALUE X.XXV

CALIBR SCALE 5(X) 19 Retract the boom completely.
LOAD SENSOR BOOM
RETRACTED LE RI 20 Lower the boom and inch towards the end until 2-4 cm remains
STORED XXXX XXXX on the lift cylinders.
011333
PRESENT XXXX XXXX

CALIBR SCALE 6(X)
24 Extend the boom completely.
LOAD SENSOR BOOM 0t
EXTENDED LE RI 25 Wait approximately five seconds to stabilise the pressure.
CALIBR XXXX XXXX
26 Check that "LOAD SENSOR BOOM" is set to 0 t. If not, adjust
010454
PRESENT XXXX XXXX

with the minus key to 0 t and save the setting with ENTER.
IMPORTANT
Check that correct weight is shown in the menu be-
fore saving the setting. Incorrectly entered weight will
result in the scale showing wrong weight.
Checking the calibration

CALIBR SCALE 7(X)
28 Lift a reference load and check that the control system calculates
ALLOWED LOAD XXXXXKg
PRESENT LOAD XXXXXKg the correct weight of the load that the machine is lifting.
LOAD STR.AXLE XXXXXKg PRESENT LOAD = Reference load  500 kg. Weight is
006804
LOAD-CENTER XXX.XXm stated in kg.

If the weight is not correct, repeat the calibration.

202 8 Control system – 8.5.2.2 Calibrate STEERING
29 Operate the machine without a load, stop the machine and check
that PRESENT LOAD = 00000  500 kg.
Check in different operating ranges, see figure. The boom should
not reach end-position when checking.
NOTE
Check when stationary. (Operating generates dynamic
010455
forces.)
30 Back out of calibration with the R-key. When the code menu ap-
pears, press Enter.
8.5.2.2 Calibrate STEERING

Joystick steering, calibration
page
–
NOTE
steps.
1 Start key in operating position.
CALIBR STEERING, menu 1

2 Go into the calibration menus and select CALIBR STEERING,
CALIBR STEERING 1(3) menu 1, see Calibration, work instructions page 197.
STEERING LEVER CENTER
POSITION STEERING LEVER CENTER POSITION
CALIBR VALUE X.XXV Description: Setting the centre position for Control joystick
000075
PRESENT VALUE X.XXV steering (R825).

PRESENT VALUE: gives the present signal value for Control joy-
stick steering (R825).
STOREDVALUE: gives the stored signal value for Control joy-
Component: Control joystick steering (R825)
Function: 5.1.3 Joystick
3 Move the joystick to desired centre position.
4 Store the position with function key for Enter.

8 Control system – 8.5.2.3 Calibrate DRIVETRAIN 203

5 Select CALIBR STEERING, menu 2.
CALIBR STEERING 2(3)
STEERING LEVER LEFT POSITION
STEERING LEVER LEFT
POSITION Description: Setting of position for max. angle left on lever steer-
CALIBR VALUE X.XXV ing control (R825).
000076
PRESENT VALUE X.XXV
PRESENT VALUE: gives the present signal value for Control joy-
6 Move steering lever to required position for max. angle left.

8 STEERING LEVER RIGHT POSITION
CALIBR STEERING 3(3)
Description: Setting of position for max. angle right on lever steer-
STEERING LEVER RIGHT
POSITION ing control (R825).
CALIBR VALUE X.XXV PRESENT VALUE: gives the present signal value for Control joy-
000077
PRESENT VALUE X.XXV stick steering (R825).

9 Move steering lever to desired position for max. angle right.
8.5.2.3 Calibrate DRIVETRAIN

Accelerator pedal, calibration
page
–
1 Start key in operating position, engine switched off.
DRIVE-TRAIN, menu 1
2 Go into the calibration menus and select DRIVE-TRAIN, menu 1,
CALIBR DRIVE-TRN 1(4) see Calibration, work instructions page 197
ACCELERATOR,
RELEASE THE PEDAL ACCELERATOR, RELEASE THE PEDAL
CALIBR VALUE X.XXV Description: setting the accelerator’s pedal zero position.
000079
PRESENT VALUE X.XXV

CALIBR: Indicates current calibrated control value from acceler-
ator pedal (R690).
PRESENT VALUE: indicates the current signal value from Accel-
erator pedal (R690).
Function: 1.1.2 Accelerator pedal
Component: Accelerator pedal (R690).
3 Release the accelerator pedal.

204 8 Control system – 8.5.2.3 Calibrate DRIVETRAIN
DRIVE-TRAIN, menu 2
5 ACCELERATOR, THE PEDAL TO FLOOR
CALIBR DRIVE-TRN 2(4) Description: Setting of full-throttle position for Accelerator pedal
ACCELERATOR, (R690).
THE PEDAL TO FLOOR
CALIBR VALUE X.XXV CALIBR: Indicates current calibrated control value from acceler-
000080
PRESENT VALUE X.XXV ator pedal (R690).
PRESENT VALUE: indicates the current signal value from Accel-
erator pedal (R690).
Function: 1.1.2 Accelerator pedal
Component: Accelerator pedal (R690).
6 Press down the accelerator pedal fully and keep it down until the
position is stored.
Transmission, calibrating (Transmission Dana)

page
–
DANGER
Do not leave the machine during calibration. The ma-
chine may start to move.
1 Park the machine on level ground, engage neutral position and

apply the parking brake. Run the engine at idle speed.
2 To select function to calibrate, first navigate to the service menu.
Then press Enter.
000056

1 23
4 5 NOTE
000060

CALIBRATION firm DRIVETRAIN with Enter.
SCALE STEERING
DRIVE-TRAIN RETURN
000078

5 Scroll with the arrow keys (1 and 2) and select DRIVETRAIN,

CALIBR DRIVE-TRN 4(4) menu 4.
GEARBOX WARM UP
MODE X 6 Check that the oil temperature is at least 61 C.
ACTUAL TEMP XXX If the oil temperature is too low then go to DRIVETRAIN, menu 4.
000082
TARGET TEMP XXX
A. Apply the foot brake so that the machine is stationary.
B. Select travel direction forward and apply full throttle for
20 seconds.
C. Engage neutral position, apply full throttle for 10 seconds
and then run the engine at idle speed.
D. Repeat steps B and C until the oil is warm.
The engine speed may be reduced towards the end of heating as
the oil from the transmission is too warm. If this occurs, leave the
gear in neutral position and hold the engine speed at 1200 rpm
for 20 seconds.
When the temperature is correct, MODE changes from 0 to 1.

7 Select DRIVETRAIN, menu 3.

CALIBR DRIVE-TRN 3(4)
GEARBOX TUNING
CLUTCH TUNING
PHASE X SUB-PH X Description: Calibration of transmission clutches.
CLUTCH X STATUS X
000081
ACTION X XXXXrpm
PHASE: Indicates current phase in the calibration.
0. Pre-filling of clutch.
1. Calibration of clutch.
4. Calibration complete.
5. Calibration incorrect.
6. Calibration paused.
CLUTCH: Indicates which clutch shall be calibrated.

F. Clutch forward.
R. Clutch reverse.
1. Clutch gear 1.
2. Clutch gear 2.
3. Clutch gear 3.
4. Clutch gear 4.
ACTION: Indicates action from mechanics (in case of fault).

0. No action (normal condition if no malfunction).
1. Increase throttle application.
2. Decrease throttle application.
3. Select neutral position.
4. Select travel direction forward.
5. Stop the vehicle (press down the brake if the ma-
chine starts to move).
6. Warm up the transmission, see step 4.
7. No action; the engine is controlled via the trans-
mission control unit.
8. Keep the accelerator pedal in its current position.
9. Check error codes.
10. Apply the parking brake.
SUB-PH: Internal value for sub-phase 1 or 0.
STATUS: Calibration status.

0. Calibration not in progress.
3. Calibration in progress
8 Check that the gear selector is in neutral position.

9 Start calibration by pressing Enter.

10 Calibration starts (takes approx. 15 minutes) and engine speed is

raised to approx. 770 rpm.
The transmission will activate different gears during calibration.
NOTE
If the machine starts to move during calibration, use the foot
brake to keep the machine stationary.
IMPORTANT
Calibration can be interrupted at any time by selecting
travel direction reverse.
11 When the engine speed decreases to idle and PHASE = 4 then

calibration is complete.
12 Turn off the ignition in order to store the values.

Transmission, calibrating (Transmission ZF)

page
–
DANGER
Do not leave the machine during calibration. The ma-
chine may start to move.
1 Park the machine on level ground, engage neutral position and

apply the parking brake. Run the engine at idle speed.
2 To select function to calibrate, first navigate to the service menu.
Then press Enter.
000056

1 23
4 5 NOTE
000060

CALIBRATION firm DRIVETRAIN with Enter.
SCALE STEERING
DRIVE-TRAIN RETURN
000078
5 Scroll with the arrow keys (1 and 2) and select DRIVETRAIN,

CALIBR DRIVE-TRN 4(4) menu 4 and confirm with Enter. If the oil temperature (ACTUAL
GEARBOX WARM UP TEMP) is lower than the target temperature (TARGET TEMP) the
MODE X transmission must be warmed up.
ACTUAL TEMP XXX
000082
TARGET TEMP XXX If oil temperature is too low:

A. Apply the foot brake so that the machine is stationary.
B. Select travel direction forward and apply full throttle for
20 seconds.
C. Engage neutral position, apply full throttle for 10 seconds
and then run the engine at idle speed.
D. Repeat steps B and C until the oil is warm. When the temper-
ature is correct, MODE changes from 0 to 1.
The engine speed may be reduced towards the end of heating as
the oil is too warm. If this occurs, leave the gear in neutral position
and hold the engine speed at 1200 rpm for 20 seconds.

6 Select DRIVETRAIN, menu 3.

CALIBR DRIVE-TRN 3(X)
7 Check that the gear selector is in neutral position.
AEB MAIN CODE XXX
AEB SUB CODE XXX 8 Start calibration by pressing Enter.
AEB CYCLE NR XXX The transmission will activate different gears during calibration.
013388
SET X XXXXrpm
NOTE
If the machine starts to move during calibration, use the foot
brake to keep the machine stationary.
IMPORTANT
Calibration can be interrupted at any time by selecting
exit from the menu, release the parking brake or turn
off the machine.
• If the calibration is carried out without error, the display

CALIBR DRIVE-TRN 3(X) shows the main code (AEB MAIN CODE) number 7 which
AEB MAIN CODE XXX means calibration is complete, see table 1. Main code (AEB
AEB SUB CODE XXX MAIN CODE) below.
AEB CYCLE NR XXX
013388
SET X XXXXrpm • If an error is detected during calibration, the display shows a

main code (AEB MAIN CODE) with a number between 8 and
14 for the component (see the table 1. Main code (AEB MAIN
CODE) below) and a sub code (AEB SUB CODE) for action
with a number between 1 and 8. Follow the instructions in the
table 2. Sub code (AEB SUB CODE) below for the identified
sub code.
Table 1. Main code (AEB MAIN CODE)
Code Explanation
0. AEB mode not selected.
1. AEB mode selected, calibrates K1.
5. AEB mode selected, calibrates KV.
6. AEB mode selected, calibrates KR.
7. AEB mode selected, calibration complete.
8. AEB mode selected, calibration interrupted.
9. AEB mode selected, calibration interrupted when

adjusting K1.

adjusting K2.

Code Explanation

adjusting K3.

adjusting K4.

adjusting KV.

adjusting KR.
Table 2. Sub code (AEB SUB CODE)
Code Action
1. Turn off and start the machine again if the error code is
"0". Repeat calibration. If the problem remains, a trans-
mission check may be needed.
2. Turn off and start the machine. Check that the travel direc-
tion lever is in neutral position. Repeat calibration.
3. Turn off and start the machine. Check that the parking
brake is in applied position. Repeat calibration.
4. Turn off and start the machine. Test the parking brake. If
the parking brake works satisfactorily, repeat calibration.
If the parking brake does not work satisfactorily, service
the parking brake. Repeat calibration.
5. Turn off and start the machine. Let the transmission reach
operating temperature. Repeat calibration.
6. Let the transmission oil cool by idling the engine in neutral.

When the oil has cooled Control unit transmission
(D7930-2) will resume calibration.
7. Increase the engine speed. Control unit transmission

(D7930-2) will resume calibration when the speed is within
the range specified.
8. Decrease the engine speed. Control unit transmission

(D7930-2) will resume calibration when the speed is within
the range specified.
9 When calibration is completed without error, the display shows

MAIN CODE number 7.
10 Turn off the ignition in order to store the values.

9 Frame, body, cab and accessories 1
9 Frame, body, cab and accessories
Table of Contents 9 Frame, body, cab and accessories

mm mm mm mm mm mm
9 Frame, body, cab and accessories............................................................... 5

9.1.1 Gear selector and multi-function lever ................................................. 12
9.1.22 Switch, direction indicators .................................................................. 13
9.2 Safety and emergency equipment ............................................................ 14
9.2.1 Control breaker .................................................................................... 14
9.2.2 Seat belt ............................................................................................... 14
9.2.3 Fire extinguisher .................................................................................. 14
9.2.4 Buzzer .................................................................................................. 14
9.3 Seat .......................................................................................................... 15
9.3.1 Seat cushion ........................................................................................ 19
9.3.2 Back rest cushion ................................................................................ 19
9.3.3 Heating coil .......................................................................................... 20
9.3.4 Bumper ................................................................................................ 21
9.3.5 Air suspension ..................................................................................... 21
9.3.6 Mechanical seat adjustment ................................................................ 22
9.3.7 Passenger seat .................................................................................... 22
9.3.8 Arm rest ............................................................................................... 22
9.3.9 Sensor, operator-in-seat ...................................................................... 23
9.4 Heating, ventilation and air conditioning ................................................... 24
9.4.1 Fresh air filter ....................................................................................... 32
9.4.2 Fresh air and recirculation damper ...................................................... 33
9.4.3 Cabin fan ............................................................................................. 36
9.4.4 Heat exchanger heat ........................................................................... 39
9.4.5 Water valve .......................................................................................... 42
9.4.6 Sensor, engine temperature ................................................................ 43
9.4.7 Compressor ......................................................................................... 43
9.4.8 Condenser ........................................................................................... 46
9.4.9 Moisture filter ....................................................................................... 48
9.4.10 Pressure switch ................................................................................... 48
9.4.11 Expansion valve ................................................................................... 49
9.4.12 Sensor, temperature refrigerant ........................................................... 51
9.4.13 Heat exchanger, cooling ...................................................................... 52
9.4.14 Air distributor ........................................................................................ 53
9.4.15 Defroster nozzles ................................................................................. 54
9.4.16 Sensor, temperature outlet fan ............................................................ 55
9.4.17 Sensor cab temperature ...................................................................... 56
9.4.18 Sensor, ambient temperature .............................................................. 57
9.5 Wiper/washer system ............................................................................... 58
9.5.1 Wiper front ........................................................................................... 58
9.5.2 Wiper roof ............................................................................................ 58
9.5.3 Wiper rear ............................................................................................ 58
9.5.4 Washer motor and reservoir ................................................................ 58
9.5.5 Wiper motor front ................................................................................. 59

2 9 Frame, body, cab and accessories
9.5.6 Wiper motor roof ................................................................................... 60

9.5.7 Wiper motor rear .................................................................................. 61
9.6 Lighting system ......................................................................................... 63
9.6.1 Headlights ............................................................................................ 68
9.6.2 Running lights ....................................................................................... 68
9.6.3 Tail lights .............................................................................................. 68
9.6.4 Brake lights ........................................................................................... 69
9.6.5 Back-up lights ....................................................................................... 69
9.6.6 Direction indicators ............................................................................... 69
9.6.7 Flashing hazard lights .......................................................................... 70
9.6.8 Revolving beacon ................................................................................. 70
9.6.9 Working lights, cab ............................................................................... 70
9.6.10 Work light boom ................................................................................... 71
9.6.11 Working lights, attachment ................................................................... 72
9.6.12 Interior lighting ...................................................................................... 72
9.7 Signalling system ...................................................................................... 73
9.7.1 Horn ...................................................................................................... 76
9.7.2 Flashing hazard lights .......................................................................... 77
9.7.3 Revolving beacon ................................................................................. 77
9.7.4 Warning parking brake ......................................................................... 77
9.7.5 Back-up alarm ...................................................................................... 77
9.8 Entertainment and communication ........................................................... 78
9.9 Glass/windows/mirrors .............................................................................. 79
9.9.1 Windscreen .......................................................................................... 80
9.9.2 Side window ......................................................................................... 82
9.9.3 Roof window ......................................................................................... 85
9.9.4 Rear window ......................................................................................... 86
9.9.5 Rear view mirror ................................................................................... 86
9.9.6 Reversing camera ................................................................................ 86
9.9.7 Monitor, reversing camera .................................................................... 87
9.10 Cab structure and suspension .................................................................. 88
9.10.1 Cab frame ............................................................................................. 88
9.10.2 Doors .................................................................................................... 89
9.10.3 Cab substructure .................................................................................. 89
9.10.4 Sliding cab ............................................................................................ 90
9.10.5 Vertically adjustable cab ..................................................................... 102
9.11 Cab interior ............................................................................................. 115
9.11.1 Instrument and control panels ............................................................ 115
9.11.2 Interior fittings, plastic ......................................................................... 116
9.11.3 Interior fittings, textile ......................................................................... 116
9.11.4 Floor covering ..................................................................................... 116
9.11.5 Insulation ............................................................................................ 116
9.11.6 Sun visors ........................................................................................... 117
9.11.7 Terminal console ................................................................................ 117
9.11.8 Writing desk ........................................................................................ 117
9.12 Chassis ................................................................................................... 118
9.13 Body structure ......................................................................................... 119

9.13.1 Wings ................................................................................................. 119

9.13.2 Hood engine compartment ................................................................ 119
9.13.3 Footsteps and hand rail ..................................................................... 120
9.13.4 Counterweights .................................................................................. 120
9.14 Central lubrication .................................................................................. 121
9.14.1 Pump unit ........................................................................................... 123
9.14.2 Distribution block ............................................................................... 124
9.14.3 Lines .................................................................................................. 124
9.15 Paint/coatings ......................................................................................... 125

4 9 Frame, body, cab and accessories

9 Frame, body, cab and

mm mm mm mm mm mm
accessories
Controls and instruments, overview
page
–
Overview
1 2 3 4 5
15
12 13 12 11 10 9 8 7 6
004852
14
1 Left instrument panel

2 Gear selector and multi-function lever (S162)
3 Steering wheel panel
4 Steering wheel
5 Switch direction indicators (S161)
6 Panel for load handling functions
7 Switch control breaker (S250)
8 Switch parking brake (S107)
9 Control lever (S815)
10 Driver’s seat
11 Accelerator pedal (B690)
12 Brake pedal
13 Declutch pedal (S220-1)
14 Electrical distribution box with fuses
15 Hour meter (P708)
A Joystick or mini-wheel

6 9 Frame, body, cab and accessories – 9.1 Controls and instruments
Left instrument panel

16 Switch fan (S118)
17 Switch temperature (S139)
18 Switch, air distribution (S117)
29 30 31 19 Switch work lights cab roof (S105-1)
24..28
20 Switch work lights attachment (S105-2)
19..23
21 Switch work lights boom (S105-3)
18
17 22 Switch rotating beacon (S110)
013031
16 23 Switch flashing hazard lights (S109)
Left instrument panel 24 Switch headlights (S100)
25 Switch seat heater (S143)
26 Switch electric heat rearview mirrors (S199-4)

27 Spare
28 Switch, pause heater (S199-1)

29 Spare
30 Spare
31 Socket 24 VDC (E804)

9 Frame, body, cab and accessories – 9.1 Controls and instruments 7
Steering wheel panel

36
35 32 Warning light low battery charging
34
33 33 Warning light low brake pressure
32
34 Indicator active error codes
35 Warning light bypass of hydraulic functions
36 Indicator light activated steering with joystick or mini-wheel

37..41 49
37 Warning light high coolant temperature
42..46 38 Warning light low oil pressure in engine
47 48 39 Indicator light preheating
40 Warning light low coolant level engine
41 Warning light high oil temperature in transmission
50 51 52 53 42 Warning light low fuel level
43 Warning light high temperature hydraulic oil
44 Indicator light, high beam
45 Indicator light, direction indicator
46 Indicator light, parking brake
47 Indicator light locked twistlocks
48 Indicator light alignment
64
54 49 Indicator light unlocked twistlocks
63
55 50 Panel warning and indicator lights
62
56 51 Display control system
000399
61 60 59 58 57 52 Indicator control system

53 Ignition key lock (S150)
Steering wheel panel with panel for warning and
indicator lights 54 Switch defroster
55 Switch windshield wiper roof, interval
56 Switch windshield wiper roof, continuous
57 Switch, interior lighting
58 Switch windshield wiper rear, interval
59 Switch windshield wiper rear, continuous
60 Function keys, control system
61 Travel direction indicator, Forward Neutral Reverse
62 Switch Shifting program A, automatic shifting
63 Switch Shifting program 1, locked to 1st gear
64 Switch Shifting program 2, locked to 2nd gear

Panel for load handling functions
65 Switch, front legs down (S1006)

65 66 67 68
66 Switch, rear legs down (S1007)
67 Switch, bypassing rotation stop (S1014)
69..72 Switch, bypassing height limit (S1015)
Switch, bypassing LC-limitation (load centre) (S1015)
68 Switch, automatic cab tilt (S199-5)

73
69 Switch, lock twistlocks (S1003)
74
76 70 Switch, clamp/loosen clamping position, legs (S1008)
75 013032
Switch, overheight legs (S1031)

Panel for load handling functions 71 Switch stop at 30’ or 35’ (S1004)
72 Switch, hydraulic sliding cab (S177)
Switch, hydraulic vertically adjustable cab (S177)
Switch, hydraulically cab tilt (S177)
73 Indicator light, support jacks down (H517)
74 Switch, support jacks (S1013)
75 Switch, automatic spreading 20'-40' (S1012)

76 Switch bypass (S1005)

Operating menus, overview
1 2 3 4
12
5
11 6
10 9 8 7
006736
13 14 15 16
1. Engine and transmission operating menu 9.

Operating menu, printer
2. 10.
Dynamic scale operating menu Operating menu, checking the dynamic scale
3. Engine operating menu 11. Service operating menu
4. Operating menu, transmission and hydraulics 12. Operating menu heating and air conditioning
5. Operating menu electrical system 13.
Operating menu statistics, operating hours
6. 14.
Operating menu, container counter Operating menu statistics, fuel consumption
7. 15.
Operating menu service interval Operating menu statistics, driving distance
8. 16.
Operating menu statistics Operating menu statistics, lift statistics

Event menus overview
1 2 3 4
15 6
14 7
13 8
006734
12 11 10 9
1. Event menu start interlock 9.

Event menu, height limitation
2. Event menu overload forward 10.
Event menu fixed scale
3. Event menu overload on steering axle 11.
Event menu open door
4. 12.
Event menu overload on steering axle Event menu rotation stop
5. Event menu alignment top lift 13.
Event menu tilt lock
6. 14.
Event menu alignment bottom lift Event menu levelling lock
7. Event menu twistlocks 15.
Event menu automatic spreading 20'-40'
8.
Event menu support jacks

Switch, replacement
page
–
NOTE
The instruction applies to switches in general.

2 Remove the dashboard panel.
3 Disconnect the connector from the switch.

4 Remove the switch from the instrument panel. Use a screwdriver
to bend in the tabs.
5 Replace the switch.

12 9 Frame, body, cab and accessories – 9.1.1 Gear selector and multi-function lever
9.1.1 Gear selector and multi-function

lever
Gear selector and multi-function lever, description
page
–
The following functions are handled by the gear and multi-function

2 lever (position 2).
3 1
0
Movement 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 front windshield. 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 front windshield. 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,
Upward Light signal
Downward High beam (on/off)

With headlights on:The gear selector and multi-
function lever are used for switching between high
and low beams.
000339
A
With headlights off: Gear and multi-function lever is
used to flash with the headlights.
The signal can be checked via the diagnostic menu.
See section 8 Control system,
group 8.4.2.6 LIGHTS, menu 6.
Inward, Horn (position A).

button The signal can be checked via the diagnostic menu.
See section 8 Control system, group 8.4.3.5 CAB,
menu 5.

9 Frame, body, cab and accessories – 9.1.22 Switch, direction indicators 13
Gear selector and multi-function lever, replacement

page
–
1 Separate the steering wheel panel.

6 attaching bolts and 2 bolts to the steering column.
Remove the steering wheel, see Steering wheel panel, replace-
ment page 115.
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
page
–

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.

14 9 Frame, body, cab and accessories – 9.2 Safety and emergency equipment
9.2 Safety and emergency

equipment
9.2.1 Control breaker
Emergency stop switch, description
page
–
See section 11 Common electrics, group 11.5.1.4 Emergency stop

switch voltage.
9.2.2 Seat belt

Seat belt, description
page
–
The seat belt is a two-point or a three-point belt, depending on the type

of seat installed in the machine. The seat belt is installed on the seat.
9.2.3 Fire extinguisher

Fire extinguisher, description
page
–
The fire extinguisher is located by the steps on the left frame member.
Instructions on use are found on the fire extinguisher.
9.2.4 Buzzer
Seat buzzer, description
page
–
See Sensor operator in seat, description page 23.

9 Frame, body, cab and accessories – 9.3 Seat 15
9.3 Seat
Seat, general
page
–
There are three versions of the operator’s seat:

• Seats, description (product alternative standard seat) page 15
• Seats, description (product alternative BE-GE 9120)

page 16
• Seats, description (product alternative Isringhausen 6800)

page 17
As an option, the machine can be equipped with a fold-down passen-

ger seat to the left of the operator.
Seats, description
page
–
(product alternative standard seat)

The seat’s function is to give the operator a good sitting position and
contribute to a good work environment. The cab’s seat has several ad-
justment possibilities and meets high comfort standards.
1 2 The seat has the following equipment:
• mechanical adjustment
3
• arm rest right
• seat belt (option until model year 2007)
4
• armrest left
• seat heating
• head rest
5
8 6
006825
7
Controls, standard seat
1. Lumber support adjustment
2. Right armrest adjustment
3. Left armrest adjustment
4. Backrest angle adjustment
5. Suspension position adjustment
6. Seat cushion angle adjustment
7. Seat cushion height adjustment
8. Fore/aft adjustment

16 9 Frame, body, cab and accessories – 9.3 Seat
Seats, description
page
–
(product alternative BE-GE 9120)
BE-GE 9120 is the same as the standard seat, but is equipped with air
1 2 suspension. Air suspension automatically adjusts seat height and sus-
pension to the operator’s weight. Air suspension is supplied by a spe-
cial compressor installed on the underside of the cab.
3
4
The seat has the following equipment:
• mechanical adjustment
• air suspension (with external compressor)
5 • arm rest right
• seat belt (option until model year 2007)
8 6
006826
• armrest left
7
Controls, Bege 9120 • seat heating
1. Lumber support adjustment
2. Right armrest adjustment • head rest
3. Left armrest adjustment

4. Backrest angle adjustment
5. Suspension position adjustment
6. Seat cushion angle adjustment
7. Seat cushion height adjustment

9 Frame, body, cab and accessories – 9.3 Seat 17
Seats, description
page
–
(product alternative Isringhausen 6800)
The Isringhausen 6800 seat has the following equipment:
• head rest
• arm rest
• air suspension (with external compressor)
• air-adjusted lumbar support
• seat belt
• seat heating
11
10
34 567
004691
9 8 2
Controls, Isringhausen 6800
2. Seat cushion adjustment
3. Seat height lowering
4. Seat cushion angle
5. Seat height raising
6. Backrest angle
7. Damping adjustment
8. Seat heating
9. Level damping OFF/ON
10. Lumbar support adjustment
11. Armrest

18 9 Frame, body, cab and accessories – 9.3 Seat
Seat, changing
page
–

2 Slide back the seat to its rear position, remove the front attaching
bolts.
3 Slide the seat to its front position, remove the rear attaching bolts.
4 Disconnect the seat’s connectors from the machine’s cabling.
5 Remove the seat.

9 Frame, body, cab and accessories – 9.3.1 Seat cushion 19
9.3.1 Seat cushion

Seat cushion, description
page
–
The function of the seat cushion is to provide comfort for the operator.
Under the seat cushion is the operator’s seat frame and a switch for
the buzzer. There may also be a heating coil ( ).
For location, see Seat, general page 15.
Seat cushion, replacement

page
–
(product alternative BE-GE)

2 Loosen the rubber bellows by removing the plastic clips
(position 1).
3 Unhook the upholstery’s rails (position 2) from the seat frame
2 5 (position 3) and remove the upholstery.
4 Remove the padding (position 4).
4
If the seat is equipped with seat heater.
Unplug the connector for the heating coil before the padding is
removed.
NOTE
The seat’s heating coil is glued to the padding. Be careful if
3
the padding is to be replaced but the heating coil is to be re-
used, or if only the coil is to be replaced.
5 Assemble in reverse order.
1
006276
1. Plastic clips rubber bellows

2. Upholstery
3. Seat frame
4. Padding
5. Heating coil
9.3.2 Back rest cushion

Back rest cushion, description
page
–
The function of the back cushion is to provide comfort for the operator.
Under the back cushion is the operator’s seat frame. There may also
be a heating coil ( ).
For location, see Seat, general page 15.

20 9 Frame, body, cab and accessories – 9.3.3 Heating coil
Back rest cushion, replacement

page
–

2 Detach the rubber bellows on the rear of the seat by removing the
plastic clips and folding down the rubber bellows. See Seat cush-
ion, replacement (product alternative BE-GE) page 19.
3
3 Remove the back rest by first removing the attaching bolts
(position 1) on the right and left side of the seat and then remove
4 the attaching bolts (position 2) for the seat belt on the right and
left side of the seat.
4 If the seat is equipped with 3-point seat belt.

Remove the belt guide (position 3) by removing the cover and the
attaching bolt (position 4).
5 5 If the seat is equipped with arm rests (position 5).

Remove the arm rest by removing the attaching bolts (position 6).
6 Place the backrest on the seat and install the attaching bolts
(position 1), do not tighten. Then install the attaching bolts for the
6 seatbelt (position 2).
Tighten the attaching bolts for the seatbelt (position 2) with a
torque of 42 Nm, then tighten the attaching bolts (position 1) with
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
006278
1 2 back rest before arm rest or seat belt is installed.
1. Attaching bolt backrest 8 Install in reverse order.

2. Attaching bolt seatbelt
3. Cover belt guide
4. Attaching bolt belt guide
5. Armrest
6. Attaching bolt armrest.
9.3.3 Heating coil

Heating coil, description
page
–
The heating coil’s function is to warm the back and seat cushions in
the operator’s seat. The heating coil is located under the upholstery on
the seat.
The heating coil (E803) is supplied with voltage when warming the cab
control unit (D790-1) by the seat heating relay (K383). The signal can
be checked with the diagnostic menu, see section 8 Control system,
Heating coil, replacement

page
–

See Seat cushion, replacement (product alternative BE-GE)
page 19.

9 Frame, body, cab and accessories – 9.3.4 Bumper 21
9.3.4 Bumper
Bumper, description
page
–
The bumpers are integrated in the suspension unit in the seat’s frame
and are self-adjusting, that is, they adjust automatically to the opera-
tor’s weight.
Bumper, replacement (product alternative BE-GE)

page
–
2 1 Machine in service position, see section B Safety.

2 Remove the operator’s seat from the frame and lift it out of the
machine. See Seat, changing page 18.
3 Remove the seat cushion, see Seat cushion, replacement
(product alternative BE-GE) page 19.
1 4 Remove the back rest cushion, see Back rest cushion, replace-
ment (product alternative BE-GE) page 20.
5 Remove the shock absorbers attaching bolts (position 2 and 3).
6 Replace the shock absorber (position 1).
006277
3 7 Assemble in reverse order.

1. Shock absorbers
2. Attaching bolt
3. Attaching bolt
9.3.5 Air suspension

Air suspension, description
page
–
The air-suspended operator’s seat consists of a seat with rubber bel-

lows and compressor. Air-suspension is self-adjusting, that is, adjust
automatically to the operator’s body weight. The compressor provides
air for the suspension unit.
9.3.5.1 Compressor, air suspension

Compressor air-suspension seat, description
page
–
BE-GE 9120:
The compressor is part of the air-suspension driver’s seat and is fitted

inside the seat’s suspension unit.
001621
Isringhausen 6800:
Compressor air-suspension seat
The compressor is an external part for the air-suspended operator’s

seat that is installed on the underside of the cab floor.

22 9 Frame, body, cab and accessories – 9.3.6 Mechanical seat adjustment
9.3.6 Mechanical seat adjustment

Mechanical seat adjustment, description
page
–
Seat adjustment is all mechanical and is adapted by the operator with

different controls in order to obtain a good sitting position.
See:
• Seats, description (product alternative standard seat) page 15
• Seats, description (product alternative BE-GE 9120) page 16
• Seats, description (product alternative Isringhausen 6800)
page 17
9.3.7 Passenger seat

Passenger seat, description
page
–
The passenger seat is collapsible (vertically) and is located on the left

side of the operator’s seat.
001627
Passenger seat with bracket
9.3.8 Arm rest

Armrests, description
page
–
The armrest is fixed to the backrest and is individually adjustable ver-

tically (around the attachment point). Depending on options there is
also an armrest for the left side.
• Mini-wheel
• Joystick control

9 Frame, body, cab and accessories – 9.3.9 Sensor, operator-in-seat 23
9.3.9 Sensor, operator-in-seat

Sensor operator in seat, description
page
–
Sensor, operator in seat (S230) senses if the operator’s seat suspen-

sion is compressed which indicates to the control system that the op-
1 erator is sitting in the seat. This is used to give the control system the
possibility to indicate with the buzzer for operator in seat (H853) if the
operator leaves the machine without applying the parking brake.
From and including model year 2009 - the signal from the sensor for
2
operator in seat (S230) is also used to put the transmission in neutral
position if the operator leaves the seat. In an emergency situation the
machine can be operated by bypassing the safety system. Activate the
switch for bypass, select the travel direction and drive the machine to
the workshop. The speed is limited to 10 km/h.
008220
DANGER
Seat seen from below
1. Sensor operator in seat (S230)
2. Buzzer (H853) Bypassing the safety systems results in a risk of tip-
ping. Use at your own risk.
Extreme hazard to personal health and risk of proper-

ty damage!
Only use bypass of safety systems in emergency

situations.
The operator-in-seat sensor (S230) is supplied with power by and

sends a voltage signal to the cab control unit (D790-1). The signal can
be checked with the diagnostic menu, see section 8 Control system,

24 9 Frame, body, cab and accessories – 9.4 Heating, ventilation and air conditioning
9.4 Heating, ventilation and air

conditioning
Heating, ventilation and air conditioning,
page
–
description
The heating system controls heating and ventilation of the cab. The
F cab can also be equipped with a climate control system ( ).
The temperature in the cab is thermostat-controlled by the cab control
unit (D790-1). The cab temperature is regulated to the set tempera-
2 ture. The temperature can be set between 16 and 28 C. The unit is
4 operated with controls on the instrument panel.
D
C Heating system (EHC)
The heating system (EHC) handles heating and ventilation. (The heat-
E E
ing system cannot provide cooling.)
3
The heating system uses heat from the engine’s cooling system via a
heating coil to heat ambient air. The fan forces the ambient air through
the heating coil on through channels in the cab interior. It is then direct-
ed to the windshield (defroster) or the feet.
6 A B Air conditioning (ECC)
The climate control system (ECC) handles for heating, ventilation,

cooling, and drying. The air is heated in the same way as for the heat-
ing system (EHC).
1 During cooling, ambient air is forced through the evaporator, which
5 G cools the air. The air can then be directed in the same way as for the
000762
heating system.
Principle illustration, climate control system The function of the air conditioning is to:
1. Fluid reservoir/filter dryer with built-in pressure • heat the air when it is cold
monitor
• dehumidify the air when it is damp
2. Heater and evaporator
3. Fan • clean the air of impurities
4. Expansion valve • cool the air when it is hot
5. Condenser
• defrost (defroster function)
6. Compressor
A. High-pressure gas
B. High-pressure fluid
C. Low-pressure fluid
D. Low-pressure gas
E. Ambient air for cab ventilation
F. Heated or cooled air to the cab
G. Ambient air for removal of heat

9 Frame, body, cab and accessories – 9.4 Heating, ventilation and air conditioning 25

page
–
2 1 D3 3 26
D1
25
D4
4 ˚C D23
D6
˚C
D5 D15 6
7 D790-1 D790-2 D795
D9
15 D15 D797-R D794
M 16 D21 12 D10
14 22 23
5 ˚C Pa ˚C
M D17
D14 21
19 20 C 24
13
M 18
D13 17
D9 9
M
10
˚C
8 11
006416
1 Switch, temperature (S139) sends a Increase: U = 2.0-2.5 V Controls and instruments, overview page 5
voltage signal to Control unit, cab Unaffected: U = 0-0.5 V D1: Diagnostic menu, see section 8 Control
(D790-1). system, group 8.4.4.5, CLIMATE menu 5
Decrease: U = 4.5-5.0 V
2 Switch, fan (S118) sends a voltage sig- Increase: U = 2.0-2.5 V Controls and instruments, overview page 5
nal to Control unit, cab (D790-1). Unaffected: U = 0-0.5 V D2: Diagnostic menu, see section 8 Control
Decrease: U = 4.5-5.0 V system, group 8.4.4.5, CLIMATE menu 5
3 Switch, air distribution (S117) sends a Scroll up: U = 2.0-2.5 V Controls and instruments, overview page 5
voltage signal to Control unit, cab Unaffected: U = 0 V D3: Diagnostic menu, see section 8 Control
Scroll down: U = 4.5-5.0 V
4 Sensor, cab temperature (B775-1) R = 10 k at 25 C Sensor, cab temperature, description

sends a voltage signal proportional to page 56
the temperature to Control unit, cab D4: Diagnostic menu, see section 8 Control


5 Sensor, temperature outlet (B775-2) R = 10 k at 25 C Sensor, temperature outlet fan, description
fan sends a voltage signal proportional page 55
to the temperature to Control unit, cab D5: Diagnostic menu, see section 8 Control
6 Sensor, ambient temperature (B774) R = 10 k at 25 C Sensor, ambient temperature, description

the temperature to Control unit, cab D6: Diagnostic menu, see section 8 Control
7 Control unit, cab (D790-1) regulates Checked by control sys- Section 11 Common electrics, group
temperature and air distribution with tem, error shown with er- 11.5.3.1 Control unit, cab
signals from sensors and controls. ror code.
8 The engine produces heat when run- - -

ning. It is cooled with the cooling sys-
tem. The heat from the cooling system
is used to heat the cab air.
9 Control unit, cab (D790-1) controls Wa- U = 0.5-4.5 V Water valve, description page 42
ter valve (Y673), which routes hot water D9: Diagnostic menu, see section 8 Control
for heat exchanger heat. system, group 8.4.4.7 CLIMATE, menu 7
The water valve’s opening (%) is sent and 8.4.4.4 CLIMATE, menu 4
back to the cab control unit (D790-1).
This gives information for controlling
the water valve’s position.
10 Sensor, engine temperature, sends a Checked by control sys- Section 1 Engine

voltage signal proportional to the en- tem, error shown with er- D10: Diagnostic menu, see section 8 Con-
gine temperature to Control unit, ror code. trol system, group 8.4.4.2, CLIMATE
engine (D794). menu 2
11 Heat exchanger heat adds heat to the - Heat exchanger heat, description page 39
cab air. Heat is transferred from the en-
gine’s cooling system to the cab air.
12 Control unit, engine (D794) transmits Checked by control sys- Section 11 Common electrics,
engine temperature in the cooling system, error shown with er- group 11.5.3.10 Control unit, engine
tem on the CAN bus. ror code.
13 Control unit, cab (D790-1) controls Ac- Checked by control sys- Fresh air filter or recirculation damper, de-
tuator motor, recirculation (M612) tem, error shown with er- scription page 33
which sets the fresh air or recirculation ror code. D13: Diagnostic menu, see section 8 Con-
damper in the required position. trol system, group 8.4.4.6, CLIMATE
menu 6
14 Control unit, cab (D790-1) controls Fan Checked by control sys- Cab fan, description page 36
motor (M657), which increases the air- tem, error shown with er- D14: Diagnostic menu, see section 8 Con-
flow in the cab. ror code. trol system, group 8.4.4.6, CLIMATE
menu 6


15 Control unit, cab (D790-1) controls U = 0.5-4.5 V Air distributor, description page 53
Damper motor (Y672), which sets the D15: Diagnostic menu, see section 8 Con-
air distributor to the required position. trol system, group 8.4.4.8 CLIMATE,
The air distributor’s position is sent menu 8 and 8.4.4.4 CLIMATE, menu 4
back to the cab control unit (D790-1).
This gives information for controlling
the air distributor’s position.
controls engagement of the tem, error shown with er- group 11.5.3.3 Control unit frame rear
AC compressor. ror code.
17 The frame control unit rear (D797-R) U = 24 V Compressor air conditioning, description
supplies voltage to the compressor’s (engine alternative Volvo) page 43
magnet clutch (645). D17: Diagnostic menu, see section 8 Con-
trol system, group 8.4.4.6, CLIMATE
menu 6
18 The compressor draws gaseous refrig- - Compressor air conditioning, description

erant from the evaporator, compresses (engine alternative Volvo) page 43
it, and forces it on to the condenser.
19 The condenser cools the refrigerant. - Condenser, description page 46

The gaseous refrigerant condenses to
liquid form and is pumped on in the
circuit.
20 The moisture filter absorbs any mois- - Moisture filter, description page 48
ture from the cooling circuit. The fluid
reservoir stores the refrigerant.
21 The pressure monitor (S246) sends a U = 24 V Pressure switch, description page 48

signal to the frame control unit rear D21: Diagnostic menu, see section 8 Con-
(D797-R) if the pressure in the system trol system, group 8.4.4.3, CLIMATE
becomes abnormally high or low. menu 3
22 The expansion valve adjusts the - Expansion valve, description page 49

amount of refrigerant that is let in to the
evaporator. If the temperature in the
evaporator’s outlet pipe increases, the
evaporator valve increases flow of re-
frigerant so that heat dissipation in the
evaporator increases.
23 Sensor, refrigerant circuit temperature, R = 10 k at 25 C Sensor, temperature refrigerant, description

the temperature to Control unit, cab D23: Diagnostic menu, see section 8 Con-
(D790-1). trol system, group 8.4.4.2, CLIMATE
menu 2.
24 Heat exchanger cooling dissipates heat - Heat exchanger, cooling, description

from the cab air. Heat is transferred page 52
from the air to the refrigerant and con-
verts the refrigerant to a gaseous state.


25 The defroster switch on Control unit KIT Checked by control sys- Section 11 Common electrics,
(D790-2) activates the defroster tem, error shown with er- group 11.5.3.11 Control unit, KIT
program for the air conditioning for ror code.
six minutes.
26 Control unit KID (D795) shows the Checked by control sys- Section 11 Common electrics,
heating and ventilation settings in the tem, error shown with er- group 11.5.3.12 Control unit, KID
display. ror code.

page
–
checking
2 Navigate to the service menu and press Enter.
000056
3 Enter code for diagnostics. Code is obtained from Cargotec

support.
1 23
4 5 NOTE
000060

nostic test, Initiation, Calibration, or Service indication).
4 Select CLIMATE.
DIAGNOSIS
CAN/POWER LIGHTS CAB Menu 1
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
000131
OP EXTRA HIST
5 Checking the desired temperature, inside temperature sensor

DIAG CLIMATE 1(8) and water valve.
REQUIRED TEMP XXX REQUIRED TEMP: 160 (16.0 C) for max. cooling and 280
PRESENT TEMP XXX (28.0 C) for max. heating. The setting is changed with the tem-
000132
WATER VALVE FEEDB. XXX perature switch.

PRESENT TEMP shows the temperature inside the cab. This is
measured by Sensor cab temperature (located down to the right
on the instrument panel, behind the rubber bushing). Blowing
through the hole should increase the value.
WATER VALVE FEEDB. should show 0 (closed) when the re-
quested temperature is 160, and 100 (open) when the requested
temperature is 280. The water valve is located under the cab.

Menu 2
6 Check of Sensor, temperature outlet fan (B775-2), engine tem-
DIAG CLIMATE 2(8) perature, Sensor, outdoor temperature (B774), and check of
TEMP COIL XXX Sensor, temperature refrigerant (B775-1).
TEMP COOLANT XXX
TEMP AMBIENT XXX TEMP COIL: temperature that the air has in the air distributor is
000133
TEMP DE-ICE XXX measured by Sensor, temperature outlet fan (B775-2).
TEMP COOLANT: engine temperature 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 measured by Sen-
sor temperature refrigerant (B775-1). If the compressor is activat-
ed the value will be low. However, if heat has been selected and
the compressor is deactivated, the value will almost be equal to
TEMP COIL.
Menu 3
7 (Only machines with ECC)

DIAG CLIMATE 3(X)
PRESENT INPUT SIGNAL Checks that the refrigerant circuit is filled.
PRESSURE SWITCH X PRESSURE SWITCH: 0 = not filled, 1 = filled.
OPT DOOR SWITCH X
006865
The sensor is located on the receiver drier which is fitted right

rear in the frame.
Menu 4
8 Checks Water valve (Y673) and Air distributor (Y642).
DIAG CLIMATE 4(8)
WATER VALVE: should work between 1.0-1.24 V and
WATER VALVE XX.XXV 2.95-3.2 V. This is checked by turning the temperature control
DRAUGHT VALVE XX.XXV and changing the temperature setting from min. to max.
000135
DRAUGHT VALVE: should work in the range 1.0-4.0 V. The dif-

ference between min. and max. should be approx 1 V. This is
checked by changing the air distribution from floor to front wind-
shield. 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.
REQUIRED TEMP XX.XXV REQUIRED TEMP: home position U = 0 V; raise U = 2-2.5 V;
REQ. DRAUGHT XX.XXV lower U = 4.5-5 V.
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)
PRESENT OUTPUT SIGNAL (M612) and Electromagnetic clutch, compressor (M645) .
FAN SPEED XXX FAN SPEED: increase and decrease fan speed, value should in-
RECIRKULATION XY crease from 0 to 255 in steps.
000137
COMPRESSOR XY
RECIRCULATION: press in the bypass switch (S1005) (on the
panel for load handling functions). When checking, the display
should show "11". Check that the damper really moves as it
should by removing the fresh air filter at the front of the climate
control system casing and feeling with your hand.
(Only machines with ECC)

COMPRESSOR: lower 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-CLOCK-
CLOCKWISE XY XY
ANTI-CLOCKWISE XY XY WISE 00 11".
ANTI-CLOCKWISE: when the temperature is decreased and the
water valve closes shows "CLOCKWISE 00 11" and "ANTI-
24V CLOCKWISE 11 11".
NOTE
The ones are only showed for a moment when the water
valve changes position, zeros are shown when the valve is
M not changing position. The water valve does not open if en-
gine temperature is low, or if outdoor temperature is high.
000138
0V

Menu 8
12 Checks the direction selector for the air distributor.
DIAG CLIMATE 8(8)
CLOCKWISE: when the air is directed against the windscreen
OUTPUT DRAUGHT VALVE
CLOCKWISE XY XY and the air distributor changes position shows "CLOCKWISE 00
ANTI-CLOCKWISE XY XY 11" and "ANTI-CLOCKWISE 11 11".
ANTI-CLOCKWISE: when the air is directed against the feet and
the air distributor changes position shows "CLOCKWISE 11 11"
24V and "ANTI-CLOCKWISE 00 11".
NOTE
The "ones" are only shown for a moment when the air dis-
tributor changes position, "zeros" are shown when the air
M distributor does not change position.
000139
0V
Pause heater, description

page
–
1 Pause heating is an option for the heating unit, which uses residual
heat in the engine’s cooling system to keep the cab warm.
An extra electrically operated water pump pumps the coolant through
the heater unit when the engine is off. The cabin fan forces air into the
cab. The pause heater is turned off automatically when the tempera-
ture in the cab is six degrees below the value set on the climate control
system. The pause heater is activated with the pause heater switch
when the ignition is on.
3 2
004909
1. Switch, pause heater (S0_OPT-1)

2. Control unit cab (D790-1)
3. Circulation pump, pause heater (M667)

32 9 Frame, body, cab and accessories – 9.4.1 Fresh air filter
9.4.1 Fresh air filter

Fresh air filter, description
page
–
The fresh air filter is located under a cover in the external unit for fresh
air intake into the cab - in front of the cab fan. A finer filter can be used
( ), but this affects maximum airflow.
2
003208
Fresh air intake, cab

1. Fresh air filter
2. Fresh air and recirculation damper

9 Frame, body, cab and accessories – 9.4.2 Fresh air and recirculation damper 33
9.4.2 Fresh air and recirculation damper

Fresh air filter or recirculation damper, description
page
–
The damper is controlled electrically and controls the air between fully
open for fresh air to recirculation of air. The damper is located in the
external unit for fresh air intake into the cab.
The signal can be checked via the diagnostic menu, section 8 Control
system, group 8.4.4.6 CLIMATE, menu 6.
2
003208

1. Fresh air filter
2. Fresh air and recirculation damper

34 9 Frame, body, cab and accessories – 9.4.2 Fresh air and recirculation damper
Motor, fresh air filter or recirculation damper,

page
–
replacement
2 Remove the wiper arms.
3 Remove the nuts which hold the wiper motor in the protective
plate.
4 Remove the protective plate.
5 Remove the fresh air filter.

9 Frame, body, cab and accessories – 9.4.2 Fresh air and recirculation damper 35
6 Remove the bolts which secure the arm and motor in the plate.
7 Detach the connector from the motor.
8 Replace the motor.
9 Install in reverse order. Tighten the wiper arm with 16-20 Nm.

36 9 Frame, body, cab and accessories – 9.4.3 Cabin fan
9.4.3 Cabin fan

Cab fan, description
page
–
The cab fan is located in the external unit for fresh air intake into the
cab. The fan consists of two single fans that are driven by a motor.
1
003209

1. Cab fan
Cab fan, replacement

page
–


9 Frame, body, cab and accessories – 9.4.3 Cabin fan 37
3 Remove the bolts which hold the wiper motor in the protective
plate.
5 Detach the washer hose from the protective plate.

38 9 Frame, body, cab and accessories – 9.4.3 Cabin fan
7 Remove the bolts which secure the plate and cab fan.
8 Detach the connector from the cab fan.

9 Remove the cab fan.
10 Replace the cab fan.

9 Frame, body, cab and accessories – 9.4.4 Heat exchanger heat 39
9.4.4 Heat exchanger heat

Heat exchanger heat, description
page
–
The heat from the engine’s coolant is transmitted to the cab via the
heat exchanger. The heat exchanger is located behind the fan in the
external unit for fresh air intake into the cab.
1, 2
3
003210

1. Heat exchanger heat
2. Heat exchanger cooling
3. Expansion valve and sensor for refrigerant
temperature

40 9 Frame, body, cab and accessories – 9.4.4 Heat exchanger heat
Heat exchanger, cooling/heating, replacement

page
–
WARNING
Personal injury, environmental damage.
Read the safety instructions for refrigerant, see

section B Safety.

2 Drain the AC system of R134a refrigerant.
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 Frame, body, cab and accessories – 9.4.4 Heat exchanger heat 41
9 Remove the plate frame.
10 Remove the cab fan.
11 Remove the heat exchanger cover plate.

42 9 Frame, body, cab and accessories – 9.4.5 Water valve
12 Detach all fluid inlets and outlets from the heat exchanger.
13 Lift out the heat exchanger carefully.
14 Replace the heat exchanger.
16 Check for leaks and refill the AC-system with refrigerant R134a,
using the intended equipment.
For volume, see section F Technical data.
IMPORTANT
authorisation.
9.4.5 Water valve

Water valve, description
page
–
The water valve controls the climate control system’s capacity for
heating from 0 (closed valve) to 100% (open valve). The water valve
is controlled electrically.
The signal can be checked from the diagnostic menu, section 8 Con-
trol system, group 8.4.4.1 CLIMATE, menu 1, 8.4.4.4 CLIMATE,
menu 4 and 8.4.4.7 CLIMATE, menu 7.
002229
Water valve position under cab floor (from below)

9 Frame, body, cab and accessories – 9.4.6 Sensor, engine temperature 43
Water valve, replacement

page
–

2 Detach the connector from the water valve.
3 Stop the flow of fluid to and from the water valve using hose
pinch-off pliers.
4 Detach the coolant hoses from the water valve.
5 Remove the water valve from the cab floor.
6 Replace the water valve.
7 Fit in the reverse order.
8 Check the coolant level.
1. Water valve
2. Steering valve
9.4.6 Sensor, engine temperature

Sensor, engine temperature, description
page
–
Sensor, coolant temperature, is fitted on the engine and detects en-

gine’s coolant temperature. See supplier documentation, engine.
system, group 8.4.4.2 CLIMATE, menu 2
For location, see section 1 Engine.
9.4.7 Compressor
Compressor air conditioning, description
page
–
The compressor drives the climate control system by working as a

pump. It draws in cold, low-pressure gas from the evaporator, com-
presses the gas which then becomes warm, and then forces out high-
pressure gas to the condenser.
The compressor is driven by V-belts directly by the machine’s engine.
Activation and deactivation of the compressor is handled by an elec-
tromagnetic clutch, which is controlled by a thermostat.
001242

44 9 Frame, body, cab and accessories – 9.4.7 Compressor
Compressor, changing (engine alternative Volvo)

page
–
WARNING

section B Safety.

IMPORTANT
authorisation.
3 Detach the coolant hoses from the compressor.

4 Loosen the belt tensioner so that the compressor belt is released.
5 Remove the bolts which secure the compressor.
1. Alternator, belt tensioner 6 Change the compressor.
2. Compressor
IMPORTANT
authorisation.

9 Frame, body, cab and accessories – 9.4.7 Compressor 45
Compressor, air conditioning, description

page
–
The compressor drives the climate control system by working as a

pump. It draws in cold, low-pressure gas from the evaporator, com-
presses the gas which then becomes warm, and then forces out high-
pressure gas to the condenser.
1
The compressor is driven by V-belts directly by the machine’s engine.
Activation and deactivation of the compressor is handled by an elec-
tromagnetic clutch, which is controlled by a thermostat.
2 The signal can be checked via the diagnostic menu, section 8 Control
005000
1. Compressor air conditioning

2. Turnbuckle
Compressor, changing
page
–
WARNING
1 Read the safety instructions for refrigerant, see
section B Safety.
2 1 Machine in service position, see section B Safety.

005000
1. Compressor air conditioning

2. Turnbuckle IMPORTANT
authorisation.
3 Detach the coolant hoses from the compressor.

4 Loosen the turnbuckle so that the compressor belt is released.
5 Remove the bolts which secure the compressor.
6 Change the compressor.

46 9 Frame, body, cab and accessories – 9.4.8 Condenser
IMPORTANT
authorisation.
9.4.8 Condenser
Condenser, description
page
–
The condenser is located on the radiator in the engine compartment.

The function of the condenser is to convert the hot, high-pressure gas
from the compressor to liquid form. Pipes and cooling fins in the con-
denser battery absorb the heat, which is dissipated with a fan.
The temperature of the refrigerant in the condenser varies from ap-
prox. 50 C to 70 C and the pressure varies between 12 and 14 bar
depending on ambient temperature and airflow through the condens-
er. When the refrigerant has been condensed to liquid, it is forced on
to the fluid reservoir/filter dryer.
002228

9 Frame, body, cab and accessories – 9.4.8 Condenser 47
Condenser, replacement
page
–
WARNING

section B Safety.
1. Radiator 2 Drain the AC system of R134a refrigerant.

2. Condenser
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.

48 9 Frame, body, cab and accessories – 9.4.9 Moisture filter
9.4.9 Moisture filter

Moisture filter, description
page
–
The moisture filter collects the liquid refrigerant, binds moisture, and
filters impurities. The reservoir functions as an expansion tank in the
1 2 cooling circuit.
When the refrigerant has passed through the dryer in the bottom of the
fluid reservoir, it rises through a standpipe. Through a sight glass, it is
possible to check that flow is without bubbles and that the system is
adequately filled with refrigerant.
002227
1. Fluid reservoir, moisture filter

2. Pressure monitor
9.4.10 Pressure switch

Pressure switch, description
page
–
The pressure switch cuts off the current to the compressor’s electro-
magnetic clutch if the pressure in the cooling circuit becomes abnor-
1 2 mally high or low.
002227
1. Fluid reservoir, moisture filter

2. Pressure monitor

9 Frame, body, cab and accessories – 9.4.11 Expansion valve 49
Pressure switch, replacement

page
–
WARNING
1 2 Personal injury, environmental damage.

section B Safety.

2 Drain the machine of refrigerant, R134a.
IMPORTANT
authorisation.
002227
3 Detach the connector from the pressure switch.

1. Fluid reservoir, moisture filter 4 Unscrew the pressure switch from its mounting.
2. Pressure monitor.
5 Replace the pressure switch.
IMPORTANT
authorisation.
9.4.11 Expansion valve

Expansion valve, description
page
–
The expansion valve is the part in the circuit that separates the high-
pressure side from the low-pressure side. The refrigerant arrives at the
expansion valve under high pressure and leaves it under low pres-
sure. After the expansion valve, the refrigerant converts to a gaseous
state and is transported to the compressor once again.
The amount of refrigerant that passes the evaporator varies depend-
ing on the heat load. The valve works from fully open to fully closed
and searches between these for an optimal evaporation point.

50 9 Frame, body, cab and accessories – 9.4.11 Expansion valve
Expansion valve, replacement

page
–
WARNING

section 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 ex-
pansion valve, see Heat exchanger, cooling/heating, replace-
ment page 40.
6 Replace the expansion valve.
IMPORTANT
authorisation.

9 Frame, body, cab and accessories – 9.4.12 Sensor, temperature refrigerant 51
9.4.12 Sensor, temperature refrigerant

Sensor, temperature refrigerant, description
page
–
Sensor, temperature refrigerant, (position 2) detects the refrigerant

temperature in the heat exchanger, cooling. This is used to control the
air conditioning.
1
3
002226
2
1. Sensor cab temperature

2. Sensor temperature refrigerant
3. Sensor temperature outlet fan
Sensor, temperature refrigerant, replacement

page
–
WARNING

section B Safety.
NOTE
Requires special authorisation.
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 40.
6 Replace the temperature sensor.

52 9 Frame, body, cab and accessories – 9.4.13 Heat exchanger, cooling
IMPORTANT
authorisation.
9.4.13 Heat exchanger, cooling

Heat exchanger, cooling, description
page
–
The heat exchanger for cooling consists of pipes and cooling fins. The
cab air is cooled as it passes through the cooling heat exchanger. The
heat exchanger is located behind the fan in the external unit for fresh
air intake into the cab.
1, 2
3
003210

1. Heat exchanger heat
2. Heat exchanger cooling
3. Expansion valve and sensor for refrigerant
temperature

9 Frame, body, cab and accessories – 9.4.14 Air distributor 53
Heat exchanger, cooling, replacement

page
–
See Heat exchanger, cooling/heating, replacement page 40.
9.4.14 Air distributor

Air distributor, description
page
–
The air distributor controls the air between defroster and floor and is
located behind the panel inside the cab. The damper is controlled elec-
trically by the control system.
The signal can be checked from the diagnostic menu, section 8 Con-
trol 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

page
–

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. Instrument panel
2. Steering column adjustment
3. Lower protective cover
7 Remove the air distributor from its mounting.
8 Replace the air distributor, fitting it in the reverse order.
Air distributor

54 9 Frame, body, cab and accessories – 9.4.15 Defroster nozzles
9.4.15 Defroster nozzles

Defroster nozzles, description
page
–
There are a number of fixed air vents in the cab’s interior: at the front
of the doors and the defroster for the windshield. There are also two
adjustable air vents (flow and direction) in the instrument panel’s out-
side corners.
There is an air inlet towards the cab’s lower part (floor).
001839
Defroster nozzles, replacement

page
–

2 Remove the air damper manually.
3 Remove the bolts which hold the other part of the defroster noz-
zle in the dashboard.

9 Frame, body, cab and accessories – 9.4.16 Sensor, temperature outlet fan 55
4 Detach the air hose from the defroster nozzle.

5 Replace the defroster nozzle.
9.4.16 Sensor, temperature outlet fan

Sensor, temperature outlet fan, description
page
–
The outlet fan temperature sensor (position 3) detects the temperature

of the air that blows out in the defroster nozzles. The air conditioning
is controlled by signals from the following sensors:
1 3. Sensor, temperature outlet fan
3 The signal can be checked via the diagnostic menu, section 8 Control
002226
Sensor, temperature outlet fan, replacement

page
–

3 Remove the lower protective cover in front of the steering wheel
shaft.
4 Detach the steering wheel shaft and angle it back against the
driver’s seat.
1. Instrument panel
2. Steering column adjustment
3. Lower protective cover

56 9 Frame, body, cab and accessories – 9.4.17 Sensor cab temperature
5 Detach the temperature sensor from the air distributor.

Air distributor including temperature sensor.
9.4.17 Sensor cab temperature

Sensor, cab temperature, description
page
–
Sensor, cab temperature (position 1) senses the temperature of the air

in the cab.
system, group 8.4.4.1 CLIMATE, menu 1
1
3
002226

3. Sensor temperature outlet fan
Sensor, cab temperature, replacement

page
–


9 Frame, body, cab and accessories – 9.4.18 Sensor, ambient temperature 57
3 Detach the hose from the temperature sensor.

4 Detach the connector from the temperature sensor.
5 Remove the temperature sensor.
9.4.18 Sensor, ambient temperature

Sensor, ambient temperature, description
page
–
Sensor, ambient temperature, detects the temperature of the air out-

side the cab.
Sensor, ambient temperature
Sensor, ambient temperature, replacement

page
–

2 Detach the connector from the temperature sensor.
3 Remove the temperature sensor from its mounting in the cab.

58 9 Frame, body, cab and accessories – 9.5 Wiper/washer system
9.5 Wiper/washer system

9.5.1 Wiper front
Wiper front, description
page
–
The front wiper is the parallel wiper type, i.e. the wiper blade is moved
in a constant vertical position over the front window.
9.5.2 Wiper roof

Wiper roof, description
page
–
Wiper roof is of the type sector wiper. Wiping angle is approx.

180 degrees.
9.5.3 Wiper rear

Wiper rear, description
page
–
The rear wiper is of the type sector wiper. The wiping angle is approx.
180 degrees.
9.5.4 Washer motor and reservoir

Washer motor and reservoir, description
page
–
Washer motors are located on the washer fluid reservoir. There are
non-return valves on the lines from the reservoir to the washer noz-
zles, preventing the washer fluid from draining back in the line be-
tween washings. This minimises the time from activation of switch
washing and washer fluid spraying on the windshield.
The washer nozzles are mounted on the wiper arms.
004924

9 Frame, body, cab and accessories – 9.5.5 Wiper motor front 59
Washer motor and reservoir, replacement

page
–

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 Change the washer fluid reservoir. Change the washer motor, if
needed.
003619
A B
Washer fluid reservoir without protective plate.
A. Washer fluid reservoir
B. Washer motors
9.5.5 Wiper motor front

Wiper motor front, description
page
–
The wiper motor drives the front windshield wiper. The wiper arm is
mounted on the motor. The motor produces the movement of the
wiper.
Wiper motor front, replacement

page
–

3 Remove the nuts which hold the motor in the protective plate.

60 9 Frame, body, cab and accessories – 9.5.6 Wiper motor roof
6 Remove the nuts which hold the motor in the cab.

7 Detach the connector from the wiper motor.
8 Replace the motor.
9 Install in reverse order. Tighten the wiper arms with 16-20 Nm.
9.5.6 Wiper motor roof

Wiper motor roof, description
page
–
The wiper motor drives the roof window’s wiper. The wiper arm is
wiper.
Wiper motor roof, replacement

page
–

2 Remove the plastic cover.
3 Detach the washer hose and the connector to the wiper motor.

9 Frame, body, cab and accessories – 9.5.7 Wiper motor rear 61
4 Undo the lock nut securing the wiper arm and disconnect the
washer fluid hose.
5 Remove and replace the wiper motor.
9.5.7 Wiper motor rear

Wiper motor rear, description
page
–
The wiper motor drives the rear window wiper. The wiper arm is
wiper.
Wiper motor rear, replacement

page
–

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.

62 9 Frame, body, cab and accessories – 9.5.7 Wiper motor rear
6 Remove the screws securing the motor and the lock nut on the
motor.
7 Replace the wiper motor.
8 Install in reverse order. Tighten the wiper arms with 16-20 Nm.

9 Frame, body, cab and accessories – 9.6 Lighting system 63
9.6 Lighting system

Lighting system, function description
page
–
The lighting is turned off automatically after 5 minute’s idling in order

to prevent discharge of the batteries. Auxiliary work lights are turned
off after 2 minutes. Lighting is 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
D4
D5
D1 D3 8
D2 9
14 10
D9
6 D6 15 D8
D17
D16 17 13 D10
16 M D13
D790-1 D790-2
26 7, 12 19 11 33
D32 D27 D797-R D797-F D791-1
D31 18 D18 D22 D23
Pa D34 D35
D29
24
D30 D21 34
32 D28 35
007417
D20 25
27 28 29 30 31 20 21 22 23

1 The switch for cab work lights (S105-1) sends a Switch in ON position: D1: Diagnostic menu, see
voltage signal to the cab control unit (D790-1). U = 24 V section 8 Control system,
group 8.4.2.1 LIGHTS, menu 1
2 Switch, working lights attachment (S105-2) Switch in ON position: D2: Diagnostic menu, see
sends a voltage signal to Control unit, cab U = 24 V section 8 Control system
(D790-1). group 8.4.2.2 LIGHTS, menu 2
3 The switch for boom work lights (S105-3) sends Switch in ON position: D3: Diagnostic menu, see
a voltage signal to the cab control unit (D790-1). U = 24 V section 8 Control system
4 Switch, headlights (S100) sends a voltage sig- Switch in ON position: D4: Diagnostic menu, see
nal to Control unit, cab (D790-1). U = 24 V section 8 Control system,
5 Switch, revolving beacon (S110) sends a volt- Switch in ON position: D5: Diagnostic menu, see
age signal to Control unit, cab (D790-1). U = 24 V section 8 Control system

64 9 Frame, body, cab and accessories – 9.6 Lighting system
6 The door NC switch (S226-LE & S226-RI) Door open: U = 24 V Interior lighting cab, description
sends a voltage signal to the cab control unit page 72
(D790-1). D6: Diagnostic menu, see
section 8 Control system
7 Control unit, cab (D790-1) transmits "switch on Checked by control Section 11 Common electrics,
lights" messages on the CAN bus. system, error shown group 11.5.3.1 Control unit, cab
with error code.
8 Multi-function lever (S162) sends a voltage sig- Lever in high beam po- Gear selector and multi-function lever,
nal to Control unit KIT (D790-2). sition: US162/56a = 24 V description page 12
D8: Diagnostic menu, see section 8
Control system group 8.4.2.6 LIGHTS,
menu 6
9 Lever, direction indicator (S161) sends a volt- Left: US161/6 = 24 V D9: Diagnostic menu, see section 8
age signal to Control unit KIT (D790-2). Control system group 8.4.2.7 LIGHTS,
Right: US161/1 = 24 V
menu 7
10 Switch, interior lighting on Control unit KIT Checked by control D10: Diagnostic menu, see
(D790-2) sends a voltage signal to Control unit system, error shown section 8 Control system
KIT (D790-2). with error code. group 8.4.2.12 LIGHTS, menu 12
11 Control unit KIT (D790-2) sends a "switch on Checked by control Section 11 Common electrics,
lights" message on the CAN bus. system, error shown group 11.5.3.11 Control unit, KIT
with error code.
12 Control unit, cab (D790-1) supplies voltage to Checked by control Section 11 Common electrics,
the lights in and around the cab. system, error shown group 11.5.3.1 Control unit, cab
with error code.
13 Work lights cab (E404-1L & E404-1R) are Light on: U = 24 V Working lights, cab, description
turned on when the cab work lights are page 70
activated. D13: Diagnostic menu, see
14 Relay, extra work lights boom (K304) is activat- UK304/30 = 24 V Work lights, boom, lights page 71
ed when the boom work lights are activated and
UK304/85 = 0 V
supplies voltage to Extra work lights, boom
(E404-5L & E404-5R). Work lights boom on:
UK304/86 = 24 V
UK304/87 = 24 V
Work lights boom off:

UK304/86 = 0 V
UK304/87 = 0 V
15 Extra work lights, boom (E404-5L & E404-5R) Light on: U = 24 V Work lights, boom, lights page 71
are turned on when the boom work lights are
activated.

16 Revolving beacon (H428) is switched on when Light on: U = 24 V Rotating beacon, description page 70
the revolving working light is activated. D16: Diagnostic menu, see
17 Interior lighting turns on when a door is opened Light on: U = 24 V Interior lighting cab, description
or if activated with the switch on the KIT control page 72
unit (D790-2). D17: Diagnostic menu, see
18 Make-contact (closing switch) brake light Brake pressure over Section 4 Brakes, group 4.3.8 Make-
(S216) sends a voltage signal to Control unit, 0.2 MPa: U = 24 V contact (closing switch) brake lights
frame front (D797-F). D18: Diagnostic menu, see
19 Control unit, frame front (D797-F) supplies volt- Checked by control Section 11 Common electrics,
age to the front lights on the machine. system, error shown group 11.5.3.2 Control unit, frame front
with error code.
20 The direction indicators front (H422 & H423) Light on: U = 24 V Direction indicators, description
come on when direction indicators or flashing page 69
hazard lights are activated. D20: Diagnostic menu, see
21 The running lights front (H416-1 & H417-1) turn Light on: U = 24 V Running lights, description page 68
on together with the headlights. D21: Diagnostic menu, see
22 Headlights, low beam (E400L & E400R) are Light on: U = 24 V Headlights, description page 68
switched on when the headlight is activated. D22: Diagnostic menu, see
23 Headlights high beam (E402L & E402R) are lit Light on: U = 24 V Headlights, description page 68
high beams are activated. D23: Diagnostic menu, see
24 Extra work lights front (E404-7L & E404-7R) are Light on: U = 24 V
turned on at the same time as high beams.
25 Extra work lights front (E404-8L & E404-8R) are Light on: U = 24 V
turned on at the same time as high beams.
26 Control unit, frame rear (D797-R) supplies volt- Checked by control Section 11 Common electrics,
age to the rear lights on the machine. system, error shown group 11.5.3.3 Control unit frame rear
with error code.

66 9 Frame, body, cab and accessories – 9.6 Lighting system
27 Tail lights, red (H412L & H412R) are switched Light on: U = 24 V Tail lights, description page 68
on when the headlight is activated. D27: Diagnostic menu, see
28 Brake lights (H411L & H411R) are switched on Light on: U = 24 V Brake lights, description page 69
when the brake is activated. D28: Diagnostic menu, see
29 The direction indicators rear (H426 & H427) Light on: U = 24 V Direction indicators, description
come on when direction indicators or flashing page 69
hazard lights are activated. D29: Diagnostic menu, see
30 Running lights, rear (H416-2 & H417-2) turn on Light on: U = 24 V Running lights, description page 68
when the headlights are activated. D30: Diagnostic menu, see
31 Back-up lights, white (E405L & E405R) are Light on: U = 24 V Back-up lights, description page 69
switched on when reverse gear is selected. D31: Diagnostic menu, see
32 Work lights, boom (E404-3L & E404-3R) are Light on: U = 24 V Work lights, boom, lights page 71
turned on when the boom work lights are D32: Diagnostic menu, see section 8
activated. Control system group 8.4.2.3 LIGHTS,
menu 3
33 Control unit, attachment (D791-1) supplies volt- Checked by control Section 11 Common electrics,
age to the attachment’s lights. system, error shown group 11.5.3.5 Control unit,
with error code. attachment
34 Work lights, attachment (E406-L & E406R) are Light on: U = 24 V Working lights, attachment, description
turned on when the attachment’s work lights are page 72
activated. D34: Diagnostic menu, see
35 Extra work lights, attachment (E404-4L & E404- Light on: U = 24 V Working lights, attachment, description
4R) are turned on when the attachment work page 72
lights are activated. D35: Diagnostic menu, see

Lighting system, component location

page
–
The purpose of lighting is to increase safety during operation and load

handling. The machine has the following lights:
NOTE
1 2 3 4 5 6 7 8
21, 22, 23, 24
006426
20 18, 19 17 16 15 14 13, 12, 11 10 9
1. Rotating beacon (H428) 13. Headlights, low beam (E400L & E400R)
Headlights, high beam (E402L & E402R)
2. Interior lighting 14. Make-contact (closing switch) brake light (S216)
3. Control unit KIT (D790-2) 15. Control unit frame front (D797-F)
4. Multi-function lever (S162) 16. Switches, see section 9 Frame, body, cab and accesso-
ries,group 9.1 Controls and instruments
5. Work lights, cab (E404-1L & E404-1R) 17. Door NC (normally closed) switch (S226-LE & S226-RI)
6. 18. Control unit, cab (D790-1)
Extra work lights, boom (E404-5L & E404-5R)
7. Work lights, boom (E404-3L & E404-3R) 19.
Relay extra work lights boom (K304)
8. Control unit, attachment (D791-1) 20. Control unit frame rear (D797-R)
9. Work lights, attachment (E406-L & E406R) 21. Running lights, rear (H416-2 & H417-2)
Extra work lights, attachment (E404-4L & E404-4R)

10. Extra work lights front (E404-7L, E404-8L, E404-7R & 22. Back-up lights, white (E405L & E405R)
E404-8R)
11. Direction indicators, front (H422 & H423) 23. Tail lights, red (H421L & H412R)
Brake lights (H411L & H411R)
12. Running lights, front (H416-1 & H417-1) 24. Direction indicators, rear (H426 & H427)

68 9 Frame, body, cab and accessories – 9.6.1 Headlights
9.6.1 Headlights
Headlights, description
page
–
Headlights are located in the front of the machine to give the operator
enhanced vision when operating in darkness, and to provide surround-
ing traffic and the environment an indication of the machine’s position.
Headlights have high beam and low beam (for meeting other traffic).
Switch between low and high beam with the gear and multi-function le-
ver. The signal goes to the cab control unit (D790-1).
High and low beam signals can be checked from the diagnostic menu,
section 8 Control system, group 8.4.2.6 LIGHTS, menu 6.
9.6.2 Running lights

Running lights, description
page
–
The running lights are fitted on the right and left-hand sides of the ma-
chine 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 goes to the cab control unit (D790-1).
The lights and their signal can be checked from the diagnostic menu,
As an option the machine can be equipped with running lights of LED

type. These are replaced as a complete unit.
9.6.3 Tail lights

Tail lights, description
page
–
Tail lights are located on the rear of the machine to provide surround-
ing traffic and the environment an indication of the machine’s position,
and a limited enhancement of visibility for the operator in darkness.
The tail lights are controlled by selecting with the headlight switch. The
signal goes to the cab control unit (D790-1).
As an option the machine can be equipped with combined LED

direction indicators rear and brake lights. These are replaced as a
complete unit.

9 Frame, body, cab and accessories – 9.6.4 Brake lights 69
9.6.4 Brake lights

Brake lights, description
page
–
The brake lights are fitted on the rear of the machine to provide sur-
rounding traffic and the environment an indication that the machine is
braking and consequently slowing down.
The brake lights are regulated by brake pedal position (via actuated
NC switch). The signal travels to the frame control unit front (D797-F),
which supplies power to the brake lights.

complete unit.
9.6.5 Back-up lights

Back-up lights, description
page
–
The back-up lights are located on the rear of the machine to provide
surrounding traffic and the environment an indication that the machine
is reversing. In addition, this provides the operator enhanced visibility
when operating in darkness.
The back-up lights are controlled by the selected travel direction with
the gear selector and multi-function lever (S162) which send a voltage
signal to Control unit KIT (D790-2).
The back-up lights are supplied voltage by Control unit, frame rear
(D797-R)
9.6.6 Direction indicators

Direction indicators, description
page
–
The direction indicators are located on both the front and rear of the
machine to provide surrounding traffic and the environment an indica-
tion that the machine is changing direction, i.e. turning.
The direction indicators are controlled by selecting with Switch, direc-
tion indicators (S161) that sends a voltage signal to Control unit KIT
(D790-2).
The direction indicators are supplied voltage by Control unit, frame
front (D797-F) and Control unit, frame rear (D797-R).

complete unit.

70 9 Frame, body, cab and accessories – 9.6.7 Flashing hazard lights
9.6.7 Flashing hazard lights

Flashing hazard lights, description
page
–
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
flashing hazard lights. The signal goes to the control unit (D790-2).
Machines for the North American market are equipped with flashing
brake lights front and rear during operation.
9.6.8 Revolving beacon

Rotating beacon, description
page
–
A rotating beacon is located high on the machine’s boom (rear part).

This is used to provide surrounding traffic and the environment an in-
dication that a working vehicle is moving and at work. Indication to by-
standers to be careful.
The rotating beacon is controlled by selecting with the rotating beacon
switch. The signal travels to the cab control unit (D790-1).
9.6.9 Working lights, cab

Working lights, cab, description
page
–
Working lights on the cab provide visibility when handling a load in

darkness.
The work lights are controlled by selecting with the switch for cab roof
work lights. The signal travels to the cab control unit (D790-1) which in
turn supplies power to the work lights.

9 Frame, body, cab and accessories – 9.6.10 Work light boom 71
Working lights, replacement

page
–
(product alternative Xenon lights)
DANGER
Xenon lights are activated with high voltage. Always
turn off the main electric power before working on xe-
non 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 Work light boom

Work lights, boom, lights
page
–
Work lights on the cab provide enhanced visibility when handling a

load in darkness.
The work lights are controlled by selecting with the work lights boom
switch. The signal goes to the cab control unit (D790-1).
The lift boom can be equipped with two auxiliary work lights ( ).

page
–
See Working lights, replacement (product alternative Xenon lights)

page 71.

72 9 Frame, body, cab and accessories – 9.6.11 Working lights, attachment
9.6.11 Working lights, attachment

Working lights, attachment, description
page
–
Working lights on the attachment provide increased visibility when

handling a load in darkness.
The work lights are controlled by selecting with the attachment work
light switch. The signal travels to the cab control unit (D790-1).
The attachment can be equipped with two extra working lights ( ).

page
–
See Working lights, replacement (product alternative Xenon lights)

page 71.
9.6.12 Interior lighting

Interior lighting cab, description
page
–
The interior lighting illuminates the cab when the doors are opened or
when activated with the interior lighting switch.
There is background lighting in all switches, function keys, and rotary
controls. This is so that the operator can read their functions and
settings in darkness. Brightness is controlled with the plus and
minus keys.

9 Frame, body, cab and accessories – 9.7 Signalling system 73
9.7 Signalling system

Signalling system, function description
page
–
NOTE
1 2 3
D2 5
D1 D3 6
18
16
17 D6
D18 D19 D5
D14 19
14
15 M
7 20
D15 D790-1 4 D790-2 D795
8
D797-R D797-F D791-1
D9 D10 12 21
9 10 D11 D10 D22
13 22
11
007418
Pos Description Signal description Reference
1 Switch, revolving beacon (S110) Switch in ON position: U = 24 V D1: Diagnostic menu, see section 8 Control
sends a voltage signal to Control system group 8.4.2.9 LIGHTS, menu 9
unit, cab (D790-1).
2 Switch, flashing hazard lights (Haz- Switch in ON position: U = 24 V D2: Diagnostic menu, see section 8 Control
ard) (S109) sends a voltage signal system group 8.4.2.8 LIGHTS, menu 8
to Control unit, cab (D790-1).
3 Switch, parking brake (S107) Switch in ON position: U = 24 V D3: Diagnostic menu, see section 8 Control
sends a voltage signal to Control system group 8.4.5.4 HYD, menu 4
unit, cab (D790-1).
4 Control unit, cab (D790-1) sends Checked by control system, er- Section 11 Common electrics,
messages about activation on the ror shown with error code. group 11.5.3.1 Control unit, cab
CAN bus.
5 Multi-function lever (S162) sends a Signal button pressed in: Gear selector and multi-function lever, de-
voltage signal to Control unit KIT US162/H = 24 V scription page 12
system group 8.4.3.5 CAB, menu 5
6 Lever, direction indicator (S161) Left: US161/6 = 24 V D6: Diagnostic menu, see section 8 Control
sends a voltage signal to Control system group 8.4.2.7 LIGHTS, menu 7
Right: US161/1 = 24 V
unit KIT (D790-2).

74 9 Frame, body, cab and accessories – 9.7 Signalling system

7 Control unit KIT (D790-2) sends Checked by control system, er- Section 11 Common electrics,
messages about activation on the ror shown with error code. group 11.5.3.11 Control unit, KIT
CAN bus.
8 Control unit, frame rear (D797-R) Checked by control system, er- Section 11 Common electrics,
supplies voltage to the rear lights ror shown with error code. group 11.5.3.3 Control unit frame rear
and buzzer on the machine.
9 Direction indicators, rear (H426 & Light on: U = 24 V Direction indicators, description page 69
H427) are turned on when the D9: Diagnostic menu, see section 8 Control
flashing hazard lights are activated. system, group 8.4.2.8 LIGHTS, menu 8
10 Back-up lights (E405L & E405R) Light on: U = 24 V Back-up lights, description page 69
are turned on when reverse gear is D10: Diagnostic menu, see section 8 Con-
selected. trol system group 8.4.2.11 LIGHTS,
menu 11
11 Back-up alarm (H965) is activated Reverse gear engaged: Reverse alarm, description page 77
when reverse gear is selected. U = 24 V D11: Diagnostic menu, see section 8 Con-
trol system, group 8.4.2.11 LIGHTS,
menu 11
12 Control unit, frame front (D797-F) Checked by control system, er- Section 11 Common electrics,
supplies voltage to the front lights ror shown with error code. group 11.5.3.2 Control unit, frame front
on the machine.
13 Direction indicators, front (H422 & Light on: U = 24 V Direction indicators, description page 69
H423) are turned on when direction D13: Diagnostic menu, see section 8 Con-
indicators are activated. trol system group 8.4.2.8 LIGHTS, menu 8
14 Horn (H850) sounds when the horn Horn active: U = 24 V Horn, description page 76
is activated. D14: Diagnostic menu, see section 8 Con-
trol system group 8.4.3.5 CAB, menu 5
15 Revolving beacon (H428) is Light on: U = 24 V Revolving beacon, description page 77

switched on when the flashing haz- S15: Diagnostic menu, see section 8 Con-
ard light is activated. trol system, group 8.4.2.9 LIGHTS, menu 9
16 Relay loud horn (K3016) is activat- UK3016/30 = 24 V Horn, description page 76

ed when horn is activated.
UK3016/85 = 0 V
Horn activated:
UK3016/86 = 24 V
UK3016/87 = 24 V
17 Loud horn (H850-1) sounds when Horn active: U = 24 V Horn, description page 76
the horn is activated.
18 Make-contact (closing switch) op- Operator in seat: U = 24 V Sensor operator in seat, description
erator-in-seat (S230) sends a volt- page 23
age signal to Control unit, cab D18: Diagnostic menu, see section 8 Con-
(D790-1) when there is a load on trol system group 8.4.3.6 CAB, menu 6
the driver’s seat.

9 Frame, body, cab and accessories – 9.7 Signalling system 75

19 In the event of warnings, Buzzer, Checked by control system, er- D19: Diagnostic menu, see section 8 Con-
cab (H853) is supplied voltage by ror shown with error code. trol system group 8.4.3.6 CAB, menu 6
Control unit KIT (D790-2) to draw
the operator’s attention to the
warning message.
20 In the event of warnings, control A clicking sound is audible Section 11 Common electrics,
unit KID (D795) activates the warn- when then termination resistor group 11.5.3.12 Control unit, KID
ing lamp to draw the operator’s at- is activated.
tention to the warning message.
21 The attachment control unit Checked by control system, er- Section 11 Common electrics,
(D791-1) supplies voltage to the ror shown with error code. group 11.5.3.5 Control unit, attachment
automatic spreading buzzer during
automatic spreading.
22 The automatic spreading buzzer Buzzer active: U = 24 V Section 7 Load handling, group 7.5.13
(H9003) is activated when auto- Buzzer, automatic spreading 20’ - 40’
matic spreading 20' - 40' is D22: Diagnostic menu, see section 8 Con-
activated. trol system, group 8.4.9.15 ATTACH,
menu 15

76 9 Frame, body, cab and accessories – 9.7.1 Horn
Signalling system, component location

page
–
1 2 3 4 5
16, 17
6
006427
15 13, 14 12 11 10 9 8 7
1. Revolving beacon (H428) 10. Switches, see section 9 Frame, body, cab and accesso-
2. Control unit KIT (D790-2) ries, group 9.1 Controls and instruments
3. Buzzer, cab (H853) 11. Horn (H850)
4. Control unit, KID (D795) 12. Make-contact (closing switch) operator-in-seat (S230)
5. Control unit, attachment (D791-1) 13. Control unit, cab (D790-1)
6. 14.
Buzzer automatic spreading (H9003) Relay loud horn (K3016)
7. Direction indicators, front (H422 & H423) 15. Control unit frame rear (D797-R)
8. Control unit frame front (D797-F) 16. Direction indicators, rear (H426 & H427)
9. 17. Reverse alarm (H965)
Loud horn (H850-1)
9.7.1 Horn
Horn, description
page
–
The horn is electromagnetic. Air horn can be selected ( ).

The horn is activated from the gear and multi-function lever. The horn
can also be activated with the switch for open twistlocks on the control
lever, when the attachment does not have contact with a container.
001247
The horn is located under the cab (the compressed air horn is located
in the rear edge of the cab roof).
As an option the machine can be equipped so that the twistlocks

button on the control lever controls the horn when there is no
alignment.

9 Frame, body, cab and accessories – 9.7.2 Flashing hazard lights 77
9.7.2 Flashing hazard lights

Flashing hazard lights, description
page
–
See Flashing hazard lights, description page 70.
9.7.3 Revolving beacon

Revolving beacon, description
page
–
See Rotating beacon, description page 70.
9.7.4 Warning parking brake

Warning parking brake, description
page
–
If the operator leaves the machine without applying the parking brake,
a buzzer sounds to alert the operator, i.e. to ensure the operator ap-
plies the parking brake.
A sensor in the operator’s seat (see Sensor operator in seat, descrip-
tion page 23) indicates to the control system if the operator leaves
the seat.
The buzzer is located in the steering wheel panel.
9.7.5 Back-up alarm

Reverse alarm, description
page
–
When reverse is selected, a warning sound and the back-up lights are
activated. This is to give others in traffic an indication that the machine
is reversing. Indication to bystanders to be careful.

78 9 Frame, body, cab and accessories – 9.8 Entertainment and communication
9.8 Entertainment and

communication
Entertainment and communication, general
page
–
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

page
–
Repairs should be left to authorised personnel.

9 Frame, body, cab and accessories – 9.9 Glass/windows/mirrors 79
9.9 Glass/windows/mirrors
Glass/windows/mirrors, description
page
–
The windows are designed to both enclose the cab and provide the op-
C erator with a good view.
The windows on the Spirit Delta cab are made of tinted hardened
D
glass, except the roof window which is made of polycarbonate plastic.
As an option, the cab can be equipped with windows of laminated

glass.
The rearview mirrors are of the convex mirror type. There is an interior
rearview mirror on all machines.
A E B 001512
A. Side windows
B. Windshield (front window)
C. Roof window
D. Rear window
E. Windshield (side window front)
Silicone adhesive, handling advice

page
–
The window panes are secured with decor strips adhesive and silicone
adhesive.
NOTE
The purpose of this instruction is to describe how silicone adhe-
sive 923854.0100 should be handled in connection with replace-
ment of the windscreen and roof window on the Spirit Delta cab.
• Silicone adhesive 923854.0100 is a quick-hardening, two-
component silicone adhesive that can withstand tempera-
tures between -50 C and +200 C. The hardening properties
of the adhesive are extremely dependent on the ambient
temperature. An increase of 10 C cuts hardening time in
half.
Silicone adhesive 923854.0100 is mixed at a ratio of 1:10 in
a static mixer. Change mixer after every interruption that
lasts more than 5 minutes. The short setting time means that
work has to be planned carefully to avoid undesired
hardening.
Fixing time:
10-20 minutes at 20 C
approx. 5 minutes at 60 C

80 9 Frame, body, cab and accessories – 9.9.1 Windscreen
Hardening time:
approx. 24 hours at 20 C
approx. 1 hour at 60 C
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 C
and +20 C. Storage in a refrigerator or a colder environment
is recommended.
9.9.1 Windscreen
Windscreen, description
page
–
The windshield consists of the front window and side windows. The
windshield is attached to the cab with a key strip and is glued to the
roof window with silicone adhesive. Front and side windows are joined
with silicone adhesive to give good all-round visibility from the opera-
tor’s station.
For location, see Glass/windows/mirrors, description page 79.
Windscreen, replacement
page
–
NOTE
Read the handling advice for silicone adhesive before starting
work. See Silicone adhesive, handling advice page 79.

2 Remove the decor strip.
Figure 1: Removing key strip

9 Frame, body, cab and accessories – 9.9.1 Windscreen 81
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 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
Acetone may not come into contact with a roof win-
dow made of polycarbonate plastic. Acetone has a
chemical effect on the polycarbonate plastic which
reduces the roof window’s strength.
4 Clean all surfaces thoroughly. Remove old remains of silicone

with a razor blade or similar.
5 Fit masking tape on the inside and outside of the window panes
by the surfaces that are to be glued.
6 When the windscreen or a side window is to be replaced, then the
1 2 3
window panes must be adjusted so that the upper edge on the
side window has the same height as the upper edge of the roof
(see Figure 2) and so that the distance between windshield and
side window is as in Figure 3.
Use spacers against the roof member to ensure that the distanc-
es are maintained.
1
006268
1,0
1
Figure 2: Adjusting side window - cab window
1. Side window
2. Rubber strip
3. Cab frame / door opening
006269
1,0
Figure 3: Adjusting side window - windshield

1. Masking tape
7 Fit the decor strip around the whole window pane.

82 9 Frame, body, cab and accessories – 9.9.2 Side window
8 Apply Silicon adhesive 923854.0100 around the 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 adhesive from the outer vertical corners
with a tool made of cardboard as shown in Figure 4. Smooth out
the joints on the inside with a finger, wet with water or soapy
water.
10 Apply silicone adhesive 923854.0100 between the strip and win-
dow pane at the bottom edge of the front corners, so-called top
sealing.
11 If the roof window is to be replaced, apply silicone adhesive
923854.0100 by the cab frame (where it was glued earlier).
12 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
down the corner screws for the roof window.
13 Apply silicone adhesive 923854.0100 by the edges and smooth
006272
out the joints with a finger, wet with water or soapy water.
Figure 4: Tool template for silicone joint, scale 1:1

IMPORTANT
Mark the window panes with "New adhesive. Do not
touch".
14 Remove the masking tape immediately after applying adhesive to

avoid edge formation. Hardening time is dependent on ambient
temperature, plan the change so that downtime is minimised.
9.9.2 Side window

Side window, description
page
–
The side windows are secured in the cab and doors with decor strips.
For further details, see Glass/windows/mirrors, description page 79.
Side window, replacement

page
–
NOTE
The method describes a general procedure.

9 Frame, body, cab and accessories – 9.9.2 Side window 83
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.

84 9 Frame, body, cab and accessories – 9.9.2 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.

9 Pull the decor strip around the whole window.

9 Frame, body, cab and accessories – 9.9.3 Roof window 85
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.
9.9.3 Roof window

Roof window, description
page
–
The roof window is made of polycarbonate plastic, which is a safety

feature for the operator, intended to protect the operator from falling
objects. The polycarbonate pane is flexible and elastic.
Safety is maintained within a temperature interval of 120 C to -45 C
(becomes brittle at -110 C, glass conversion temperature 145 C).
The roof window has a patented surface layer that increases its resist-
ance to wear, UV light and chemicals.
The roof window is joined with the windshield. Joints between the win-
dow panes and between roof window and cab are sealed with silicone
adhesive. Place a new seal of silicone adhesive when replacing.
For location, see Glass/windows/mirrors, description page 79.
WARNING
The strength of the roof window may be significantly
reduced in case of exposure to substances contain-
ing aromatic hydrocarbons, ketones, esters, and
chlorinated hydrocarbons.
Low strength! Danger!
Check the roof window’s surface at regular intervals,

and only clean with washer fluid or mild cleaning
agents. Rinse with lukewarm water. Replace the roof
window if it is damaged, cracked, or scratched!
Roof window, replacement

page
–
See Windscreen, replacement page 80, for the general procedure.

The roof window is combined with the windshield. The joint is sealed
with silicone. Add a new silicone seal when replacing.

86 9 Frame, body, cab and accessories – 9.9.4 Rear window
9.9.4 Rear window

Rear window, description
page
–
The rear window is attached to the cab with a decor strip.
On machines with hydraulic sliding cab or hydraulic cab lift and

lower, the rear window can be opened to provide an emergency exit.
For further details, see Glass/windows/mirrors, description page 79.
Rear window, replacement

page
–
See Side window, replacement page 82 for the general procedure.
9.9.5 Rear view mirror

Rear view mirror, description
page
–
The cab has a rearview mirror (position A) located in the cab as well
as rearview mirrors (position B) on left and right front wing. The func-
tion of the rearview mirror is to give the operator visibility around the
machine.
001510
A B As an option the machine can be equipped with electrically controlled

and heated external rearview mirrors.
A. Rearview mirror
B. External mirror
9.9.6 Reversing camera

Reversing camera, description
page
–
The back-up camera is located at the rear edge of the horizontal coun-
terweight, at the back on the machine. It is designed to provide im-
proved vision when reversing. The back-up camera is waterproof and
has a microphone and infrared lighting for night vision. In addition, the
camera is equipped with automatic heating which is activated at ambi-
ent temperatures below +10 C.
1
2 The reversing camera sends colour images and audio to the monitor
in the cab; see Monitor, reversing camera, description page 87.
1
007425
3
1. IR-diodes
As an option the machine can be equipped with an extra camera at the
2. Camera
front of the machine for improved visibility in front of the machine.
3. Microphone
Switching between displaying the image from the front and rear cam-
eras is controlled with a button on the monitor.

9 Frame, body, cab and accessories – 9.9.7 Monitor, reversing camera 87
9.9.7 Monitor, reversing camera

Monitor, reversing camera, description
page
–
The screen shows picture and sound from the back-up camera. The
CA.SE
L
1 picture is shown in colour and light intensity is automatically adjusted
according to light conditions in the cab. The monitor can handle sig-
MENU
2 nals from two different cameras.

VOL
The monitor is mounted on a hinged bracket to the left in front of the
3 door in the cab.
BRI
4
007416
5
1. Choice of camera
2. Menu
3. Light intensity
4. Volume setting
5. On and off

88 9 Frame, body, cab and accessories – 9.10 Cab structure and suspension
9.10 Cab structure and

suspension
Cab structure and suspension, description
page
–
The cab is mounted in a cab undercarriage via strong rubber insulators

located on the underside of the cab. This minimises vibrations from the
frame to the cab. There is an insulator at four points - one at each cor-
1 ner. Each insulator mounting has one rubber bushing and one bolt.
3
003206
4
Cab Spirit Delta
1. Cab frame
2. Door
3. Cab suspension
4. Cab undercarriage
9.10.1 Cab frame

Cab frame, description
page
–
The cab frame is made of high-strength steel sheet profiles. The cab
is dimensioned to handle impacts and, to some degree, dropped
loads. The frame must not be modified!
002210
Cab Spirit Delta

9 Frame, body, cab and accessories – 9.10.2 Doors 89
9.10.2 Doors
Doors, description
page
–
The cab has two doors, the left is the operator’s door and the right is
the emergency exit. The door has:
• hand rail
• handle
• key lock
• openable window (passenger door )

Switches in the doors’ locks sense if the door is open. The switch is
used to turn on the interior lighting and warn of an open door.
The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.2.12 CAB, menu 12 or 8.4.11.2 SLIDING-
CAB, menu 1.
9.10.3 Cab substructure

Cab undercarriage, description
page
–
The cab is mounted on a cab undercarriage via strong rubber insula-

tors located on the underside of the cab. This is to minimise vibrations
from the frame to the cab.
The cab undercarriage is installed on the machine’s chassis (frame)
via a mounting. The chassis mounting depends on if the machine is
equipped with hydraulic cab tilt.
• manual sliding cab
• hydraulic sliding cab
• hydraulic vertically adjustable cab
• hydraulically tiltable cab.
9.10.3.1 Cab undercarriage, sliding cab

Cab undercarriage, sliding cab, description
page
–

via a mounting. The mounting to the chassis consists of four ball bear-
ing metal rollers which run in rails on top of the machine’s frame.

90 9 Frame, body, cab and accessories – 9.10.3.2 Cab undercarriage, vertically adjustable cab
9.10.3.2 Cab undercarriage, vertically

adjustable cab
Cab undercarriage, vertically adjustable cab, description
page
–
1 2 3
via a mounting. The mounting runs in a lift mast which is secured in the
machine’s chassis behind the right front fender which means that the
cab is positioned above the right drive wheel.
The lift mast consists of outer mast, inner mast lift cylinder, and chains.
The inner mast runs in the outer mast on ball bearing rollers.
4
001873
1. Hydraulic cylinder, vertically adjustable cab

2. Mast, vertically adjustable cab
3. Cab undercarriage, vertically adjustable cab
4. Safety lock

9 Frame, body, cab and accessories – 9.10.4 Sliding cab 91
9.10.4 Sliding cab

Manual sliding cab, description
page
–
Manual sliding cab means that the cab can be moved forward to facil-
itate access for service and maintenance in the engine compartment.
The cab is pushed for and aft by hand. Two cable chains on each side
ensure that hoses and electric cabling to and from the cab are not
damaged when the cab is moved. The cab is secured in the rear posi-
tion during operation with two lock handles at the rear edge of the cab.
A
DANGER
The cab is very heavy and the machine must not be
moved without first securing the cab.
Fatal danger! Risk of crushing!
Secure the cab on both sides, with both lock handles

and pins before starting to operate the machine.
000270
B C WARNING
B. Lock pin
It is important to that the lock handles are intact! They
should be checked regularly. However, it is not in-
cluded as part of the service schedule for preventive
maintenance!

92 9 Frame, body, cab and accessories – 9.10.4 Sliding cab
Hydraulic sliding cab, function description

page
–

Doors Closed Doors, description page 89.
D1 2
D2
1
3, 13
D790-1
D12
D797-O
4,14
5
D4
P1
A 12
7 LS
TP 11, 17
T1 B
8 6, 9, 15 10, 16
006901
1 Switch (S177) sliding cab sends a volt- U = 24 V Controls and instruments, overview page 5
age signal to Control unit, cab (D790-1). D1: Diagnostic menu, see section 8 Control
system, group 8.4.11.2 SLIDING CAB,
menu 1
2 Contact closed door, sends signal to U = 24 V Doors, description page 89
control unit cab when door is closed. D2: Diagnostic menu, see section 8 Control
menu 1
3 The cab control unit (D790-1) sends Checked by control sys- Section 11 Common electrics,
cab forward or cab backward on the tem, error shown with group 11.5.3.1 Control unit, cab
4 Control unit frame option (D797-O) sup- I = 435–650 mA Section 11 Common electrics,
plies voltage to servo valve sliding cab group 11.5.3.4 Control unit frame option
forward or servo valve sliding cab back- D4: Diagnostic menu, see section 8 Control
ward on control valve option frame. system, group 8.4.11.2 SLIDING CAB,
menu 3 and 4

9 Frame, body, cab and accessories – 9.10.4 Sliding cab 93
5 Servo valve sliding cab forward or servo - Control valve, option frame, description
valve sliding cab backward pressurises page 94
the sliding cab slide in control valve, op- D4: Diagnostic menu, see section 8 Control
tion frame. system, group 8.4.11.2 SLIDING CAB,
menu 3 and 4
6 Control valve option frame sends a con- - Control valve, option frame, description
trol signal to shuttle valve option. page 94
7 The shuttle valve sends the strongest - Shuttle valve, frame option, description
control signal to main pumps if several page 98
functions are activated at the same time.
8 The main pumps pump oil from the tank. Pressure plate "Max. Section 10 Common hydraulics, group 10.4.2
pressure hydraulic oil Axial piston pump with variable displacement
pumps" on left frame
member.
9 Control valve, option frame pressurises - Control valve, option frame, description
valve block sliding cab. page 94
10 Valve block sliding cab pressurises hy- - Valve block sliding cab, description page 99
draulic motor for sliding cab.
11 Hydraulic motor, sliding cab pulls the cab - Hydraulic motor sliding cab, description
forward or backward. page 99
12 Sensor end position (B769-2) sends a U = 24 V Sensor damping end-position, description
voltage signal to the cab control unit page 101
(D790-1) when cab is close to the end D12: Diagnostic menu, see section 8 Control
position. system, group 8.4.11.2 SLIDING CAB,
menu 2
13 Control unit, cab (D790-1) sends "damp- Checked by control sys- Section 11 Common electrics,
en sliding cab" on the CAN-bus. tem, error shown with group 11.5.3.1 Control unit, cab
error code.
14 Control unit frame option (D797-O) re- - Section 11 Common electrics,
duces the control current to servo valve group 11.5.3.4 Control unit frame option
sliding cab forward or servo valve sliding D4: Diagnostic menu, see section 8 Control
cab backward on in the control valve op- system, group 8.4.11.2 SLIDING CAB,
tion frame. menu 3 and 4
15 Control valve, option frame reduces the - Control valve, option frame, description
hydraulic pressure to valve block sliding page 94
cab. D4: Diagnostic menu, see section 8 Control
menu 3 and 4
16 Valve block sliding cab lets pressure - Valve block sliding cab, description page 99
through to hydraulic motor sliding cab.
17 Hydraulic motor sliding cab reduces the - Hydraulic motor sliding cab, description
speed of sliding cab. page 99
Hydraulic diagram, sliding cab

Hydraulic diagram, sliding cab + support jacks

94 9 Frame, body, cab and accessories – 9.10.4.1 Cab cradle
9.10.4.1 Cab cradle

Cab cradle, description
page
–
The cab is secured on a cradle which runs on wheels in rails on the

frame. See Cab undercarriage, description page 89.

Hydraulic oil pump, description
page
–
The hydraulic sliding cab is pressurised from hydraulic oil pump 1 and
2, see section 10 Common hydraulics group 10.4.2 Axial piston pump

page
–
The hydraulic sliding cab is controlled by a separate section in the con-

trol valve, option frame.
pressure and reducing valves convert electric current to servo pres-
sure. The servo pressure controls the spring-centred valve slides,
which control pressure and flow for the function in question. The valve
simultaneously.
The control valve is located at the front of the engine compartment and
is controlled by Control unit, frame option (D797-O). Control valve, op-
tion frame is made up of several sections, each section controls one
function. The following functions are controlled by control valve, option
frame:
• Support jacks
• Sliding cab / Vertically adjustable cab
• Cab tilt

9 Frame, body, cab and accessories – 9.10.4.3 Control valve option frame 95
Valve slide, sliding cab

1 The valve slide controls the direction and speed of the sliding cab by
controlling hydraulic motor pressure, sliding cab.
6 2
The valve slide is controlled by servo valve front and servo valve rear.
5 3 Servo valve sliding cab forward

Servo valve sliding cab forward controls servo pressure to valve slide
4 sliding cab so that this controls oil pressure to hydraulic motor sliding
cab forward.
Servo valve sliding cab forward regulates electrically with the solenoid
valve sliding cab forward (Y6016), which is activated by Control unit,
section 8 Control system, group 8.4.11.2 SLIDING-CAB, menu 3.
Servo valve sliding cab backward

000624
Servo valve sliding cab backward controls servo pressure to valve

1. Load signal (LS) slide steering so that this controls oil pressure to hydraulic motor slid-
2. Pressure supply (P) ing cab forward.
3. Tank return (T1) Servo valve sliding cab backward regulates electrically with the sole-
4. Connection hydraulic motor (B) noid valve sliding cab backward (Y6017), which is activated by Control
5. Tank return (TP) unit, frame option (D797-O).
6. Connection hydraulic motor (A) The signal can be checked via the diagnostic menu. See

96 9 Frame, body, cab and accessories – 9.10.4.3 Control valve option frame

page
–
NOTE
section B Safety.
section B Safety.
1
NOTE
4
NOTE
NOTE
000624

1. Load signal (LS)
mixed up.
3. Tank return (T1) 7 Mark up the servo valves on the new control valve.
4. Connection hydraulic motor (B) 8 Fit the valve.
5. Tank return (TP)
6. Connection hydraulic motor (A)
marking.
the marking.
NOTE
position.

NOTE
CAUTION

010475

the engine.

CAUTION
product damage.

cavitation.

98 9 Frame, body, cab and accessories – 9.10.4.4 Shuttle valve option frame
CAUTION
Do not overfill!

9.10.4.4 Shuttle valve option frame

Shuttle valve, frame option, description
page
–

9 Frame, body, cab and accessories – 9.10.4.5 Valve block sliding cab 99
9.10.4.5 Valve block sliding cab

Valve block sliding cab, description
page
–
Valve block sliding cab is fitted on hydraulic motor sliding cab and pre-
vents the motor rotating when sliding cab is not activated.
9.10.4.6 Hydraulic motor sliding cab

Hydraulic motor sliding cab, description
page
–
1 2 3 4 5 6
The hydraulic motor is located at the front on the right side of the cab
chain. The hydraulic motor pulls the chain which in turn pulls the cab
001862
back and forth.
1. Sensor, damping (rear edge of cab on left side)

2. Indicator plate, damping
3. Chain, sliding cab
4. Hydraulic motor sliding cab
5. Control valve, sliding cab
Hydraulic motor, sliding cab, changing

page
–
NOTE
section B Safety.
2 Depressurise the hydraulic systems, See section B Safety.
3 Remove the protective cover.
4 Slacken the chain, loosen the chain tensioner and the adjusting
screw.
5 Disconnect the chain from its mounting.
6 Remove the hydraulic hoses from the motor.
7 Remove the ring gear.
8 Remove the hydraulic motor from its mounting.
1. Protective cover
9 Change the hydraulic motor.
2. Hydraulic motor
3. Chain tensioner

100 9 Frame, body, cab and accessories – 9.10.4.6 Hydraulic motor sliding cab
NOTE
CAUTION

010475

the engine.

CAUTION
Do not overfill!


9 Frame, body, cab and accessories – 9.10.4.7 Chain sliding cab 101
9.10.4.7 Chain sliding cab

Chain sliding cab, description
page
–
1 2 3 4 5 6
The chain pulls the cab back and forth and is secured in the front and
rear edges on the cab undercarriage. The chain tension is adjusted by
moving the hydraulic motor for sliding cab.
001862
1. Sensor, damping (rear edge of cab on left side)

3. Chain, sliding cab
5. Control valve, sliding cab
Chain and chain wheel, sliding cab, changing

page
–

2 Slacken the chain, loosen the chain tensioner and the adjusting
screw.
3 Disconnect the chain at the front edge.
4 Disconnect the chain at the rear edge.
5 Change chain.
7 Adjust the chain with the adjusting screw.
8 Tighten the chain tensioner.
9.10.4.8 Sensor damping, end-position

Sensor damping end-position, description
page
–
Sensor end-position damping indicates when the cab is near the end-
position and is used to activate end-position damping.

page
–

102 9 Frame, body, cab and accessories – 9.10.5 Vertically adjustable cab
9.10.5 Vertically adjustable cab

Vertically adjustable cab, function description
page
–

Doors Closed. Doors, description page 89.
If the door is open with the cab lifted, the lift and lower
functions for the boom are limited.
2
D1
D2
1
3, 16, 22 D15
D790-1
D797-O D13 15
4, 14, 17
D4 D17
10
5 18
12, 21
11, 20 13
P1 A
LS B
TP
7
T1 T3
6, 9, 19
8
013033

1 Switch vertically adjustable cab U = 24 V Controls and instruments, overview page 5
(S177) sends a voltage signal to D1: Diagnostic menu, see section 8 Control sys-
Control unit, cab (D790-1). tem, group 8.4.11.2 SLIDING CAB, menu 1
2 Contact closed door, sends signal U = 24 V Doors, description page 89

to Control unit cab (D790-1) when D2: Diagnostic menu, see section 8 Control sys-
door is closed. tem, group 8.4.11.2 SLIDING CAB, menu 1
3 The cab control unit (D790-1) sends Checked by control sys- Section 11 Common electrics,
"cab up" or "cab down" on the tem, error shown with er- group 11.5.3.1 Control unit, cab
CAN bus. ror code.

9 Frame, body, cab and accessories – 9.10.5 Vertically adjustable cab 103

4 Control unit, frame option (D797-O) I = 435–650 mA Section 11 Common electrics,
supplies voltage to Servo valve group 11.5.3.4 Control unit frame option
raise cab (Y6016) or servo lower D4: Diagnostic menu, see section 8 Control
valve cab (Y6017) on Control valve, system, group 8.4.11.2 SLIDING CAB,
option frame. menu 3 and 4
5 Servo valve, raise cab (Y6016) or - Control valve, option frame, description
servo valve, lower cab (Y6017) page 105
pressurises the sliding cab slide in D4: Diagnostic menu, see section 8 Control
Control valve, option frame. system, group 8.4.11.2 SLIDING CAB,
menu 3 and 4
6 Control valve option frame sends a - Control valve, option frame, description
control signal to Shuttle valve page 105
option.
7 The shuttle valve sends the strong- - Shuttle valve, frame option, description page 98
est control signal to main pumps if
several functions are activated at
the same time.
8 The main pumps pump oil from the See the pressure plate on Section 10 Common hydraulics, group 10.4.2
tank. the left-hand frame beam. Axial piston pump with variable displacement
9 Control valve, option frame pressu- - Control valve, option frame, description
rises the accumulator and the load page 105
control valve.
10 The accumulator stores pressure. - Accumulator, vertically adjustable cab, descrip-

tion page 106
11 The load control valve lets the pres- - Load control valve, description page 106
sure through to hydraulic cylinder
for vertically adjustable cab.
When lowering, the load control
valve changes position and restricts
flow from hydraulic cylinder for ver-
tically adjustable cab.
12 Hydraulic cylinder for vertically ad- - Hydraulic cylinder, vertically adjustable cab, de-
justable cab lifts or lowers the cab. scription page 107
13 Sensor lowered cab (B777-2) stops U = 24 V Sensor, lowered cab, description page 111
sending a voltage signal to Control D13: Diagnostic menu, see section 8 Control
unit, frame option (D797-O) when system, group 8.4.11.2 SLIDING CAB, menu 2
the cab leaves the lowest position.
14 Control unit, frame option (D797-O) Checked by control sys- Section 11 Common electrics,
sends "cab up" on the CAN bus. tem, error shown with er- group 11.5.3.4 Control unit frame option
ror code.
15 Sensor end-position damping U = 24 V Sensor damping end-position, description

(B769-2) sends a voltage signal to page 112
the cab control unit (D790-1) when D15: Diagnostic menu, see section 8 Control
cab is close to the end-position. system, group 8.4.11.2 SLIDING CAB, menu 2

104 9 Frame, body, cab and accessories – 9.10.5.1 Hydraulic oil pump

16 Control unit, cab (D790-1) sends Checked by control sys- Section 11 Common electrics,
"cab lift" on the CAN-bus. tem, error shown with er- group 11.5.3.1 Control unit, cab
ror code.
17 Control unit, frame option (D797-O) - Section 11 Common electrics,

reduces the control current to servo group 11.5.3.4 Control unit frame option
valve raise cab (Y6016) or servo D17: Diagnostic menu, see section 8 Control
lower valve cab (Y6017) in control system, group 8.4.11.2 SLIDING CAB,
valve, option frame. menu 3 and 4
18 Servo valve, raise cab (Y6016) or - Control valve, option frame, description
servo valve, lower cab (Y6017) con- page 105
trols the pressure to the sliding cab D17: Diagnostic menu, see section 8 Control
slide in control valve, option frame. system, group 8.4.11.2 SLIDING CAB,
menu 3 and 4
19 Control valve, option frame reduces - Control valve, option frame, description
hydraulic pressure to valve block page 105
vertically adjustable cab.
20 Valve block lift cylinder for vertically - Load control valve, description page 106
adjustable cab lets pressure
through to hydraulic cylinder for ver-
tically adjustable cab.
21 Hydraulic cylinder for vertically ad- - Hydraulic cylinder, vertically adjustable cab, de-
justable cab reduces the speed of scription page 107
raising or lowering the cab.
22 When the cab is lifted the cab con- Max. speed: 5 km/h. Section 11 Common electrics,
trol unit (D790-1) activates speed group 11.5.3.1 Control unit, cab
limitation.
Hydraulic diagram cab lift and support jacks

Hydraulic oil pump, description
page
–
The hydraulic sliding cab is pressurised from hydraulic oil pump 1 and
2, see section 10 Common hydraulics group 10.4.2 Axial piston pump


page
–
1
The vertically adjustable cab is controlled by a separate section in con-
trol valve, option frame, for details see Control valve, option frame, de-
6 2
scription page 94.
5 3 Valve slide raise/lower cab

The valve slide controls the direction and speed of raising and lower-
4 ing the cab by controlling the hydraulic pressure for hydraulic cylinder,
vertically adjustable cab.
The valve slide is controlled by servo valve raise cab and servo valve
lower cab.
Servo valve raise cab

Servo valve raise cab controls servo pressure to valve slide raise/low-
er cab so that this controls oil pressure to hydraulic cylinder, vertically
adjustable cab, for raising the cab.
000624
Servo valve raise cab regulates electrically with the solenoid valve
1. Load signal (LS) raise cab (Y6016), which is activated by Control unit, frame option
2. Pressure supply (P) (D797-O).
3. Tank return (T1) The signal can be checked via the diagnostic menu. See
4. Connection, hydraulic cylinder (B) section 8 Control system, group 8.4.11.2 SLIDING-CAB, menu 3.
5. Tank return (TP)
6. Connection, hydraulic cylinder (A) Servo valve lower cab
Servo valve lower cab controls servo pressure to valve slide raise/low-
er cab so that this drains hydraulic cylinder, vertically adjustable cab,
for lowering the cab.
Servo valve lower cab is controlled electrically with the solenoid valve
raise cab (Y6017), which is activated by Control unit, frame option
(D797-O).
Servo valve lower cab can be checked via the diagnostic menu. See

page
–
See Control valve, option frame, changing page 96.
9.10.5.3 Shuttle valve option frame

Shuttle valve, frame option, description
page
–

106 9 Frame, body, cab and accessories – 9.10.5.4 Accumulator, vertically adjustable cab
9.10.5.4 Accumulator, vertically adjustable cab

Accumulator, vertically adjustable cab, description
page
–
The accumulator stores pressure so that the cab does not lower if the
engine stops and the machine becomes depressurised.
9.10.5.5 Load control valve

Load control valve, description
page
–
The load control valve reduces the speed when lowering the cab.
When the pressure is released behind the valve, the valve slide chang-
es position and restricts the channel through the valve.
000621

9 Frame, body, cab and accessories – 9.10.5.6 Hydraulic cylinder vertically adjustable cab 107
9.10.5.6 Hydraulic cylinder vertically

adjustable cab
Hydraulic cylinder, vertically adjustable cab, description
page
–
1 2 3
The hydraulic cylinder lifts the inner mast and thus the cab.
4
001873

4. Safety lock
Hydraulic cylinder, vertically adjustable cab, changing

page
–
NOTE
section B Safety.
1 Raise the cab so high to secure its position with both lock lugs
(position A).
Lower the cab so that it rests on the safety brackets.
CAUTION
When working under a raised cab.
A Extreme danger!
Secure the cab with the lock lugs (position A) on both

001977
sides of the cab frame.

A. Lock lug

3 Depressurise the brake and hydraulic system, see
section B Safety.
4 Mark up and disconnect the hydraulic hoses from the extension
cylinder.

108 9 Frame, body, cab and accessories – 9.10.5.6 Hydraulic cylinder vertically adjustable cab
NOTE
5 Disconnect the upper cylinder mounting (position 1) from the
moving part of the cab frame.
3 008206
1. Upper mounting hydraulic cylinder

2. Retaining bracket hydraulic cylinder
6 Remove the load control valve and compress the hydraulic
cylinder.
NOTE
7 Connect lifting equipment to the hydraulic cylinder.
8 Remove the hydraulic cylinder’s retaining brackets from the fixed
part of the cab frame.
9 Tilt and lift out the hydraulic cylinder upward.
10 Transfer parts to the new hydraulic cylinder.
11 Install the hydraulic cylinder in reverse order.
000621
Load control valve

9 Frame, body, cab and accessories – 9.10.5.6 Hydraulic cylinder vertically adjustable cab 109
NOTE
CAUTION

010475

the engine.
CAUTION
Do not overfill!


page
–

110 9 Frame, body, cab and accessories – 9.10.5.7 Mast, vertically adjustable cab
9.10.5.7 Mast, vertically adjustable cab

Mast, vertically adjustable cab, description
page
–
1 2 3
The mast holds the cab secure and enables raising and lowering.
4
001873

4. Safety lock

9 Frame, body, cab and accessories – 9.10.5.8 Sensor, lowered cab 111
9.10.5.8 Sensor, lowered cab

Sensor, lowered cab, description
page
–
The sensor indicates when the cab is completely lowered. When the
cab is raised, the machine’s speed is reduced and the transmission is
1 blocked in second gear.
2
000618
1. Sensor, end-position damping

2. Sensor, end-position lowered cab

page
–

112 9 Frame, body, cab and accessories – 9.10.5.9 Sensor damping, end-position
9.10.5.9 Sensor damping, end-position

Sensor damping end-position, description
page
–
Sensor damping end-position indicates when the cab is close to end

position. This is used to activate end-position damping. When the cab
1 is raised, the machine’s speed is reduced and the transmission is
blocked in second gear.
2
000618
1. Sensor, end-position damping

2. Sensor, end-position lowered cab

page
–

9 Frame, body, cab and accessories – 9.10.5.10 Emergency lowering valve 113
9.10.5.10 Emergency lowering valve

Emergency lowering valve, description
page
–
The emergency lowering valve (position A) opens a connection be-

tween the hydraulic cylinder’s piston side and tank, and makes it
possible to lower the cab if the machine becomes depressurised or
de-energised.
001978
A. Position, emergency lowering valve
9.10.5.11 Safety lock, vertically adjustable cab

Safety lock, vertically adjustable cab, description
page
–
There are two lock lugs on the mast, which are used to secure the cab
in the raised position during maintenance work with raised cab.
A
001977
A. Lock lug

114 9 Frame, body, cab and accessories – 9.10.5.12 Door catch
9.10.5.12 Door catch

Door catch, description
page
–
The mechanical catch prevents the operator from opening the left door
A
accidentally when the cab is raised. The catch releases the operator’s
door when the cab is lowered to its lowest position.
014270
A. Lock lug

9 Frame, body, cab and accessories – 9.11 Cab interior 115
9.11 Cab interior

9.11.1 Instrument and control panels
Steering wheel panel, description
page
–
The steering wheel panel is secured to the steering column and con-
tains warning and indicator lights, display (KID), function keys (KIT)
and switches.
Left-hand dashboard panel, description

page
–
The left instrument panel is located in the left corner of the cab. It con-
tains rotary controls, switches, and ventilation.
Panel for load handling functions, description

page
–
The panel is mounted on the operator’s seat. The panel includes

switches for load handling functions and safety switches to interrupt
ongoing load handling functions. The control lever is located next to
the panel.
Steering wheel panel, replacement

page
–

2 Remove the steering wheel centre cover.
3 Remove the nut and the steering wheel.
4 Remove the bolts on the underside of the steering wheel panel.

116 9 Frame, body, cab and accessories – 9.11.2 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
page
–
The interior of the cab consists of recyclable material.
9.11.3 Interior fittings, textile

Interior fittings, textile, description
page
–
The interior of the cab consists of recyclable material.
9.11.4 Floor covering

Floor covering, description
page
–
The floor covering is a wear-resistant and recyclable material.
9.11.5 Insulation
Insulation, description
page
–
The cab insulation consists of recyclable material.

9 Frame, body, cab and accessories – 9.11.6 Sun visors 117
9.11.6 Sun visors

Sun visors, description
page
–
Sun visors can be specified for the front window (windshield) and the
roof window.
1. Sun visor, front windshield: Can be raised and lowered using a
cord on the right side. Stops in selected position.
2. Sun visor, roof window: Extends forward to fasten in two hooks in
the front edge of the window.
9.11.7 Terminal console

Terminal console, description
page
–
The function of terminal desk is to provide a work surface for a com-

puter/terminal. It is located to the right of the steering wheel, easily ac-
cessible for the operator.
008227
9.11.8 Writing desk

Writing desk, description
page
–
The writing table with reading light is located on a flexible attachment

to the right in front of the door in the cab. That is where work orders,
etc. can be fastened.
008228

118 9 Frame, body, cab and accessories – 9.12 Chassis
9.12 Chassis
Chassis, description
page
–
The frame is a modular construction and consists of front section, rear

section, and a member pair. This construction provides advantages in
terms of rigidity and strength.
There are mounting points in the frame for engine, transmission, drive
axle, steering axle, fuel and hydraulic tanks, cab, boom, and body
parts.
The space in the rear section of the frame is used for counterweights,
the number of which is adapted to the machine in question. The coun-
terweights are designed to allow as good visibility as possible to
the rear.
The front wings are bolted into the frame (which has advantages when
delivering the machine).
4
6 7 8
3 2
001511
1
1. Frame’s front section with drive axle mounting

2. Cab mounting (4 points)
3. Steering axle mounting
4. Frame’s rear section with counterweights
5. Boom mounting
6. Engine compartment with mountings for engine and transmission
7. Beam pair
8. Bracket for front wings

9 Frame, body, cab and accessories – 9.13 Body structure 119
9.13 Body structure

Body structure, description
page
–
The body structure’s components comprise:
3
2 1
002213
1. Wings
2. Hood engine compartment
3. Counterweight
9.13.1 Wings
Wings, description
page
–
There are fenders over the wheels to protect from dirt thrown up by the
wheels during operation. The design of the counterweight (see Coun-
terweights, description page 120) acts as a mudguard for the rear
wheels.
The fenders can be equipped with extra mudguards when the ma-
chine’s work environment requires such ( ).
9.13.2 Hood engine compartment

Hood engine compartment, description
page
–
The machine’s engine compartment is protected by tread plates which

function as an engine hood. The tread plates are divided into five sec-
tions and are secured with attaching bolts. The tread plates are de-
signed to be walked on and are ribbed to provide sure footing.

120 9 Frame, body, cab and accessories – 9.13.3 Footsteps and hand rail
9.13.3 Footsteps and hand rail

Footsteps and hand rail, description
page
–
The cab has footsteps and handrail for easy access.
Railing is also available on the front fenders ( ).
9.13.4 Counterweights
Counterweights, description
page
–
The machine has counterweights to balance the machine’s lift capac-

ity and these may therefore vary in quantity and weight.
The counterweights are located at the very back of the frame for max-
imal leverage.
The machine has counterweights in the following 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 counter-
weights whose dimensions and quantity are adapted to balance
the machine’s lifting capacity.
DANGER
The counterweights are factory fitted and are adapted
according to the machine’s properties.
The machine’s operating characteristics are

changed!
Never change the quantity of counterweights.

9 Frame, body, cab and accessories – 9.14 Central lubrication 121
9.14 Central lubrication

Central lubrication, checking
page
–
1 Check that no grease has been forced out through the safety
valve (position 2).
If grease has been forced out through the safety valve it means
that there is a stop in the system. Determine which line is clogged
by feeling the connections at the distribution blocks. A clogged
hose remains pressurised and the connection becomes hard.
NOTE
If several distribution blocks are connected in series, a
clogged line will be pressurised all the way to the first distri-
bution block.
2 Turn the start key to position I.
3 Operate the pump manually and check that the indicator pin
moves in and out on the distribution blocks.
To operate the pump, loosen the cover and press in the switch for
manual operation (position 5).
If the indicator pins do not move even when the pump is running,
Overview central lubrication pump unit and distribution
troubleshoot the pump unit.
block. Example image.
1. Grease nipple, filling of grease
2. Safety valve
NOTE
3. Grease nipple, manual system lubrication The system can be lubricated manually through the grease
4. Indicator pin nipple on the distribution block (position 3).
5. Switch, manual operation 4 Fill grease in the pump unit through the filler nipple, see

122 9 Frame, body, cab and accessories – 9.14 Central lubrication
Central lubrication, adjusting lubrication times

page
–
The central lubrication’s pause and run time must be set after replace-
ment, the setting is unique to each machine, depending on the ma-
chine’s equipment. When replacing, the new pump unit should be set
in the same way as the old.
If the machine does not grease correctly, pause and run time can be
adjusted. Primarily, run time should be adjusted so that all grease
points on the machine are greased every time. If large amounts of
grease are pressed out at all grease points, pause time can be
increased.
NOTE
Adjust only one step each time. Small adjustments make a big
difference.
Test or extra greasing

Central lubrication can be operated manually by holding in the button
for manual operation (position 3) for 2 seconds. This starts an extra lu-
brication cycle.
Pause time
Example figure
Pause time is the length of the interval between greasings. The inter-
1. Setting pause time (red)
val is adjusted in whole hours between 1 and 15 hours. Pause time is
2. Setting run time (blue)
adjusted with the red handle (position 1).
3. Manual operation of pump
Switch position 1 2 3 4 5 6 7 8 9 A B C D E F
Pause time [hours] 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Run-time
Run time is how long the pump is activated every time. Run time can
be adjusted between 2 and 30 minutes. Pause time is adjusted with
the blue handle (position 2).
Switch position 1 2 3 4 5 6 7 8 9 A B C D E F
Run-time [minutes] 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30

9 Frame, body, cab and accessories – 9.14.1 Pump unit 123
9.14.1 Pump unit

Pump unit, description
page
–
The pump unit consists of containers with stirrer, pump housing with
built-in motor, timer, pump element, filler nipple, and safety valve.
The central lubrication works with lubrication cycles (pause and
running time as well as read-in time). In the pump there is a circuit
board with a timer with which one can set the pump motor’s run and
pause time.
When the central lubrication works, it greases the grease points one
at a time in series. If a stop should occur in a grease point, the pres-
sure will increase and the safety valve will release grease and also the
following grease points will not be greased.
NOTE
The safety valve will press out grease if a grease point cannot be
greased. If a grease point is not greased, none of the following
grease points will be greased. Therefore, it is very important to
check the safety valve.
Example figure components central lubrication

1. Pump unit
2. Safety valve
3. Distribution block

124 9 Frame, body, cab and accessories – 9.14.2 Distribution block
9.14.2 Distribution block

Distribution block, description
page
–
The distribution blocks distribute grease from the pump unit to grease
points or on to other distribution blocks. The number of distribution
blocks can vary depending on how may (and which) grease points
have been selected.
The distribution blocks consist of pistons that meter out grease to each
grease point. The pistons are driven by the grease and do not have
springs and gaskets. It is the grease that drives the pistons inside the
distributor. The shape of the pistons and channels in the distribution
block enable the pistons to move in a predetermined way. Each piston
must have completed its motion before the next piston can move. The
pistons are dependent on each other. It is technically impossible to
skip any connected grease point. If a grease point cannot be greased,
the whole system is blocked and grease is pressed out through the
safety valve.
The system’s first distribution block (i.e. the block closest to the pump)
has an indicator pin. If the pin moves forward and backward (in time
with the piston movements), this indicates that grease is pumped
Example figure components central lubrication through the system. If a distribution block is unable to supply grease
1. Pump unit to any of its lubrication points, the pin stops and accordingly the entire
2. Safety valve system.
3. Distribution block
If there is clogging in the system, that line will be pressurised, from the
pump to the stop, through all the distribution blocks on the way. This
makes it easy to find a block in the system. By feeling the distribution
blocks’ connections and feeling which connection is stiff, the blockage
can be traced. Keep in mind that several distribution blocks may be
connected in series.
9.14.3 Lines
Lines, description
page
–
Central lubrication works under very high pressure, only use lines that
meet the following specifications.
Main hose
Diameter 8.4 mm
Explosion pressure min. 60.0 MPa

9 Frame, body, cab and accessories – 9.15 Paint/coatings 125
9.15 Paint/coatings
Paint/coatings, description
page
–
The machine is painted with an alkyd-based mono-component paint

that is applied with a brush or a spray gun. For paint codes (RAL), see
machine card.
Check the machine frequently for stone chips, dents and paint scratch-
es, remedy immediately to prevent corrosion on the underlying metal.
Only use touch-up paint for small stone chips and scratches. Major
paint damage should be repaired by a paint workshop.
NOTE
Before touching up, the surfaces to be touched up must be thor-
oughly cleaned.
Please contact Cargotec for information about other surface treatment
and material colours.

126 9 Frame, body, cab and accessories – 9.15 Paint/coatings

10 Common hydraulics 1
Table of Contents 10 Common hydraulics

mm mm mm mm mm mm
10 Common hydraulics....................................................................................... 3
10.2 Safety valves .............................................................................................. 3
10.2.1 Accumulator drain valve ........................................................................ 3
10.2.2 Relief valve, attachment ........................................................................ 4
10.2.3 Pipes and hoses .................................................................................... 4
10.3 Tanks and accumulators ............................................................................ 5
10.3.1 Tank ....................................................................................................... 5
10.3.2 Pipes and hoses .................................................................................... 5
10.4 Pumps ........................................................................................................ 6
10.4.1 Gear pump with fixed displacement ....................................................... 6
10.4.2 Axial piston pump with variable displacement ..................................... 15
10.4.3 Pipes and hoses .................................................................................. 42
10.5 Hoses, pipes and valves .......................................................................... 43
10.5.1 Pipes and hoses .................................................................................. 43
10.5.2 Priority valve ........................................................................................ 44
10.5.3 Shuttle valve ........................................................................................ 44
10.5.4 Collection block, filtered returns ........................................................... 46
10.5.5 Collection block, unfiltered returns ....................................................... 46
10.6 Temperature control, cleaning and hydraulic oil ....................................... 47
10.6.1 Tank heater .......................................................................................... 48
10.6.2 Hydraulic oil cooler .............................................................................. 49
10.6.3 Cooling fan ........................................................................................... 51
10.6.4 Sensor hydraulic oil temperature ......................................................... 51
10.6.5 Bypass valve, cooler ............................................................................ 53
10.6.6 Breather filter hydraulic oil tank ........................................................... 54
10.6.7 Hydraulic oil filter ................................................................................. 55
10.6.8 Hydraulic oil ......................................................................................... 60
10.6.9 Fine filter hydraulic oil .......................................................................... 60
10.6.10 Pipes and hoses .................................................................................. 61
10.7 Other ........................................................................................................ 62
10.7.1 Hydraulic cylinders ............................................................................... 62

2 10 Common hydraulics

10 Common hydraulics 3
mm mm mm mm mm mm
10.2 Safety valves

10.2.1 Accumulator drain valve
Accumulator drain valve, description
page
–
The accumulator drain valve is located on the accumulator charging

valve. See section 4 Brakes, group 4.3.3 Accumulator charging valve.
000434

4 10 Common hydraulics – 10.2.2 Relief valve, attachment

page
–
The relief valve is located on the lift cylinder beam. See section 7 Load
handling, group 7.4.8 Attachment relief valve.
002269

Pipes and hoses, general
page
–
See Pipes and hoses, general page 43.

10 Common hydraulics – 10.3 Tanks and accumulators 5
10.3 Tanks and accumulators

10.3.1 Tank
Tank, description
page
–
The hydraulic oil tank forms part of the side panel on the right side of
1 2 1 3 4
the machine. The oil filters for the working hydraulics are located in-
side the tank. These are accessible through hatches on top of the tank.
Hydraulic oil is filled directly into the tank through the filler caps on the
filter manhole covers. For oil capacity and grade, see section F Tech-
nical data. The entire filter unit can be removed to facilitate access for
cleaning. There is a drain plug at the bottom of the tank.
The tank 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
5 5
hydraulic cylinders are in the bottom position.
001457
1. Hydraulic oil filler plug

2. Cover for hydraulic oil filter
3. Sight glass hydraulic oil
4. Breather filter hydraulic oil tank
5. Drain plugs hydraulic oil

page
–

6 10 Common hydraulics – 10.4 Pumps
10.4 Pumps
10.4.1 Gear pump with fixed displacement
Gear pump with fixed displacement, description
page
–
There are two gear pumps with fixed displacement. One supplies the
brake system with pressure, see section 4 Brakes, group 4.3.1 Oil
pump brake oil. The other gear pump circulates hydraulic oil for work-
ing hydraulics through the cooler and filter.
The gear pump pumps oil using two gears wheels that rotate opposite
each other. One is driven by the pump’s input shaft and the other ro-
tates freely. The gear pump’s flow is directly dependent on the speed
of the input shaft.
The cooing pump is located on the right main pump and is driven by
the main pump’s shaft from the transmission’s power take-off. Pump
1 speed is directly dependent on engine speed. Pump flow increases as
the engine speed increases.
2
000006
The illustration shows hydraulic oil pump alternative

Dana/Rexroth
1. Oil pump brake system
1
013342
The illustration shows hydraulic oil pump alternative

ZF/Rexroth
1. Oil pump brake system

10 Common hydraulics – 10.4.1 Gear pump with fixed displacement 7
Gear pump, changing (Dana/Rexroth)

page
–
NOTE
section B Safety.
section B Safety.
3 Mark up and disconnect the hydraulic hoses from the gear pump.
4 Remove the gear pump.

Remove the attaching bolts, pull the pump backward and lift
it away.
5 Transfer the connection adapters to the new gear pump.
6 Remove the spacer ring from the gear pump or axial piston pump.
the gear pump, see section F Technical data.
NOTE
Only use silicone on the side facing the gear pump.

8 10 Common hydraulics – 10.4.1 Gear pump with fixed displacement
8 Install the spacer ring on the axial piston pump.
9 Brush sealing silicone on the gear pump’s sealing against the

10 Install the gear pump on the axial piston pump.
Install the pump and check that the gear engages in the shaft and
that the spacer ring is installed directly against the gear pump. In-
stall the pump’s attaching bolts.
11 Connect the hydraulic hoses to the gear pump.
NOTE

CAUTION
010475
the engine.
14 Turn on the system voltage and start the engine.

15 Check that hose connections and seal between gear pump and
axial piston pump are sealed tightly.
16 Check the oil level in the brake or hydraulic system, depending
on which pump has been replaced, fill if necessary.
CAUTION
Do not overfill!

NOTE
and filters in the brake system as well.
17 If oil pump brake oil has been changed:
Check the brake pressure; see section 4 Brakes, group 4.3.1 Oil
pump brake oil.
Gear pump with fixed displacement, changing

page
–
NOTE
section B Safety.
2 Depressurise the brake and hydraulic systems, see Workshop
manual section B Safety.

NOTE
it away.
Workshop manual section F Technical data.

NOTE
position.
9 Close the drain valve and tighten the lock ring on the accumulator
charging valve.
CAUTION

010475

the engine.

13 If oil pump brake oil has been changed:
Check the brake pressure; see section 4 Brakes, group 4.3.1 Oil
pump brake oil.

14 Check the oil level in the brake or hydraulic system, depending

on which pump has been replaced, fill if necessary.
CAUTION
Do not overfill!

NOTE
Gear pump with fixed displacement, changing

page
–
(ZF/Rexroth)
NOTE
section B Safety.
section B Safety.
1
NOTE
014322

it away.
014349
014367
NOTE
position.
014348

9 Close the drain valve and tighten the lock ring on the accumulator
charging valve.
CAUTION

010475

the engine.

13 Check the oil level in the hydraulic system, fill if necessary.
CAUTION
Do not overfill!

NOTE

10 Common hydraulics – 10.4.2 Axial piston pump with variable displacement 15
10.4.2 Axial piston pump with variable

displacement
Axial piston pump with variable displacement,
page
–
The hydraulic oil pumps are of the type variable axial piston pump, and
1 2 3 4 5 6
are controlled by load signals depending on the flow demand from
each function.
The hydraulic oil pumps are assembled in pairs with an inlet section
for the suction line. The inlet section leads oil to and from the pumps.
At the inlet section is a connection block containing pressure check
connections for checking pump pressure. On the connection block are
non-return valves that prevent the oil being pumped around between
the pumps instead of out into the hydraulic system.
10 One of the left pumps’ connection blocks also contains a branching
unit to the attachment hydraulics with a separate non-return valve.
8 7
000528
Hydraulic oil pump unit

1. Adjusting screw standby pressure front pump
2. Adjusting screw max. pressure front pump
3. Pressure check connection pump pressure rear
pump
4. Connection pressure side rear pump
5. Connection pressure side front pump
6. Pressure check connection pump pressure front
pump
7. Left hydraulic oil pump unit
8. Right hydraulic oil pump unit
9. Adjusting screw max. pressure rear pump
10. Adjusting screw standby pressure rear pump

16 10 Common hydraulics – 10.4.2 Axial piston pump with variable displacement

page
–
description (Dana/Sauer-Danfoss)
7 5
are controlled by load signals depending on the flow demand from
6 each function.
The left hydraulic oil pump (pump 2, position 2) supplies the control
valve for lift and extension and also supplies the attachment’s control
valve. At boom in pump 2 is disconnected.
The right hydraulic oil pump (pump 1, position 1) supplies the control
system as well as the control valve for lift and extension. The priority
3
4 valve ensures that there is always pressure to the control system, the
3 4 residual flow is led to the control valve for lift and extension.
There is a connection block on the pumps’ pressure side. On the con-
2 nection blocks there are non-return valves that prevent the oil being
pumped around between the pumps instead of out into the hydraulic
system.
1
On the right pump’s connection block is a branching unit to the attach-
ment hydraulics with a separate non-return valve. On the connection
block there is also a pressure check connection for checking pump
pressure.
On the left pump’s connection block is a branching unit to pressure re-
duction. On this branching unit there is also a pressure check connec-
tion for this pump.
011055
Hydraulic oil pump unit Dana/Sauer-Danfoss

1. Right hydraulic oil pump
2. Left hydraulic oil pump
3. Adjusting screw standby pressure pump
4. Adjusting screw max. pressure pump
5. Spacer block pressure side pump
6. Pressure check connection pump pressure left
pump
7. Pressure check connection pump pressure right
pump


page
–
description (ZF/Rexroth)
1 are controlled by load signals depending on the flow demand from
each function.
3
The left hydraulic oil pump (pump 2, position 2) supplies the control
4
valve for lift and extension and also supplies the attachment’s control
valve. At boom in pump 2 is disconnected.
The right hydraulic oil pump (pump 1, position 1) supplies the control
3 system as well as the control valve for lift and extension. The priority
valve ensures that there is always pressure to the control system, the
4 residual flow is led to the control valve for lift and extension.
There is a connection block on the pumps’ pressure side. On the con-
2 nection blocks there are non-return valves that prevent the oil being
pumped around between the pumps instead of out into the hydraulic
system.
On the right pump’s connection block is a branching unit to the attach-
ment hydraulics with a separate non-return valve. On the connection
block there is also a pressure check connection for checking pump
pressure.
On the left pump’s connection block is a branching unit to pressure re-
duction. On this branching unit there is also a pressure check connec-
tion for this pump.
013343
Hydraulic oil pump unit ZF/Rexroth

1. Right hydraulic oil pump
2. Left hydraulic oil pump
3. Adjusting screw standby pressure pump
4. Adjusting screw max. pressure pump


page
–
function description (Dana/Rexroth)
D790-1
1
D797-R 7, 16 12
P P
P1
LS D16 LS
P
2, 13 EF CF
LS 15
P
8
4, 17 5, 9 C15
C3 C14
C6 C10
No 1 No 2 No 3 No 4
11
006417
6 6, 10 3, 14 3, 14

1 The lift and extension control valve sends a See pressure plate Servo Section 7 Load handling, group 7.2 Lift-
load signal when a function is activated. pressure lift and exten- ing/lowering
sion on left frame
member.
2 Control signal goes to the shuttle valve that See pressure plate Servo Shuttle valve, description (hydraulic oil
sends the load signal on to hydraulic oil pressure lift and exten- pump alternative Dana/Rexroth) page 44
pump 3 and 4. sion on left frame
member.
3 Hydraulic oil pumps 3 and 4 increase the See pressure plate Max. Axial piston pump with variable displace-
flow. pressure hydraulic oil ment, description (Dana/Rexroth)
pumps on left frame page 15
member.
4 Solenoid valve, unloading main pump See pressure plate Servo Section 7 Load handling,
(Y6062) leads load signal on to hydraulic oil pressure lift and exten- group 7.3.9 Valve block pump unloading
pump 1 and the shuttle valve (position 5). sion on left frame
member.
5 The shuttle valve sends load signal on to See pressure plate Servo Shuttle valve, description (hydraulic oil
hydraulic oil pump 2. pressure lift and exten- pump alternative Dana/Rexroth) page 44
sion on left frame
member.
6 Hydraulic oil pumps 1 and 2 increase See pressure plate Max. Axial piston pump with variable displace-
the flow. pressure hydraulic oil ment, description (Dana/Rexroth)
member.


7 If any attachment function is activated then U = 24 V Section 11 Common electrics,
Control unit, frame rear (D797-R) activates group 11.5.3.3 Control unit frame rear
Solenoid valve, top hydraulics (Y6003). Diagnostic menu, see section 8 Control
system, group 8.4.5.6 HYD, menu 6.
8 The solenoid valve, top lift hydraulics - Section 7 Load handling, group 7.4.2
(Y6003) directs an unloaded constant pres- Valve block, top lift hydraulics
sure to hydraulic oil pump 2, this functions
as a load signal.
9 The shuttle valve sends load signal on to - Shuttle valve, description (hydraulic oil
hydraulic oil pump 2. pump alternative Dana/Rexroth) page 44
10 Hydraulic oil pump 2 increases the flow. See pressure plate Max. Axial piston pump with variable displace-
pressure hydraulic oil ment, description (Dana/Rexroth)
member.
11 When solenoid valve, top hydraulics - Section 7 Load handling, group 7.4.2
(Y6003) is not activated, the unloaded Valve block, top lift hydraulics
pressure is directed to tank.
12 The steering valve sends a load signal - Section 5 Steering, group 5.2.3 Steering
when the steering wheel is turned. valve.
13 The shuttle valve sends load signal on to - Shuttle valve, description (hydraulic oil
hydraulic oil pump 3 and 4. pump alternative Dana/Rexroth) page 44
14 Hydraulic oil pumps 3 and 4 increase See the pressure plate, Axial piston pump with variable displace-
the flow. Steering pressure, on the ment, description (Dana/Rexroth)
left frame member. page 15
15 The priority valve controls the pressure See the pressure plate, Section 5 Steering, group 5.2.2 Priority
from the pumps to the steering valve. Steering pressure, on the valve.
left frame member.
16 For boom in Control unit, frame rear U = 24 V Section 11 Common electrics,

(D797-R) activates Solenoid valve, pump group 11.5.3.3 Control unit frame rear
unloading (Y6062). Diagnostic menu, see section 8 Control
system , group 8.4.8.2 BOOM, menu 2
17 Solenoid valve pump unloading (Y6062) - Section 7 Load handling, group 7.3.9
leads the pressure from the control valve Valve block pump unloading
to tank.


page
–
function description (Dana/Sauer-Danfoss + ZF/

Rexroth)
D790-1
1 12
D797-R
P P
7, 16
LS
P1
LS
D7 D7 P
2, 13 EF CF
LS 15
P
4, 17 5, 9 C15
C6 C6
8, 11, 18
6, 10 3, 14
No 1 No 2
011051
1 The lift and extension control valve See pressure plate Servo Section 7 Load handling, group 7.2 Lifting/
sends a load signal when a function is pressure lift and exten- lowering
activated. sion on left frame
member.
2 Control signal goes to the shuttle valve See pressure plate Servo Shuttle valve, description (hydraulic oil pump
that sends the load signal on to hydrau- pressure lift and exten- alternative Dana/Rexroth) page 44
lic oil pump 2. sion on left frame
member.
pressure hydraulic oil ment, description (Dana/Sauer-Danfoss)
member.
4 Solenoid valve, unloading main pump See pressure plate Servo Section 7 Load handling, group 7.3.9 Valve
(Y6062) leads load signal on to hydrau- pressure lift and exten- block pump unloading
lic oil pump 1 and the shuttle valve sion on left frame
(position 5). member.
5 The shuttle valve sends load signal on to See pressure plate Servo Shuttle valve, description (hydraulic oil pump
hydraulic oil pump 1. pressure lift and exten- alternative Dana/Rexroth) page 44
sion on left frame
member.


pressure hydraulic oil ment, description (Dana/Rexroth) page 15
pumps on left frame
member.
7 If any attachment function is activated U = 24 V Section 11 Common electrics,

then Control unit, frame rear (D797-R) group 11.5.3.3 Control unit frame rear
activates Solenoid valve, top hydraulics Diagnostic menu, see section 8 Control sys-
(Y6003). tem, group 8.4.5.6 HYD, menu 6.
8 The solenoid valve, top lift hydraulics - Section 7 Load handling, group 7.4.2 Valve
(Y6003) directs an unloaded constant block, top lift hydraulics
pressure to hydraulic oil pump 1, this
functions as a load signal.
9 The shuttle valve sends load signal on to - Shuttle valve, description (hydraulic oil pump
hydraulic oil pump 1. alternative Dana/Rexroth) page 44
pressure hydraulic oil ment, description (Dana/Rexroth) page 15
pumps on left frame
member.
11 When solenoid valve, top hydraulics - Section 7 Load handling, group 7.4.2 Valve
(Y6003) is not activated, the unloaded block, top lift hydraulics
12 The steering valve sends a load signal - Section 5 Steering, group 5.2.3 Steering
when the steering wheel is turned. valve.
13 The shuttle valve sends load signal on to - Shuttle valve, description (hydraulic oil pump
hydraulic oil pump 2. alternative Dana/Rexroth) page 44
14 Hydraulic oil pump 2 increases the flow. See the pressure plate, Axial piston pump with variable displace-
Steering pressure, on the ment, description (Dana/Rexroth) page 15
left frame member.
15 The priority valve controls the pressure See the pressure plate, Section 5 Steering, group 5.2.2 Priority
from the pumps to the steering valve. Steering pressure, on the valve.
left frame member.
16 For boom in Control unit, frame rear U = 24 V Section 11 Common electrics, group
(D797-R) activates Solenoid valve, 11.5.3.3 Control unit frame rear
pump unloading (Y6062). Diagnostic menu, see section 8 Control sys-
tem, group 8.4.8.2 BOOM, menu 2
17 Solenoid valve pump unloading (Y6062) - Section 7 Load handling, group 7.3.9 Valve
leads the pressure from the control block pump unloading
valve to Solenoid valve (Y6003).
18 When solenoid valve, top hydraulics - Section 7 Load handling, group 7.3.9 Valve
(Y6003) is not activated, the unloaded block pump unloading

Axial piston pump, checking (Dana/Rexroth)

page
–
NOTE
section B Safety.
es operating temperature, approx. 50 C.
2 Turn off engine.
3 Connect a pressure gauge to pressure check connection on hy-
draulic oil pump 1.
5 Check the standby pressure for one pump at a time in the follow-
ing order:
Hydraulic oil pump 1: 1.8 MPa
1. Hydraulic oil pump 1 The settings apply to standard machine, certain machines can
2. Hydraulic oil pump 2 have higher standby pressure. For correct standby pressure, see
3. Hydraulic oil pump 3 pressure plate. However, the difference in pressure between the
4. Hydraulic oil pump 4 different pumps must always be maintained.
6 Increase engine speed to approx. 1100 rpm and run the exten-
sion function against end-position (overflow).
Run out the boom to max. and continue to request max. exten-
sion with the control lever. This will cause overflow of the exten-
sion function.
7 Check the max. pressure on hydraulic oil pump 1, the pressure
should correspond with the value on the pressure plate.
MPa All pumps shall give the same pressure. The order between the
pumps is of no importance.
8 Turn off engine.
9 Transfer the pressure gauge to the next pump and repeat steps
MPa
MPa
3-8 on all four pumps.
MPa MPa MPa
MPa
MPa
MPa MPa
001028
920643.0024

Axial piston pump, checking (Dana/Sauer-Danfoss)

page
–
NOTE
section B Safety.
2 Turn off engine.
draulic oil pump 1.
ing order:
The settings apply to standard machine, certain machines can
1. Hydraulic oil pump 1 have higher standby pressure. For correct standby pressure, see
2. Hydraulic oil pump 2 pressure plate. However, the difference in pressure between the
different pumps must always be maintained.
sion function.
MPa Both pumps shall give the same pressure. The order between the
MPa
8 Turn off engine.

9 Transfer the pressure gauge to pump 2 and repeat steps 3-8.
MPa
MPa
A49195.0400

Axial piston pump, checking (ZF/Rexroth)

page
–
NOTE
section B Safety.
2 Turn off engine.
draulic oil pump 1.
ing order:
The settings apply to standard machine, certain machines can
have higher standby pressure. For correct standby pressure, see
pressure plate. However, the difference in pressure between the
different pumps must always be maintained.
sion function.
MPa Both pumps shall give the same pressure. The order between the
MPa
8 Turn off engine.

9 Transfer the pressure gauge to pump 2 and repeat steps 4-8.
MPa
MPa
011086
A49195.0400


page
–
changing (Dana/Rexroth)
NOTE
section B Safety.
1 Park the machine with the cab in the rearmost position and the
boom fully raised, and half extended.
CAUTION
Make sure that the oil level in the hydraulic oil tank is
below the opening of the axial piston pump’s suction
hose.
If there is not enough room to lift the boom, the hydraulic oil tank
must be drained, see Hydraulic oil, changing page 60.
2 Turn off the system voltage.
section B Safety.
4 Disconnect oil pump brae oil or cooling pump from the hydraulic
oil pump depending on the pump to be replaced.
5 Suspend the gear pump.
6 Use a plastic bag or similar to protect the connection to the gear
pump.
7 Mark up and disconnect the hydraulic hoses from the axial piston
pump.
NOTE

8 Connect lifting equipment to the axial piston pump.

9 Remove the axial piston pump.
Remove the attaching bolts and lift away the pump.
10 Clean the flange on the transmission, removing all silicone

remains.
CAUTION
Be careful and make sure that no gasket remains fall
down into the transmission.
Gasket remains may fall into the transmission and

cause product damage.
11 Transfer the connection adapters to the new axial piston pump.
NOTE
12 Brush sealing silicone on the axial piston pump flange facing the
transmission, see section F Technical data.
13 Install the axial piston pump.
Position the axial piston pump so that the pump shaft engages
the transmission’s gearing. Install the attaching bolts.
14 Connect the suction hose to the axial piston pump.

15 Fill the pump with oil through the connections on the top.
16 Connect the hydraulic hoses to the axial piston pump according

to the marking.
NOTE
17 If the spacer ring is still on the axial piston pump. Remove the
spacer ring between the gear pump and axial piston pump.
If the spacer ring remains in place on the gear pump, go to
step 20.
the gear pump, see section F Technical data.
NOTE
Only use silicone on one side, the side facing the brake
pump.
19 Install the spacer ring on the axial piston pump.

20 Brush sealing silicone on the gear pump’s sealing against the

The illustration shows a loose pump.

21 Install the gear pump.
Place the gear pump on the axial piston pump and install the at-
taching bolts. Be careful so that the O-ring on the spacer ring is
located correctly and that the gear pump’s shaft engages the ax-
ial piston pump’s output shaft.
22 Bleed the axial piston pump, see Axial piston pump with variable
displacement, bleeding (Dana/Rexroth) page 39.
CAUTION
Bleed the axial piston pump before starting the
engine.
The oil in the axial piston pump may cavitate and



CAUTION
010475
the engine.

26 Check that the hose connections and seal between the axial pis-
ton pump and gear pump seal tight.
27 Check the pump pressures, see Axial piston pump, checking
(Dana/Rexroth) page 22.
NOTE
and filter in the hydraulic system as well.
CAUTION
Do not overfill!
Leakage and environmental damage.



page
–
changing (Dana/Sauer-Danfoss)
NOTE
section B Safety.
CAUTION
hose.
section B Safety.
4 Disconnect oil pump brake oil or cooling pump from the oil pump
hydraulic oil depending on the pump to be replaced.
pump.
Axial piston pump 2 (left)

Axial piston pump 1 (right) 7 Mark up and disconnect the hydraulic hoses from the axial piston
pump.

NOTE
remains.
CAUTION

NOTE

Axial piston pump 1 (right)


Axial piston pump 1 (right) 16 Connect the hydraulic hoses to the axial piston pump according
to the marking.
NOTE
17 Brush sealing silicone onto the sealing face of the gear pump
against the spacer ring, see section F Technical data.
The illustration shows a loose pump.

Install the gear pump on the axial piston pump and install the at-
taching bolts. Be careful so that the gear pump’s shaft engages
the axial piston pump’s output shaft.
displacement, bleeding (Dana/Sauer-Danfoss) page 40.
CAUTION
engine.
The illustration shows the gear pump pre-assembled
on hydraulic oil pump 1 The oil in the axial piston pump may cavitate and


CAUTION

010475

the engine.

24 Check the pump pressures, see Axial piston pump, checking
(Dana/Sauer-Danfoss) page 23.
NOTE
CAUTION



page
–
changing (ZF/Rexroth)
NOTE
section B Safety.
CAUTION
hose.
section B Safety.
4 Disconnect oil pump brake oil or cooling pump from the oil pump
hydraulic oil depending on the pump to be replaced.
pump.
014347

014351
014355

7 Mark up and disconnect the hydraulic hoses from the axial piston
Axial piston pump 1 (right) pump.
NOTE
remains.
CAUTION
014354


NOTE
014357
014358
014359
014360

Axial piston pump 1 (right)

014351
014355

16 Connect the hydraulic hoses to the axial piston pump according
Axial piston pump 1 (right) to the marking.
NOTE
position.
17 Brush sealing silicone onto the sealing face of the gear pump
against the spacer ring, see section F Technical data.
NOTE
Only use silicone on the side facing the oil pump brake
system.
014361


Place the gear pump on the axial piston pump and install the at-
taching bolts.
Be careful so that the gear pump’s shaft engages the axial piston
pump’s output shaft.
displacement, bleeding (Dana/Sauer-Danfoss) page 40.
CAUTION
engine.
The oil in the axial piston pump may cavitate and

014347

The illustration shows the gear pump pre-assembled
on hydraulic oil pump 1

CAUTION

010475

the engine.

24 Check the pump pressures, see Axial piston pump, checking (ZF/
Rexroth) page 24.

NOTE
CAUTION
Do not overfill!


page
–
bleeding (Dana/Rexroth)
NOTE
section B Safety.

section B Safety.
3 Remove the hydraulic oil tank’s breather filter.
4 Connect compressed air at max. pressure max. 10 kPa to the hy-
draulic oil tank’s connection for breather filter.
5 Loosen the hoses to the hydraulic system’s feed from the axial
piston pump one at a time and let oil flow out. Tighten the connec-
tions when oil free of air flows out.
6 Remove the compressed air from the tank and install the breather
filter.
8 Let the engine idle for at least one minute. Check that all connec-
tions seal tight.
9 Lower the boom and raise it again very slowly so that the pump
operates under minimum load while air pockets are eliminated.
10 Turn off engine.
11 Wash the engine compartment.


page
–
bleeding (Dana/Sauer-Danfoss)
NOTE
section B Safety.

section B Safety.

Axial piston pump 1 (right) 5 Loosen the hoses to the hydraulic system’s feed from the axial
piston pump (1 or 2), one at a time and let oil flow out. Tighten the
connections when oil free of air flows out.
filter.
tions seal tight.
10 Turn off engine.


page
–
bleeding (ZF/Rexroth)
NOTE
section B Safety.

section B Safety.
014351
014355

5 Loosen the hoses to the hydraulic system’s feed from the axial
Axial piston pump 1 (right) piston pump (1 or 2), one at a time and let oil flow out. Tighten the
connections when oil free of air flows out.
filter.

42 10 Common hydraulics – 10.4.3 Pipes and hoses

tions seal tight.
10 Turn off engine.

page
–

10 Common hydraulics – 10.5 Hoses, pipes and valves 43
10.5 Hoses, pipes and valves

page
–
Hoses with ORFS-couplings are used almost exclusively. For maxi-

mum service life and function, the following should be observed when
replacing hoses.
1. To avoid stresses in the connection, there should be a length of
straight hose after the connection.
2. The hose must not be twisted. (A twist of 7% reduces service life
by 90%.)
3. Minimise the number of bends by using correct couplings.
4. Avoid sharp bends.
5. Keep the hoses clean internally. Leave the plugs in place as long
as possible when installing.
6. Check the position of the O-rings and tighten to the correct torque,
NOTE
Straight coupling requires a counterhold wrench to prevent
damage to the O-ring.
7. The O-rings must not be oiled when fitted.
Hose length
C/L
Hose length is measured on a laid-out hose between the sealing sur-
faces. On angled connections, measure from the sealing surface cen-
tre line [C/L] according to the figure.
Cleanliness
The function and service life of hydraulic components depend to a
great extent on how clean the hydraulic oil is. Therefore, it is very im-
portant to prevent dirt from entering the brake and hydraulic system.
Some simple advice to keep the hydraulic system clean.
• Always clean the area around a component before starting to
001015
work.
C/L line for measuring hose length • Plug hose connections immediately after disconnecting. If possi-
ble, use correct plugs for the connection type. If plugs are missing,
use clean plastic bags and cable ties or tape to seal the
connection.
• Never re-use oil that has been drained from the machine.
• If possible, filter the oil before pouring it into the machine. Oil bar-
rels often contain impurities.
When filling hydraulic oil, fill through the caps at the hydraulic oil
filters in the tank so that the oil is filtered.

44 10 Common hydraulics – 10.5.2 Priority valve
10.5.2 Priority valve

Priority valve, description
page
–
See section 5 Steering, group 5.2.2 Priority valve.
10.5.3 Shuttle valve

Shuttle valve, description (hydraulic oil pump
page
–
alternative Dana/Rexroth)
A shuttle valve chooses between two pressure signals and sends on
the strongest. The shuttle valves are used to sends load signals to the
hydraulic oil pumps. This means that the pumps are controlled by the
function that demands the highest pressure, if several functions are
1 activated at the same time.
Depending on options, there are between two and four shuttle valves.
2 The shuttle valves are located on a bracket for oil filling between the
engine and transmission.
3 The shuttle valves choose between the following control signals:
1. Chooses between the pressure signal from the control valve for
4
lift, lower and extension and the pressure signal from valve block
top lift hydraulics. The shuttle valve sends the pressure signal on
to hydraulic oil pump 4. See Axial piston pump with variable dis-
placement, description (Dana/Rexroth) page 15.
lift, lower and extension and the pressure signal from the steering
valve. The shuttle valve sends the pressure signal on to control
hydraulic oil pump 2. See Axial piston pump with variable dis-
002203
3.
1. Shuttle valve attachment Chooses between the pressure signal from shuttle valve steering
2. Shuttle valve control (position 2) and the pressure signal from the control valve option
frame. The shuttle valve sends the pressure signal on to hydraulic
3. Shuttle valve for mini-wheel or joystick control
oil pumps 3 and 4. See Axial piston pump with variable displace-
4. Shuttle valve option frame ment, description (Dana/Rexroth) page 15.
This shuttle valve is installed if the machine is equipped with joy-
stick control or mini-wheel.
4.
Chooses between the pressure signal from shuttle valve attach-
ment (position 1) and the pressure signal from the control valve
option frame. The shuttle valve sends the pressure signal on to
This shuttle valve is installed if the machine is equipped with sup-
port jacks, hydraulic sliding cab, or vertically adjustable cab.

10 Common hydraulics – 10.5.3 Shuttle valve 45
Shuttle valve, description (hydraulic oil pump

page
–
alternative Dana/Sauer-Danfoss +
ZF/Rexroth)
A shuttle valve chooses between two pressure signals and sends on
the strongest. The shuttle valves are used to sends load signals to the
hydraulic oil pumps. This means that the pumps are controlled by the
function that demands the highest pressure, if several functions are
1 activated at the same time.
Depending on options, there are between two and four shuttle valves.
2 The shuttle valves are located on a bracket for oil filling between the
engine and transmission.
3 The shuttle valves choose between the following pressure signals:
4
lift, lower and extension and the pressure signal from valve block
top lift hydraulics. The shuttle valve sends the pressure signal on
to main pump 1. See Axial piston pump with variable displace-
ment, description (Dana/Sauer-Danfoss) page 16.
lift, lower and extension and the pressure signal from the steering
valve. The shuttle valve sends the pressure signal on to control
placement, description (Dana/Sauer-Danfoss) page 16.
002203
3.
1. Shuttle valve attachment Chooses between the pressure signal from control valve option
2. Shuttle valve control frame and the pressure signal from the shuttle valve option frame
(position 4). The shuttle valve sends the pressure signal on to hy-
3. Shuttle valve for mini-wheel or joystick control
draulic oil pump 2. See Axial piston pump with variable displace-
4. Shuttle valve option frame ment, description (Dana/Sauer-Danfoss) page 16.
This shuttle valve is installed if the machine is equipped with joy-
stick control or mini-wheel.
4.
Chooses between the pressure signal from shuttle valve attach-
ment (position 1) and the pressure signal from the control valve
option frame. The shuttle valve sends the pressure signal on to
placement, description (Dana/Sauer-Danfoss) page 16.
This shuttle valve is installed if the machine is equipped with sup-
port jacks, hydraulic sliding cab, or vertically adjustable cab.

46 10 Common hydraulics – 10.5.4 Collection block, filtered returns
10.5.4 Collection block, filtered returns

Collection block, unfiltered returns, description
page
–
The block collects several return lines from different components and
1 2 leads these back to the tank through the tank filter.
The block is installed on top of the lifting beam in front of the
transmission.
003205
1. Collection block, unfiltered returns

2. Collection block, filtered returns
10.5.5 Collection block, unfiltered returns

Collection block, unfiltered return lines, description
page
–
The block collects several return lines from different valves and leads
1 2 these directly back to the tank.
The drain lines are very sensitive to back-pressure, if pressure builds
up in the drain lines the valves will not work properly.
The block is installed to the side of the lifting beam in front of the
transmission.
003205
1. Collection block, unfiltered returns

2. Collection block, filtered returns

10 Common hydraulics – 10.6 Temperature control, cleaning and hydraulic oil 47
10.6 Temperature control,

cleaning and hydraulic oil
Temperature control, cleaning and hydraulic oil,
page
–
The oil of the hydraulic system is cooled and cleaned by a separate
pump that circulates the oil through the cooler and filters. The cooler
˚C
has a temperature-controlled electric fan that prevents overheating.
9 ˚C
D795 Temperature control consists of a hydraulic oil tank, hydraulic oil
pump, valve block, hydraulic oil cooler, cooling fan, hydraulic oil filter,
D797-R fine filter, hydraulic oil temperature sensor, and bypass valve.
D3 4 D4 The hydraulic oil pump pumps oil (from the tank) which is cooled in the
hydraulic oil cooler and cleaned by the oil filters in the tank. Some of
5 M the oil is filtered by the fine filter. An electric cooling fan increases the
air flow through the cooler when the temperature needs to be lowered.
2
A bypass valve leads the hydraulic oil past the cooler directly to the
tank if the resistance through the cooler and filters is too high. The
8 temperature sensor controls fan activation and temperature display.
1 6
7
007414
˚C 3
Pos Description Signal value Reference

1 The hydraulic oil pump pumps oil from - Gear pump with fixed displacement, de-
the hydraulic oil tank. scription page 6
2 The hydraulic oil cooler cools the oil. - Hydraulic oil cooler, description page 49
3 Sensor, hydraulic oil temperature (B776) U = 0.5-4.5 V Sensor, hydraulic oil temperature, descrip-
sends a voltage signal proportional to the tion page 51
hydraulic oil temperature to Control unit, D3: Diagnostic menu, see section 8 Control
frame rear (D797-R). system, group 8.4.5.1 HYD, menu 1
4 Control unit, frame rear (D797-R) trans- Hydraulic fan active: Section 11 Common electrics, group
mits temperature on the CAN bus and U = 24 V 11.5.3.3 Control unit frame rear
supplies power to the cooling fan as D4: Diagnostic menu, see section 8 Control
necessary. system, group 8.4.5.1 HYD, menu 1
5 The cooling fan (M668) increases air flow - Cooling fan, description page 51
through the cooler.
6 The hydraulic oil filters clean the - Hydraulic oil filter, description page 55
hydraulic oil.
7 Some of the oil is pumped through the - Fine filter hydraulic oil, description page 60
hydraulic oil fine filter for deep cleaning.
8 If resistance through the oil cooler and - Bypass valve, cooler, description page 53
hydraulic oil filter becomes too high, the
cooler bypass valve opens and directs
the oil to the tank.

48 10 Common hydraulics – 10.6.1 Tank heater
Pos Description Signal value Reference

9 Control unit KID (D795) shows hydraulic Checked by control sys- Section 11 Common electrics,
oil temperature in the display. tem, error shown with group 11.5.3.12 Control unit, KID
error code.
10.6.1 Tank heater

Tank heater, safety
page
–
CAUTION
The tank heater is connected to high voltage. Connec-
tion and reconnection of the tank heater may only be
performed by personnel authorised for work with high
voltage.
Tank heater, description

page
–
The tank can be equipped with a heater. The tank heater is designed
for cold climates.
The tank heater runs on high voltage. Heater output is adapted
through different connections and adaptation to different operating
voltages - 110, 230 or 400 V AC. Higher voltage generates higher
heater output. The heater is mounted in a hole in the connection cover
at the bottom of the short side of the tank.
The tank heater can be equipped with a programmable thermostat
000430
which maintains the temperature at an even level. The thermostat is

installed directly onto the heating coil and can be adjusted with a knob
on the junction box. Recommended temperature setting is 20-30 C.

10 Common hydraulics – 10.6.2 Hydraulic oil cooler 49
10.6.2 Hydraulic oil cooler

Hydraulic oil cooler, description
page
–
The working hydraulics use a through-flow cooler with electric cooling

fan (the same type of cooler as used for the brake system). The oil is
cooled when it passes the cooler, which sits inside the side panel on
the right side behind the hydraulic oil tank.
001013
Hydraulic oil cooler, replacement

page
–
NOTE
section B Safety.

2 Drain the oil from the hydraulic oil tank, see Hydraulic oil, chang-
ing page 60.

50 10 Common hydraulics – 10.6.2 Hydraulic oil cooler
3 Mark up and disconnect hydraulic hoses from the cooler. Let the
oil in the cooler drain into the collection container.
NOTE
4 Disconnect the cable harness from the cooling fan.
5 Remove the attaching bolts and lift away the cooler.
6 Transfer the cooling fan to the new cooler.
7 Fit the cooler.
8 Connect the cable harness to the cooling fan.
9 Connect the hydraulic hoses to the cooler.
1. Cooling fan
2. Connector NOTE
3. Cooler Check that the O-rings are intact and installed correctly.
CAUTION
Do not overfill!
Leakage and environmental damage.


10 Common hydraulics – 10.6.3 Cooling fan 51
10.6.3 Cooling fan

Cooling fan, description
page
–
The electric cooling fan is pushing. The cooling fan is located at the
rear of the cooler. The fan draws air from the machine’s outside
through the cooler. Openings in the side cover allows air to pass
through the cooler.
The cooler is supplied voltage by the rear frame control unit (D797-R)
upon activation when the engine is running. The cooling fan is activat-
ed when temperature of the oil in the hydraulic oil tank is 65 C and is
deactivated when the temperature is 55 C.
section 8 Control system, group 8.4.5.1 HYD, menu 1.7
001014
10.6.4 Sensor hydraulic oil temperature

Sensor, hydraulic oil temperature, description
page
–
The hydraulic oil temperature sensor (B776) detects the temperature

of the hydraulic oil. The sensor is located on the hydraulic oil tank’s
rear short end.
The sensor detects the oil temperature in the tank, determining the ac-
cumulated heat in the hydraulic oil. This means that the cooling fan
may continue to run after the machine has been parked and turned off.
Sensor, hydraulic oil temperature (B776) is supplied with voltage by
and sends a voltage signal proportional to the oil temperature to Con-
trol unit, frame rear (D797-R).
001092

52 10 Common hydraulics – 10.6.4 Sensor hydraulic oil temperature
Sensor, hydraulic oil temperature, replacement

page
–
NOTE
section B Safety.

ing page 60.
3 Disconnect the cable harness from Sensor, hydraulic oil
temperature (B776).
4 Replace Sensor, hydraulic oil temperature (B776).
NOTE
position.
5 Connect the cable harness to the sensor.
008222
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 XXX TEMP indicates hydraulic oil temperature in C. Check that cor-
FAN XY rect temperature is shown.
000141
Diagnostic menu Hyd, menu 1

10 Common hydraulics – 10.6.5 Bypass valve, cooler 53
10.6.5 Bypass valve, cooler

Bypass valve, cooler, description
page
–
The bypass valve protects the cooler from overpressure. The valve
opens a passage past the cooler directly to the tank if resistance in the
cooler becomes too high.
007426
Bypass valve, cooler, replacement

page
–
NOTE
section B Safety.
IMPORTANT
Ensure cleanliness around the filter and filling point
when working on the hydraulic tank.
Dirt particles may cause machine damage.

2 Depressurising removed.
ing page 60.
4 Disconnect the bypass valve from the tank.
NOTE
Note how the bypass valve faces; the valve is marked with
an arrow.
5 Install the new bypass valve, turning the valve to face the same
way as the old. Use Loctite when installing the bypass valve.
007426
Bypass valve

54 10 Common hydraulics – 10.6.6 Breather filter hydraulic oil tank
CAUTION
Do not overfill!

10.6.6 Breather filter hydraulic oil tank

Breather filter hydraulic oil tank, description
page
–
A breather filter of insert type is mounted on the hydraulic oil tank to

protect the tank from impurities. On top of the filter housing is an indi-
cator that shows when the filter is clogged and should be changed.
001454

10 Common hydraulics – 10.6.7 Hydraulic oil filter 55
10.6.7 Hydraulic oil filter

Hydraulic oil filter, description
page
–
The oil in the hydraulic system is cleaned by two return filters located
inside the hydraulic oil tank. The oil is pumped through the cooler and
back through the filters by the cooling pump. Some of the return oil
from the load handling functions also passes through the filters.
001455
Hydraulic oil filter, description (high-pressure filter)

page
–
As an option the machine can be equipped with two additional high-

pressure filters that are installed directly after the axial piston pumps.
The filters are placed in front of the transmission under the lifting
beam. The filters are used in conjunction with the hydraulic oil filters in
the tank.
003602

56 10 Common hydraulics – 10.6.7 Hydraulic oil filter
Hydraulic oil filter, replacement

page
–
NOTE
section B Safety.
IMPORTANT
2 Remove the cover plates (position 1) over the hydraulic oil filters.
3 Lift up the filter unit and place it in the receptacle. Let the hydrau-
lic oil drain.
4 Part the filter unit and remove the filter insert. Handle the filter in-
sert as environmentally hazardous waste. Note the position of the
parts.
1. Cover for oil filter

2. Filling point hydraulic oil
3. Level glass hydraulic oil
5 Clean the filter holder’s parts. Be especially thorough with the
magnetic rod.
6 Install the new filters and assemble the filter units.
7 Install the filter units and the covers. Tighten the bolts crosswise.
Magnetic rod

CAUTION
Do not overfill!

Hydraulic oil filter (high-pressure filter), changing

page
–
NOTE
section B Safety.
IMPORTANT

section B Safety.

58 10 Common hydraulics – 10.6.7 Hydraulic oil filter
3 Remove the drain plugs in the bottom of the filters.

Let the oil run out. Wait awhile since it runs out slowly.
4 Remove the filter holders.
NOTE
The filter holders are heavy, loosen them carefully.
5 Clean the filter holders.
6 Remove the filter inserts.
NOTE
Note the position of the O-rings.
7 Install the O-rings on the filter inserts and filter holders. Lubricate
the O-rings with hydraulic oil.
003602
8 Install the new filter inserts on the filter bracket.
High-pressure filter, under machine 9 Install the filter holder and drain plug.
NOTE
CAUTION

010475

the engine.

13 Check that the filter holders do not leak.

CAUTION


60 10 Common hydraulics – 10.6.8 Hydraulic oil
10.6.8 Hydraulic oil

Hydraulic oil, changing
page
–
NOTE
section B Safety.
IMPORTANT

2 Remove the filler cap and pump out the hydraulic oil into a
receptacle.
3 When most possible oil has been pumped out. Place a collection
container under the hydraulic oil tank’s drain plug and drain the
last of the hydraulic oil.
4 Install the drain plug when the oil has drained out.
1. Cover for oil filter NOTE

2. Filling point hydraulic oil Make sure that the seal washer is installed as well.
3. Level glass hydraulic oil
5 If the hydraulic oil filters are to be changed, change them before
filling the tank with oil, see Hydraulic oil filter, replacement
page 56 and Hydraulic oil filter (high-pressure filter), changing
page 57.
6 Fill new hydraulic oil through the filler holes on the filters’ covers.
This results in filtering of the oil that is filled and protects the hy-
draulic system from impurities.
Fill oil until the oil level is in the middle of the level glass. For vol-
ume and grade, see section F Technical data.
10.6.9 Fine filter hydraulic oil

Fine filter hydraulic oil, description
page
–
The fine filter is located on the frame member in the engine compart-
ment. The filter is connected to hydraulic oil pump cooling and filtra-
tion. The filter is connected in parallel to the hydraulic oil filters in the
hydraulic oil tank.
Oil is pumped from the hydraulic oil tank through the fine filter and then
back to the hydraulic oil tank.
The fine filter cleans a smaller amount of oil but with a higher degree
of filtration when the machine is running.

10 Common hydraulics – 10.6.10 Pipes and hoses 61
Fine filter hydraulic oil, replacement

page
–
NOTE
section B Safety.
IMPORTANT
Make sure that the area around the filter is clean when
working.

2 Remove the cover.
3 Lift up the filter insert and place it in the receptacle. Let the hy-
draulic oil drain.
4 Fit the new filter insert and refit the cover over the fine filter.
CAUTION
Do not overfill!


page
–

62 10 Common hydraulics – 10.7 Other
10.7 Other
10.7.1 Hydraulic cylinders
page
–
Fault tracing, leakage
CAUTION
All troubleshooting tracing should be carried out with
as low a pressure in the system as possible so that
the leakage can be detected. High pressure causes
the seals to close tighter, which prevents detection of
leaks.
1 Carefully check the source of the leak before taking any action. It
may be possible to solve the problem without removing.
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. Both problems can be solved with the cyl-
inder in place.
• 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 leaks. Pressurise the cylinder and check if the
1. Piston rod
piston sinks back.
2. Scraper
3. Cylinder head This could be due to a worn piston seal.
4. Piston rod seal
5. O-ring with support ring
Dismantling of cylinders
6. Cylinder barrel
7. Sleeve coupling
8. Welded cylinder end CAUTION
9. Piston
10. Piston seal, double-acting
Always check before removing that the piston rod is
11. Example of weld
free from any paint remains. Also check that there are
no burrs or impact marks by connections and
couplings.
Make sure that the chamfer up to the chromium sur-

face of the piston rod is free from burrs and residual
paint.

10 Common hydraulics – 10.7.1 Hydraulic cylinders 63
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
1 Inspect the sealing surfaces. Always bearing mind the function of
the seals and the type of sealing surfaces they have. See the fol-
lowing descriptions:
• O-ring groove, internal and external
• piston rod seal in the cylinder head
• sealing groove on the piston
• cylinder barrel surface
• piston rod surface. The piston rod is chromium-plated with a
layer thickness of 20-50 my. Slight damage to the chromium-
plating may not necessarily be the direct cause of leakage.
• all slide surfaces (dynamic surfaces), e.g. cylinder barrel and
piston rod. These are always the hardest to seal
CAUTION
When fitting the cylinder head:
Get it absolutely straight. This is best done by hand.

Under no circumstances hit it with a mallet of any
type.
If the cylinder head enters at an angle, the seal lip on

the piston rod seal may be damaged and the sealing
function may be lost. This applies for all types of pis-
ton rod seals.

64 10 Common hydraulics – 10.7.1 Hydraulic cylinders
Function and removal of the seals
2 Piston rod seal

The piston rod seal is the seal that is located in the groove in the cyl-
inder head and seals against the piston rod. This seal is subject to ex-
1
tensive wear since it is both a dynamic and a static seal, i.e., it seals
against a moving surface on the piston rod while the sealing surface
with the cylinder head is fixed. There are different types of piston rod
seals:
3 • Single V-seal
• Pre-stressed V-seal with support ring
• Compressible seal
4
6 The simple V seal has a V-shaped section with two lips that seal in
opposite directions. The hydraulic pressure works in the V-shape,
pressing the sealing lips out towards the sealing surfaces on the piston
rod and in the cylinder barrel. Even minor damage to the sealing lips
can generate large leaks. Examine the sealing lips by carefully using
a fingernail to feel around the seal. To remove, use a screwdriver to
prise the seal outward and bend it up (see illustration). It is extremely
important that the screwdriver is always inserted in the V shape so that
001497
5 it cannot touch and thereby damage a sealing surface. A mark from a

1. Hydraulic pressure screwdriver on a sealing surface can have a devastating effect and
2. The sealing lip is pressed outward against the cause major leakage.
piston rod
3. The sealing lip is pressed inward against the
cylinder head
4. Piston rod sealing surface
5. Cylinder head sealing surface
6. Screwdriver

The pretensioned V seal also has an O-ring in the seal’s V-shaped

2
space. The O-ring creates a strong seal at low hydraulic pressure
1 since the O-ring already presses the sealing lips out toward the sealing
surfaces when unloaded. It is just as sensitive to damage as the V
seal. Examine in the same manner. To remove, use a screwdriver to
prise the seal outward and bend it up (see illustration). It is extremely
important that the screwdriver is always inserted in the V shape so that
3 it cannot touch and thereby damage a sealing surface. A mark from a
7
screwdriver on a sealing surface can have a devastating effect and
6 4 cause major leakage.
001498
5
1. Hydraulic pressure
2. The sealing lip is pressed outward against the
piston rod
cylinder head
6. Screwdriver
7. O-ring

The compressible piston rod seal consists of a solid rubber profile

2
and provides a larger sealing surface than the V seals. To remove, use
a screwdriver to prise the seal outward and bend it up (see illustration).
1
With this type of seal with sealing surfaces that cover so much of the
3 seal groove, it is particularly important that marks are not made with
the screwdriver.
6
4
5 001499
5
2. The sealing lip is pressed outward against the
piston rod
cylinder head
6. Screwdriver
Support ring and O-ring
The support ring and O-ring combination is used for sealing between
two fixed surfaces, such as between cylinder barrel and cylinder head.
The purpose of the support ring is to lend rigidity to the O-ring so that
it is not deformed. The O-ring is pressed against the support ring and
3
the sealing surface by the hydraulic pressure in the cylinder.
4 When the cylinder head is mounted in the barrel: Take extreme care
to avoid damaging the O-ring.
2
001506
1
2. O-ring
3. Support ring

Scraper
øD+10
The purpose of the scraper is to scrape the piston rod clean and pre-
1 vent impurities from entering the cylinder barrel.
The scraper is installed with a special installation tool, which has a
greater outer diameter than the scraper so that the press force against
2 the scraper ceases right when the scraper is pressed into position. If
the scraper were to be pressed in further, the metal casing will be de-
formed (see lower illustration), which would impair the function of the
4 scraper.
3 To prevent the scraper from bottoming in its recess in the cylinder
head, the recess is slightly deeper than the width of the scraper.
øD
6
001496
1. Correct installation tool

2. Scraper, correctly installed
3. Cylinder head
4. Play between scraper and bottom of cylinder
head slot
5. Incorrect installation tool
6. Deformed scraper
A screwdriver can be used for removal. This must always be applied
1 against the outer edge of the scraper (see illustration). Carefully tap
the screwdriver down between the scraper and the cylinder head and
2 then pry out the scraper. Polish off any damage to the cylinder head.
CAUTION
No tool must be applied from the inside. This could
3 generate burrs on the cylinder head which in turn
could damage the piston rod. Burrs may also damage
the piston rod seal when installing the piston.
001551
1. Screwdriver
2. Scraper
3. Cylinder head

On the single-acting V-seal it is always the long side that seals

2
against the fixed surface and the short side that seals against the mov-
ing surface.
1 To remove, use a screwdriver to pry the seal outward and bend it up
(see illustration). It is extremely important that the screwdriver is al-
ways inserted in the V shape so that it cannot touch and thereby dam-
age a sealing surface. A mark from a screwdriver on a sealing surface
3 can have a devastating effect and cause major leakage.
6 4
002370
5
2. Seal is pressed outward against the cylinder barrel
3. Seal is pressed inward against the piston
4. Cylinder barrel sealing surface
5. Piston sealing surface
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 eas-
ily 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

5 4 3 1 6
The double-acting seal functions with pressure from both sides, e.g. in
a steering cylinder.
All of the interior surface of the cylinder barrel is a sealing surface
and it is therefore extremely important that it is completely free from
damage.
Exercise caution when fitting the piston in the cylinder barrel, making
2
sure that the seal is not damaged by the cylinder barrel threads.
002951
1. Moving sealing surface to cylinder barrel

2. Fixed sealing surface with piston
3. Guide ring
4. Support ring
5. Piston head
6. Cylinder barrel

Dismantling:
1 Remove guide rings and support rings.
2 Move the seal body over to one side of the sealing groove.
3 Press up the material so that there is a gap between seal and
piston.
4 Without damaging the surface of the piston - cut off the seal with
a knife.
5 Carefully examine the seal to find any damage that can cause
leakage. This will be easier if you bend the seal sharply bit by bit
and feel over the sealing surface with a fingernail.
Assembly:
1 All double-acting piston seals are of similar design: a middle seal
body, then support rings and farthest out guide rings.
2 First fit the seal body, then the support rings and finally the guide
rings - all must be done by hand without tools to avoid damage.
Repairing the piston rod surface

A small impact mark on a piston rod may be sufficient to cause leak-
1 2 3
age. The chromium-plating on the piston rod has a thickness of
20-50 micrometre and can be polished to repair minor damage. This
may be a satisfactory alternative to costly dismantling.
1 Locate the damage using your fingertips and fingernails.
4 2 Use a small, highly-polished hammer and work the surrounding

material inwards towards the damage, starting from the outside.
3 Instead of a small sharp mark there will now be a small uniform
concavity in the chromium plating.
4 Polish with emery cloth, progressing from number 240 to 600.
Wrap the emery cloth round a file to give it good support. Note
that there must always be chromium-plating present at the
damage.
5 It is important to treat small impact marks before disassembly and
assembly to avoid damaging the cylinder head.
6 Repairing larger damage on a piston rod:
002952
• fill the damage with weld metal, use chromium or stainless

1. Piston steel electrodes
2. Chromium-plating • remove all slag completely
3. Impact marks
• file the weld down to the same level as the chrome
4. Highly polished hammer
• polish evenly using emery cloth

Dismantling the steering cylinders

It can prove extremely difficult to extract the piston rod from the cylin-
der barrel on steering cylinders because the O-ring in the cylinder
head jams in the retaining ring’s groove in the cylinder barrel. There-
fore it is best to remove the O-ring before trying to pull out 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 Common electrics 1
11 Common electrics
Table of Contents 11 Common electrics

mm mm mm mm mm mm
11 Common electrics .......................................................................................... 3

11.2 Electric protection ....................................................................................... 3
11.2.1 Battery disconnector .............................................................................. 3
11.2.2 Fuses ..................................................................................................... 3
11.2.3 Control breaker ...................................................................................... 3
11.3 Batteries ..................................................................................................... 4
11.3.1 Start battery ........................................................................................... 4
11.4 Alternator .................................................................................................... 6
11.4.1 Alternator ............................................................................................... 6
11.5 Distribution of electricity ............................................................................. 7
11.5.1 Voltage feed ........................................................................................... 7
11.5.2 Electronic box ...................................................................................... 16
11.5.3 Control units ......................................................................................... 18
11.5.5 Cable harness ...................................................................................... 33
11.6 Communication ........................................................................................ 43
11.6.1 CAN bus .............................................................................................. 43
11.6.2 Redundant CAN bus ............................................................................ 45
11.6.3 CAN bus drive-train ............................................................................. 48
11.6.4 Communication between PC and machine .......................................... 49
11.6.5 RMI (Remote Machine Interface) ......................................................... 50
11.6.6 Kalmar CAN Customer Gateway ......................................................... 51

2 11 Common electrics

11 Common electrics 3
11 Common electrics
mm mm mm mm mm mm
11.2 Electric protection

11.2.1 Battery disconnector
Battery disconnector, description
page
–
The positive terminals of the batteries connected in series are con-

nected to the machine’s electrical system via the battery 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 discon-
A nector when the engine is running. This could dam-
age the alternator.
Battery disconnector must not be used for emergency

stop!
000268
A. Position of battery disconnector
11.2.2 Fuses
Fuses, changing
page
–
When checking and changing the main fuse:

1. Turn off the system voltage (battery disconnector).
2. Remove the plastic cover.
3. Check that fuses are intact. Change when needed.
The fuses are 25 A.
When checking and changing fuses:
1. Turn off the system voltage (battery disconnector).
2. Remove the cover from the electronic box.
3. Check and, if necessary, replace fuses.
The fuse plate gives information about each fuse.
11.2.3 Control breaker

Emergency stop switch, description
page
–
See Emergency stop switch voltage (15E), function description

page 11.

4 11 Common electrics – 11.3 Batteries
11.3 Batteries
11.3.1 Start battery
Start battery, description
page
–
The machine’s electrical system is supplied by two 12 V batteries con-

nected in series.
The negative terminal is connected to the frame. The positive terminal
is connected to the battery disconnector.
The batteries are charged by the alternator, see Alternator, description
(engine alternative Volvo) page 6.
WARNING
The batteries’ electrolyte contains corrosive sulphu-
ric acid.
Risk of corrosive injuries, health hazard!
Immediately remove electrolyte from the skin. Wash

with soap and plenty of water. If electrolyte gets in the
000269
eyes, rinse with plenty of water and seek medical help

immediately.
WARNING
Risk of explosion!
Personal injury!
During charging, hydrogen gas forms by the batter-

ies. Sparks could ignite the hydrogen gas, causing an
explosion. Disconnect the battery with the battery
013022
disconnector.
Alternative position for batteries
WARNING
Short-circuiting of battery.
Risk of explosion! Fire hazard! Risk of injury!
The battery’s terminals must not be connected to

each other or to common grounding point (chassis).

11 Common electrics – 11.3.1 Start battery 5
Start battery, replacement

page
–

2 Disconnect the cables from the battery terminals, starting with the
negative (minus) cable.
3 Replace the batteries.
4 Connect the cables to the battery terminals. Connect the nega-
tive cable last.
NOTE
Take great care when reconnecting the cables to prevent
short circuiting.
000269

6 11 Common electrics – 11.4 Alternator
11.4 Alternator
11.4.1 Alternator
Alternator, description (engine alternative Volvo)
page
–
The alternator generates current during operation and supplies this to

the batteries. The alternator produces AC current and has an integrat-
ed charge regulator.
The alternator is driven by the engine via a belt. Malfunctions are indi-
cated by the warning light for low battery charging.
system, section 8.4.6.4 ENGINE, menu 4.
001905
The illustration shows engine alternative Volvo

TWD1240VE
Alternator, description
page
–

The alternator generates current during operation and supplies this to
the batteries. The alternator produces AC current and has an integrat-
ed charge regulator.
The alternator is driven by the engine via a belt. Malfunctions are indi-
cated by the warning light for low battery charging.
system, section 8.4.6.4 ENGINE, menu 4.
007444
Alternator, replacement
page
–

11 Common electrics – 11.5 Distribution of electricity 7
11.5 Distribution of electricity

11.5.1 Voltage feed
11.5.1.2 Redundant voltage feed of control
units
Redundant voltage feed of control units, function
page
–
description
1 2 3 4
D793
D1 D2 D3 D4 D794
- +
D8 D7 D9
D11
D795 D790-1 D797-R D797-F D797-O

11 5, 6 8 7 9
10 12 13 14
D790-2 D791-1 D791-2 D791-3 D791-4
015269
D10 D12 D13 D14
Pos Explanation Signal Reference

description
1 The NC switch, operator’s door (S 266-RI) U = 24 V Section 9 Frame, body, cab and accessories,
or the NC switch, passenger door group 9.10.2 Doors
(S 266-RI) sends a voltage signal to the cab D1: Diagnostic menu, see section 8 Control system,
control unit (D790-1) when the door is group 8.4.2.12 LIGHTS, menu 12 or 8.4.11.2 SLID-
opened. ING-CAB, menu 1
2 Switch, interior lighting on Control unit KIT - Section 9 Frame, body, cab and accessories,
(D790-2) cab sends a voltage signal to group 9.6.12 Interior lighting
Control unit cab (D790-1). D2: Diagnostic menu, see section 8 Control system,
3 Switch, flashing hazard lights (S109) U = 24 V Section 9 Frame, body, cab and accessories,
sends a voltage signal to Control unit, group 9.6.7 Flashing hazard lights
cab (D790-1). D3: Diagnostic menu, see section 8 Control system,
4 When the ignition (S150) is turned to posi- U = 24 V Section 9 Frame, body, cab and accessories,
tion I, it sends a voltage signal to the cab group 9.1 Controls and instruments
control unit (D790-1). D4: Diagnostic menu, see section 8 Control system,
group 8.4.1.4 CAN/POWER, menu 4

8 11 Common electrics – 11.5.1.2 Redundant voltage feed of control units

description
5 Control unit, cab (D790-1) activates a hold - Cab control unit, description page 19
circuit, which activates the control unit’s
control logic.
6 Control unit, cab (D790-1) activates a re- UK11:7 = 24 V Cab control unit, description page 19
dundant voltage feed to other control units.
U K11:8 = 24 V
The cab control unit (D790-1) has 4 outputs
UK11:9 = 24 V
for redundant voltage feed while other con-
trol units have two inputs for redundant volt- UK11:10 = 24 V
age feed. In case of a malfunction of one
voltage feed the control unit is supplied by
the other feed.
7 Control unit, cab (D790-1) supplies voltage UK2:7 = 24 V Control unit, frame front, description page 20
to the control logic of the other control units D7: Diagnostic menu, see section 8 Control system,
UK2:8 = 24 V
via the redundant voltage feed. group 8.4.1.8 CAN/POWER, menu 8
8 UK2:7 = 24 V Control unit, frame rear, description page 21
UK2:8 = 24 V D8: Diagnostic menu, see section 8 Control system,

9 UK2:7 = 24 V Control unit, frame option, description page 22
UK2:8 = 24 V D9: Diagnostic menu, see section 8 Control system,

10 UK2:7 = 24 V Control unit, attachment, description page 23
UK2:8 = 24 V D10: Diagnostic menu, see section 8 Control sys-

tem, group 8.4.1.16 CAN/POWER, menu 16
11 UK2:7 = 24 V Control unit KID, description page 31

12 UK2:7 = 24 V Control unit, attachment option, description page 24

13 UK2:7 = 24 V Control unit, attachment left leg pair, description

page 25
UK2:8 = 24 V
D13: Diagnostic menu, see section 8 Control sys-
14 UK2:7 = 24 V Control unit, attachment right leg pair, description

page 26
UK2:8 = 24 V
D14: Diagnostic menu, see section 8 Control sys-

11 Common electrics – 11.5.1.3 Ignition voltage (15) 9
11.5.1.3 Ignition voltage (15)

Ignition voltage (15), function description
page
–

Battery disconnector In position 1 Battery disconnector, description page 3
Redundant voltage feed Activated Redundant voltage feed of control units, function description
page 7
Redundant CAN bus Communication established Redundant CAN bus, description page 45
- + D4
1 2
D1 6
D2 D3 3
7
D794
D793
12
4, 5
D12
D8 D9 D10 D11
D795 D790-1 D797-R D797-F D797-O

2, 8 9 10 11
D790-2 D791-1 D791-2 D791-3 D791-4
015270
description
1 Warning light turns on and sends a U = 24 V Section 9 Frame, body, cab and accessories,
voltage signal to the Control unit, cab group 9.6.7 Flashing hazard lights
(D790-1). D1: Diagnostic menu, see section 8 Control system,
2 Start key is turned to position I and U = 24 V Section 9 Frame, body, cab and accessories,
sends a voltage signal to the cab con- group 9.1 Controls and instruments
trol unit (D790-1). D2: Diagnostic menu, see section 8 Control system,
3 Control unit, cab (D790-1) supplies U = 24 V Cab control unit, description page 19
voltage to Relay, ignition voltage D3: Diagnostic menu, see section 8 Control system,
K315-1 in the frame electronic box group 8.4.1.4 CAN/POWER, menu 4
and Relay, ignition voltage K315-2.

10 11 Common electrics – 11.5.1.3 Ignition voltage (15)

description
4 Relay, ignition voltage K315-1 sup- U = 24 V -
plies voltage to fuse holder in the cab
electronic box and in the frame elec-
tronic box.
5 The fuses feed voltage to control U = 24 V -

units, relays, solenoid valves and oth-
er electronic components.
6 Relay, ignition voltage K315-2 sup- U = 24 V Control unit, engine, description (engine alternative
plies voltage to Control unit, engine Volvo TWD1240VE) page 28
(D794).
7 The drive-train’s CAN-bus establish- Checked by control CAN bus drive-train, description page 48
es communication. system, error
shown with error
code.
8 Ignition voltage to Control unit, cab UK1:2 = 24 V Cab control unit, description page 19
(D790-1). D8: Diagnostic menu, see section 8 Control system,
UK1:3 = 24 V
UK1:4 = 24 V
9 Ignition voltage to Control unit, frame UK2:1 = 24 V Control unit, frame rear, description page 21
rear (D797-R). D9: Diagnostic menu, see section 8 Control system,
UK2:9 = 24 V
10 Ignition voltage to Control unit, frame UK2:1 = 24 V Control unit, frame front, description page 20
front (D797-F). D10: Diagnostic menu, see section 8 Control system,
UK2:9 = 24 V
UK2:10 = 24 V
11 Ignition voltage to Control unit, frame UK2:10 = 24 V Control unit, frame option, description page 22
option (D797-O). D11: Diagnostic menu, see section 8 Control system,
12 Ignition voltage to Control unit, UA1 = 24 V Control unit, transmission, description page 27
transmission (D793). D12: Diagnostic menu, see section 8 Control system,

11 Common electrics – 11.5.1.4 Emergency stop switch voltage 11
11.5.1.4 Emergency stop switch voltage

Emergency stop switch voltage (15E), function description
page
–

value
Redundant volt- Activated Redundant voltage feed of control units, function description page 7
age feed
Ignition voltage Activated Ignition voltage (15), function description page 9
Control breaker Not activated Section 9 Frame, body, cab and accessories, group 9.1 Controls and instruments
D794
3, 4 6
D793
- + 3, 4 6
D4 D5
- + D2
D4 D5
D7 D8
D2 D7 D8
D795 D790-1 D797-R D797-F D797-O D793
D795 D790-1
1, 2, 5 D797-R 7 D797-F 8 D797-O
1, 2, 5 7 8
12 11 10 9
D790-2 D791-1
12 D791-2
11 D791-310 D791-49 D794
D790-2 D791-1 D791-2 D791-3 D791-4
007422
D12 D11 D10 D9
015271
D12 D11 D10 D9

1 Ignition voltage is activated by the cab Checked by control sys- Ignition voltage (15), function description
control unit (D790-1). tem, error shown with page 9
error code.
2 Control unit, cab (D790-1) supplies volt- UK3009-1/86 = 24 V Cab control unit, description page 19
age to Relay, emergency stop switch volt- D2: Diagnostic menu, see section 8 Control
age (K3009-1) in the frame electronic box. system, group 8.4.1.5 CAN/POWER,
menu 5
3 Relay, emergency stop switch voltage UK3009-2/87 = 24 V Electronic box frame, description page 17
(K3009-1) supplies voltage to Relay, D3: Diagnostic menu, see section 8 Control
emergency stop switch voltage (K3009-2) system, group 8.4.1.5 CAN/POWER,
in the frame electronic box. menu 5

12 11 Common electrics – 11.5.1.4 Emergency stop switch voltage

(K3009-1) also sends a voltage signal to D4: Diagnostic menu, see section 8 Control
UK3009-2/87= 0 V
the Control unit, cab (D790-1), which veri- system, group 8.4.1.5 CAN/POWER,
fies that Relay, emergency stop switch menu 5
voltage (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 Re- UK3009-2/86 = 24 V Cab control unit, description page 19
lay, emergency stop switch voltage D5: Diagnostic menu, see section 8 Control
(K3009-2) in the electronic box. system, group 8.4.1.5 CAN/POWER,
menu 5
K3009-2 supplies voltage to the emergen-
cy stop switch circuit.

11 Common electrics – 11.5.1.4 Emergency stop switch voltage 13

7 The control units are supplied with emer- Emergency stop switch Control unit, frame front, description
gency stop voltage as long as the emer- in home position: page 20
gency stop switch is not depressed. UK2:6 = 24 V D7: Diagnostic menu, see section 8 Control
The control units on the attachment is only system, group 8.4.1.8 CAN/POWER,
supplied with voltage by the emergency menu 8
stop switch, thus all attachment functions
8 Emergency stop switch Control unit, frame option, description
stop if the emergency stop switch is
in home position: page 22
activated.
UK2:6 = 24 V D8: Diagnostic menu, see section 8 Control
If the emergency stop switch is de-
system, group 8.4.1.12 CAN/POWER,
pressed, ignition voltage to Control unit,
menu 12
cab (D790-1) is cut off, thereby cutting off
9 control current to Relay, emergency stop Emergency stop switch Control unit, attachment right leg pair, de-
switch voltage (K3009-1) and Relay, in home position: scription page 26
emergency stop switch voltage (K3009-2). UK2:1 = 24 V D9: Diagnostic menu, see section 8 Control
Power supply to the control units is cut off system, group 8.4.1.19 CAN/POWER,
Emergency stop switch
and functions stop working.
in home position: menu 19
As an extra safety measure, the cab con- UK2:11 = 24 V
trol unit (D790-1) also transmits the status
10 of the emergency stop switch the CAN Emergency stop switch Control unit, attachment left leg pair, de-
bus. Thus, functions are also cut off at the in home position: scription page 25
signal level. UK2:1 = 24 V D10: Diagnostic menu, see section 8 Con-
Emergency stop switch trol system, group 8.4.1.18 CAN/POWER,
UK2:11 = 24 V
11 Emergency stop switch Control unit, attachment option, description

UK2:1 = 24 V D11: Diagnostic menu, see section 8 Con-
UK2:11 = 24 V
12 Emergency stop switch Control unit, attachment, description

UK2:1 = 24 V D12: Diagnostic menu, see section 8 Con-
UK2:9 = 24 V

in home position:
UK2:10 = 24 V

in home position:
UK2:11 = 24 V

14 11 Common electrics – 11.5.1.5 Voltage converter
Emergency stop switch, checking

page
–
1 Start the machine and active any load handling function.

2 Activate lift.
3 Press in the emergency stop switch and check that the lift move-
ment stops.
4 Reset the emergency stop switch (turn in the direction of the ar-
rows) and check that the lift function is working again.
000039
Control breaker
11.5.1.5 Voltage converter

Voltage converter, description
page
–
The voltage converter is located under a protective casing to the left

behind the driver’s seat.
The voltage converter converts 24 volt to 12 volt. 12 V voltage is avail-
able for accessories by means of a connector X067 in the cab elec-
tronic box. (Contains 15, 30-voltage, ground and 12 V.)

11 Common electrics – 11.5.1.5 Voltage converter 15
Voltage converter, replacement

page
–

2 Remove the covers behind the driver’s seat.
3 Detach the electrical cables from the converter.
4 Remove the voltage converter.
The voltage converter is located diagonally behind the

driver’s seat.

16 11 Common electrics – 11.5.2 Electronic box
11.5.2 Electronic box

11.5.2.1 Electronic box, cab
Electronic box, cab, description
page
–
The electronic box is mounted on the rear wall of the cab, on the left.
Located there are:
• Control unit, cab (D790-1)
• Circuit fuses
• Buzzer for alarm if, for example, the operator leaves the machine
without the parking brake being applied
• Connectors
• Relays
•
Voltage converter 24 V to 12 V
• Connector customer accessory. Output voltage 24 V, max. 10 A.
1 Connector 9-pin Universal mate-n-lock. For part number see
Spare parts catalogue.
2
3 NOTE
This connector is not fitted on the machine if the machine is
4 equipped with voltage converter.
6
014144
1. Control unit cab (D790-1)

2. Socket for programming control units
3. Socket for CAN-bus drivetrain
4. Fuse holder
5. Connector customer accessories (X067) 24V/10A
and 12V/20A
6. Voltage converter
Customer accessory connector (X067)

page
–
The connector is designed for customer accessories and contains

3 2 1 connections for 24V. On machines with voltage converter 24V to 12V
there is also a connection for 12V .
4 • Pin 1. 24V, ignition voltage, 10A
• Pin 2. 24V, battery voltage, 10A
014169
• Pin 2. Ground
• Pin 4. 12V, ignition voltage, 20A

11 Common electrics – 11.5.2.2 Electronic box frame 17
11.5.2.2 Electronic box frame

Electronic box frame, description
page
–
The electronic box is fitted on the side of the machine. Also located
3 4
2 there are:
1 5
4
• Circuit fuses
F5
6
D7
9 3
• Outlet for programming Control unit, transmission (D793)
F5
9 7
F5
68
8-1
X1
F5
K1
8-2
• Main fuses
8-3
K3 K4
K2
• Control unit, transmission (D793)
8 • Power relays for voltage feed to the machine’s functions.
004923
1. Circuit fuses
2. Socket for programming transmission control unit
(D793)
3. Power relay (K315-1)
4. Main fuses
5. Transmission control unit (D793)
6. Main fuse
7. Relay (K315-2)

18 11 Common electrics – 11.5.3 Control units
11.5.3 Control units

Control units, location
page
–
1 2 3 4 5
15
7
14
010503
13 12 11 10 9 8
1. Control unit, cab (D790-1) 10. Control unit, transmission (D793)

2. Control unit, KID (D795) 11. Control unit, engine (D794)
3. Control unit KIT (D790-2) 12. Control unit frame rear (D797-R)
4. Control unit frame front (D797-F) 13.
Control unit, cab option (D790-3)
5. .
Frame control unit, option (D797-O) Only on machines with both the combi attachment and
6. Control unit, attachment (D791-1) mini-wheel or combi attachment and joystick control
7. 14.
Control unit, attachment option (D791-2) Control unit CAN gateway RMI (D795-2)
8. 15.
Control unit, attachment left leg pair (D791-3) Control unit, Kalmar CAN customer gateway (D795-2)
9.
Control unit, attachment right leg pair (D791-4)

11 Common electrics – 11.5.3.1 Control unit, cab 19
11.5.3.1 Control unit, cab

Cab control unit, description
page
–
The cab control unit (D790-1) is the central control unit of the control
2 1
system. The cab control unit (D790-1) sends activation signals to other
units and controls and monitors their functions. It administrates work
in the control unit network. The control unit controls the redundant volt-
age feed and handles communication via a redundant CAN bus and
gateway for the drivetrain CAN bus. The cab control unit (D790-1) also
processes all input signals from cab controls and transmits these sig-
5 6 nals on the CAN bus.
4
3
000041
2 The control unit has four indicator lights that indicate the control unit’s
1. Connection terminals for fan, work lights, wind- function (see illustration).
shield wiper
2. Connection terminals, other Lamp 1 Green light on when there is battery voltage to the unit.
3. Light 1, battery voltage The light is physically controlled by voltage feed to the
4. Light 2, redundant voltage feed, redundant CAN control unit.
bus and power supply Lamp 2 Flashes green when redundant voltage feed to control
5. Light 3, communication units and redundant CAN bus communication are ac-
6. Light 4, malfunction indication tive. No power in system.
Green light when power electronics and 15-voltage are
supplied voltage.
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

page
–

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 DRIVETRAIN.
7 Set the fresh air damper at fully closed and fully open, wait a few
seconds in each position so that the damper has time to go to the
end-position.

20 11 Common electrics – 11.5.3.2 Control unit, frame front
11.5.3.2 Control unit, frame front

Control unit, frame front, description
page
–
Control unit, frame front (D797-F) processes input data from sensors
1 and sends control signals to relays and solenoid valves in the ma-
chine’s front half.
2
The control unit has four indicator lights that indicate the control unit’s
3 function (see illustration).
4 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 volt-
000043
6 5 age feed right or 15-voltage.

1. Light 1, battery voltage Green light when redundant voltage feed left, redun-
2. Light 2, redundant voltage feed and power supply dant voltage feed right and 15-voltage are supplied
3. Light 3, communication voltage.
4. Light 4, fault indication
Lamp 3 Single yellow flash during communication with the dis-
5. Control signals (input and output signals)
play (KID) or cab control unit (D790-1).
6. Power feed (redundant voltage feed control units,
redundant CAN bus) and input data Double yellow flash during communication with the dis-
play and the cab control unit (D790-1).
Control unit, frame front, changing

page
–

2 Disconnect the cables from control unit frame front (D797-F).
group 8.5.2.1 Calibrate SCALE (pressure sensor).
6 Verify lowering speed, see section 7 Load handling,
group 7.2 Lifting/lowering. In case of deviations contact
Cargotec.
DANGER


11 Common electrics – 11.5.3.3 Control unit, frame rear 21
11.5.3.3 Control unit, frame rear

Control unit, frame rear, description
page
–
Control unit, frame rear (D797-R) processes input data from sensors
1 and sends control signals to relays and solenoid valves for functions
in the machine’s rear half.
2

control unit.

000043
Control unit, frame rear, changing

page
–

2 Disconnect the cables from control unit frame rear (D797-R).
group 8.5.2.1 Calibrate SCALE (length sensor, angle sensor).

22 11 Common electrics – 11.5.3.4 Frame control unit, option
11.5.3.4 Frame control unit, option

Control unit, frame option, description
page
–
1
Control unit, frame option (D797-O) is a unit that processes input data
2 from sensors and sends control signals to relays and solenoid valves
for the optional functions in the machine’s front half.
3
Lamp 1 Green light on when there is battery voltage to the unit.

000043
control unit.

6 5
1. Light 1, battery voltage
age feed right or 15-voltage.
2. Light 2, redundant voltage feed and power supply
3. Light 3, communication Green light when redundant voltage feed left, redun-
4. Light 4, fault indication dant voltage feed right and 15-voltage are supplied
5. Control signals (input and output signals) voltage.
6. Power feed (redundant voltage feed control units, Lamp 3 Single yellow flash during communication with the dis-
redundant CAN bus) and input data play (KID) or cab control unit (D790-1).
Double yellow flash during communication with the dis-
Control unit, frame option, changing

page
–

2 Disconnect the cable harness from the control unit.
5 The control unit is not calibrated.

11 Common electrics – 11.5.3.5 Control unit, attachment 23
11.5.3.5 Control unit, attachment

Control unit, attachment, description
page
–
The attachment control unit (D791) processes input data from sensors
1 and sends control signals to relays and solenoid valves’ functions for
top lift attachment.
2

control unit.

000043
Control unit, attachment, replacement

page
–


24 11 Common electrics – 11.5.3.6 Attachment control unit, option
11.5.3.6 Attachment control unit, option

Control unit, attachment option, description
page
–
1
The control unit attachment option (D791-2) processes input data from
2 sensors and sends control signals to relays and solenoid valves’ op-
tional functions for top lift attachment.
3

000043
control unit.

6 5
1. Light 1, battery voltage
3. Light 3, communication Green light when redundant voltage feed left, redun-
4. Light 4, fault indication dant voltage feed right and 15-voltage are supplied
5. Control signals (input and output signals) voltage.
6. Power feed (redundant voltage feed control units, Lamp 3 Single yellow flash during communication with the dis-
redundant CAN bus) and input data play (KID) or cab control unit (D790-1).
Control unit, attachment option, changing

page
–


11 Common electrics – 11.5.3.7 Control unit, attachment left leg pair 25
11.5.3.7 Control unit, attachment left leg pair

Control unit, attachment left leg pair, description
page
–
1
Control unit, attachment left leg pair (D791-3) processes input data
to control the left leg pair on the attachment with lifting legs. See sec-
3 tion 7 Load handling, group 7.9.2 Twistlock and lift legs.
function (see illustration).

000043 control unit.
6 5
1. Light 1, battery voltage missing: redundant voltage feed left, redundant volt-
3. Light 3, communication
4. Light 4, fault indication Green light when redundant voltage feed left, redun-
5. Control signals (input and output signals) dant voltage feed right and 15-voltage are supplied
6. Power feed (redundant voltage feed control units, voltage.
redundant CAN bus) and input data Lamp 3 Single yellow flash during communication with the dis-
Control unit, attachment left leg pair, changing

page
–

6 Start the machine and drive to a free space. Operate the folding
DIAG COMBI 14(17) sequence for lifting legs up and down. Use the diagnostic menu
SEQUENCE MODE Combi, menu 14 and check that the lifting legs go through all the
LE RI sequence modes from 1-5.
FRONT X X
000227
REAR X X
Diagnostic menu Combi, menu 14

26 11 Common electrics – 11.5.3.8 Control unit, attachment right leg pair
11.5.3.8 Control unit, attachment right leg pair

Control unit, attachment right leg pair, description
page
–
1
Control unit, attachment right leg pair (D791-4) processes input data
to control the right leg pair on the attachment with lift legs. See section
3 7 Load handling, group 7.9.2 Twistlock and lift legs.

control unit.
000043
6 5
4. Light 4, fault indication Green light when redundant voltage feed left, redun-
5. Control signals (input and output signals) dant voltage feed right and 15-voltage are supplied
6. Power feed (redundant voltage feed control units, voltage.
redundant CAN bus) and input data Lamp 3 Single yellow flash during communication with the dis-
Control unit, attachment right leg pair, changing

page
–

6 Start the machine and drive to an open space. Operate the fold-
DIAG COMBI 14(17) ing sequence for lifting legs up and down. Use the diagnostic
SEQUENCE MODE menu Combi, menu 14 and check that the lifting legs go through
LE RI all the sequence modes from 1-5.
FRONT X X
000227
REAR X X
Diagnostic menu Combi, menu 14

11 Common electrics – 11.5.3.9 Transmission control unit 27
11.5.3.9 Transmission control unit

Control unit, transmission, description
page
–
Control unit, transmission TCU (D793) is part of the drive-train control

1 2 3
and handles the transmission’s function, selection of gear at load and
engine speed, etc.
The transmission control unit TCU (D793) is connected via separate
D
M CAN bus communication to the engine, which is connected to the cab
E
F S control unit (D790-1). The cab control unit (D790-1) sends drivetrain
information on to other units.
The control unit has two function keys and three status lights
(see illustration).
000045
Function button M Select display group.
1. Display
Function button S Select mode within display group.
2. Status lights
3. Function keys Status light D Yellow light indicates test mode.
Status light E Yellow light indicates malfunction in unit.
Status light F Red light indicates during reset.
Control units can show information in the display in three display

groups with various status information. The M and S function keys are
used to navigate in the display and select display group and status
information.
The following status information can be shown in the display:
Display group I
• GPOS - shows transmission’s direction of rotation
• VSPD - shows speed in km/h
• dist - shows distance driven in km or miles
Display group II
• CPOS - shows gear position
• Tspd - shows measured turbine speed in km/h or mph
• Espd - shows measured engine speed in rpm
• Ospd - shows measured speed out from the transmission in rpm
• Srat - shows the turbine speed ratio (Tspd)/engine speed (Espd)
• TQ I - shows measured torque (Nm) of transmission in
• Ttmp - shows measured temperature in the oil sump (Celsius or
Fahrenheit)
• Ctmp - shows measured temperature in the converter (Celsius or
Fahrenheit)
Display group III
• Err - shows error codes (current and history)

28 11 Common electrics – 11.5.3.10 Engine control unit
Control unit, transmission, replacement

page
–

2 Disconnect the cable harness from the TCU control unit.
5 Calibrate the new control unit; see section 8 Control system,
group 8.5.2.3 Calibrate DRIVE-TRAIN and section 2 Transmis-
sion, group 2.8 Control system, transmission.
11.5.3.10 Engine control unit

Control unit, engine, description (engine alternative Volvo
page
–
TWD1240VE)
Control unit, engine (D794) is part of the drive-train control and han-
dles engine function, fuel injection, etc.
1 The engine control unit (D794) is connected via separate CAN bus
communication to the transmission, which is connected to the cab
control unit (D790-1). The cab control unit (D790-1) sends drivetrain
2 The control unit is located on the engine has no function keys or dis-
play. All functions are controlled via the CAN bus and an external con-
trol system.
007427
3
The control unit monitors the following values in order to optimise en-
Control unit, engine gine performance.
1. Connector 1 (black)
• engine speed
2. Connector 2 (red)
3. Cooling channel for control unit (fuel) • camshaft position
• boost pressure
• charge air temperature
• coolant temperature
• oil pressure
• oil temperature
• water in fuel
• fuel pressure
• coolant level
The data gives exact information about the operating conditions and
makes it possible for the control unit to, for example, calculate the cor-
rect fuel volume and to check the condition of the engine.

11 Common electrics – 11.5.3.10 Engine control unit 29
Control unit, engine, description (engine alternative Volvo

page
–
TAD1250VE)
1 dles engine function, fuel injection, etc.
The engine control unit (D794) is connected via separate CAN bus
2 communication to the transmission, which is connected to the cab
3 information on to other units.
The control unit is located on the engine has no function keys or dis-
trol system.
007424
Control unit, engine gine performance.
1. Cooling channel for control unit (fuel) • engine speed
2. Connector A (black)
• camshaft position
3. Connector B (grey)
• boost pressure
• oil pressure
• oil temperature
• oil level
• crankcase pressure
• water in fuel
• fuel pressure
• coolant level

30 11 Common electrics – 11.5.3.11 Control unit KIT
Control unit, engine, description (engine alternative

page
–
Cummins)
1 2 3
dles engine function, fuel injection, etc.
The engine control unit (D794) is connected via separate CAN bus
communication to the transmission, which is connected to the cab
The control unit is located on the engine has no function keys or dis-
007423
trol system.
gine performance.
1. Connector OEM
• engine speed
2. Connector, Actuator
3. Connector, Sensor • boost pressure
• oil pressure
• oil temperature
• coolant level
• water in fuel
• air pressure
Control unit, engine, replacement

page
–
11.5.3.11 Control unit KIT

Control unit KIT, description
page
–
The KIT control unit (D790-2) handles functions for the gear and multi-
1 2
function lever, the direction indicator switch and start key positions II
and III. It also handles the key panel (B) for the control system and its
panel for warning and indicator lights (A).
Control unit KIT (D790-2) has several individual function keys and in-
dicator lights (see illustration).
See the operator’s manual for detailed information on warning and in-
dicator lights and function keys.
000049
1. Panel, warning and indicator lights

2. Panel, keys

11 Common electrics – 11.5.3.12 Control unit KID 31
Control unit KIT, replacement

page
–

panel.
3 Disconnect KIT from the steering wheel panel.
4 Detach the connector sockets.
5 Remove the warning panel for warning and indicator lights.
7 KIT is not calibrated.
11.5.3.12 Control unit KID

Control unit KID, description
page
–
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 sys-
tem. Error code and information are shown in 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

page
–

panel.
3 Disconnect the connector from KID.
4 Disconnect KID from the steering wheel panel.
6 KID is not calibrated.

32 11 Common electrics – 11.5.3.13 Control unit cab, option
11.5.3.13 Control unit cab, option

Control unit, cab option, description
page
–
1
Control unit, cab option (D790-3) is only available on machines with
2 both combi attachment and joystick control or combi attachment and
mini-wheel. The control unit handles the signals to and from the joy-
3 stick or mini-wheel and sends the information further on the CAN bus.

control unit.
000043
6 5
4. Light 4, fault indication Green light when redundant voltage feed left, and right
5. Control signals (input and output signals) and 15-voltage are supplied voltage.
6. Power feed (redundant voltage feed control units, Lamp 3 Single yellow flash during communication with either
redundant CAN bus) and input data Control unit KID (D795) or cab control unit (D790-1).
Double yellow flash during communication with both
Control unit KID (D795) and cab control unit (D790-1).
Control unit, cab option, changing

page
–


11 Common electrics – 11.5.5 Cable harness 33
11.5.5 Cable harness

Connectors, overview
page
–
The list includes all connectors on the machine with a brief description
of their locations and to which functions the signals in them are related.
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) Windscreen wipers

Cooling fan
Actuator motor, recirculation
X004 Control unit, cab (D790-1) Air conditioning
X005 Control unit, cab (D790-1) Switch, option

Switch flashing hazard lights (Hazard)
Air conditioning
Extra sensors
Accelerator
X006 Control unit, cab (D790-1) Dimmer, instrument lighting

Switch, working lights
Switch, option
Seat heater
Accelerator
Brake pedal
X007 Control unit, cab (D790-1) Control lever

Indicator light support jacks down
X008 Control unit, cab (D790-1) Control lever

Switch, bypass
Switch parking brake
Switch sliding cab
Switch support jacks
Switch 30-35 stop
Switch, option
Switch, twistlocks
X009 Control unit, cab (D790-1) Combi attachment

Overheight
Joystick control or mini-wheel
X009A Extension X009A Joystick control or mini-wheel

34 11 Common electrics – 11.5.5 Cable harness

X010 Control unit, cab (D790-1) Sensor, end-position cab
Water valve
Seat heat
Relay, working lights
Hour counter
Relay, compressor
Power supply relay K315-1, K3009-1, K3009-2 and K315-2
Windshield washer
Windshield wiper, roof
X011 Control unit, cab (D790-1) Ignition

Lighting Control unit, KID (D795)
Break contacts (opening switches), cab doors
Buzzer
Interior lighting
Power supply, Control unit, cab (D790-1)
Horn
Break contact (opening switch), seat
Feedback relay K3009-1
Seat heat
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) Control, windscreen wipers

Control, gear
Control, high and low beams
X018 Control unit KIT (D790-2) Sensor steering wheel movement

Switch, direction indicators
X018A Extension X018 Sensor steering wheel movement
X020 Control unit, KID (D795) CAN bus

RS232 Printer
Power supply and ground connection Control unit KID (D795)
X021 Control unit, cab option (D790-3) Joystick control or mini-wheel


X022 Control unit, cab option (D790-3) Power supply and ground connection Control unit, cab option (D790-3)
CAN bus Control unit cab option (D790-3)
X033 Air conditioning Control, fan

Control, temperature
Control, air distribution
X034 Air conditioning Heater fan

Water valve
X035 Air conditioning Valve, air distribution

Sensor, air temperature
X036 Air conditioning Actuator motor, recirculation

Sensor, air temperature
X038 Instrument panel, cab Accelerator

Declutch pedal
X039 Electronic box, cab Hour counter

Relay, compressor air-suspension seat
Break contact (opening switch), cab door
Actuator motor, recirculation
Fan motor, heating
Water valve, ECC
X048 Electronic box, cab Termination resistor
X049 Electronic box, cab CAN bus
X050 Electronic box, cab D-sub

RS232 Control unit, cab (D790-1)
X051 Electronic box, cab Power supply, Control unit, cab (D790-1)
CAN bus

Control relays K315-1, K3009-1, K3009-2 and K315-2
X054 Electronic box, cab Interior lighting

Working lights
Flashing hazard lights
X055 Electronic box, cab Windscreen wiper, roof

Power, CD player
Power, COM radio


X056 Electronic box, cab Flashing hazard lights
Work light boom
Working lights, cab
X057 Electronic box, cab Windscreen wiper, rear

Power supply, back-up camera
X058 Electronic box, cab Motor, windscreen washing

Start interlock, engine heater
X059 Electronic box, cab CAN bus,

Power supply Control unit, cab option (D790-3)

Interior lighting
X060A Extension X060 CAN bus

Interior lighting
X061 Electronic box, cab Ground connection, Control unit, KID (D795)
Ground connection, Control unit KIT (D790-2)
Windscreen wiper, front
Motor, recirculation
X061A Extension X061 Ground connection, Control unit, KID (D795)

Ground connection, Control unit KIT (D790-2)
X062 Electronic box, cab Horn

Map lighting
Cigarette lighter 12V
X063 Electronic box, cab Seat heater

Compressed-air damped seat
X064 Electronic box, cab Sensor, end-position cab
X071-1 Electronic box, cab Power supply, cab
X071-2 Electronic box, cab Ground connection, cab
X072 To Right Behind Seat Current outlet
X073 Right side of instrument panel Cigarette socket 12V
X080 Instrument panel, cab Switch, working lights

Switch, high beam
Switch, flashing hazard lights
Switch, seat heater
Switch, seat heater


X081 Instrument panel, cab Switch, seat heater
Extra sensors
Hour counter
X082 Instrument panel, cab Break-contact (opening switch), cab door left side
X168 Electronic box frame Power supply, boom and attachment
X200 Boom mounting CAN bus

Redundant power supply, control units
X201 Electronic box frame Ground connection and power supply, Control unit, transmission (D793)
X202 Boom mounting Sensor boom length

Sensor boom angle
Sensor, damping boom out
Sensor, damping boom in
Sensor, damping boom up
Sensor, damping boom down
Ground connection and power supply, boom sensor
Solenoid valve, regeneration extension
Solenoid valve, blocking extension
Work light boom
X203 Electronic box frame Termination resistor
X205 Electronic box frame CAN bus

Control unit, transmission (D793)
X206 Boom mounting Rotating beacon, boom

Work light boom
X210 Between engine and transmission Power supply and ground connection Control unit, engine (D794)
CAN bus, Control unit, engine (D794)
X211 Control unit frame front (D797-F) 42-pin connector to Control unit, frame front (D797-F)
X212 Control unit frame front (D797-F) Power supply and ground connection, frame control unit front (D797-F)
CAN bus, Control unit, frame front (D797-F)
Temperature brake oil
Control breaker
X221 Control unit frame rear (D797-R) 42-pin connector to Control unit, frame rear (D797-R)


X222 Control unit frame rear (D797-R) Power supply and ground connection, frame control unit rear (D797-R)
CAN bus, Control unit, frame rear (D797-R)
Temperature hydraulic oil
Fuel gauge
Control breaker
D+ alternator
X231 Frame control unit, option 42-pin connector to Control unit, frame option (D797-O)
(D797-O)
X232 Frame control unit, option Power supply and ground connection, frame control unit option (D797-O)
(D797-O) CAN bus, Control unit, frame option (D797-O)
Control breaker
X233 Frame control unit, option Sensor support jacks

(D797-O) Solenoid valve support jacks up and down
X235 Frame control unit, option Solenoid valve steering left and right (joystick control or mini-wheel)
(D797-O)
X246 AC compressor Power supply sensor pressure refrigerant
X251 Control unit, transmission (D793), 30-pin connector for Control unit, transmission (D793)
electronic box frame
X252 Control unit, transmission (D793), 18-pin connector for Control unit, transmission (D793)
electronic box frame
X253 Transmission Solenoid valves, transmission

Pressure sensor, transmission
X254 Electronic box frame Power supply and ground connection Control unit, transmission (D793)
X259 Transmission Temperature sensor, transmission oil to cooler
X260 Electronic box frame CAN bus, Control unit, transmission (D793)
X261 Electronic box frame RS232 Control unit, transmission (D793)
X264 Electronic box frame Solenoid valve, brake transmission
X265 Cab Reversing camera
X270 Light bracket left frame 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 Back-up lights
Tail lights
Brake light
Side marker lights
X273 Lamp bracket right rear Back-up lights

Tail lights
Brake light
Side marker lights
X278 Between engine and transmission Electromagnetic clutch, compressor

Solenoid valve, engagement of hydraulics for top lift
Sensor pressure refrigerant
Solenoid valve deactivation of hydraulics
X279 Engine Power supply and ground connection Control unit, engine (D794)
CAN bus Drive-train
X282 Cable connected to printer RS232 Printer
X301 Boom mounting Fuse holder power supply and ground connection to boom and
attachment
X400 Boom nose Fuse holder power supply and ground connection to boom and
attachment
X401 Boom nose CAN bus control units on boom nose and attachment
Redundant power supply control units on boom nose and attachment
X403A Attachment, right side Sensor, alignment right side

Sensor, twistlocks right side
X403B Attachment, right side Sensor, alignment right side

Sensor, twistlocks right side
X404 Attachment left side Sensor, alignment left side

Sensor, twistlocks left side
X405 Boom nose Indicator light locked twistlocks

Indicator light unlocked twistlocks
Indicator light alignment
X406 Attachment centre section Extra work lights combi attachment
X408 Boom nose Indicator light overheight legs raised
X411 Control unit, attachment (D791-1) 42-pin connector for Control unit attachment (D791-1)


X412 Control unit, attachment (D791-1) Power supply and earth connection, Control unit attachment (D791-1)
CAN bus, attachment control unit (D791-1)
Control breaker
X414 Boom nose CAN bus and power supply control unit attachment right leg pair (D791-4)
X415 Boom nose Combi attachment
X416 Attachment centre section Rotation stop
X421 Control unit, attachment option 42-pin connector for Control unit attachment option (D791-2)
(D791-2)
X422 Control unit, attachment option Power supply and ground connection, Control unit attachment option
(D791-2) (D791-2)
CAN bus Control unit attachment option (D791-2)
Control breaker
X428 Boom Revolving beacon
X431 Control unit, attachment left leg 42-pin connector for Control unit, attachment left leg pair (D791-3).
pair (D791-3)
X432 Control unit, attachment left leg Power supply and ground connection, Control unit attachment left jack
pair (D791-3) pair (D791-3)
CAN bus, Control unit, attachment left jack pair (D791-3)
Control breaker
X433 Control unit, attachment left leg Levelling

pair (D791-3) Indicator lights, alignment combi attachment
X434 Combi attachment, left side front Sensor, clamping position left front jack
Sensor, alignment left front jack
X435 Combi attachment, left side rear Sensor, clamping position left rear jack
Sensor, alignment left rear jack
X441 Control unit, attachment right leg 42-pin connector for Control unit, attachment right jack pair (D791-4).
pair (D791-4)
X442 Control unit, attachment right leg Power supply and ground connection, Control unit attachment right jack
pair (D791-4) pair (D791-4)
CAN bus, Control unit, attachment right jack pair (D791-4)
Control breaker
X443 Control unit, attachment right leg Solenoid valve, tilt in and out
pair (D791-4) Indicator lights: Front jacks up and down
Indicator lights: Clamping position front and rear jacks
X444 Combi attachment, right side front Sensor, clamping position right front jack
Sensor, alignment right front jack
X445 Combi attachment, right side rear Sensor, clamping position right rear jack
Sensor, alignment right front jack


X489 Attachment centre section Sensor, overheight jacks up and down
Indicator light, overheight jacks up and down
Solenoid valve overheight jacks up and down
X901 Voltage converter, cab Voltage converter 24V/12V or only joint
X905 Cab panel 12V socket for Com radio
Signal types, general

page
–
The machine’s control units use a number of different types of signals

to receive signals from sensors and switches and control solenoid
valves, lights, etc. The table below describes the different signal types.
Signal type Explanation Application area
Analogue input signals
Rheostat Resistance input 0–200 . Linear work range with accuracy of 3%. E.g. fuel level sensor.
Temperature Rheostat input with non-linear work area. The resistance value is equiva- E.g. hydraulic oil temper-
lent to temperature and the work range of approx. -40 to 150 C. ature sensor and air con-
There are two different resistance curves, one for Control unit, cab ditioning temperature
(D790-1) and one for the frame and attachment control units. sensor.
Accuracy is 0.5 C in the interval 0 –100 C (sensor’s measurement in-

accuracy not included). Outside of the interval 0 –100 C, accuracy is
2 C.
Voltage An analogue signal 0–5 V. The work range is 0.5 to 4.5 V. E.g. accelerator pedal
and analogue cab con-
trols (operating lever and
heater controls).
Analogue outputs
Current feedback A modulated signal between 0 V and system voltage, i.e. 24 V. The work Hydraulics, e.g. lifting/
voltage out, PWM range is 0 to 2 A. lowering of the boom.
A modulated signal is a digital signal translated to an analogue (continu- Used when the output
ous) signal adapted for a purpose, such as solenoid valve control. signal actuates propor-
When the spool in a solenoid valve gets hot, resistance drops. This gen- tional solenoid valves.
erates a lower current through the valve spool, which can cause the
valve’s servo pressure to remain constant. An internal ammeter 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, re- A modulated signal between 0 V and system voltage, i.e. 24 V. Requires E.g. cab fan.
versed polarity, 24 V as reference.
NPN PWM

Signal type Explanation Application area
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 lighting search 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, Logical one (1) generates voltage out, U >= 22.5 V E.g. working lights and
5 A Max. load 5 A wiper motors.
Open load 0.9 A

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 found
Open load 1.9 A on the frame and attach-
ment control units.
H-bridge Logical one (1) generates voltage out, U >= 22.5 V or grounded output, E.g. air conditioning wa-
U=0V ter 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 logic one (1), one output
gives voltage while the other output is grounded. At logic zero (0), the out-
puts switch voltage levels.

11 Common electrics – 11.6 Communication 43
11.6 Communication
11.6.1 CAN bus
CAN bus, description
page
–
Communication between the control units takes place using so-called

1 2
"CAN buses" (Controller Area Network) based on the ISO 11898
standard and CAN specification 2.0B.
The CAN bus is a fast control bus with logical hardware circuits. A sim-
120 ohm 120 ohm
ple technology that is highly reliable (low error frequency), which is a
requirement for control signals to be able to control systems based on
varying conditions and requirements.
CAN specifies:
5 5
• that the signal traffic is carried by "twisted pair" cables.
3
4 • that termination resistors (position 1) are necessary (adapted to
2 cables’ impedance) so that the pulse train (position 4) should ob-
U [V]
tain a sharp signal.

• that the signal valve is given as the potential difference between
3 the cables, CAN + and CAN - (position 2 and 3).
000026
t [S]
• form of signal messages.
Messages run in time and signal goes high
(voltage high) or low (voltage low).
1. Terminating resistor (120 ohm)
2. CAN + (voltage high)
3. CAN - (voltage low)
4. Pulse
5. Control unit
Message
There are two types of messages:
A
• CAN Standard, has identity field of 11 bits
• CAN Extended, has identity field of 29 bits
B C D E F G CAN works in messages sent in frames of 8 bytes (64 bits). A com-

000027
plete message is approx. 100 bits long. The illustration shows how a
t [S]
message is structured.
Messages run in time and signal goes high
(voltage high) or low (voltage low). Start bit (B)
A. Length message Indicates that the transmission of a frame, i.e. a message, is now
B. Start bit beginning.
C. Identity field/Priority Identity field (C)
D. Control field (length of data segment)
Indicates what kind of information the message contains, e.g. meas-
E. Data segment
urement information on engine speed.
F. Checksum for error detection
G. Acknowledge bit Does not indicate address to control unit. CAN does not work with ad-
dressing. All control units receive messages and send them on.
Control field (D)
Indicates how the length of the data segment that follows.

44 11 Common electrics – 11.6.1 CAN bus
Data segment (E)

Contains the information to be conveyed to control units in the
network.
Checksum for error detection (F)
Calculates a checksum for the message. This makes it possible for the
receiving control unit to detect errors in the sent message.
Acknowledge (G)
The transmitting control unit sets a bit to logic one (1) when the mes-
sage is sent. The first control unit to receive the message sends it on
and sets the bit to logic zero (0).
Communication
The CAN network consists of control units and segment. The segment
(bus) is a twisted pair cable that leads CAN + and CAN - signal levels
from control unit to control unit.
Each control unit measures the potential difference of its two inputs.
3,5 V The potential difference generates logic zero and logic one. The illus-
tration depicts an approved interval according to the standard for po-
tential levels. CAN + has a recommended value of 3.5 V and CAN -
U [V]
has 1.5 V. As a worst case scenario, the potential difference can be

0,5 V 0.5 V and still be approved. In practice, a potential difference of 2 V is
recommended for reliable communication.
A pulse train can only be observed using an oscilloscope, NOT with a
1,5 V digital multimeter.
When a message is sent, all control units in the network listen. Mes-
sages are saved in the control unit and relevant information is proc-
essed. The control unit that receives the message first confirms
000028
t [S] receipt (sets an acknowledge bit). The transmitting control unit then
knows that the message has been received by at least one
Potential levels CAN + and CAN -
control unit.
One control unit at a time sends the message. Other control units lis-
ten and wait until the bus is available. If two messages are to be sent
simultaneously then the sending of the message with the lowest prior-
ity (highest value in identity field) is concluded. This means that mes-
sages do not need to be re-sent in the event of a communication
conflict but only in the event of a bus error (erroneous message).
The CAN bus exchanges around 100 messages per second in the
network.
Different bus systems can be used e.g. random sending or primary
(master) / secondary (slave).

11 Common electrics – 11.6.2 Redundant CAN bus 45
HLP High Layer Protocol

CAN only specifies messages and how communication shall take
place, i.e. one protocol. In order to manage the network the CAN pro-
tocol needs to be supplemented by a HLP which specifies:
• flow control
• transport of data above a length of 8 bits in 8 bit messages
(division)
• how control units are addressed in the network
• how bits in the message’s data field should be interpreted
11.6.2 Redundant CAN bus

Redundant CAN bus, description
page
–
The redundant CAN bus handles communication between all of the

D791-4 D791-3 D791-2 D791-1 machine’s control units except Control unit, transmission (D793) and
CAN R CAN L 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 48.
Redundant CAN bus means that the control units are connected to a
D790-1 D790-2 D795
CAN R CAN L CAN R CAN L network that communicates via a CAN bus (see CAN bus, description
page 43) and that there are double communication routes on the net-
work. The network is divided into control units and segments (seg-
CAN L CAN R CAN L CAN R CAN L CAN R
003170
D797-R D797-O D797-F ments are cables between the control units). The number of active
segments depends on the number of control units the machine has,
Outline view, redundant CAN bus which depends on the machine’s equipment level (options).
The network is built on the CAN kingdom principle, which means that
one control unit is central and is the master unit. In this case, it is the
cab control unit (D790-1). Other control units in the network are sec-
ondary (slaves) and handle special areas, e.g., in cab.
The control units have two CAN bus connections - CAN L (left) and
CAN R (right). The control units are connected to one another in series
in a loop.
The redundant CAN bus can handle the loss of a segment. The link is
analysed upon start-up. If a segment is faulty, messages are sent via
another route.
If several segments are lost, one or more control units lose communi-
cation and work independently, often with significantly limited
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.

46 11 Common electrics – 11.6.2 Redundant CAN bus
Connection of redundant CAN bus

Battery disconnector In position 1 Battery disconnector, description page 3
Redundant voltage feed Activated. Redundant voltage feed of control units, function description page 7
S5
S2
D791-1 S2
D791-2
22 3
10 D790-2 S3
S9 S8
S1 D790-1 S5
D795 S4
1, 11 9
S3
D791-3 S4 D791-4
D797-R D797-F
4 5
6 S6 D797-O S7 8
7
013023
The illustration shows two alternatives for how the segment numbering
is changed depending on the number of control units on the machine:
Solid lines show the CAN-bus with a minimal number of control units.
Dotted lines show the CAN-bus with a maximal number of control
units.

1 Control unit, cab (D790-1) establishes Checked by control Cab control unit, description page 19
redundant CAN bus communication by system, error shown Diagnostic menu, see section 8 Control sys-
sending a request on the CAN bus via with error code. tem, group 8.4.1.1 CAN/POWER, menu 1 and
CAN R. 8.4.1.2 CAN/POWER, menu 2
2 The attachment control unit (D791-1) A clicking sound is Control unit, attachment, description page 23
sends a response back on the CAN bus audible when then Diagnostic menu, see section 8 Control sys-
via CAN L and sends the request on via termination resistor is tem, group 8.4.1.1 CAN/POWER, menu 1 and
CAN R. activated. 8.4.1.2 CAN/POWER, menu 2
Termination resistors in the control
nodes ensure communication segment
by segment.

11 Common electrics – 11.6.2 Redundant CAN bus 47

3 The attachment control unit option A clicking sound is Control unit, attachment option, description
(D791-2) sends a response back on the audible when then page 24
CAN bus via CAN L and sends the re- termination resistor is Diagnostic menu, see section 8 Control sys-
quest on via CAN R. activated. tem, group 8.4.1.1 CAN/POWER, menu 1 and
Termination resistors in the control 8.4.1.2 CAN/POWER, menu 2
by segment.
4 The attachment control unit left leg pair A clicking sound is Control unit, attachment left leg pair, descrip-
(D791-3) sends a response back on the audible when then tion page 25
by segment.
5 The attachment control unit right leg pair A clicking sound is Control unit, attachment right leg pair, descrip-
(D791-4) sends a response back on the audible when then tion page 26
by segment.
6 Control unit frame rear (D797-R) sends A clicking sound is Control unit, frame rear, description page 21
a response back on the CAN bus via audible when then Diagnostic menu, see section 8 Control sys-
CAN L and sends the request on via termination resistor is tem, group 8.4.1.1 CAN/POWER, menu 1 and
by segment.
7 Control unit frame option (D797-O) A clicking sound is Control unit, frame option, description page 22
sends a response back on the CAN bus audible when then Diagnostic menu, see section 8 Control sys-
via CAN L and sends the request on via termination resistor is tem, group 8.4.1.1 CAN/POWER, menu 1 and
by segment.
8 Control unit frame front (D797-F) sends A clicking sound is Control unit, frame front, description page 20
a response back on the CAN bus via audible when then Diagnostic menu, see section 8 Control sys-
CAN L and sends the request on via termination resistor is tem, group 8.4.1.1 CAN/POWER, menu 1 and
by segment.

48 11 Common electrics – 11.6.3 CAN bus drive-train

9 Control unit KID (D795) sends a re- A clicking sound is Control unit KID, description page 31
sponse back on the CAN bus via CAN L audible when then Diagnostic menu, see section 8 Control sys-
and sends the request on via CAN R. termination resistor is tem, group 8.4.1.1 CAN/POWER, menu 1 and
Termination resistors in the control activated. 8.4.1.2 CAN/POWER, menu 2
by segment.
10 The KIT control unit (D790-2) is not con- A clicking sound is Control unit KIT, description page 30
nected to the redundant CAN bus. The audible when then
KIT control unit (D790-2) does not com- termination resistor is
municate until ignition voltage (15) is activated.
activated.
11 If all control units have responded, the Checked by control Diagnostic menu, see section 8 Control sys-
cab control unit (D790-1) deactivates system, error shown tem, group 8.4.1.1 CAN/POWER, menu 1 and
the segment to the attachment control with error code. 8.4.1.2 CAN/POWER, menu 2
unit (D791-1).
If a control unit has not responded, then
Control unit, cab (D790-1) uses both
CAN L and CAN R to keep communica-
tion open and analyses which segment
is faulty.
11.6.3 CAN bus drive-train

CAN bus drive-train, description
page
–
The drive-train CAN bus is based on the SAE J1939 standard where
4 6
selected messages are used to control engine and transmission.
SAE J1939 is a standard from SAE (Society of Automotive Engineers)
for data communication in vehicles. The standard regulates hardware
interface, bit times and message composition.
D790-1 3 5
Control units for engine and transmission come from the respective
transmission and engine supplier. The control units use the same
standard of communication and therefore the messages for each en-
gine are constructed using the same structure.
Communication with Control unit, engine (D794) and Control unit,
transmission (D793) are separate from the redundant CAN bus.
section 8 Control system, group 8.4.1.3 CAN/POWER, menu 3.
000033
1 2
1. Redundant CAN bus
2. CAN bus drivetrain
3. Engine control unit
4. Engine
5. Transmission control unit
6. Transmission

11 Common electrics – 11.6.4 Communication between PC and machine 49
11.6.4 Communication between PC and

machine
Communication between PC and machine,
page
–
description
The machine has three or four sockets for communication between
control units and PC. Two are located in electronic box cab and one or
1 two in electronic box cab frame. It is the socket for communication with
engine alternative Volvo that varies.
2 Sockets for programming control units in 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 drivetrain in electronic box cab (position 2) are
used for communicating with the engine alternative and transmission
via CAN bus.
The VODIA socket in the frame electronic box (position 3) (only engine
alternative Volvo) is used to connect 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
006887
1. Diagnostic socket, machine

2. Diagnostic socket engine, CAN bus drivetrain (en-
gine alternative Cummins QSM11)
3. Diagnostic socket, engine VODIA (Volvo engine)
4. Diagnostic socket, transmission

50 11 Common electrics – 11.6.5 RMI (Remote Machine Interface)
11.6.5 RMI (Remote Machine Interface)

RMI (Remote Machine Interface), description
page
–
Remote Machine Interface is a tool to read data from the machine at

a distance. The RMI consists of a control unit which is connected to
the machine, antenna for communication and GPS-antenna ( ) for
007443
positioning.
RMI interface (A911)
RMI interface (A911) records communication on the CAN-bus and
sends the information to a central RMI server. In case of a fault in the
machine the control unit can send the information via GSM, GPRS,
WLAN, radio modem, SMS or e-mail.
From the RMI-server, the data from the machine can be analysed and
processed to read out different values. For example, when it is time for
service or if there are error codes stored in the machine.
As an option, there is a GPS-antenna, making it possible to read

off the machine’s position.
Control unit CAN gateway RMI (D795-2) sends some information from
010504
the machine’s CAN bus on to the RMI interface (A911), which sends it
Control unit CAN gateway RMI (D795-2) on via the RMI server.
NOTE
RMI only sends data from the machine, but no data can be sent
to the machine. RMI cannot be used to control the machine.

11 Common electrics – 11.6.6 Kalmar CAN Customer Gateway 51
11.6.6 Kalmar CAN Customer Gateway

Kalmar CAN Customer Gateway
page
–
Kalmar CAN Customer Gateway is an interface to connect an external

equipment in order to store machine data.
The Kalmar CAN Customer Gateway control unit (D795-2) translates
communication on the machine’s CAN bus to RS232 and CAN for con-
nection to external devices according to a predetermined protocol.
010504
Control unit, Kalmar CAN Customer Gateway NOTE
(D795-2) Kalmar CAN Customer Gateway only sends data from the ma-
chine, no data can be sent to the machine. Kalmar CAN Custom-
er Gateway cannot be used to control the machine.
The following data are examples of data available to the customer via
Kalmar CAN Customer Gateway:
• Operating time
• Temperature values
• Fuel consumption
• Current speed
• Current weight of load
• Operating time remaining until next service
• Number of lifted containers, different counters for different sizes
• Position of twistlock (locked/open)
• Boom position

52 11 Common electrics – 11.6.6 Kalmar CAN Customer Gateway

D Error codes 1
D Error codes
Table of Contents D Error codes

mm mm mm mm mm mm
D Error codes ................................................................................................. 3

Error codes, explanation ........................................................................................ 3
Error code menu, description ................................................................................. 4
Reading out error code ........................................................................................... 7
1 Engine ............................................................................................................. 9
Error codes engine, general ................................................................................... 9
Error codes engine (engine alternative Volvo) ..................................................... 10
Error codes engine (engine alternative Cummins QSM11) .................................. 28
2 Transmission................................................................................................ 41
Error codes transmission
Dana TE32 FF ...................................................................................................... 41
Error codes transmission ZF 5WG261 ................................................................. 87
8 Control system ........................................................................................... 101
Error codes machine .......................................................................................... 101

2 D Error codes

D Error codes 3
D Error codes
mm mm mm mm mm mm
Error codes, explanation

page
–
The error codes are explained in table form for Engine, Transmission
as well as Control system. They are sorted according to error code
number.
The error code table has the following information:
• Code, error code's number, shown in field C on display.
C
• Description, explanation of the error code and when it's
D E generated.
• Limitation, in case of certain error codes certain functions are im-
B
000389
paired or limited to protect the machine and operator.

• Action, information of what should be checked to find the cause of
B. Error code level (symbol)
the error code.
C. Error code number
D. Cause of error (symbol) • Diagnostic menu, reference to suitable diagnostic menu to rectify
E. Function (symbol) the problem, read signal value or check the function.
In addition to the explanation of the display figure, the description
of the diagnostic menus contains reference to circuit diagrams
that are found in section E Schematics and reference to function
group for further information about functions and components.
• Function group is a reference to which function group the error
code is associated. This field is used to search for more informa-
tion as necessary. Different types of information can be localized
with the function group.
Sections 0-12 contain a description of the function and its compo-
nents, component location and work instructions for different
tasks.

4 D Error codes
Error code menu, description

page
–
The control and monitoring system’s display is divided into four fields
C where the information is shown (see figure to the left).
D E • Field B: Error code level is shown with a symbol.

• 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 affect operator safety or
cause machine breakdown. The error code must be taken care of
D E
immediately. Stop working with the machine and contact service
immediately.
000350
• Warning
C Indicates machine malfunction that should be taken care of as
soon as possible. After finished work shift with the machine, con-
D E
tact service as soon as possible.
000351
• Information
C Information to the operator that something should be fixed, e.g.,
broken bulb. Fix the cause of the error code as soon as possible.
D E See section 6 Inspection and maintenance in the Operator’s
manual.
000352
The error code is stored in the error code list under operating
menu for service.

D Error codes 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
001343
level is shown for the most serious error code.
• Transmission:
XXX/YY Shown with error code number XX/YY on display.
B
001344
Field D: Type of error

1. Temperature too high/too low.
1 2 3
2. Incorrect signal to solenoid valve.
3. Incorrect hydraulic pressure.
4. Incorrect sensor signal.
4 5 6 5. Incorrect signal from control.

6. Incorrect signal to bulb.
7. Incorrect signal, for example, open circuit.
7
000396

6 D Error codes
Field E: Affected function

1. Attachment
1 2 3
2. Rotation of attachment
3. Side shift, attachment
4. Length adjustment attachment
4 5 6 5. Levelling attachment
6. Twistlocks
7. Tilt attachment
7 8 9 8. Bottom lift attachment
9. Bottom lift attachment, clamping position
10. Bottom lift attachment, jacks up/down
10 11 12 11. Boom up/down

12. Boom in/out
13. Pressure sensor lift cylinder (overload system, OP)
14. Overload system (not installed)
13 14 15
15. Support jacks up/down
16. Hydraulic functions
17. Brake system
16 17 18
18. Steering
19. Engine
20. Transmission
19 20 21 21. Central lubrication
22. Control unit
23. Hardware-related error
22 23 24 24. Cab
25. Air conditioning
26. Fuel system
25 26 27 27. Headlights
28. Windscreen wipers
29. Battery voltage
28 29 30 30. Bulb for lighting

000397

D Error codes 7
Reading out error code

page
–
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 Safety menu is shown. Press and hold in Enter for at least

two seconds.
1 23
4 5
000060
4 The error code list is shown on the display. Active error code is
shown on display where field C shows error code number togeth-
er with X(Y). X shows sequence number for shown error code
and (Y) shows number of active error codes.
Scroll between error codes with key 1 and 2 (arrow function).
001998
Error codes disappear from the list when the cause has been
remedied.

8 D Error codes
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
B • Error cause is shown with a symbol in field D
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.

D Error codes – 1 Engine 9
1 Engine
mm mm mm mm mm mm
Error codes engine, general

page
–
When contacting engine suppliers, use the Volvo/Cummins code.

• Display indicates error code according to SAE J1939
SPN/FMI
• J1587 indicates error code according to SAE J1587 (for Volvo:
Vodia).
PID, PPID, SID, PSID / FMI
Table 1. Specifications FMI
FMI Description SAE-text

0 Too high value. Data valid, but higher than normal operating range.
1 Too low value. Data valid, but lower than normal operating range.
2 Incorrect data. Intermittent or incorrect data.
3 Electrical problem. Abnormally high voltage or short-circuit to higher voltage.
4 Electrical problem. Abnormally low voltage or short-circuit to lower voltage.
5 Electrical problem. Abnormally low current or open circuit.
6 Electrical problem. Abnormally high current or short-circuit to ground.
7 Mechanical problem. Incorrect response from mechanical system.
8 Mechanical problem or electrical problem. Abnormal frequency.
9 Communication error. Abnormal update rate.
10 Mechanical problem or electrical problem. Abnormally wide variations.
11 Unknown malfunction. Non-identifiable malfunction.
12 Component error. Incorrect unit or component.
13 Incorrect calibration. Values outside calibration values.
14 Unknown malfunction. Special instructions.
15 Unknown malfunction. Reserved for future use.
16 Too high value. Data valid but above normal operational range, moderately severe
level
17 Too low value. Data valid but below normal operational range, the least severe
level
18 Too low value. Data valid but below normal operational 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 that is Not available or condition exists
identified by the SPN exists.

10 D Error codes – 1 Engine
Error codes engine

page
–

Description Limitation Action Connections Diagnostic
and menu
components
Code J1587
94/FMI PID94/ Sensor fuel No limitation. Check the cable har- Volvo -
FMI pressure, ness between control TWD1240VE:
short-circuited unit and component. D794/2:3
to voltage, Check the sensor. Volvo
ground, or TAD1250VE:
open circuit. D794/B:16
94/FMI PID94/ Low fuel No limitation. Change the fuel filter. - -

FMI pressure Change the fuel
(feed). prefilter.
Check if pressure can
be built up with the
hand pump.
97/1 PID97/1 Water in fuel. No limitation. Drain water separator. - -

Clean metal filter in the
fuel feed’s hose con-
nection on the engine.
Check fuel filter and
fuel pre-filter.
97/3 PID97/3 Sensor water- No limitation. Check the cable har- Volvo -
in-fuel short- ness between control TWD1240VE:
circuited to unit and component. D794/2:4
ground or Check the sensor. Volvo
open circuit. TAD1250VE:
D794/B:8
98/FMI PID98/ Low oil level. No limitation. Check the oil level. - Engine,
FMI menu 6
98/FMI PID98/ Sensor oil lev- No limitation. Check the cable har- Volvo ENGINE,
FMI el, short- ness between control TAD1250VE: menu 6
circuited to unit and component. D794/B:3, B:4,
voltage, Check the sensor. A:31
ground, or
open circuit.


and menu
components
Code J1587
100/1 PID100/1 Low engine oil The engine is Check the oil level. - ENGINE,
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 PID100/3 Sensor oil No limitation. Check the cable har- Volvo ENGINE,
pressure ca- ness between control TWD1240VE: menu 6
ble, short cir- unit and component. D794/1:14
cuit to voltage. Check the sensor. Volvo
TAD1250VE:
D794/B:11
pressure, ness between control TWD1240VE: menu 6
open circuit or unit and component. D794/1:14
short circuit to Check the sensor. Volvo
ground. TAD1250VE:
D794/B:11
102/0 PID102/0 High booster No limitation. Check turbocharger. - ENGINE,

pressure. Check the sensor. menu 6
Check fuel quality and

injectors.
102/1 PID102/1 Boost pres- Reduced engine Check the air filter. - ENGINE,
sure low. power. Check turbocharger. menu 6
Check the sensor.

Check the fuel feed
pressure.
102/3 PID102/3 Sensor, boost The engine jerks Check the cable har- Volvo ENGINE,
pressure, ca- more than nor- ness between control TWD1240VE: menu 7
ble short- mal during accel- unit and component. D794/1:3
circuited to eration or load. Check the sensor. Volvo
voltage. TAD1250VE:
D794/A:22


and menu
components
Code J1587
102/4 PID102/4 Sensor boost The engine jerks Check the cable har- Volvo ENGINE,
pressure, ca- more than nor- ness between control TWD1240VE: menu 7
ble short cir- mal during accel- unit and component. D794/1:3
cuit to ground eration or load. Check the sensor. Volvo
or open TAD1250VE:
circuit. D794/A:22
105/0 PID105/0 High The engine is Check the coolant - ENGINE,

charge-air switched off. level. menu 7
temperature. Check that charge-air
cooler is clean.
Check the thermostat.
Check the sensor.
105/3 PID105/3 Sensor No limitation. Check the cable har- Volvo ENGINE,
charge-air ness between control TWD1240VE: menu 7
temperature, unit and component. D794/1:2
cable short- Check the sensor. Volvo
circuited to TAD1250VE:
voltage or D794/A:47
open circuit.
105/4 PID105/4 Sensor No limitation. Check the cable har- Volvo ENGINE,
charge-air ness between control TWD1240VE: menu 7
temperature, unit and component. D794/1:2
cable short Check the sensor. Volvo
circuit to TAD1250VE:
ground or D794/A:47
open circuit.
106/FMI PID106/ Sensor boost The engine jerks Check the cable har- Volvo ENGINE,
FMI pressure, more than nor- ness between control TWD1240VE: menu 6
short-circuited mal during accel- unit and component. D794/1:3
to voltage, eration or load. Check the sensor. Volvo
frame, or open TAD1250VE:
circuit. D794/A:22
106/FMI PID106/ High charge- No limitation. Check the cable har- - ENGINE,
FMI air pressure. ness between control menu 6
unit and component.
Check the sensor.


and menu
components
Code J1587
110/0 PID110/0 High coolant Volvo Check the coolant - ENGINE,
temperature. TWD1240VE: level. menu 7
Engine is turned Check that radiator is
off. clean.
Volvo Check the thermostat.
TAD1250VE: No
Check the cap on the
limitation.
expansion tank.
Check if there is air in
coolant system.
Check the sensor.
110/3 PID110/3 Sensor cool- Preheating is ac- Check the cable har- Volvo ENGINE,
ant tempera- tivated even if ness between control TWD1240VE: menu 7
ture, cable engine is warm. unit and component. D794/1:25
short-circuited Check the sensor. Volvo
to voltage or TAD1250VE:
open circuit. D794/B:27
110/4 PID110/4 Sensor cool- Preheating is ac- Check the cable har- Volvo ENGINE,
ant tempera- tivated even if ness between control TWD1240VE: menu 7
ture, cable engine is warm. unit and component. D794/1:25
short circuit to Check the sensor. Volvo
ground. TAD1250VE:
D794/B:27
111/1 PID111/1 Low coolant Volvo Check the coolant lev- - -

level. TWD1250VE: el; fill if necessary.
Engine is turned Check the sensor.
off.
Volvo
TAD1250VE: No
limitation.
111/FMI PID111/ Sensor cool- Volvo Check the cable har- Volvo -
FMI ant level, short TWD1240VE: ness between control TWD1240VE:
circuit to Engine is turned unit and component. D794/2:7
voltage. off. Check the sensor. Volvo
Volvo TAD1250VE:
TAD1250VE: No D794/B:23
limitation.


and menu
components
Code J1587
153/FMI PID153/ Too high No limitation. Clean the crankcase - -
FMI crankcase ventilation.
ventilation Check for wear on cyl-
pressure. inder liner, piston and
piston rings.
153/FMI PID153/ Crankcase No limitation. Check the cable har- Volvo -

FMI ventilation ness between control TAD1250VE:
pressure sen- unit and component. D794/B:28
sor, short cir- Check the sensor.
cuit to voltage,
ground or
open circuit.
158/FMI PID158/ Low battery The engine may Check and charge the - -
FMI voltage. be difficult to batteries.
start. Check alternator.
Check the battery
cables.
172/FMI PID172/ Sensor air No limitation. Check the cable har- Volvo ENGINE,
FMI temperature ness between control TWD1240VE: menu 7
inlet, short- unit and component. D794/1:2
circuited to Check the sensor. Volvo
voltage, TAD1250VE:
ground, or D794/A:47
open circuit.
175/0 PID175/0 High Reduced engine Check the oil level. - ENGINE,
engine oil power. Check lubrication sys- menu 7
temperature. tem’s thermostat.
Check the sensor.
175/3 PID175/3 Sensor, oil No limitation. Check the cable har- Volvo ENGINE,
temperature, ness between control TWD1240VE: menu 7
cable short- unit and component. D794/1:1
circuited to Check the sensor. Volvo
voltage or TAD1250VE:
open circuit. D794/A:31, B:3,
B:4


and menu
components
Code J1587
temperature, ness between control TWD1240VE: menu 7
cable short unit and component. D794/1:1
circuit to Check the sensor. Volvo
ground. TAD1250VE:
D794/A:31, B:3,
B:4
190/FMI PID190/ Engine speed No limitation. Ease off throttle or se- - -

FMI too high. lect higher gear.
608/FMI PPID98/ Signal error No limitation. Check CAN bus - CAN/POW-

FMI for start and drivetrain. ER, menu 3
stop.
620/3 SID232/3 Voltage feed Several error Check the cable har- Volvo -
1079/2 to sensor, ca- codes for sensor ness between control TWD1240VE:
ble short error. unit and component. D794/1:5
circuited to Reduced engine Volvo
voltage. power. TAD1250VE:
Incorrect instru- D794/B:17
ment values.
620/4 SID232/4 Voltage feed Several error Check the cable har- Volvo -
1079/3 to sensor, ca- codes for sensor ness between control TWD1240VE:
ble short error. unit and component. D794/1:4
circuited to Reduced engine Volvo
ground. power. TAD1250VE.
Incorrect instru- D794/B:17
ment values.
626/3 PID45/3 Preheating re- Preheating can- Check the cable har- Volvo ENGINE,
lay, cable not be activated. ness between control TWD1240VE: menu 5
short-circuited unit and component. D794/2:36
to voltage. Check the relay. Volvo
TAD1250VE:
D794/B:25
626/4 PID45/4 Preheating re- Preheating is Check the cable har- Volvo ENGINE,
lay, cable constantly ness between control TWD1240VE: menu 5
short-circuited activated. unit and component. D794/2:36
to ground. Check the relay. Volvo
TAD1250VE:
D794/B:25


and menu
components
Code J1587
626/5 PID45/5 Preheating re- Preheating can- Check the cable har- Volvo ENGINE,
lay, open cir- not be activated. ness between control TWD1240VE: menu 5
cuit on cable unit and component. D794/2:36
or defective Check the relay. Volvo
component. TAD1250VE:
D794/B:25
629/FMI SID254/ Engine control The engine does Change the control - -
FMI unit (D794), not start. unit.
internal error. Engine runs
rough.
630/FMI SID253/ Control unit, The engine does Reprogram the control - -
FMI engine (D794) not start. unit.
memory error.
636/3 SID21/3 Sensor rota- Engine takes Check the cable har- Volvo -
tion speed longer time to ness between control TWD1240VE:
camshaft, no start than nor- unit and component. D794/1:7, 1:18
signal. mal. Engine runs Check the sensor. Volvo
normally when it TAD1250VE:
has started. D794/B:45,
B:46
636/8 SID21/8 Sensor en- Engine takes Check the cable har- Volvo -
gine speed, longer time to ness between control TWD1240VE:
camshaft, ab- start than nor- unit and component. D794/1:7, 1:18
normal mal. Engine runs Check the sensor. Volvo
frequency. normally when it TAD1250VE:
has started. D794/B:45,
B:46
637/2 SID22/2 Engine rpm The engine is ex- Check the cable har- Volvo ENGINE,
sensor, fly- tremely difficult ness between control TWD1240VE: menu 2
wheel, irregu- to start and runs unit and component. D794/1:30, 1:31
lar signal. rough, if it runs. Check the sensor. Volvo
TAD1250VE:
D794/B:37,
B:38
637/3 SID22/3 Sensor en- The engine is ex- Check the cable har- Volvo ENGINE,
gine speed, tremely difficult ness between control TWD1240VE: menu 2
flywheel, ab- to start and runs unit and component. D794/1:30, 1:31
normal rough, if it runs. Check the sensor. Volvo
frequency. TAD1250VE:
D794/B:37,
B:38


and menu
components
Code J1587
637/8 SID22/8 Sensor en- The engine is ex- Check the cable har- Volvo ENGINE,
gine speed, tremely difficult ness between control TWD1240VE: menu 2
flywheel, ab- to start and runs unit and component. D794/1:30, 1:31
normal rough, if it runs. Check that the sensor Volvo
frequency. is connected correctly. TAD1250VE:
D794/B:37,
B:38
639/FMI SID231/ Communica- Engine switched Use diagnostic menu Volvo CAN/POW-
FMI tion error with off: engine can- to find incorrect TWD1240VE: ER, menu 3
Control unit, not be started. segment. D794/2:1, 2:2
engine Engine on: en- Check the cable har- Volvo
(D794), gine goes to idle ness between control TAD1250VE:
configuration and can only be unit and component. D794/B:51,
error. stopped by using B:55
Check the control unit.
the emergency
stop.
639/FMI SID231/ Communica- Instruments and Use diagnostic menu - CAN/POW-

FMI tion error with controls do not to find incorrect ER, menu 3
Control unit, work. segment.
engine Check the cable har-
(D794), ness between control
configuration unit and component.
error.
639/FMI SID240/ Engine control It may not be Reprogram the control - -

FMI unit, memory possible to start unit.
error. the engine.
651/2 SID1/2 Electric fail- Engine only runs Check the cable har- Volvo -
ure, injector on 5 cylinders, ness between control TWD1240VE:
cylinder 1. sounds rough unit and component. D794/1:11, 1:12
and has reduced Check the injector. Volvo
power. TAD1250VE:
D794/A:20,
A:24
power. TAD1250VE:
D794/A:20,
A:24


and menu
components
Code J1587
power. TAD1250VE:
D794/A:20,
A:24
power. TAD1250VE:
D794/A:20,
A:24
651/7 SID1/7 Incorrect com- Runs rough at Check the fuel Volvo -
pression or low rpm and low pressure. TWD1240VE:
defective load. Check valve D794/1:11, 1:12
injector clearance. Volvo
cylinder 1. TAD1250VE:
Check the cable har-
ness between control D794/A:20,
unit and component. A:24
Check the injector.

Perform compression
test and check
cylinder 1.
power. TAD1250VE:
D794/A:20,
A:24
power. TAD1250VE:
D794/A:20,
A:24


and menu
components
Code J1587
power. TAD1250VE:
D794/A:12,
A:16
power. TAD1250VE:
D794/A:12,
A:16
power. TAD1250VE:
D794/A:12,
A:16
Check the injector.

Perform compression
test and check
cylinder 2.
power. TAD1250VE:
D794/A:12,
A:16


and menu
components
Code J1587
power. TAD1250VE:
D794/A:28,
A:32
power. TAD1250VE:
D794/A:28,
A:32
power. TAD1250VE:
D794/A:28,
A:32
power. TAD1250VE:
D794/A:28,
A:32
Check the injector.

Perform compression
test and check
cylinder 3.


and menu
components
Code J1587
power. TAD1250VE:
D794/A:28,
A:32
power. TAD1250VE:
D794/A:52,
A:56
power. TAD1250VE:
D794/A:52,
A:56
power. TAD1250VE:
D794/A:52,
A:56
power. TAD1250VE:
D794/A:52,
A:56


and menu
components
Code J1587
defective in- load. Check valve D794/1:34, 1:24
jector clearance. Volvo
Check the injector.

Perform compression
test and check
cylinder 4.
power. TAD1250VE:
D794/A:52,
A:56
power. TAD1250VE:
D794/A:44,
A:48
power. TAD1250VE:
D794/A:44,
A:48
power. TAD1250VE:
D794/A:44,
A:48


and menu
components
Code J1587
power. TAD1250VE:
D794/A:44,
A:48
655/7 SID5/7 Incorrect com- Engine only runs Check that cabling to Volvo -
pression or on 5 cylinders, the injectors is not TWD1240VE:
defective sounds rough damaged. D794/1:35, 1:24
injector and has reduced Check the cable har- Volvo
cylinder 5. power. ness between control TAD1250VE:
unit and component. D794/A:44,
Check the injector. A:48
Perform compression
test and check
cylinder 5.
power. TAD1250VE:
D794/A:44,
A:48
and has reduced Check the component. Volvo
power. TAD1250VE:
D794/A:36,
A:40
power. TAD1250VE:
D794/A:36,
A:40


and menu
components
Code J1587
power. TAD1250VE:
D794/A:36,
A:40
power. TAD1250VE:
D794/A:36,
A:40
defective in- load. Check valve D794/1:36, 1:24
jector clearance. Volvo
Check the injector.

Perform compression
test and check
cylinder 6.
power. TAD1250VED7
94/A:36, A:40
677/FMI PPID3/ Starter motor The engine does Check the cable har- Volvo ENGINE,
FMI relay, short not start. ness between control TWD1240VE: menu 5
SID39/ circuit to volt- Engine starts im- unit and component. D794/2:31
FMI age/ground. mediately when Check the motor. Volvo
ignition is TAD1250VED7
turned on. 94/B:29


and menu
components
Code J1587
1485/3 PPID5/3 Main relay, The instrument Check the cable har- Volvo -
cable short- panel loses volt- ness between control TWD1240VE:
circuited to age when the ig- unit and component. D794/1:32
voltage. nition key is Check the relay. Volvo
turned to the start TAD1250VE:
position. The en- D794/A:8
gine will not start.
2017/FMI PSID201/ Communica- Engine switched Use diagnostic menu Volvo CAN/POW-
FMI tion error with off: engine can- to find incorrect TWD1240VE: ER, menu 3
Control unit, not be started. segment. D794/2:1, 2:2
engine Engine on: en- Check the cable har- Volvo
(D794), con- gine goes to idle ness between control TAD1250VE:
figuration and can only be unit and component. D794/B:51,
error. stopped by using B:55
the emergency
stop.
2047/xx Undetectable - Contact the engine D794 -

error code supplier for further
from the information.
engine.
2791/3 PPID19 Internal EGR: The engine con- Check the wiring Volvo -
Wiring error trol unit limits en- (boost pressure TAD1250VE:
(boost pres- gine output. sensor). D794/B:30
sure sensor). IEGR cannot be Contact an authorised
Mechanical activated. Volvo Penta
error on IEGR. workshop.
Check the component
(IEGR).
Check the component
(IEGR).


and menu
components
Code J1587
Check the component
(IEGR).
2791/7 PPID19 Internal EGR: Could damage Check the wiring Volvo -
Mechanical the turbine wheel (boost pressure TAD1250VE:
error on IEGR. of the turbo- sensor). D794/B:30
charger and in- Contact an authorised
crease force and Volvo Penta
emissions. workshop.
Check the component
(IEGR).
520192/1 PPID8 Sensor piston No limitation. Check the cable har- Volvo -
cooling pres- ness between control TAD1250VE:
sure, short- unit and component. D794/B:14
circuited to Check the sensor.
voltage,
ground, or
open circuit.
520192/3 PPID8 Low piston No limitation. Check that engine oil - -

cooling pressure is over 175
pressure. kPa.
520194/3 PPID4 Start input Engine cannot Check that connec- D794 -
CIU: be started. tions to the start key
Short circuited Engine starts im- are not damaged.
to minus (-). mediately when Check that the start
Activated too the ignition is key cabling is not
long. turned on. damaged.
520194/4 PPID4 Start input Engine cannot Check that connec- D794 -
CIU: be started. tions to the start key
Short circuited Engine starts im- are not damaged.
to minus (-). mediately when Check that the start
Activated too the ignition is key cabling is not
long. turned on. damaged.


and menu
components
Code J1587
520195/4 PPID6 Stop input on The engine can Check that connec- Volvo -
control unit: only be stopped tions and cabling to the TAD1250VE:
Short circuited with the auxiliary start key are not D794/B:27
to minus (-). stop. damaged. Volvo
Activated too TWD1240VE:
long. D794/2:6

Error codes engine (engine

page
–
alternative Cummins QSM11)

and menu
components
Code J1587
84/2 PID084/2 Electrical error, Engine speed Check the cable har- - -
speed sensor, limited to maxi- ness between control
invalid data. mum speed unit and component.
without gear. Check the sensor.
84/10 PID084/10 Electrical error, Engine speed Check the cable har- - -
speed sensor, limited to maxi- ness between control
signal manipula- mum speed unit and component.
tion detected. without gear. Check the sensor.
91/3 PID091/3 Electrical error, The engine Check the cable har- - -
accelerator ped- does not re- ness between control
al, cable short spond to throttle unit and component.
circuit to application. Check the component.
voltage.
al, cable short spond to throttle unit and component.
circuit to ground. application. Check the component.
al, frequency spond to throttle unit and component.
too low. application. Check the component.
al, frequency spond to throttle unit and component.
too high. application. Check the component.
91/19 SID091/2 Communication Engine only Use diagnostic menu - CAN/POW-

error with Con- running at idle. to find incorrect ER, menu 3
trol unit, cab segment.
(D790-1), elec-
trical error, ac-
celerator pedal.
97/3 PID097/3 Electrical error, No limitation. Check the cable har- D794/ -
water-in-fuel ness between control Sensor:09
sensor, cable unit and component.
short circuit to Check the component.
voltage.


and menu
components
Code J1587
97/4 PID097/4 Electrical error, No limitation. Check the cable har- D794/ -
water-in-fuel ness between control Sensor:09
short circuit to Check the component.
ground.
97/15 PID097/15 Water in fuel. Risk of white Drain water from the - -
exhaust smoke fuel filter.
and reduced
engine output.
100/1 PID100/1 Low engine oil Engine output is Check the oil level in - ENGINE,
pressure. reduced gradu- the engine, top up if menu 6
ally. The engine necessary.
is turned off af-
ter 30 seconds.
100/2 PID100/2 Sensor, oil pres- No warning for Check the sensor. D794/ ENGINE,
sure, data error. low engine oil Sensor:44 menu 6
pressure.
100/3 PID100/3 Sensor oil pres- No warning for Check the cable har- D794/Sen- ENGINE,
sure cable, short low engine oil ness between control sor:44 menu 6
circuit to pressure. unit and component.
voltage. Check the sensor.
100/4 PID100/4 Sensor oil pres- No warning for Check the cable har- D794/Black:14 ENGINE,
sure, open cir- low engine oil ness between control menu 6
cuit or short pressure. unit and component.
circuit to ground. Check the sensor.
100/18 PID100/1 Low engine oil No limitation. Check the oil level in - ENGINE,
pressure. the engine; fill if menu 6
necessary.
Check the sensor.
102/2 PID102/2 Sensor boost Reduced en- Check the cable har- D794/Sen- ENGINE,
pressure indi- gine power. ness between control sor:39 menu 7
cates high boost unit and component.
pressure, but Check the sensor.
other engine
data indicates
that pressure
should be
normal.


and menu
components
Code J1587
102/3 PID102/3 Sensor, boost Reduced en- Check the cable har- D794/ ENGINE,
pressure, cable gine power. ness between control Sensor:39 menu 7
short-circuited to unit and component.
voltage. Check the sensor.
102/4 PID102/4 Sensor boost Reduced en- Check cable harness D794/Black:3 ENGINE,
pressure, cable gine power. between control unit menu 7
short circuit to and component.
ground or open Check the boost pres-
circuit. sure sensor.
103/16 PID103/0 Overspeed pro- Reduced en- Check the component. - -

tection, turbo. gine power.
105/0 PID105/0 Intake air too Engine output is Check the coolant lev- - ENGINE,
warm. reduced gradu- el in the engine; fill if menu 7
ally. The engine necessary.
is turned off af- Check that the charge
ter 30 seconds. air cooler is clean,
clean if necessary.
Check that fan belts
are intact. Check
sensor inlet air
temperature.
105/3 PID105/3 Sensor charge- Risk of white Check cable harness D794/ ENGINE,
air temperature, exhaust smoke. between control unit Sensor:38 menu 7
cable short- No warning for and component.
circuited to volt- high coolant Check that the charge-
age or open temperature. air temperature sensor
circuit. is correctly installed
and connected.
Check the charge-air
temperature sensor.
105/4 PID105/4 Sensor charge- Risk of white Check the cable har- D794/ ENGINE,
air temperature, exhaust smoke. ness between control Sensor:38 menu 7
cable short cir- No warning for unit and component.
cuit to ground or high coolant Check that the sensor
open circuit. temperature. is correctly installed
and connected.
Check the sensor.
108/2 PID108/2 Electrical error, Reduced en- Check the sensor. - -

air pressure gine power.
sensor, data
error.


and menu
components
Code J1587
108/3 PID108/3 Electrical error, Reduced en- Check the cable har- D794/ -
air pressure gine power. ness between control Sensor:06
short circuit to Check the sensor.
voltage.
108/4 PID108/4 Electrical error, Reduced en- Check the cable har- D794/ -
air pressure gine power. ness between control Sensor:06
ground.
110/0 PID110/0 High coolant Engine output is Check the coolant - ENGINE,
temperature. reduced gradu- level. menu 7
ally. The engine Check that radiator is
is turned off af- clean.
ter 30 seconds.
Check if there is air in
coolant system.
Check the cap on the
expansion tank.
Check the sensor.
Check the thermostat.
110/3 PID110/3 Sensor coolant No display of Check the cable har- D794/Sen- ENGINE,
temperature, ca- engine ness between control sor:02 menu 7
ble short- temperature. unit and component.
circuited to volt-
age or open
circuit.
110/4 PID110/4 Sensor coolant No display of Check the cable har- D794/ ENGINE,
temperature, ca- engine ness between control Sensor:02 menu 7
ble short circuit temperature. unit and component.
to ground. Check that the sensor
is connected correctly.
Check the sensor.
111/1 PID111/1 Low coolant Engine output is Check the coolant lev- - -
level. reduced gradu- el; fill if necessary.
ally. The engine Check the sensor.
is turned off af-
ter 30 seconds.
111/2 PID111/2 Electrical error, No warning for Check the cable har- D794/ -
sensor coolant low coolant ness between control Sensor:09
level, data error. level. unit and component.
Check the sensor.


and menu
components
Code J1587
166/2 PID116/2 Output imbal- Rough idle. Check fuel quality. The - -
ance between error code could be
cylinders. generated if the fuel
system has been
opened, allowing air to
enter the system.
Troubleshoot the
engine.
167/1 PID167/1 Low battery Warning active Check batteries and D794/OEM:7, -
voltage. until voltage is alternator. 8, 17, 18, 28
correct.
167/16 PID167/0 Low battery Warning active Check fuses. Check D794/OEM:7, -
voltage. until voltage is batteries and 8, 17, 18, 28
correct. alternator.
167/18 PID167/1 High battery Warning active Check batteries and D794/OEM:7, -
voltage. until voltage is alternator. 8, 17, 18, 28
correct. The en-
gine runs at in-
creased idle in
order to in-
crease voltage.
168/16 PID168/0 High voltage No limitation. Check fuses. Check D794/OEM:7, -

feed to control batteries and 8, 17, 18, 28
unit. alternator.
168/18 PID168/1 Low voltage Rough idle. Check fuses. Check D794/OEM:7, -
feed to control batteries and 8, 17, 18, 28
unit. alternator.
175/0 PID175/0 High engine oil Engine output is Check the coolant and - ENGINE,
temperature. reduced gradu- oil level in the engine, menu 7
ally. The engine top up if necessary.
is turned off af- Check that the oil cool-
ter 30 seconds. er is clean, clean if
necessary.
Check that the fan
belts are intact.
Check the sensor.
175/3 PID175/3 Sensor, oil tem- No display of Check the cable har- D794/ ENGINE,
perature, cable engine oil ness between control Sensor:42 menu 7
short-circuited to temperature. unit and component.
voltage or open Check that the sensor
circuit. is connected correctly.


and menu
components
Code J1587
175/4 PID175/4 Sensor oil tem- No display of Check the cable har- D794/ ENGINE,
perature, cable engine oil ness between control Sensor:42 menu 7
short circuit to temperature. unit and component.
ground. Check the sensor.
188/4 SID032/4 Electrical error, Reduced en- Check the cable har- D794/
wastegate sole- gine power. ness between control Actuator:24
noid valve 1 unit and component.
short circuit to Check the solenoid
ground. valve.
190/0 PID190/0 Engine speed Fuel supply re- Ease off the throttle or - -
too high. stricted until en- select higher gear.
gine speed is
below permitted
value.
190/2 PID190/2 Electrical error, The engine Check the cable har- D794/Sen- -
sensor rotation stops and ness between control sor:47, 50
speed/ignition cannot be unit and component.
mode; no signal restarted. Check the sensor.
from any
sensors.
190/10 PID190/10 Electrical error, No limitation. Check the cable har- D794/Sensor: -
sensor rotation ness between control 47, 50
speed/ignition unit and component.
mode, one of Check the sensor.
two signals
missing.
191/16 PID191/0 Speed limitation Speed is Decrease throttle - -

activated. reduced. application.
191/18 PID191/1 Speed warning Engine only Increase throttle - -

for low speed. running at idle. application.
251/2 PID251/2 Internal error en- - - - -

gine control unit.
441/3 PID441/3 Extra tempera- No warning for Check the cable har- D794/Sensor:
ture sensor, high tempera- ness between control 12
short circuit to ture, Control unit and component.
ground. unit, engine Check the sensor.
(D794).


and menu
components
Code J1587
441/4 PID441/4 Extra tempera- No warning for Check the cable har- D794/Sensor:
ture sensor, high tempera- ness between control 12
short circuit to ture, Control unit and component.
voltage. unit, engine Check the sensor.
(D794).
558/2 SID230/2 Electrical error, No limitation. Check cable between D794/OEM: -

sensor accelera- control unit and 03, 13
tor pedal, idle component.
switch, data Check component.
error.
558/4 SID230/4 Electrical error, The engine Check cable between D794/OEM: -
sensor accelera- does not re- control unit and 03, 13
tor pedal, idle spond to throttle component.
switch, cable application. Check component.
short circuit to
ground.
558/13 SID230/13 Electrical error, Engine only Check cable between D794/OEM: 13 -
sensor accelera- running at idle. control unit and
tor pedal, idle component.
switch, calibra- Check component.
tion error.
608/2 SID250/2 Communication No limitation. Check the control unit. D794/OEM: 26,
error with Con- 27, 36, 37, 46
trol unit, engine
(D794).
608/9 SID250/9 Communication No limitation. Check the control unit. D794/OEM: 26,
error with Con- 27, 36, 37, 46
trol unit, engine
(D794).
620/3 SID232/3 Electrical error, Reduced en- Check the cable har- D794/Sensor: -
1080/3 reference volt- gine power. No ness between control 18, 25, 45
age to sensor warning for low unit and component.
short circuit to oil pressure or Check the control unit.
voltage. low coolant
level.
1081/4 reference volt- gine power. No ness between control 18, 25, 45
age to sensor warning for low unit and component.
short circuit to oil pressure or Check the component.
ground. low coolant
level.


and menu
components
Code J1587
626/11 SID237/11 Electrical error Preheating Check the cable har- D794/ ENGINE,
to control of re- does not work. ness between control Actuator:34 menu 5
lay preheating. Risk of white unit and component.
smoke. Check the component.
627/2 SID251/2 Voltage feed to Reduced en- Check fuses. D794/OEM:7, -

control unit dis- gine power. En- Check batteries and 8, 17, 18, 28
appears without gine difficult to alternator.
ignition off. start or stops.
629/12 SID254/12 Internal error en- The engine Check the control unit. - -
gine control unit. does not start.
629/12 SID254/12 Internal error en- No limitation. Check the control unit. - -
gine control unit.
630/2 SID253/2 Software error Reduced en- Reprogram the soft- - -

Control unit gine power. En- ware in Control unit,
engine (D794). gine difficult to engine (D794).
start or stops.
632/3 SID017/3 Electrical error, No limitation. Check the cable har- D794/ -
fuel cut-off sole- ness between control Actuator:33
noid valve, cable unit and component.
voltage. valve.
632/4 SID017/4 Electrical error, The engine is Check the cable har- D794/ -
fuel cut-off sole- switched off. ness between control Actuator:33
noid valve, cable unit and component.
ground. valve.
639/2 SID231/2 Communication Functions via Use diagnostic menu - CAN/POW-

error with Con- CAN bus not to find incorrect ER, menu 2
trol unit, engine working. segment.
(D794).

(D794).

(D794), timeout
error.


and menu
components
Code J1587
(D794), configu-
ration error.
644/2 SID030/2 Electrical error, The engine is Check the cable har- - -
accelerator ped- switched off. ness between control
al, signal not unit and component.
within valid Check the component.
interval.
647/4 SID033/4 Electrical error, Cooling fan Check the cable har- D794/ -
fan connection, runs constantly. ness between control Actuator:10,
cable short cir- unit and component. Actuator:9
cuit to ground. Check the component.
651/5 SID001/5 Electrical error, Engine only Check the cable har- D794/ -
injector runs on 5 cylin- ness between control Actuator:10,
cylinder 1, open ders, sounds unit and component. Actuator:9
circuit on cable. rough and has Check the injector.
reduced power.
injector runs on 5 cylin- ness between control Actuator:10,
cylinder 1, ca- ders, sounds unit and component. Actuator:9
ble short circuit rough and has Check the injector.
to ground. reduced power.
652/5 SID002/5 Electrical error, Engine only Check the cable har- D794/Actuator: -
injector runs on 5 cylin- ness between control 7, 8
cylinder 2, open ders, sounds unit and component.
reduced power.
injector cylinder runs on 5 cylin- ness between control Actuator:7, 8
2, cable short ders, sounds unit and component.
circuit to ground. rough and has Check the injector.
reduced power.
injector cylinder runs on 5 cylin- ness between control Actuator:6, 16
3, open circuit ders, sounds unit and component.
on cable. rough and has Check the injector.
reduced power.


and menu
components
Code J1587
653/6 SID003/6 Electrical error, Engine only Check cable between D794/ -
injector cylinder runs on 5 cylin- control unit and Actuator:6, 16
3, cable short ders, sounds component.
circuit to ground. rough and has Check component.
reduced power.
injector runs on 5 cylin- ness between control Actuator:26, 36
reduced power.
654/6 SID004/6 Electrical error, Engine only Check the cable har- D794/Actua- -
injector runs on 5 cylin- ness between control tor:26, 36
cylinder 4, ca- ders, sounds unit and component.
injector runs on 5 cylin- ness between control Actuator: 3, 4
reduced power.
injector runs on 5 cylin- control unit and Actuator: 3, 4
cylinder 5, ca- ders, sounds component.
ble short circuit rough and has Check component.
injector runs on 5 cylin- control unit and com- Actuator: 1, 2
cylinder 6, open ders, sounds ponent.
circuit on cable. rough and has Check component.
reduced power.
injector runs on 5 cylin- ness between control Actuator: 1, 2
cylinder 6, ca- ders, sounds unit and component.
PID154/3 auxiliary output ness between control Actuator:14
2, cable short unit and component.
circuit to Check the component.
voltage.


and menu
components
Code J1587
auxiliary output ness between control Actuator:45
2, cable short unit and component.
circuit to Check the component.
voltage.
974/3 SID029/3 Electrical error, The engine Check the cable har- D794/OEM: 21 -
extra accelera- does not re- ness between control
tor pedal, cable spond to throttle unit and component.
short circuit to application. Check the component.
voltage.
974/4 SID029/4 Electrical error, The engine Check the cable har- D794/OEM: 21 -
extra accelera- does not re- ness between control
tor pedal, cable spond to throttle unit and component.
short circuit to application. Check the component.
ground.
974/19 SID029/2 Communication The engine Use diagnostic menu - CAN/POW-

error with Con- does not re- to find incorrect ER, menu 2
trol unit, cab spond to throttle segment.
(D790-1), elec- application.
trical error, ac-
celerator pedal.
1043/3 PID221/3 Electrical error, Engine only Check the cable har- D794/OEM: 48 -
accelerator ped- running at idle. ness between control
al reference volt- unit and component.
age, cable short Check the component.
circuit to
voltage.
1043/4 PID221/4 Electrical error, Engine only Check the cable har- D794/OEM: 48 -
accelerator ped- running at idle. ness between control
al reference volt- unit and component.
age, cable short Check the component.
circuit to ground.
1072/11 SID070/11 Electrical error, Engine brake 1 Check the cable har- D794/ -
solenoid valve cannot be ness between control Actuator:44
engine brake 2. activated. unit and component.
Check the solenoid
valve.
1073/11 SID029/11 Electrical error, Engine brake 2 Check the cable har- D794/ -
solenoid valve cannot be ness between control Actuator:44
engine brake 2. activated. unit and component.
Check the solenoid
valve.


and menu
components
Code J1587
reference volt- gine power. ness between control 17, 37
age to sensor unit and component.
voltage.
reference volt- gine power. ness between control 17, 37
age to sensor unit and component.
ground.
1188/3 SID032/3 Electrical error, Reduced en- Check the cable har- D794/ -
solenoid valve gine power. ness between control Actuator:24
wastegate 1 unit and component.
voltage. valve.
solenoid valve gine power. ness between control Actuator: 23
wastegate 2 unit and component.
voltage. valve.
wastegate sole- gine power. ness between control Actuator: 23
noid valve 2 unit and component.
ground. valve.
1265/4 SID085/4 Electrical error, No limitation. Check the cable har- - -

oil-burn solenoid ness between control
valve, cable unit and component.
ground. valve.
1319/2 PID102/2 Electrical error, Reduced en- Check the cable har- D794/Sensor: 9 -
boost pressure gine power. ness between control
sensor. unit and component.
Check the sensor.
1380/1 PID017/1 Low oil level No limitation. Check the oil level in - -
engine. the engine, top up if
necessary.


and menu
components
Code J1587
1383/31 SID151/11 Engine turned No limitation. Turn off the engine - -
off other than with the start key.
with start key,
causing load.
1384/31 SID029/14 Engine turned No limitation. Turn off the engine - -

off other than with the start key.
with start key,
causing load.
1387/3 PID223/3 Electrical error, No protection Check the cable har- D794/ -
extra pressure for pressure ness between control Sensor: 19
sensor, cable (customer-spe- unit and component.
short circuit to cific option). Check the sensor.
voltage.
1387/4 PID223/4 Electrical error, No protection Check the cable har- D794/ -
extra pressure for pressure ness between control Sensor: 19
sensor, cable (customer-spe- unit and component.
short circuit to cific option). Check the sensor.
ground.
1484/31 SID216/11 Error codes in No limitation. Check error codes for - -

other control other machine control
units. units, particularly the
Control unit, cab
(D790-1) and Control
unit, transmission
(D793).

D Error codes – 2 Transmission 41
2 Transmission
mm mm mm mm mm mm
Error codes transmission

page
–
Dana TE32 FF
Control unit transmission can generate two states with reduced func-
tionality to protect the transmission in the event of serious malfunc-
tions:
• "Limp-home".
In this mode only 1-2 gear in both directions can be used. If the
malfunction occurs in a higher gear then downshifting has to be
performed manually to 1st gear or 2nd.
• "Shutdown"
In this mode the transmission is permanently in neutral as there is
no oil pressure to enable gear selection.
Connections
Diagnostic
Description Limitation Action and
menu
components
Code SPN/
FM1
00/50 7F09D/C Memory error in con- Transmission - - -
trol unit locked in neutral
transmission. position
(Shut-down).

(Shut-down).

(Shut-down).

(Shut-down).
20/60 7F065/1 Sensor gear 1/3 - D793/A2 - -

(B6067) indicates B6067
low oil pressure
when there should
be pressure.

42 D Error codes – 2 Transmission
Connections
Diagnostic
menu
components
Code SPN/
FM1
20/61 7F065/0 Sensor gear 1/3 - D793/A2 - -
(B6067) indicates oil B6067
pressure when there
should not be any oil
pressure.
21/00 7F069/1 Sensor oil pressure Transmission Check feed - -

(1) has too low oil locked in neutral pressure to
pressure. position transmission.
(Shut-down). Save information
about current pres-
sure when the
problem occurred.
21/01 7F069/0 Sensor oil pressure Transmission Check feed - -

(1) has too high oil locked in neutral pressure to trans-
pressure. position mission.
about current pres-
sure when the
problem occurred.
22/00 7F06A/1 Sensor oil pressure Transmission Check feed - -

about current pres-
sure when the
problem occurred.
22/01 7F06A/0 Sensor oil pressure Transmission Check feed - -

(2) has too high oil locked in neutral pressure to
about current pres-
sure when the
problem occurred.
23/00 7F06B/1 Sensor oil pressure Transmission Check feed - -

about current pres-
sure when the
problem occurred.

Connections
Diagnostic
menu
components
Code SPN/
FM1
23/01 7F06B/0 Sensor oil pressure Transmission Check feed - -
about current pres-
sure when the
problem occurred.
24/00 7F06C/1 Sensor oil pressure Transmission Check feed - -

about current pres-
sure when the
problem occurred.
24/01 7F06C/0 Sensor oil pressure Transmission Check feed - -

about current pres-
sure when the
problem occurred.
30/04 7F090/1 Low battery voltage. Control unit saves Check the cable - CAN/POW-
stored information harness to the con- ER, menu 15
to flash memory trol unit.
and restarts to Check alternator,
clear memory. battery and cable
harness between
battery and
alternator.
30/05 7F090/0 High battery voltage. Control unit re- Check voltage - CAN/POW-
ceives reduced feed. ER, menu 15
proportional con- If equipment for
trol precision de- assisted start is
pending on connected, discon-
reduced PWM nect it.
work cycle.
31/00 7F093/1 Reference voltage Control unit re- Check the voltage - CAN/POW-
sensor 8 V, too low. ceives reduced feed. ER, menu 15
sensor signals. Check the control
unit.

Connections
Diagnostic
menu
components
Code SPN/
FM1
31/01 7F093/0 Reference voltage Control unit re- Check the voltage - CAN/POW-
sensor 8 V, too high. ceives reduced feed. ER, menu 15
sensor signals. Check the control
unit.
34/00 7F0BB/ Sensor drum speed Transmission Check the cable - TRANSM,
1F (B752) defective. locked to 1st and harness between menu 6
2nd gear gearshift lever and
(Limp-home). sensor.
Check the sensor.
34/01 7F0BC/1 Measured turbine Transmission Check the cable - -

rpm at start is too locked in neutral harness between
low. position gearshift lever and
(Shut-down). sensor.
Check the sensor.
Check feed
pressure to
transmission.
34/02 7F0BD/0 Measured turbine Transmission Check cabling be- - -

rpm at start is too locked in neutral tween gear selec-
high. position tor and sensor rpm
(Shut-down). drum.
Check the sensor.
34/03 7F0BE/1 Transmission indi- Transmission Check sensor rpm - -

cates that system locked in neutral drum.
pressure is missing position Check solenoid
even though there (Shut-down). valve RSP Drive
should be pressure. (Y6066).
Feed pressure to
transmission too
low.
34/04 7F0BE/0 Transmission indi- Transmission Check cabling be- - -

cates that there is locked in neutral tween gear selec-
system pressure position tor and sensor rpm
even though there (Shut-down). drum.
should not be Check the sensor.
pressure.
Check solenoid
valve RSP Drive
(Y6066).

Connections
Diagnostic
menu
components
Code SPN/
FM1
40/06 7F05E/2 Incorrect direction Control unit locks Check cabling to - TRANSM,
from gear selector. transmission in gear selector with menu 2
neutral. regards to forward
and reverse signal.
40/08 7F041/1F The seat’s direction Transmission Check the seat’s - -

was changed when locked in neutral direction or show
the parking brake position the operator how
was not activated, (Shut-down). the seat is turned
and/or the gear se- around acc. to cor-
lector was not in neu- rect method.
tral, and/or the
machine was not
stationary.
41/06 7F05F/2 Incorrect gear selec- Control unit does Check cabling to - TRANSM,
tion from gear not allow change gear selector with menu 2
selector. of range, however, regards to signal
operation of ma- range.
chine is possible.
42/04 7F080/1 Actual gear ratio too Control unit indi- Check transmis- - TRANSM,
low. cates that one or sion with purpose menu 6
several clutches to understand if
are slipping. and, if that is the
case, which clutch
is slipping.
Check the set gear
ratio for the control
unit.
42/05 7F080/0 Actual gear ratio too Control unit indi- Check transmis- - TRANSM,
high. cates that one or sion with purpose menu 6
several clutches to understand if
are slipping. and, if that is the
case, which clutch
is slipping.
Check the set gear
ratio for the control
unit.
43/03 7F063/0 Signal from sensor Control unit indi- Check the cable D793/H3 - TRANSM,
oil temperature cates the error. harness between B7660 menu 10
(B7660) outside valid control unit and
interval. component.
Check the sensor.

Connections
Diagnostic
menu
components
Code SPN/
FM1
43/07 7F063/10 Torque converter Control unit indi- Check the trans- D793/H3 - TRANSM,
temperature ex- cates the error to mission oil cooler, B7660 menu 10
ceeds 100 C. make operator clean if necessary.
aware of the warn- Check the thermo-
ing’s level. stat in the trans-
mission oil cooler.
43/08 7F063/0 Torque converter The control unit Check the trans- D793/H3 - TRANSM,
temperature ex- protects the transmission oil cooler, B7660 menu 10
ceeds 120 C. mission and does clean if necessary.
not allow the tem- Check the thermo-
perature in the stat in the trans-
torque converter to mission oil cooler.
exceed the limit
value.
The control unit
locks the transmis-
sion in neutral po-
sition, the engine
is restricted to
50% of max. rpm.
44/10 7F0C6/9 Faulty signal for ac- - Use diagnostic - CAN/POW-

celerator pedal posi- menu to find incor- ER, menu 3
tion from engine rect segment.
control unit (D794).
45/06 7F048/2 Invalid combination Control unit limits Check the speed - -
for redundant digital the machine’s sensors.
speed inputs. speed to the re-
duced speed.
46/05 7F036/F Max. torque for inch- - - - -

ing has been
exceeded.
47/01 7F07B/ Transmission has Control unit indi- Let up the acceler- - -
10 exceeded limit value cates the error. ator pedal and
for upper rpm. slow down the
machine.
48/00 7F0B3/0 Disengaged 4WD/ Control unit indi- Check the 4WD/ - -
2WD-selector has cates the error. 2WD-selector.
jammed in engaged Check if digital
position or the feed- feedback is on and
back signal is wrong. connected to con-
trol unit.

Connections
Diagnostic
menu
components
Code SPN/
FM1
48/01 7F0B3/1 Engaged 4WD/2WD- Control unit indi- Check the 4WD/ - -
selector has jammed cates the error. 2WD-selector.
in engaged position Check if digital
or the return signal is feedback is on and
wrong. connected to con-
trol unit.
49/00 7F0B4/0 Disengaged Low/ Control unit indi- Check Low/High - -

High-selector has cates the error. gear selector.
jammed in engaged Check if digital
position or the feed- feedback is on and
back signal is wrong. connected to con-
trol unit.
49/01 7F0B4/1 Engaged Low/High- Control unit indi- Check Low/High - -

selector has jammed cates the error. gear selector.
in engaged position Check if digital
or the return signal is feedback is on and
wrong. connected to con-
trol unit.
50/00 7F010/4 Sensor gear 1/3 Transmission Check the cable D793/A2 - TRANSM,
(B6067), short- locked to 1st and harness between B6067 menu 10
circuited to ground. 2nd gear control unit and
(Limp-home). sensor.
Check the sensor.
50/01 7F010/3 Sensor gear 1/3 Transmission Check the cable D793/A2 - TRANSM,
(B6067), not con- locked to 1st and harness between B6067 menu 10
nected or open 2nd gear control unit and
circuit. (Limp-home). component.
Check the sensor.
50/04 7F010/11 Sensor gear 1/3 Control unit indi- Check the cable D793/A2 - TRANSM,
(B6067), value below cates error and harness between B6067 menu 10
lowest calibrated uses lowest value control unit and
value. in its settings. component.
Check the sensor.
50/05 7F010/F Sensor gear 1/3 Control unit indi- Check the cable D793/A2 -
(B6067), value cates error and harness between B6067
above highest cali- uses highest value control unit and
brated value. in its settings. component.
Check the sensor.

Connections
Diagnostic
menu
components
Code SPN/
FM1
51/00 7F011/4 Sensor oil tempera- The control unit Check the cable D793/H3 - TRANSM,
ture, cable (B7660) limits the transmis- harness between B7660 menu 10
short circuit to sion’s temperature control unit and
ground. measurement to sensor.
the lowest value in Check the sensor.
its settings, which
results in poor
temperature
compensation.
51/01 7F011/3 Sensor, oil tempera- The control unit Check the cable D793/H3 - TRANSM,
ture (7660) not con- limits the transmis- harness between B7660 menu 10
nected or open sion’s temperature control unit and
circuit. measurement to sensor.
the highest value Check the sensor.
in its settings,
which results in
poor temperature
compensation.
51/04 7F011/11 Sensor oil tempera- The control unit Check the cable D793/H3 - TRANSM,
ture (B7660), value limits the transmis- harness between B7660 menu 10
below lowest cali- sion’s temperature control unit and
brated value. measurement to component.
the lowest value in Check the sensor.
its settings.
51/05 7F011/F Sensor oil tempera- The control unit Check the cable D793/H3 - TRANSM,
ture (B7660), value limits the transmis- harness between B7660 menu 10
above highest cali- sion’s temperature control unit and
brated value. measurement to component.
in its settings.
52/00 7F012/4 Temperature monitor The control unit Check the cable D793/J3 - TRANSM,
torque converter limits the transmis- harness between S2210 menu 10
(S2210) short- sion’s temperature control unit and
circuited to ground. measurement to sensor.
in its settings,
which results in
poor temperature
compensation.

Connections
Diagnostic
menu
components
Code SPN/
FM1
52/01 7F012/3 Temperature monitor The control unit Check the cable D793/J3 - TRANSM,
(S2210) is not sion’s temperature control unit and
connected. measurement to sensor.
in its settings,
which results in
poor temperature
compensation.
52/04 7F012/11 Temperature monitor The control unit Check the cable D793/J3B - TRANSM,
(S2210), value below sion’s temperature control unit and
lowest calibrated measurement to component.
value. the lowest value in Check the sensor.
its settings, which
results in poor
temperature
compensation.
52/05 7F012/F Temperature monitor The control unit Check the cable D793/J3B - TRANSM,
(S2210), value sion’s temperature control unit and
above highest cali- measurement to component.
brated value. the highest value Check the sensor.
in its settings,
which results in
poor temperature
compensation.
53/00 7F013/4 Analogue input sig- Depending on Check the cable - -

nal 3, short circuit to which function is harness between
ground. on the pin: control unit and
Pressure feed- component.
back: Transmis- Check the
sion locked to 1st component.
and 2nd gear
(Limp-home).
Sensor oil pres-
sure: Control unit
locks transmis-
sion in neutral.
Other: Control unit
uses the lowest
value in its
settings.

Connections
Diagnostic
menu
components
Code SPN/
FM1
53/01 7F013/3 Analogue input Depending on Check the cable - -
signal 3 is not function which is harness between
connected. on the pin: control unit and
and 2nd gear
(Limp-home).
Sensor oil pres-
sure: Control unit
locks transmis-
sion in neutral.
Other: Control unit
uses the lowest
value in its
settings.
53/04 7F013/11 Analogue input sig- Control unit indi- Check the cable - -
nal 3, the value is be- cates error and harness between
low lowest calibrated uses lowest value control unit and
Check the
component.
53/05 7F013/F Analogue input sig- Control unit indi- Check the cable - -
nal 3, the value is cates error and harness between
Check the
component.
54/00 7F014/4 Reference voltage - Check the cable D793/M1 - CAN/POW-

sensor 5 V short- harness between S2210, B7667, ER, menu 15
circuiting to frame control unit and B6069
ground. component.
Check the sensor.
54/01 7F014/3 Reference voltage - Check the cable D793/M1 - CAN/POW-

sensor 5 V, short- harness between S2210, B7667, ER, menu 15
circuited to voltage. control unit and B6069
component.
Check the sensor.

Connections
Diagnostic
menu
components
Code SPN/
FM1
nal, short circuit to which function is harness between
and 2nd gear
(Limp-home).
Sensor oil pres-
sure: Control unit
locks transmis-
sion in neutral.
Other: Control unit
uses the lowest
value in its
settings.

signal 5 is not which function is harness between
and 2nd gear
(Limp-home).
Sensor oil pres-
sure: Control unit
locks transmis-
sion in neutral.
Other: Control unit
uses the lowest
value in its
settings.
Check the
component.

Connections
Diagnostic
menu
components
Code SPN/
FM1
Check the
component.
56/00 7F016/4 Pressure sensor Depending on Check the cable D793/S1 - TRANSM,
gear 2/4 (B6069), which function is harness between B6069 menu 10
short-circuited to on the pin: control unit and
ground. Pressure feed- component.
and 2nd gear
(Limp-home).
Sensor oil pres-
sure: Control unit
locks transmis-
sion in neutral.
Other: Control unit
uses the lowest
value in its
settings.
56/01 7F016/3 Pressure sensor Depending on Check the cable D793/S1 - TRANSM,
gear 2/4 (B6069) is which function is harness between B6069 menu 10
not connected. on the pin: control unit and
and 2nd gear
(Limp-home).
Sensor oil pres-
sure: Control unit
locks transmis-
sion in neutral.
Other: Control unit
uses the lowest
value in its
settings.

Connections
Diagnostic
menu
components
Code SPN/
FM1
56/04 7F016/11 Pressure sensor Control unit indi- Check the cable D793/S1 - TRANSM,
gear 2/4 (B6069), cates error and harness between B6069 menu 10
value below lowest uses lowest value control unit and
calibrated value. in its settings. component.
Check the
component.
56/05 7F016/F Pressure sensor Control unit indi- Check the cable D793/S1 - TRANSM,
gear 2/4 (B6069), cates error and harness between B6069 menu 10
value above highest uses highest value control unit and
calibrated value. in its settings. component.
Check the
component.

and 2nd gear
(Limp-home).
Sensor oil pres-
sure: Control unit
locks transmis-
sion in neutral.
Other: Control unit
uses the lowest
value in its
settings.

Connections
Diagnostic
menu
components
Code SPN/
FM1
and 2nd gear
(Limp-home).
Sensor oil pres-
sure: Control unit
locks transmis-
sion in neutral.
Other: Control unit
uses the lowest
value in its
settings.
Check the
component.
Check the
component.

Connections
Diagnostic
menu
components
Code SPN/
FM1
and 2nd gear
(Limp-home).
Sensor oil pres-
sure: Control unit
locks transmis-
sion in neutral.
Other: Control unit
uses the lowest
value in its
settings.

and 2nd gear
(Limp-home).
Sensor oil pres-
sure: Control unit
locks transmis-
sion in neutral.
Other: Control unit
uses the lowest
value in its
settings.
Check the
component.

Connections
Diagnostic
menu
components
Code SPN/
FM1
Check the
component.
60/00 7F01A/6 Sensor drum speed When only one Check cable be- D793/C3 - TRANSM,
(B7520) short circuit rpm signal that is tween control unit B7520 menu 6
to ground. not the engine rpm and sensor.
signal is incorrect, Check the sensor.
the control unit
calculates the
missing rpm.
If several rpm sig-
nals or the engine
rpm signal are de-
fective the control
unit locks the
transmission to
gear 1-2
(Limp-home).
60/01 7F01A/5 Sensor rpm drum When only one Check cable be- D793/C3 - TRANSM,
(B7520) not rpm signal that is tween control unit B7520 menu 6
connected. not the engine rpm and sensor.
the control unit
calculates the
missing rpm.
If several rpm sig-
nals or the engine
rpm signal are de-
fective the control
unit locks the
transmission to
gear 1-2
(Limp-home).
60/03 7F01A/A Sensor drum speed Control unit indi- Check cable be- D793/C3 - TRANSM,
(B7520), value out- cates the error. tween control unit B7520 menu 6
side limit values. and component.
Check component.

Connections
Diagnostic
menu
components
Code SPN/
FM1
60/04 7F01A/1 Sensor rpm drum This message is Check transmis- D793/C3 - TRANSM,
(B7520), pulse count given as supple- sion to find out if B7520 menu 6
too low. mentary informa- and which clutch is
tion for slipping.
malfunctions in the Check transmis-
transmission. sion’s settings for
gear ratio in control
unit.
60/05 7F01A/0 Sensor rpm drum This message is Check transmis- D793/C3 - TRANSM,
too high. mentary informa- and which clutch is
tion for slipping.
unit.
61/00 7F01B/6 Sensor rpm output When only one Check cable be- D793/E3 - TRANSM,
shaft (B7580) short- rpm signal that is tween control unit B7580 menu 6
circuited to ground. not the engine rpm and sensor.
the control unit
calculates the
missing rpm.
If several rpm sig-
nals or the engine
rpm signal are de-
fective the control
unit locks the
transmission to
gear 1-2
(Limp-home).

Connections
Diagnostic
menu
components
Code SPN/
FM1
61/01 7F01B/5 Sensor rpm output When only one Check cable be- D793/E3 - TRANSM,
shaft (B7580) not rpm signal that is tween control unit B7580 menu 6
the control unit
calculates the
missing rpm.
If several rpm sig-
nals or the engine
rpm signal are de-
fective the control
unit locks the
transmission to
gear 1-2
(Limp-home).
61/03 7F01B/A Sensor rpm output Control unit indi- Check cable be- D793/E3 - TRANSM,
shaft (B7580), value cates the error. tween control unit B7580 menu 6
outside limit values. and component.
Check the sensor.
61/04 7F01B/1 Sensor rpm output This message is Check transmis- D793/E3 - TRANSM,
shaft (B7580), pulse given as supple- sion to find out if B7580 menu 6
count too low. mentary informa- and which clutch is
tion for slipping.
unit.
61/05 7F01B/0 Sensor rpm output This message is Check transmis- D793/E3 - TRANSM,
shaft (B7580), pulse given as supple- sion to find out if B7580 menu 6
count too high. mentary informa- and which clutch is
tion for slipping.
unit.

Connections
Diagnostic
menu
components
Code SPN/
FM1
62/00 7F01C/6 Sensor engine rpm When only one Check cable be- D793/F3 - TRANSM,
(B7530), short- rpm signal that is tween control unit B7530 menu 6
circuited to ground. not the engine rpm and sensor.
the control unit
calculates the
missing rpm.
If several rpm sig-
nals or the engine
rpm signal are de-
fective the control
unit locks the
transmission to
gear 1-2 (Limp-
home).
62/01 7F01C/5 Sensor engine rpm When only one Check cable be- D793/F3 - TRANSM,
(B7530), not con- rpm signal that is tween control unit B7530 menu 6
nected or has open not the engine rpm and sensor.
circuit. signal is incorrect, Check the sensor.
the control unit
calculates the
missing rpm.
If several rpm sig-
nals or the engine
rpm signal are de-
fective the control
unit locks the
transmission to
gear 1-2
(Limp-home).
62/03 7F01C/A Engine rpm informa- Transmission in Use diagnostic - -

tion not available. Limp-home. menu to find incor-
rect segment.
62/04 7F01C/1 Sensor engine rpm This message is Check transmis- D793//F3 - TRANSM,
tion for slipping.
unit.

Connections
Diagnostic
menu
components
Code SPN/
FM1
62/05 7F01C/0 Sensor engine rpm This message is Check transmis- D793/F3 - TRANSM,
tion for slipping.
unit.
62/06 7F07A/1 Incorrect engine rpm Transmission in Check sensor en- D793/F3 - TRANSM,
information when tur- Limp-home. gine rpm speed. B7530 menu 6
bine rpm is Check compo-
calculated nent’s position.
63/00 7F01D/6 Sensor turbine When only one Check cable be- D793/G3 - TRANSM,
speed (B7510) short rpm signal that is tween control unit B7510 menu 6
circuit to ground. not the engine rpm and sensor.
the control unit
calculates the
missing rpm.
If several rpm sig-
nals or the engine
rpm signal are de-
fective the control
unit locks the
transmission to
gear 1-2
(Limp-home).
63/01 7F01D/5 Sensor rpm turbine When only one Check cable be- D793/G3 - TRANSM,
(B7510) not rpm signal that is tween control unit B7510 menu 6
the control unit
calculates the
missing rpm.
If several rpm sig-
nals or the engine
rpm signal are de-
fective the control
unit locks the
transmission to
gear 1-2
(Limp-home).

Connections
Diagnostic
menu
components
Code SPN/
FM1
63/03 7F01D/A Sensor turbine Control unit indi- Check cable be- D793/G3 - TRANSM,
speed (B7510), cates the error. tween control unit B7510 menu 6
value outside limit and component.
values. Check component.
63/04 7F01D/1 Sensor rpm turbine This message is Check transmis- D793/G3 - TRANSM,
tion for slipping.
unit.
63/05 7F01D/0 Sensor rpm turbine This message is Check transmis- D793/G3 - TRANSM,
tion for slipping.
unit.
70/00 7F020/4 Servo valve gear for- Transmission Check the cable D793/B1 - TRANSM,
ward and reverse locked to 1st and harness between Y6300, D793/ menu 8
(Y6300), short- 2nd gear control unit and so- C1 - Y6300
circuited to each oth- (Limp-home). lenoid valve.
er, signal cable Check the sole-
short-circuited to noid valve.
voltage, or plus-ca-
ble short-circuited to
frame ground.
(Y6300) open circuit 2nd gear control unit and so- C1 - Y6300
or short-circuit (Limp-home). lenoid valve.
voltage. Check the sole-
noid valve.

Connections
Diagnostic
menu
components
Code SPN/
FM1
(Y6300), control 2nd gear control unit and so- C1 - Y6300
current above (Limp-home). lenoid valve.
1400 mA. Check the sole-
noid valve.
ward and reverse locked in neutral harness between Y6300, D793/ menu 9
(Y6300), control cur- position control unit and so- C1 - Y6300
rent outside ap- (Shut-down). lenoid valve.
proved interval. Check the sole-
Wrong impedance. noid valve.
(Y6300), not 2nd gear control unit and C1 - Y6300
connected. (Limp-home). component.
Check the sole-
noid valve.
71/00 7F021/4 Solenoid valve gear Transmission Check the cable D793/D1 - TRANSM,
selection 1/3 locked to 1st and harness between Y6067, D793/ menu 8
(Y6067), short- 2nd gear control unit and so- E1 - Y6067
frame ground.
(Y6067) open circuit 2nd gear control unit and so- E1 - Y6067
or short-circuited (Limp-home). lenoid valve.
noid valve.

Connections
Diagnostic
menu
components
Code SPN/
FM1
(Y6067), control cur- 2nd gear control unit and so- E1 - Y6067
rent higher than (Limp-home). lenoid valve.
noid valve.
(Y6067), control cur- 2nd gear control unit and so- E1 - Y6067
rent outside ap- (Limp-home). lenoid valve.
proved interval Check the sole-
(incorrect noid valve.
impedance).
(Y6067), not 2nd gear control unit and E1 - Y6067
Check the sole-
noid valve.
72/00 7F022/4 Solenoid valve gear Transmission Check the cable D793/F1 - -
selection 2/4 locked to 1st and harness between Y6069, D793/
(Y6069), short- 2nd gear control unit and so- G1 - Y6069
frame ground.
(Y6069) open circuit 2nd gear control unit and so- G1 - Y6069
or short-circuited (Limp-home). lenoid valve.
noid valve.

Connections
Diagnostic
menu
components
Code SPN/
FM1
(Y6069), control cur- 2nd gear control unit and so- G1 - Y6069
rent higher than (Limp-home). lenoid valve.
noid valve.
(Y6069), control cur- 2nd gear control unit and so- G1 - Y6069
rent outside ap- (Limp-home). lenoid valve.
proved interval Check the sole-
(incorrect noid valve.
impedance).
(Y6069), not 2nd gear control unit and G1 - Y6069
Check the
component.
73/00 7F023/4 Analogue output sig- Transmission Check the cable - TRANSM,
nal 3, cables short- locked to 1st and harness between menu 8
circuited to each oth- 2nd gear control unit and so-
er, signal cable (Limp-home). lenoid valve.
short-circuited to Check the sole-
voltage, or plus-ca- noid valve.
frame ground.
73/01 7F023/3 Analogue output sig- Transmission Check the cable - TRANSM,
nal 3, open circuit or locked to 1st and harness between menu 8
short-circuited 2nd gear control unit and so-
voltage. (Limp-home). lenoid valve.
Check the sole-
noid valve.

Connections
Diagnostic
menu
components
Code SPN/
FM1
73/02 7F023/6 Analog output signal Transmission Check the cable - TRANSM,
3, control current locked to 1st and harness between menu 9
above 1400 mA. 2nd gear control unit and so-
(Limp-home). lenoid valve.
Check the sole-
noid valve.
73/03 7F023/8 Analog output signal Transmission Check the cable - TRANSM,
3, control current locked to 1st and harness between menu 9
outside approved in- 2nd gear control unit and so-
terval (wrong (Limp-home). lenoid valve.
impedance). Check the sole-
noid valve.
73/09 7F023/5 Analogue output Transmission Check the cable - -

signal 3, not locked to 1st and harness between
connected. 2nd gear control unit and
(Limp-home). component.
Check the sole-
noid valve.
74/00 7F024/4 Analogue output sig- Control unit indi- Check the cable - -
nal 4, short circuit to cates the error. harness between
ground. control unit and
component.
Check the
component.
nal 4, not connected cates the error. harness between
or short-circuited to control unit and
voltage. component.
Check the
component.
component.
Check the
component.

Connections
Diagnostic
menu
components
Code SPN/
FM1
voltage. component.
Check the
component.
component.
Check the
component.
voltage. component.
Check the
component.
76/02 7F026/6 Analog output signal Control unit indi- Check the cable - -
6, control current cates the error. harness between
above 1400 mA. control unit and
component.
Check the
component.
76/03 7F026/8 Analog output Control unit indi- Check the cable - -
signal 6, output cates the error. harness between
signal outside control unit and
approved interval component.
(wrong impedance). Check the
component.
76/09 7F026/5 Analogue output Control unit indi- Check the cable - -
signal 6, not cates the error. harness between
connected. control unit and
component.
Check the
component.
77/02 7F02F/ All gear packs Transmission - - -

1F disengaged. locked in neutral
position
(Shut-down).

Connections
Diagnostic
menu
components
Code SPN/
FM1
80/00 7F027/4 Solenoid valve drive Transmission Check the cable D793/K1 - Dana
forward (Y6066F), locked to 1st and harness between Y6066F TRANSM,
plus-cable short- 2nd gear control unit and menu 7
circuited to frame. (Limp-home). component.
Check the sole-
noid valve.
80/01 7F027/3 Solenoid valve drive Transmission Check the cable D793/K1 - Dana
forward (Y6066F), locked to 1st and harness between Y6066F TRANSM,
cable is not connect- 2nd gear control unit and menu 7
ed or short-circuited (Limp-home). component.
to voltage. Check the sole-
noid valve.
80/09 7F027/5 Solenoid valve drive Transmission Check the cable D793/K1 - TRANSM,
forward (Y6066F) locked to 1st and harness between Y6066F menu 7
not connected. 2nd gear control unit and
Check the sole-
noid valve.
81/00 7F028/4 Solenoid valve drive Transmission Check the cable D793/E2 - TRANSM,
reverse (Y6066R), locked to 1st and harness between Y6066R menu 7
plus-cable short- 2nd gear control unit and so-
circuited to frame. (Limp-home). lenoid valve.
Check the sole-
noid valve.
plus-cable short- 2nd gear control unit and so-
circuited to voltage. (Limp-home). lenoid valve.
Check the sole-
noid valve.
not connected. 2nd gear control unit and
Check the sole-
noid valve.

Connections
Diagnostic
menu
components
Code SPN/
FM1
82/00 7F029/4 Solenoid valve gear Transmission Check the cable D793/F2 - TRANSM,
selection 1/3 locked to 1st and harness between Y6075 menu 7
(Y6075), cable short- 2nd gear control unit and so-
circuited to frame (Limp-home). lenoid valve.
ground. Check the sole-
noid valve.
(Y6075), cable short- 2nd gear control unit and so-
circuited to voltage. (Limp-home). lenoid valve.
Check the sole-
noid valve.
(Y6075), not 2nd gear control unit and so-
connected. (Limp-home). lenoid valve.
Check the sole-
noid valve.
83/00 7F02A/3 Solenoid valve gear Transmission Check the cable D793/K2 - Dana
selection 2/4 locked in neutral harness between Y6074 TRANSM,
(Y6074), cable short- position control unit and menu 7
circuited to frame (Shut-down). component.
ground. Check the
component.
83/01 7F02A/4 Solenoid valve gear Transmission Check the cable D793/K2 - Dana
selection 2/4 locked in neutral harness between Y6074 TRANSM,
(Y6074), cable short- position control unit and menu 7
circuited to voltage. (Shut-down). component.
Check the
component.
90/01 7F0F0/1 Software error - - - -

Control unit,

Control unit,

Control unit,

Connections
Diagnostic
menu
components
Code SPN/
FM1
Control unit,

Control unit,

Control unit,

Control unit,

Control unit,

Control unit,
90/11 7F0F0/B Software error - - - -

Control unit,
90/12 7F0F0/C Software error - - - -

Control unit,
90/13 7F0F0/D Software error - - - -

Control unit,
90/14 7F0F0/E Software error - - - -

Control unit,
90/15 7F0F0/F Software error - - - -

Control unit,

Control unit,

Control unit,

Connections
Diagnostic
menu
components
Code SPN/
FM1
Control unit,

Control unit,
90/90 7F0A0/ Defective software in Transmission - - -

1F Control unit locked in neutral
transmission (D793). position
(Shut-down).
90/xx - 7F000/0 System error. Transmission - D793/A:20 -

99/xx locked in neutral
position
(Shut-down).

Control unit,

Control unit,

Control unit,

Control unit,

Control unit,

Control unit,
91/50 7F0F7/A Software error - - - -

Control unit,
91/51 7F0F7/B Software error - - - -

Control unit,

Connections
Diagnostic
menu
components
Code SPN/
FM1
91/52 7F0F7/C Software error - - - -
Control unit,
91/53 7F0F7/D Software error - - - -

Control unit,
91/54 7F0F7/E Software error - - - -

Control unit,
91/55 7F0F7/F Software error - - - -

Control unit,

Control unit,

Control unit,

Control unit,

Control unit,

Control unit,
91/70 7F0F7/ Software error - - - -

1E Control unit,

Control unit,
92/01 7F0F2/1 Shifting missing Transmission - - -

direction. locked in neutral
position
(Shut-down).

Connections
Diagnostic
menu
components
Code SPN/
FM1
92/02 7F0F2/2 Doubled direction. Transmission Note the time and - -
locked in neutral contact Cargotec
position support.
(Shut-down).
92/03 7F0F2/3 Doubled gear. Transmission Note the time and - -

position support.
(Shut-down).
92/04 7F0F2/4 Doubled shock Transmission Note the time and - -

pattern. locked in neutral contact Cargotec
position support.
(Shut-down).
92/06 7F0F2/6 Wrong digital input Transmission Note the time and - -
signal. locked in neutral contact Cargotec
position support.
(Shut-down).
92/07 7F0F2/7 Digital input signal in Transmission Note the time and - -
conflict with gear se- locked in neutral contact Cargotec
lector’s position. position support.
(Shut-down).
92/08 7F0F2/8 Digital input signal Transmission Note the time and - -
"Transmission locked in neutral contact Cargotec
locked in neutral" position support.
wrong. (Shut-down).
92/09 7F0F2/9 Digital input signal Transmission Note the time and - -
doubled assignment. locked in neutral contact Cargotec
position support.
(Shut-down).
92/10 7F0F2/A Digital output signal Transmission Note the time and - -
doubled assignment. locked in neutral contact Cargotec
position support.
(Shut-down).
92/11 7F0F2/B Digital output signal Transmission Note the time and - -
selected on uncon- locked in neutral contact Cargotec
figured output. position (Shut- support.
down).
92/12 7F0F2/C Digital output signal Transmission Note the time and - -
wrong. locked in neutral contact Cargotec
position support.
(Shut-down).

Connections
Diagnostic
menu
components
Code SPN/
FM1
92/13 7F0F2/D Digital output signal Transmission Note the time and - -
selected on trans- locked in neutral contact Cargotec
mission cable. position support.
(Shut-down).
92/14 7F0F2/E Wrong assignment in Transmission Note the time and - -

speed sensor 1-2. locked in neutral contact Cargotec
position support.
(Shut-down).
92/15 7F0F2/F Wrong assignment in Transmission Note the time and - -

speed sensor 3. locked in neutral contact Cargotec
position support.
(Shut-down).
92/16 7F0F2/10 Doubled assignment Transmission Note the time and - -

in speed sensor. locked in neutral contact Cargotec
position support.
(Shut-down).
92/17 7F0F2/11 Wrong feed voltage Transmission Note the time and - -
selected. locked in neutral contact Cargotec
position support.
(Shut-down).
92/18 7F0F2/12 Doubled input signal. Transmission Note the time and - -
position support.
(Shut-down).
92/19 7F0F2/13 Cabling sensor pres- Transmission Note the time and - -
sure in conflict with locked in neutral contact Cargotec
cabling analogue in- position support.
put signal. (Shut-down).
92/20 7F0F2/14 Wrong configuration Transmission Note the time and - -

for servo motor or locked in neutral contact Cargotec
brake valve (ana- position support.
logue output signal (Shut-down).
4-5-6).
92/30 7F0F2/ Wrong configuration Transmission Note the time and - -

1E for full-flow selection locked in neutral contact Cargotec
and earlier digital position support.
problem-solving. (Shut-down).

Control unit,

Connections
Diagnostic
menu
components
Code SPN/
FM1
Control unit,

Control unit,
93/00 7F0F3/0 Failed initiation of Transmission Turn off the ma- - -

necessary control locked in neutral chine and turn off
unit data in flash position the main electric
memory, caused by (Shut-down). power.
memory conflict.

memory conflict.

memory conflict.

memory conflict.

memory conflict.

memory conflict.

memory conflict.

Connections
Diagnostic
menu
components
Code SPN/
FM1
93/10 7F0F3/A Initiation of statistical Control unit indi- Turn off the ma- - -
data in flash cates the error. chine and turn off
memory, caused by the main electric
firmware update or power.
memory conflict.
93/11 7F0F3/B Initiation of stored er- Control unit indi- Turn off the ma- - -
ror data in flash cates the error. chine and turn off
memory, caused by the main electric
firmware update or power.
memory conflict.
94/00 7F0F4/0 Failed initiation of Transmission Note the time and - -

necessary control locked in neutral contact Cargotec
unit data in flash position support.
memory, caused by (Shut-down).
memory conflict.

memory conflict.

memory conflict.

memory conflict.

memory conflict.

memory conflict.

Connections
Diagnostic
menu
components
Code SPN/
FM1
memory conflict.
95/00 7F0F5/0 - - - - -
95/70 7F0F5/14 Software error Transmission

Control unit, locked in neutral
transmission (D793). position
(Shut-down).
95/71 7F09B/ Control unit cannot Transmission -

1F interpret input data. locked in neutral
position
(Shut-down).

Control unit,

Control unit,
99/90 7F0F6/0 Incorrect software - - - -

in control unit
transmission.

Control unit,

Control unit,

Control unit,
99/95 7F0CA/ Overload of CAN- - - - -

1F bus detected: Con-
trol unit transmission
could for the moment
not handle all incom-
ing information, due
to too many CAN
requests.

Connections
Diagnostic
menu
components
Code SPN/
FM1
Control unit, trans-
mission (D793).
E0/01 7F0E1/F Machine speed is too - - - -

high to enable
downshift.
E1/01 7F0E2/F Machine speed is too - - - -

high to change travel
direction.
E2/01 7F0E3/F Engine’s rpm is too - - - -

high to enable direc-
tion change or select
same direction
again.
E3/00 7F0E4/E Machine’s speed lim- - - - -

itation is activated.
E3/01 7F0E4/F Machine’s speed lim- - - - -

itation is activated re-
gardless of if speed
is above limit value.
E3/02 7F0E4/ Machine’s speed is - - - -

10 higher than upper
limit value.
E4/00 7F0E5/ Abnormal speed Transmission dis- - - -

11 reduction. engages automat-
ic shifting for some
time.
E4/01 7F0E5/F Abnormal Transmission dis- - - -

acceleration. engages automat-
ic shifting for some
time.
E5/01 7F0E0/D Time with active gear - Calibrate the - -

exceeded time for transmission.
recalibration.
E6/00 7F0E6/ Operator not sitting - - - -

1F in operator’s seat
and gear selector is
not in neutral and/or
parking brake is not
activated.

Connections
Diagnostic
menu
components
Code SPN/
FM1
E7/01 7F0E7/F Turbine rpm exceeds Control unit forces - - -
limit value. engine to idle to
prevent damage.
E8/01 7F0E8/F Conditions to shift - - - -

between 2WD and
4WD not fulfilled.
Machine must be
stationary.
E9/01 7F0E9/F Conditions to shift

between High and
Low not fulfilled. Ma-
chine must be
stationary.
xx/49 - Undefined failure. Control unit indi-

cates the error -
action depends on
problem.
E.1.01 7F0FA - Calibration drive Calibration is Download correct - -

-05 7F0FD mode pressure, un- cancelled. parameters and
wanted algorithm repeat calibration.
answer. Make sure that the
machine does not
move.
Check response
on engine rpm.
E.1.06 7F0FA - Calibration drive Control unit indi- Measure the - -

7F0FD/6 mode pressure, tur- cates the error and clutch’s pressure
bine rpm’s signal calibration is to detect leakage.
does not go down to cancelled. Check the signal
the min. value. dur- from sensor tur-
ing calibration. bine speed.
Check set speed to
detect slipping
clutch.

Connections
Diagnostic
menu
components
Code SPN/
FM1
-09 7F0FD mode pressure, cancelled. parameters and
unwanted algorithm repeat calibration.
machine does not
move.
Check response
on engine rpm.
E.1.10 7F0FA - Calibration drive Calibration is Find the reason for - -

7F0FD/A mode pressure, cancelled. calibration being
transmission error cancelled.
during calibration.

machine does not
move.
Check response
on engine rpm.

7F0FD/E mode pressure, tur- cates the error and clutch’s pressure
bine speed does not calibration is to detect leakage.
decrease during cancelled. Check the signal
calibration. from sensor tur-
bine speed.

7F0FD mode pressure, cancelled. parameters and
machine does not
move.
Check response
on engine rpm.

7F0FD/ mode pressure, tur- cates the error and clutch’s pressure
10 bine speed is too low calibration is to detect leakage.
to start calibration. cancelled. Check the signal
from sensor tur-
bine speed.

Connections
Diagnostic
menu
components
Code SPN/
FM1
unwanted algorithm continue
answer. calibration.
Check if the ma-
chine starts to
move.
Check response
on engine rpm.
E.1.25 7F0FA - Calibration drive Control unit indi- Calibrate at higher - -

7F0FD/ mode pressure, cates the error and temperatures
19 mesh starting point is calibration is (90-100 °C).
too early during cali- cancelled. Check speed sen-
bration. Too much sors (error code
rimpull. 42/04 or 42/05).
Check servo
valves.

7F0FD/ mode pressure, cates the error and temperatures
1A mesh starting point calibration is (90-100 °C).
cannot be found. cancelled. Check speed sen-
sors (error code
42/04 or 42/05).
Check servo
valves.

7F0FD mode pressure, cancelled. parameters and
unwanted algorithm continue
Check if the ma-
chine starts to
move.
Check response
on engine rpm.

7F0FD/ mode pressure, tur- cates the error and clutch’s pressure
1C bine speed does not calibration is to detect leakage.
reach value 0 rpm at cancelled. Check the signal
finish phase of from sensor tur-
calibration. bine speed.

Connections
Diagnostic
menu
components
Code SPN/
FM1
7F0FD/ mode pressure, tur- cates the error and temperatures
1D bine rpm does not calibration is (90-100 °C).
reach up to correct cancelled. Check speed sen-
value at release sors (error code
phase of mesh start- 42/04 or 42/05).
ing point during
Check servo
calibration.
valves.
E.2.01 7F0FA - Calibration optimiz- Calibration is Download correct - -

-05 7F0FD ing fill time, unex- cancelled. parameters and
pected algorithm repeat calibration.
machine does not
move.
Check response
on engine rpm.
E.2.06 7F0FA - Calibration optimiz- Control unit indi- Measure the - -

7F0FD/6 ing fill time, turbine cates the error and clutch’s pressure
rpm’s signal does not calibration is to detect leakage.
go down to the min. cancelled. Check the signal
value. during from sensor tur-
Check set speed to
detect slipping
clutch.

machine does not
move.
Check response
on engine rpm.
E.2.10 7F0FA - Calibration optimiz- Calibration is Find the reason for - -

7F0FD/A ing fill time, transmis- cancelled. calibration being
sion error during cancelled.
calibration.

Connections
Diagnostic
menu
components
Code SPN/
FM1
machine does not
move.
Check response
on engine rpm.

7F0FD/E ing fill time, turbine cates the error and clutch’s pressure
speed does not de- calibration is to detect leakage.
crease during cancelled. Check the signal
bine speed.

7F0FD ing fill time, unex- cancelled. parameters and
machine does not
move.
Check response
on engine rpm.

7F0FD/ ing fill time, turbine cates the error and clutch’s pressure
10 speed is too low to calibration is to detect leakage.
start calibration. cancelled. Check the signal
from sensor tur-
bine speed.

pected algorithm continue
Check if the ma-
chine starts to
move.
Check response
on engine rpm.

Connections
Diagnostic
menu
components
Code SPN/
FM1
E.2.25 7F0FA - Calibration optimiz- Control unit indi- Calibrate at higher - -
7F0FD/ ing fill time, mesh cates the error and temperatures
19 starting point is too calibration is (90-100 °C).
early during calibra- cancelled. Check speed sen-
tion. Too much sors (error code
rimpull. 42/04 or 42/05).
Check servo
valves.
E.2.26 7F0FA - Calibration optimiz- Control unit indi- Calibrate at higher - -

7F0FD/ ing fill time, mesh cates the error and temperatures
1A starting point cannot calibration is can- (90-100 °C).
be found. celled. Check speed sen-
sors (error code
42/04 or 42/05).
Check servo
valves.

7F0FD ing fill time, unex- cancelled. parameters and
pected algorithm continue
Check if the ma-
chine starts to
move.
Check response
on engine rpm.

7F0FD/ ing fill time, turbine cates the error and clutch’s pressure
1C speed does not calibration is to detect leakage.
reach value 0 rpm at cancelled. Check the signal
finish phase of from sensor tur-
E.229 7F0FA - Calibration optimiz- Control unit indi- Calibrate at higher - -

7F0FD/ ing fill time, turbine cates the error and temperatures
1D rpm does not reach calibration is (90-100 °C).
up to correct value at cancelled. Check speed sen-
release phase of sors (error code
mesh starting point 42/04 or 42/05).
during calibration.
Check servo
valves.

Connections
Diagnostic
menu
components
Code SPN/
FM1
machine does not
move.
Check response
on engine rpm.

7F0FD/6 ing fill time, turbine cates the error and clutch’s pressure
rpm’s signal does not calibration is to detect leakage.
go down to the min. cancelled. Check the signal
value. during from sensor tur-
Check set speed to
detect slipping
clutch.
E.3.07 7F0FA - Calibration of control Calibration is Download correct - -

-09 7F0FD current for pressure, cancelled. parameters and
unexpected algo- repeat calibration.
rithm answer. Make sure that the
machine does not
move.
Check response
on engine rpm.
E.3.10 7F0FA - Calibration of control Calibration is Find the reason for - -

7F0FD/A current for pressure, cancelled. calibration being
transmission error cancelled.
during calibration.

machine does not
move.
Check response
on engine rpm.

Connections
Diagnostic
menu
components
Code SPN/
FM1
E.3.14 7F0FA - Calibration of control Control unit indi- Measure the - -
7F0FD/E current for pressure, cates the error and clutch’s pressure
turbine speed does calibration is to detect leakage.
not decrease during cancelled. Check the signal
bine speed.

7F0FD current for pressure, cancelled. parameters and
machine does not
move.
Check response
on engine rpm.

7F0FD/ current for pressure, cates the error and clutch’s pressure
10 turbine speed is too calibration is to detect leakage.
low to start cancelled. Check the signal
bine speed.

unexpected algo- continue
rithm answer. calibration.
Check if the ma-
chine starts to
move.
Check response
on engine rpm.
E.3.25 7F0FA - Calibration of control Control unit indi- Calibrate at higher - -

7F0FD/ current for pressure, cates the error and temperatures
19 mesh starting point is calibration is (90-100 °C).
too early during cali- cancelled. Check speed sen-
bration. Too much sors (error code
rimpull. 42/04 or 42/05).
Check servo
valves.

Connections
Diagnostic
menu
components
Code SPN/
FM1
1A mesh starting point calibration is (90-100 °C).
cannot be found. cancelled. Check speed sen-
sors (error code
42/04 or 42/05).
Check servo
valves.

7F0FD current for pressure, cancelled. parameters and
unexpected algo- continue
rithm answer. calibration.
Check if the ma-
chine starts to
move.
Check response
on engine rpm.

7F0FD/ current for pressure, cates the error and clutch’s pressure
1C turbine speed does calibration is to detect leakage.
not reach value cancelled. Check the signal
0 rpm at finish phase from sensor tur-
of calibration. bine speed.

1D turbine rpm does not calibration is (90-100 °C).
reach up to correct cancelled. Check speed sen-
value at release sors (error code
phase of mesh start- 42/04 or 42/05).
ing point during
Check servo
calibration.
valves.

Error codes transmission ZF

page
–
5WG261
In the event of serious faults in the transmission the control unit uses
four conditions with reduced functionality in order to protect the trans-
mission from damage. These are:
• "Substitute clutch control".
In this mode, the operator can use the machine as usual. Shifting
and change of travel direction, however, are not under control of
normal modulation. The control unit uses the default values for
modulating the clutches.
• "Limp-home".
In this mode, the driver can use one of the transmission’s gears in
each direction. In some cases, only one direction of travel is pos-
sible. To continue operation in the event of a fault that activates
limp-home mode, the machine must be stopped and made sta-
tionary and the gear selector moved to neutral before a gear can
again be selected.
• "Transmission shutdown".
In this mode, the transmission is permanently in neutral as the so-
lenoid valves for the clutches and parts of the power supply to the
transmission are turned off. Park the machine and turn off the
engine.
• "TCU shutdown".
In this mode, the transmission is permanently in neutral as all
solenoid valves and all power supply to the transmission are
turned off.

and menu
components
Code ZF code
(dec) (hex)
37 25 The transistor has No limitation. Check the cable har- D7930-2/39 - TRANSM.,
been tripped due to ness between control A3/8 menu 10
short circuit to voltage unit and component.
or open circuit in the Check the sensor. The
circuit for Sensor, oil sensor is installed in-
temperature sump. side the transmission.
been tripped due to ness between control A3/8 menu 10
short circuit to ground unit and component.
in the circuit for Sen- Check the sensor. The
sor, oil temperature sensor is installed in-
sump, transmission. side the transmission.


and menu
components
Code ZF code
(dec) (hex)
been tripped due to ness between control B7660/1 menu 10
short circuit to voltage unit and component.
or open circuit in the Check the sensor.
circuit for Sensor,
oil temperature
transmission (B7660).
been tripped due to ness between control B7660/1 menu 10
short circuit to ground unit and component.
in the circuit for Sen- Check the sensor.
sor, oil temperature
transmission (B7660).
49 31 The transistor has Hard shifting Check the cable har- D7930-2/19 - TRANSM.,
been tripped due to (Substitute clutch ness between control B7530/1 menu 6
short circuit to voltage control). unit and component.
circuit for Sensor, en-
gine speed (B7530).
Voltage over 7.0 V.
50 32 The transistor has Hard shifting Check the cable har- D7930-2/19 - TRANSM.,
short circuit to ground control). unit and component.
sor, engine speed
(B7530).
Voltage below 0.45 V.
51 33 Logical error Sensor Hard shifting Check the cable har- D7930-2/19 - TRANSM.,
engine speed (Substitute clutch ness between control B7530/1 menu 6
(B7530). control). unit and component.
Sudden loss of speed Check that the sensor
signal. is connected correctly.
Check that the sensor
is installed correctly.
Check the sensor.


and menu
components
Code ZF code
(dec) (hex)
52 34 The transistor has Hard shifting Check the cable har- D7930-2/41 - -
been tripped due to (Substitute clutch ness between control B7510/1
or open circuit in the If any of the error Check the sensor.
circuit for Sensor, tur- codes 52-54 are
bine speed (B7510). set at the same
Voltage over 7.0 V. time, the trans-
mission is locked
in neutral
(Shut-down).
in the circuit for Sen- If any of the error Check the sensor.
sor, turbine speed codes 52-54 are
(B7510). set at the same
Voltage below 0.45 V. time, the trans-
mission is locked
in neutral
(Shut-down).
54 36 Logical error Sensor Hard shifting Check the cable har- D7930-2/41 - -
turbine speed (Substitute clutch ness between control B7510/1
Sudden loss of speed If any of the error Check that the sensor
signal. codes 52-54 are is connected correctly.
set at the same Check that the sensor
time, the trans- is installed correctly.
mission is locked
Check the sensor.
in neutral
(Shut-down).
circuit for Sensor,
drum speed (B7520).
Voltage over 7.0 V.


and menu
components
Code ZF code
(dec) (hex)
sor, drum speed
(B7520).
Voltage below 0.45 V.
57 39 Logical error Sensor Hard shifting Check the cable har- D7930-2/42 - -
drum speed (B7520). (Substitute clutch ness between control B7520/1
Sudden loss of speed control). unit and component.
signal. Check that the sensor
is connected correctly.
Check that the sensor
is installed correctly.
Check the sensor.
58 3A The transistor has Hard shifting Check the cable har- D7930-2/62 - TRANSM.,
or open circuit in the If any of the error Check the sensor.
circuit for Sensor, out- codes 58-60 are
put shaft (B7580). set at the same
Voltage over 12.5 V. time, the trans-
mission is locked
in neutral
(Shut-down).
59 3B The transistor has Hard shifting Check the cable har- D7930-2/62 - TRANSM.,
in the circuit for Sen- If any of the error Check the sensor.
sor, output shaft codes 58-60 are
(B7580). set at the same
Voltage below 1.0 V. time, the trans-
mission is locked
in neutral.


and menu
components
Code ZF code
(dec) (hex)
60 3C Logical error Sensor Hard shifting Check the cable har- D7930-2/62 - TRANSM.,
speed output shaft (Substitute clutch ness between control B7580/2 menu 6
Sudden loss of speed If any of the error Check that the sensor
signal. codes 58-60 are is connected correctly.
set at the same Check that the sensor
time, the trans- is installed correctly.
mission is locked
Check the sensor.
in neutral.
62 3E Logical error Sensor Hard shifting Check that the sensor D7930-2/62 - TRANSM.,
speed output shaft (Substitute clutch is installed correctly. B7580/2 menu 6
(B760). control). Check the sensor.
Speed signal is 0, in If any of the error
spite of the other sen- codes 58-60 are
sor indicating that it set at the same
should be higher. time, the trans-
mission shifts to
neutral (Limp
home).
84 54 Incorrect CAN mes- - Check CAN bus drive- - CAN/POW-

sage from Control unit train with diagnostic ER, menu 3
KID (D795). menus.
Check Control unit, KID
(D795).
85 55 Incorrect CAN mes- If joystick control Check CAN bus drive- - CAN/POW-
sage from Control unit is activated, the train with diagnostic ER, menu 3
cab (D790-1). transmission menus.
switches to Check Control unit, cab
neutral. (D790-1).
86 56 Incorrect CAN mes- Hard shifting Check CAN bus drive- - CAN/POW-
sage from Control unit (Substitute clutch train with diagnostic ER, menu 3
engine (D794). control). menus.
Check Control unit,
engine (D794).
89 59 Logical error AEB re- - Check the software in - -

quest at the same Control unit
time as parking brake transmission (D793).
request via the
CAN bus.


and menu
components
Code ZF code
(dec) (hex)
97 61 Incorrect AEB request - Check CAN bus drive- - CAN/POW-

via the CAN bus. train with diagnostic ER, menu 3
menus.
Check the control unit’s
connections.
Check Control unit,
113 71 The transistor has The transmission Check the cable har- D7930-2/32 - -
been tripped due to is locked in neu- ness between control A3/3
short circuit to voltage tral position. unit and component.
in the circuit to the So- In case of mal- Check the cable
lenoid valve clutch K1. function of sever- harness in the
al clutches: transmission.
Transmission Check the solenoid
locked in neutral valve.
position
(Shut-down).
short circuit to ground tral position. unit and component.
position
(Shut-down).
been tripped due to shifts to neutral ness between control A3/3
open circuit in the cir- (Limp-home). unit and component.
cuit to the Solenoid In case of mal- Check the cable
valve clutch K1. function of sever- harness in the
position
(Shut-down).


and menu
components
Code ZF code
(dec) (hex)
short circuit to voltage tral position. unit and component.
position
(Shut-down).
short circuit to ground (Limp-home). unit and component.
position
(Shut-down).
position
(Shut-down).
short circuit to voltage (Limp-home). unit and component.
position
(Shut-down).


and menu
components
Code ZF code
(dec) (hex)
position
(Shut-down).
position
(Shut-down).
position
(Shut-down).
position
(Shut-down).


and menu
components
Code ZF code
(dec) (hex)
position
(Shut-down).
in the circuit to the In case of mal- Check the cable
Solenoid valve function of sever- harness in the
clutch KV. al clutches: transmission.
position
(Shut-down).
clutch KV. al clutches: transmission.
position
(Shut-down).
valve clutch KV. function of sever- harness in the
position
(Shut-down).


and menu
components
Code ZF code
(dec) (hex)
clutch KR. al clutches: transmission.
position
(Shut-down).
clutch KR. al clutches: transmission.
position
(Shut-down).
valve clutch KR. function of sever- harness in the
position
(Shut-down).
177 B1 Clutch K1 slips. The transmission Check the supply oil - -

The difference be- shifts to neutral pressure to the clutch.
tween the input and (Limp-home). Check the main oil
output shaft speed is In case of mal- pressure.
too high when the function of sever- Check the speed
clutch is locked. al clutches: sensors.
Transmission
locked in neutral
position
(Shut-down).


and menu
components
Code ZF code
(dec) (hex)

Transmission
locked in neutral
position
(Shut-down).

Transmission
locked in neutral
position
(Shut-down).

Transmission
locked in neutral
position
(Shut-down).
181 B5 Clutch KV slips. The transmission Check the supply oil - -

Transmission
locked in neutral
position
(Shut-down).


and menu
components
Code ZF code
(dec) (hex)
182 B6 Clutch KR slips. The transmission Check the supply oil - -

Transmission
locked in neutral
position
(Shut-down).
183 B7 Transmission oil tem- No limitation. Check the oil level. D7930-2/39 - TRANSM,
perature sump too Check transmission oil A3/8 menu6
high. cooler.
Temperature over Check the sensor.
100 C.
186 BA The transistor has No limitation. Change oil filter. D7930-2/17 - -

been tripped due to Check the cable har- B2710/1
short circuit to voltage ness between control
or open circuit in the unit and component.
circuit for Sensor,
Check the sensor.
transmission oil filter
(B2710).
188 BC Speed limitation - - - -

exceeded.
194 C2 Torque limit input - - - -

shaft too high.
195 C3 Transmission oil tem- No limitation. Check the oil level. D7930-2/49 - TRANSM,
perature Torque con- Check transmission oil B7660/1 menu6
verter too high. cooler.
Temperature over Check the sensor.
120 C.
209 D1 The transistor has - Check the cable har- D7930-2/46 - -

been tripped due to ness between control B7660,
short circuit to voltage unit and component. D7930-2/46 -
in the circuit for the Check the component. S2710,
power supply to D7930-2/46 -
sensors. A3
Voltage over 6 V.


and menu
components
Code ZF code
(dec) (hex)
210 D2 The transistor has - Check the cable har- D7930-2/46 - -

been tripped due to ness between control B7660,
short circuit to ground unit and component. D7930-2/46 -
in the circuit for the Check the component. S2710,
power supply to D7930-2/46 -
sensors. A3
Voltage below 4 V.
211 D3 Low battery voltage Transmission Check alternator, bat- D7930-2/23, -

Voltage below 18 V. locked in neutral tery, and cable harness 68 - F58-1/5:1
position between battery and D7930-2/45 -
(Shut-down). alternator. F58-2/5:1
212 D4 High battery voltage. Transmission Check alternator and D7930-2/23, -

Voltage over 32.5 V. locked in neutral battery. 68 - F58-1/5:1
position If equipment for assist- D7930-2/45 -
(Shut-down). ed start is connected, F58-2/5:1
disconnect it.
213 D5 The transistor has Transmission Check the cable har- D793/12 -A3/ -
been tripped due to locked in neutral ness between control 7
short circuit to voltage position unit and solenoid valve. D793/13 - A3/
or open circuit in the (Shut-down). Check the control unit. 7
circuit for power sup-
Check the solenoid
ply for solenoid valves
valve.
VPS 1.
214 D6 The transistor has Transmission Check the cable har- D7930-2/8 - -
been tripped due to locked in neutral ness between control D7930-2/53 -
short circuit to voltage position unit and solenoid valve.
or open circuit in the (Shut-down). Check the control unit.
circuit for power sup-
Check the solenoid
ply for solenoid valves
valve.
VPS 2.
227 E3 The transistor has - Check the cable har- - -

been tripped due to ness between the con-
short circuit to voltage trol unit and display.
on the CAN-bus to the Check the display.
display.
228 E4 The transistor has - Check the cable har- - -

been tripped due to ness between the con-
short circuit to ground trol unit and display.
to the CAN-bus to the Check the display.
display.


and menu
components
Code ZF code
(dec) (hex)
229 E5 Incorrect CAN mes- The transmission Check the cable har- - -
sage from the display. shifts to neutral ness between the con-
(Limp-home). trol unit and display.
Check the display.
230 E6 Incorrect CAN mes- The transmission - - -

sage for identification. shifts to neutral
(Limp-home).
241 F1 Memory error Control Transmission Replace the control - -

unit, transmission locked in neutral unit.
(D7930-2). position
(Shut-down).
242 F2 Incorrect configuration Transmission Reprogram Control - -

Control unit transmis- locked in neutral unit, transmission
sion (D7930-2). position (D7930-2).
(Shut-down).
243 F3 Program error Control Transmission Replace the control - -

unit, transmission locked in neutral unit.
(D7930-2). position
(Shut-down).
245 F5 Connection error dur- Transmission Check the transmission - -

ing calibration. locked in neutral after incorrect
position connections.
(Shut-down).
246 F6 Calibration data No limitation. Calibrate the transmis- - -

incorrect. sion, see section 8
Control system,
group 8.5.2.3 Calibrate
GEARBOX.

D Error codes – 8 Control system 101
8 Control system
mm mm mm mm mm mm
Error codes machine

page
–
Code Description Limitation Action Connections Diagnostic Group

and menu
components
1 Communication error Attachment Use diagnostic menu D791-1 CAN/POW- 11.6.2 Redun-
with Control unit, at- functions not to find incorrect ER, menu 2 dant CAN bus
tachment (D791-1). working. segment.
2 Communication error Levelling, tilt, Use diagnostic menu D791-2 CAN/POW- 11.6.2 Redun-
with Control unit, at- overheight ex- to find incorrect ER, menu 2 dant CAN bus
tachment option tension not segment.
(D791-2). working.
3 Communication error Left side of bot- Use diagnostic menu D791-3 CAN/POW- 11.6.2 Redun-
with Control unit, at- tom lift not to find incorrect ER, menu 2 dant CAN bus
tachment left jack pair working. segment.
(D791-3).
4 Communication error Right side of Use diagnostic menu D791-4 CAN/POW- 11.6.2 Redun-
with Control unit, at- bottom lift not to find incorrect ER, menu 2 dant CAN bus
tachment right jack pair working. segment.
(D791-4).
5 Communication error Lighting rear, Use diagnostic menu D797-R CAN/POW- 11.6.2 Redun-
with Control unit, frame hydraulic oil to find incorrect ER, menu 2 dant CAN bus
rear (D797-R). cooling, over- segment.
load system,
extension not
working.
6 Communication error Front lighting, Use diagnostic menu D797-F CAN/POW- 11.6.2 Redun-
with Control unit, frame lift, extension, to find incorrect ER, menu 2 dant CAN bus
front (D797-F). brake lights, segment.
brake cooling
not working.
7 Communication error Sliding cab, Use diagnostic menu D797-O CAN/POW- 11.6.2 Redun-
with Control unit, frame support jacks, to find incorrect ER, menu 2 dant CAN bus
option (D797-O). joystick control, segment.
mini-wheel,
cab lift and cab
tilt not working.
8 Communication error Controls in Use diagnostic menu D795 CAN/POW- 11.6.2 Redun-
with Control unit KID steering wheel to find incorrect ER, menu 2 dant CAN bus
(D795). panel and segment.
display not
working.

102 D Error codes – 8 Control system

and menu
components
9 Communication error Mini-wheel or Use diagnostic menu D790-3 CAN/POW- 11.6.2 Redun-
with Control unit, cab joystick control to find incorrect ER, menu 2 dant CAN bus
option (D790-3). not working segment.
11 Cable harness fault No limitation. Use diagnostic menu Varies depend- CAN/POW- 11.6.2 Redun-
CAN bus segment 1. to find incorrect ing on machine ER, menu 1 dant CAN bus
segment. configuration. and 21
20 Accelerator pedal Poor sensitivi- Calibrate the acceler- D790-1/K6:11 – CALIBRA- 1. Engine
(B690) not calibrated. ty in accelera- ator pedal. See sec- B690 TION:
tor pedal. tion 8 Control system, DRIVE-
group 8.5.2.3 Cali- TRAIN,
brate DRIVE-TRAIN. menu 1 and 2
21 Communication error Gear selection Use diagnostic D790-1/K13:1 – CAN/POW- 11.6.3 CAN
with Control unit, trans- not working. menu to check D793/M2 ER, menu 3 bus drive-train
mission (D793). communication. D790-1/K13:2 –
Check the cable har- D793/L2
ness between Control
unit, cab (D790-1)
and Control unit,


and menu
components
22 Communication error Engine does Use diagnostic Volvo: D790-1/ CAN/POW- 11.6.3 CAN
with Control unit, not respond to menu to check K13:1, K13:2 – ER, menu 3 bus drive-train
engine (D794). commands communication. D794/2, 1
from the cab. Check the cable har- Cummins:
ness between Control D790-1/K13:1,
unit, cab (D790-1) and K13:2 – D794/
Control unit, engine 46, 37
(D794).
23 The set-up file cannot No controls in Contact Cargotec D790-1 - 11.5.3.1 Con-
be read in Control unit, the cab are support. trol unit, cab
cab (D790-1). working.
24 Power supply to cab Cab fan not Check fuse F58-5/3. D790-1/K2:8 – - 9.4.3 Cabin
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 En-
software download. stored in Con- and on. menu 8 gine control
26
Buffer for error codes trol unit, engine Repeat software unit
27 from Control unit, en- (D794). download.
gine (D794), active er-
28
ror code when
29 downloading.
30
31 Incorrect power supply Controls in cab Check fuse F58-5/1. D790-1/K1:2, CAN/POW- 11.5.1.3 Igni-
to cab control unit not working. Check cabling be- K1:3, K1:4 – ER, menu 6 tion voltage
(D790-1). Voltage un- tween the control unit F58-5/1:1, 1:2 (15)
der 18 V or over 32 V. and the component
with diagnostic menu.
32 Incorrect 5 V reference Analogue con- Check cabling be- D790-1/K4:5, K CAN/POW- 11.5.3.1 Con-
voltage to analogue trols in cab not tween the control unit 5:11, K5:13, ER, menu 6 trol unit, cab
cab controls. Voltage working (mini- and the component K7:2, K 9:7,
under 4.9 V or over wheel/steering with diagnostic menu. K10:3
5.1 V. lever and con- Check the
trols for air component.
conditioning).
33 No feedback signal for The emergen- Check fuse F58-3/8. D790-1/K11:13 CAN/POW- 11.5.1.4
emergency stop switch cy stop switch Check cabling be- – K3009-1/87 ER, menu 5 Emergency
voltage from Relay, cannot be dis- tween the control unit stop switch
emergency stop switch engaged. All and the component voltage (15E)
voltage (K3009-1). hydraulic func- with diagnostic menu.
tions are
blocked.


and menu
components
34 Incorrect signal from Parking brake Check cabling be- D791-1/K8:5 – HYD, menu 5 4.5 Parking
Switch, parking brake cannot be re- tween the control unit S107/7 brake
(S107), indicates released. and the component D791-1/K8:13 –
leased and applied at with diagnostic menu. S107/1
same time or nothing Check the switch.
at all.
35 Interference during Error code Switch the ignition off D793 TRANSM, 11.5.3.9
software download. stored in Con- and on. menu 13 Transmission
36
Buffer for error codes trol unit, Repeat software control unit
37 from Control unit, transmission download.
transmission (D793), (D793).
38
active error code when
39 downloading.
40
41 Transistor has been Wiper rear not Check cabling be- D790-1/K2:4 – CAB, menu 3 9.5.7 Wiper
triggered due to short working. tween the control unit M650-2/53 motor rear
circuit in circuit for rear and the component
wiper motor (M650-2). with diagnostic menu.
Check the motor.
42 Transistor has been Revolving Check cabling be- D790-1/K2:5 – LIGHTS, 9.6.8 Revolv-
triggered due to short beacon not tween the control unit H428 menu 9 ing beacon
circuit in circuit for ro- working. and the component
tating beacon (H428). with diagnostic menu.
Check the
component.
43 The transistor has Work light cab Check bulb. D790-1/K2:6 – LIGHTS, 9.6.9 Work
been triggered due to left not Check cabling be- E404-1L menu 1 light, cab
short circuit in the cir- working. tween the control unit
cuit for Working light, and the component
cab left (E404-1L). with diagnostic menu.
44 The transistor has Work light, cab Check bulb. D790-1/K2:7 – LIGHTS, 9.6.9 Work
been triggered due to right not Check cabling be- E404-1R menu 1 light, cab
short circuit in the cir- working. tween the control unit
cuit for Work light, cab and the component
right (E404-1R). with diagnostic menu.
45 Transistor has been Wiper front not Check cabling be- D790-1/K2:1 – CAB, menu 2 9.5.1 Wiper
triggered due to short working. tween the control unit M650-1/53 front
circuit in circuit for front and the component
wiper motor (M650-1). with diagnostic menu.
Check the motor.


and menu
components
46 Transistor has been Cab fan not Check cabling be- D790-1/K2:2 – CLIMATE, 9.4.3 Cabin
triggered due to short working. tween the control unit M657-1/2 menu 6 fan
circuit in circuit for fan and the component
motor (M657-1). with diagnostic menu.
Check the motor.
47 Transistor has been Recirculation Check cabling be- D790-1/K2:3 – CLIMATE, 9.4.2 Fresh air
triggered due to short damper for tween the control unit M612/3 menu 6 and recircula-
circuit in circuit for ac- ventilation not and the component tion damper
tuator recirculation working. with diagnostic menu.
(M612). Check the motor.
48 Transistor has been Heat in cab Check cabling be- D790-1/K4:1 – CLIMATE, 9.4.5 Water
triggered due to short cannot be tween the control unit Y673/5 menu 7 valve
circuit in circuit for wa- adjusted. and the component
ter valve (M673). with diagnostic menu.
Check the motor.
49 Transistor has been Heat in cab Check cabling be- D790-1/K4:2 – CLIMATE, 9.4.5 Water
triggered due to short cannot be tween the control unit Y673/6 menu 7 valve
circuit in circuit for wa- adjusted. and the component
ter valve (M673). with diagnostic menu.
Check the motor.
50 Transistor has been Air distribution Check cabling be- D790-1/K4:3 – CLIMATE, 9.4.14 Air dis-
triggered due to short in cab cannot tween the control unit Y672/5 menu 8 tributor
circuit in circuit for be adjusted. and the component
damper motor (Y672). with diagnostic menu.
Check the motor.
51 Transistor has been Air distribution Check cabling be- D790-1/K4:4 – CLIMATE, 9.4.14 Air dis-
triggered due to short in cab cannot tween the control unit Y672/6 menu 8 tributor
circuit in circuit for be adjusted. and the component
damper motor (Y672). with diagnostic menu.
Check the motor.
53 Transistor has been Windscreen Check cabling be- D790-1/K5:4 – CAB, menu 1 9.5.4 Washer
triggered due to short washer rear tween the control unit M651-2 motor and
circuit in circuit for and roof not and the component reservoir
washer motor roof and working. with diagnostic menu.
rear (M651-2). Check the motor.
54 Transistor has been Flashing haz- Check cabling be- D790-1/K5:5 – LIGHTS, 9.6.7 Flashing
triggered due to short ard lights not tween the control unit S109/9 menu 7 hazard lights
circuit or open circuit in working. and the component
circuit for control light with diagnostic menu.
switch flashing hazard Check the switch.
light (S109).


and menu
components
55 Transistor has been Reduced or no Check bulbs for back- D7901/K6:1, K LIGHTS, 9.1 Controls
triggered due to short background ground lighting, re- 8:15, K 9:2, K menu 13 and instru-
circuit in circuit for lighting in in- place if necessary. 10:5, all inputs ments
background lighting in struments and Check the cable har- of type A
switches and controls. ness for background Digital in
instruments. lighting.
56 The transistor has Indication for Check cabling be- D790-1/K7:8 – - 7.1.1 Control
been triggered due to tilt lock in con- tween the control unit S815/5 lever
short circuit or open cir- trol lever not il- and the component
cuit in circuit for LED- luminated. with diagnostic menu.
indication for tilt lock in Check the switch.
control lever (S815).
57 The transistor has Indication for Check cabling be- D790-1/K7:9 – - 7.1.1 Control
been triggered due to levelling lock in tween the control unit S815/7 lever
short circuit or open cir- control lever and the component
cuit in circuit for LED- not illuminated. with diagnostic menu.
indication for levelling Check the switch.
lock in control lever
(S815).
60 Transistor has been Seat heating Check cabling be- D790-1/K10:7 – CAB, menu 8 9.3.3 Heating
triggered due to short does not work. tween the control unit K383/86 coil
circuit or open circuit in and the component
circuit for relay seat with diagnostic menu.
heating (K383). Check the
component.
61 Transistor has been Extra work Check cabling be- D790-1/K10:8 – LIGHTS, 9.6.10 Work
triggered due to short lights boom not tween the control unit K304/86 menu 3 lights, boom
circuit or open circuit in working. and the component
circuit for extra work with diagnostic menu.
light boom (K304). Check the
component.
62 The transistor has Hour meter and Check cabling be- D790-1/K10:9 – CAN/POW- 9.3.5 Air
been triggered due to air-suspension tween the control unit P708, K358/86 ER, menu 7 suspension
short circuit or open cir- seat not and the component
cuit for simulated D+ working. with diagnostic menu.
feed for hour meter Check the
(P708) and Relay, component.
compressor air-sus-
pension seat (K358).


and menu
components
63 Transistor has been No ignition volt- Check cabling be- D790-1/K10:10 CAN/POW- 11.5.1.3 igni-
triggered due to short age to the ma- tween the control unit – K315-1/86 ER, menu 4 tion voltage
circuit or open circuit in chine’s Control and the component (15)
circuit for relay ignition units. with diagnostic menu.
voltage (K315-1). Check the
component.
64 The transistor has No emergency Check cabling be- D790-1/K10:11 CAN/POW- 11.5.1.4
been triggered due to stop switch tween the control unit – K3009-1/86 ER, menu 5 Emergency
short circuit or open cir- voltage to the and the component stop switch
cuit in circuit for Relay, machine’s with diagnostic menu. voltage
emergency stop switch Control units. Check the
voltage (K3009-1). component.
65 The transistor has No emergency Check cabling be- D790-1/K10:11 CAN/POW- 11.5.1.4
been triggered due to stop switch tween the control unit – K3009-1/86 ER, menu 5 Emergency
short circuit or open cir- voltage to the and the component stop switch
cuit in circuit for Relay, machine’s with diagnostic menu. voltage
emergency stop switch Control units. Check the
voltage (K3009-2). component.
66 Transistor has been Windshield Check cabling be- D790-1/K10:13 CAB, menu 1 9.5.4 Washer
triggered due to short washer not tween the control unit – M651-1 motor and
circuit in circuit for working. and the component reservoir
washer motor wind- with diagnostic menu.
shield (M651-1). Check the
component.
67 Transistor has been Wiper roof not Check cabling be- D790-1/K10:14 CAB, menu 4 9.5.6 Wiper
triggered due to short working. tween the control unit – M650-3/53 motor roof
circuit for wiper motor with diagnostic menu.
roof (M650-3). Check the motor.
68 Transistor has been Pause heater Check cabling be- D790-1/K10:15 - 9.4 Heating,
triggered due to short not working. tween the control unit – M667 ventilation
circuit or open circuit in and the component and air
circuit for Circulation with diagnostic menu. conditioning
pump pause heater Check the motor.
(M667).
69 Transistor has been No voltage Check cabling be- D790-1/K10:16 CAN/POW- 11.5.1.3 Igni-
triggered due to short feed to tween the control unit – K315-2/86 ER, menu 4 tion voltage
circuit or open circuit in engine and and the component (15)
circuit for relay ignition transmission. with diagnostic menu.
voltage drivetrain Check the
(K315-2). component.


and menu
components
71 Transistor has been Interior lighting Check bulb. D790-1/K11:6 – LIGHTS, 9.6.12 Interior
triggered due to short in cab not Check cabling be- E434-1 menu 12 lighting cab
circuit in circuit for working. tween the control unit
interior lighting cab and the component
(E434-1). with diagnostic menu.
74 The transistor has Horn/loud horn Check cabling be- D790-1/K11:11 CAB, menu 5 9.7.1 Horn
been triggered due to not working. tween the control unit – H850/1,
short circuit in the cir- and the component K3016/86
cuit for Horn (H850) or with diagnostic menu.
Relay, loud horn Check the
(K3016) component.
75 Relay ignition voltage The cab control Check cabling be- - CAN/POW- 11.5.1.3 Igni-
(K315-1) has jammed unit (D790-1) tween the control unit ER, menu 4 tion voltage
in position on. still has a pow- and the component
er supply and is with diagnostic menu.
thereby active. Check the
component.
80 No signal from Pres- Air conditioning Check the drive belt D797-R/K1:37 CLIMATE, 9.4.10 Pres-
sure switch, air condi- not working. for the compressor for – S246 menu 3 sure switch
tioning (S246), despite air conditioning.
the AC compressor be- Check that compres-
ing activated. sor for air conditioning
is activated.
Check cabling be-
tween the control unit
and the component
81 Faulty signal from Air distribution Check cabling be- D790-1/K4:7 – CLIMATE, 9.4.6 Fresh air
damper motor (Y672). cannot be tween the control unit Y672/9 menu 4 and recircula-
Signal voltage under adjusted. and the component tion damper
0.2 V or over 4.8 V. with diagnostic menu.
Check the motor.
85 Faulty signal from ac- Engine speed Check cabling be- D790-1/K6:11 – ENGINE, 1 Engine
celerator pedal (R690). limited to idle. tween the control unit R690/2 menu 1
Signal voltage under and the component
0.2 V or over 4.8 V. with diagnostic menu.
Check the
component.
87 Defective signal from Lift and lower Check cabling be- D790-1/K7:3 – BOOM, 7.1.1 Control
control lever (S815-P1) not working. tween the control unit S815-P1/8 menu 1 lever
for lift and lower. Signal and the component
voltage under 0.2 V or with diagnostic menu.
over 4.8 V. Check the switch.


and menu
components
88 Defective signal from Extension not Check cabling be- D790-1/K7:4 – BOOM, 7.1.1 Control
control lever (S815-P2) working. tween the control unit S815-P2/4 menu 1 lever
for extension. Signal and the component
voltage under 0.2 V or with diagnostic menu.
over 4.8 V. Check the switch.
89 Defective signal from Rotation not Check cabling be- D790-1/K7:5 – ATTACH, 7.1.1 Control
control lever (S815-P3) working. tween the control unit S815-P3/11 menu 1 lever
for rotation. Signal volt- and the component
age under 0.2 V or over with diagnostic menu.
4.8 V. Check the switch.
90 Defective signal from Controllable tilt Check cabling be- D790-1/K7:6 – ATTACH, 7.1.1 Control
control lever (S815-P4) not working. tween the control unit S815-P4/1 menu 1 lever
for tilt. Signal voltage and the component
under 0.2 V or over with diagnostic menu.
4.8 V. Check the switch.
92 Faulty signal from Joystick control Check cabling be- D790-1/K9:8 – STEERING, 5.1.2 Mini-
steering lever (R825-1) or mini-wheel tween the control unit R825-1/P2 menu 1 wheel
or mini-wheel not working. and the component 5.1.3 Joystick
(R825-1). Signal volt- with diagnostic menu.
age under 0.2 V or Check the switch.
over 4.8 V.
93 Faulty signal from mini- Joystick control Check cabling be- D790-1/K9:9 – STEERING, 5.1.2 Mini
wheel (R825-2). Signal or mini-wheel tween the control unit R825-2/H2 menu 1 steering wheel
voltage under 0.2 V or not working. and the component
over 4.8 V. with diagnostic menu.
Check the switch.
94 Faulty signal from wa- Cab heat Check cabling be- D790-1/K10:4 – CLIMATE, 9.4.5 Water
ter valve cab heat cannot be tween the control unit Y673/9 menu 4 valve
(Y673). Signal voltage adjusted. and the component
under 0.2 V or over with diagnostic menu.
4.8 V. Check the motor.
96 Faulty signal from cab Air conditioning Check cabling be- D790-1/K4:8 – CLIMATE, 9.4.17 Sensor
temperature sensor not working. tween the control unit B775-1/2 menu 1 cab
(B775-1) Sensor indi- and the component temperature
cates temperature un- with diagnostic menu.
der -43 C or over Check the sensor.
105 C.
97 Faulty signal from out- Air conditioning Check cabling be- D790-1/K4:9 – CLIMATE, 9.4.18 Sensor,
door temperature not working. tween the control unit B774/2 menu 2 ambient tem-
sensor (B774). Tem- and the component perature
perature signal over with diagnostic menu.
105 C. Check the sensor.


and menu
components
98 Faulty signal from out- Air conditioning Check cabling be- D790-1/K4:10 – CLIMATE, 9.4.16 Sensor,
let fan temperature not working. tween the control unit B775-2/2 menu 2 temperature
sensor (B775-2) Sen- and the component outlet fan
sor indicates tempera- with diagnostic menu.
ture under -43 C or Check the sensor.
over 105 C.
99 Faulty signal from re- Air conditioning Check cabling be- D790-1/K4:11 – CLIMATE, 9.4.12 Sensor
frigerant temperature not working. tween the control unit B775-3/2 menu 2 temperature
sensor (B775-3) Sen- and the component refrigerant
sor indicates tempera- with diagnostic menu.
ture under -43 C or Check the sensor.
over 105 C.
101 Redundant voltage - Check cabling be- D797-F/K2:7 CAN/POW- 11.5.1.2 Re-
feed left to frame con- tween the control unit ER, menu 8 dundant volt-
trol unit front (D797-F) and the component age feed of
does not reach with diagnostic menu. Control units
destination. Check the control unit.
102 Redundant voltage - Check cabling be- D797-F/K2:8 CAN/POW- 11.5.1.2 Re-
feed right to frame con- tween the control unit ER, menu 8 dundant volt-
trol unit front (D797-F) and the component age feed of
103 Incorrect power supply No electric Check fuse F58-2/1, D797-F/K2:1, CAN/POW- 11.5.1.3 Igni-
to control unit frame power feed to replace if necessary. K2:9, K2:10 – ER, menu 8 tion voltage
front (D797-F). Voltage components. Check cabling be- F58-2/1:1, 1:2 (15)
under 18 V or over tween the control unit
32 V. and the component
104 Incorrect control break- Functions nor- Check fuse F58-3/2, D797-F/K2:11 CAN/POW- 11.5.1.4
er voltage to Control mally supplied replace if necessary. – F58-3/2:1 ER, menu 8 Emergency
unit, frame front emergency Check cabling be- stop switch
(D797-F). stop switch tween the control unit voltage
voltage have and the component
no feed. All hy- with diagnostic menu.
draulic func-
tions blocked.
105 Incorrect 5 V reference Regeneration Check cabling be- D797-F/K1:8 – CAN/POW- 8.2.1.7 Sensor
voltage to pressure lift, weight indi- tween the control unit B768-R1/1, ER, menu 9 hydraulic
sensor. Voltage under cator and over- and the component B768-R2/1, pressure lift
4.9 V or over 5.1 V. load system with diagnostic menu. B768-L1/1, cylinder
not working. Check the sensor. B768-L2/1


and menu
components
106 Transistor has been Cooling fan Check cabling be- D797-F/K1:14 HYD, menu 2 4.8.8 Cooling
triggered due to short brake oil not tween the control unit – M674/1 fan
circuit in circuit for cool- working. and the component
ing fan brake oil with diagnostic menu.
107 Transistor has been Left high beam Check bulb. D797-F/K1:1 – LIGHTS, 9.6.1
triggered due to short not working. Check the bulb E402L/1 menu 6 Headlights
circuit or open circuit in holder.
circuit for high beam
Check cabling be-
light left (E402L).
and the component
108 Transistor has been Right high Check bulb. D797-F/K1:15 LIGHTS, 9.6.1
triggered due to short beam not Check the bulb – E402R/1 menu 6 Headlights
circuit or open circuit in working. holder.
circuit for high beam
Check cabling be-
light right (E402R).
and the component
110 Transistor has been Low beams not Check bulb. D797-F/K1:42 LIGHTS, 9.6.1 Head-
triggered due to short working. Check the bulb – E400L/1, menu 6 lights
circuit or open circuit in holder. E400R/1
circuit for low beam
Check cabling be-
light (E400L/E400R).
and the component
111 The transistor has Lift not Check cabling be- D797-F/K1:2 – BOOM, 7.2.5 Control
been triggered due to working. tween the control unit Y6005/1 menu 4 valve lift, low-
short circuit in the cir- and the component er, and
cuit for Solenoid valve with diagnostic menu. extension
boom up (Y6005). Check the solenoid
valve.
112 The transistor has Lower not Check cabling be- D797-F/K1:3 – BOOM, 7.2.5 Control
been triggered due to working. tween the control unit Y6004/1 menu 5 valve lift, low-
cuit for Solenoid valve, with diagnostic menu. extension
boom down (Y6004). Check the solenoid
valve.


and menu
components
113 The transistor has Extension out Check cabling be- D797-F/K1:4 – BOOM, 7.3.5 Control
been triggered due to not working. tween the control unit Y6006/1 menu 7 valve lift, low-
cuit for Solenoid valve, with diagnostic menu. extension
boom out (Y6006). Check the solenoid
valve.
114 The transistor has Extension in Check cabling be- D797-F/K1:5 – BOOM, 7.3.5 Control
been triggered due to not working. tween the control unit Y6007/1 menu 6 valve lift, low-
cuit for Solenoid valve with diagnostic menu. extension
boom in (Y6007). Check the solenoid
valve.
115 Transistor has been Lift and lower Check cabling be- D797-F/K1:30 BOOM, 7.2.7 Valve
triggered due to short not working. tween the control unit – Y6002/1 menu 2 block lift
circuit or open circuit in and the component cylinder
circuit for Solenoid with diagnostic menu.
valve blocking lift left Check the solenoid
(Y6002). valve.
116 Transistor has been Lift and lower Check cabling be- D797-F/K1:31 BOOM, 7.2.7 Valve
triggered due to short not working. tween the control unit – Y6001/1 menu 2 block lift
valve blocking lift right Check the solenoid
(Y6001). valve.
117 Transistor has been Regeneration Check cabling be- D797-F/K1:32 BOOM, 7.2.7 Valve
triggered due to short lift not working. tween the control unit – Y6051/1 menu 3 block lift
valve regeneration lift Check the solenoid
right (Y6051). valve.
118 Transistor has been Regeneration Check cabling be- D797-F/K1:33 BOOM, 7.2.7 Valve
triggered due to short lift not working. tween the control unit – Y6052/1 menu 3 block lift
valve regeneration lift Check the solenoid
left (Y6052). valve.
119 Transistor has been Parking brake Check cabling be- D797-F/K1:7 – HYD, menu 5 4.5.3 Solenoid
triggered due to short cannot be tween the control unit Y642/1 valve parking
circuit or open circuit in released. and the component brake
valve parking brake Check the solenoid
(Y642). valve.


and menu
components
120 Transistor has been Left direction Check bulb. D797-F/K1:9 – LIGHTS, 9.6.6 Direction
triggered due to short indicator front Check the bulb H422/1 menu 8 indicators
circuit or open circuit in not working. holder.
circuit for bulb direction
indicator left front Check cabling be-
(H422). tween the control unit
and the component
121 Transistor has been Right direction Check bulb. D797-F/K1:10 LIGHTS, 9.6.6 Direction
triggered due to short indicator front Check the bulb – H423/1 menu 8 indicators
indicator right front Check cabling be-
(H423). tween the control unit
and the component
122 Transistor has been Running light Check bulb. D797-F/K1:25 LIGHTS, 9.6.2 Running
triggered due to short left front not Check the bulb – H416-1/1 menu 5 lights
circuit for bulb running
light left front (H416-1). Check cabling be-
and the component
123 Transistor has been Running light Check bulb. D797-F/K1:29 LIGHTS, 9.6.2 Running
triggered due to short right front not Check the bulb – H417-1/1 menu 5 lights
light right front Check cabling be-
(H417-1). tween the control unit
and the component
124 Incorrect 24 V refer- Indicator light Check cabling be- D797-F/K1:39 CAN/POW- 4.5.5 Break
ence voltage to Break parking brake tween the control unit – S200/1, ER, menu 9 contact (open-
contact (opening and warning for and the component S204/1, S216/ ing switch)
switch) parking brake low brake pres- with diagnostic menu. 1, S220/1 parking brake
(S200), Break contact sure do not turn Check the sensor. 4.3.8 Make-
(opening switch) low off. Brake lights contact (clos-
brake pressure (S204), and declutch ing switch)
Make-contact (closing do not work. brake lights
switch) brake lights Gear cannot be
4.3.7 Break
(S216) and Break con- engaged since
contact (open-
tact (opening switch) the signal for
ing switch)
declutch (S220-2). released park-
brake pres-
ing brake does
sure
not work.


and menu
components
133 Defective signal from Overload sys- Check cabling be- D797-F/K1:21 OP, menu 3 7.2.9 Sensor
Sensor hydraulic pres- tem not work- tween the control unit – B768-L1/3 [V] hydraulic
sure lift cylinder left ing. All lift and the component HYD, menu 6 pressure lift
(B768-L1). Signal volt- functions oper- with diagnostic menu. [bar] cylinder
age under 0.2 V or over ate at reduced Check the sensor.
4.8 V. speed. Error
code 150
activated.
Sensor hydraulic pres- tem not work- tween the control unit – B768-L2/3 [V] hydraulic
sure lift cylinder left ing. All lift and the component HYD, menu 6 pressure lift
(B768-L2). Signal volt- functions oper- with diagnostic menu. [bar] cylinder
age under 0.2 V or ate at reduced Check the sensor.
over 4.8 V. speed. Error
code 150
activated.
Sensor hydraulic pres- tem not work- tween the control unit – B768-R1/3 [V] hydraulic
sure lift cylinder right ing. All lift and the component HYD, menu 6 pressure lift
(B768-R1). Signal volt- functions oper- with diagnostic menu. [bar] cylinder
code 150
activated.
Sensor hydraulic pres- tem not work- tween the control unit – B768-R2/3 [V] hydraulic
sure lift cylinder right ing. All lift and the component HYD, menu 6 pressure lift
(B768-R2). Signal volt- functions oper- with diagnostic menu. [bar] cylinder
code 150
activated.
137 Faulty signal from sole- Lift not work- Check cabling be- D797-F/K1:16 BOOM, 7.2.5 Control
noid valve boom up ing. tween the control unit – Y6005/2 menu 4 valve lift, low-
(Y6005). Return cur- and the component er, and
rent does not match with diagnostic menu. extension
control current. Check the solenoid
valve.
138 Faulty signal from sole- Lower not Check cabling be- D797-F/K1:17 BOOM, 7.2.5 Control
noid valve boom down working. tween the control unit – Y6004/2 menu 5 valve lift, low-
valve.


and menu
components
139 Faulty signal from sole- Extension out Check cabling be- D797-F/K1:18 BOOM, 7.3.5 Control
noid valve boom out not working. tween the control unit – Y6006/2 menu 7 valve lift, low-
valve.
140 Faulty signal from sole- Extension in Check cabling be- D797-F/K1:19 BOOM, 7.3.5 Control
noid valve boom in not working. tween the control unit – Y6007/2 menu 6 valve lift, low-
valve.
145 Defective signal from Overload sys- Check sensor arm - OP, menu 4 8.2.1.5 Sensor
Sensor boom angle tem not work- mounting. boom angle
(B771). Logic error, ing. All lift Check the sensor.
signal does not change functions oper-
when lift or lower is ate at reduced Check cabling be-
activated. speed. Error tween the control unit
code 150 and the component
activated. with diagnostic menu.
146 Defective signal from Overload sys- Check the cable to the - OP, menu 4 8.2.1.6 Sensor
Sensor boom length tem not work- sensor. boom length
(B777). Logic error, ing. All lift Check the sensor.
signal does not change functions oper-
when extension is Check cabling be-
ate at reduced
activated. tween the control unit
speed. Error
and the component
code 150
activated.
147 High brake oil Reduced brak- Check that cooling fan D797-F/K2:13 HYD, menu 2 4.8 Tempera-
temperature. ing capacity. is working. – B762/1 ture control,
Check that the radia- cleaning and
tor is not clogged. brake oil
Check the sensor.
148 Faulty signal from sen- Model year Check the sensor. D797-F/K2:13 HYD, menu 2 4.8.10 Sensor
sor brake oil tempera- 2009-: Check cabling be- – B762/1 brake oil
ture (Y762). Signal Machine tween the control unit temperature
voltage under 0.2 V or speed limited and the component
over 4.8 V. to 5 km/h. with diagnostic menu.
149 Incorrect load curve or Lift and lower Contact Cargotec - - 7.2 Lift and
load curve missing. as well as ex- support. lower. 7.3
tension not Extension
working.


and menu
components
150 Defective overload Overload sys- Check if there are er- - OP, menu 1 8.2.1 Over-
protection. tem not work- ror codes for sensors –5 load system
This error code cannot ing. All lift in the overload
be removed with functions oper- system.
Reset. ate at reduced
speed.
151 Redundant voltage - Check cabling be- D797-R/K2:7 CAN/POW- 11.5.1.2 Re-
trol unit rear (D797-R) and the component age feed of
152 Redundant voltage - Check cabling be- D797-R/K2:8 CAN/POW- 11.5.1.2 Re-
feed right to frame con- tween the control unit ER, menu 10 dundant volt-
trol unit rear (D797-R) and the component age feed of
153 Incorrect power supply - Check fuse F58-2/3, D797-R/K2:1, CAN/POW- 11.5.1.3 Igni-
to control unit frame replace if necessary. K2:9, K2:10 – ER, menu 10 tion voltage
rear (D797-R). Voltage Check cabling be- F58-2/3:1 (15)
under 18 V or over tween the control unit
32 V. and the component
154 Incorrect power supply - Check fuse F58-2/3, D797-R/K2:11 CAN/POW- 11.5.1.4
to Control unit, frame replace if necessary. – F58-2/3:2 ER, menu 10 Emergency
rear (D797-R). Check cabling be- stop switch
tween the control unit voltage
and the component
155 Incorrect 5 V reference Overload sys- Check cabling be- D797-R/K1:8 – CAN/POW- 8.2.1.5 Sensor
voltage to analogue tem and weight tween the control unit B771/1, B777/1 ER, menu 11 boom angle
sensors. Voltage under indicator not and the component 8.2.1.6 Sen-
4.9 V or over 5.1 V. working. with diagnostic menu. sor, boom
Check the sensor. length (ana-
logue sensor)
156 Transistor has been Cooling fan hy- Check cabling be- D797-R/K1:14 HYD, menu 1 10.6.3 Cooling
triggered due to short draulic oil not tween the control unit – M668/1 fan
circuit in circuit for cool- working. and the component
ing fan hydraulic oil with diagnostic menu.


and menu
components
157 Transistor has been Work light Check bulb. D797-R/K1:1 – LIGHTS, 9.6.10 Work
triggered due to short boom left not Check the bulb E404-3L menu 3 lights, boom
circuit for bulb work
light boom left Check cabling be-
(E404-3L). tween the control unit
and the component
158 Transistor has been Work light Check bulb. D797-R/K1:15 LIGHTS, 9.6.10 Work
triggered due to short boom right not Check the bulb – E404-3R menu 3 lights, boom
light boom right Check cabling be-
(E404-3R). tween the control unit
and the component
159 Transistor has been Left back-up Check bulb. D797-R/K1:28 LIGHTS, 9.6.5 Back-up
triggered due to short light not Check the bulb – E405L menu 11 lights
circuit for bulb back-up
light left (E405L). Check cabling be-
and the component
160 Transistor has been Right back-up Check bulb. D797-R/K1:42 LIGHTS, 9.6.5 Back-up
triggered due to short light not Check the bulb – E405R menu 11 lights
circuit for bulb back-up
light right (E405R). Check cabling be-
and the component
161 Transistor has been Overload sys- Check cabling be- D797-R/K1:2 – OP, menu 1 8.2.1.4 Sen-
triggered due to short tem indicates tween the control unit B7221L/A, sor, steering
circuit or open circuit in overload. and the component B7221R/A axle load
circuit for Sensor steer- with diagnostic menu.
ing axle load (B7221L Check the sensor.
and B7221R).
162 Transistor has been Damping in/ Check cabling be- D797-R/K1:2 – OP, menu 1 8.2.1.6 Sen-
triggered due to short out/1.5 m not tween the control unit B777/A, B769- BOOM, sor, boom
circuit or open circuit in working. and the component 3/A, B769-4/A menu 8 length (posi-
circuit for Sensor posi- with diagnostic menu. tion sensor)
tion sensor (boom Check the sensor.
length).


and menu
components
163 Transistor has been Regeneration Check cabling be- D797-R/K1:4 – BOOM, 7.3.7 Valve
triggered due to short extension not tween the control unit Y6046/1 menu 3 block exten-
circuit or open circuit in working. and the component sion cylinder
valve regeneration ex- Check the solenoid
tension right (Y6046). valve.
164 Transistor has been Extension not Check cabling be- D797-R/K1:5 – BOOM, 7.3.7 Valve
triggered due to short working. tween the control unit Y6050/1 menu 2 block exten-
circuit or open circuit in and the component sion cylinder
valve blocking exten- Check the solenoid
sion right (Y6050). valve.
165 The transistor has Back-up alarm Check cabling be- D797-R/K1:30 LIGHTS, 9.7.5 Back-up
been triggered due to not working. tween the control unit – H965/1 menu 11 alarm
short circuit or open cir- and the component
cuit in circuit for Back- with diagnostic menu.
up warning device Check the
(H965). component.
166 Transistor has been Attachment Check cabling be- D797-R/K1:31 HYD, menu 6 7.4.2 Valve
triggered due to short functions not tween the control unit – Y6003/1 block top lift
circuit or open circuit in working. and the component hydraulics
valve top hydraulics Check the solenoid
(Y6003). valve.
167 Transistor has been Brake light left Check bulb. D797-R/K1:32 LIGHTS, 9.6.4 Brake
triggered due to short not working. Check the bulb – H411L/1 menu 11 light
circuit for bulb brake
Check cabling be-
light left (H411L).
and the component
168 Transistor has been Brake light right Check bulb. D797-R/K1:33 LIGHTS, 9.6.4 Brake
triggered due to short not working. Check the bulb – H411R/1 menu 11 light
circuit for bulb brake
Check cabling be-
light right (H411R).
and the component


and menu
components
169 Transistor has been Running light Check bulb. D797-R/K1:7 – LIGHTS, 9.6.2 Running
triggered due to short left rear not Check the bulb H416-2/1 menu 5 lights
light left (H416-2). Check cabling be-
and the component
170 Transistor has been Running light Check bulb. D797-R/K1:9 – LIGHTS, 9.6.2 Running
triggered due to short right rear not Check the bulb H417-2/1 menu 5 lights
light right (H417-2). Check cabling be-
and the component
171 Transistor has been Left tail light not Check bulb. D797-R/K1:10 LIGHTS, 9.6.3 Tail
triggered due to short working. Check the bulb – H412L/1 menu 5 lights
circuit for bulb tail light
light left (H421L). Check the bulb
holder.
172 Transistor has been Left tail light not Check bulb. D797-R/K1:25 LIGHTS, 9.6.3 Tail
triggered due to short working. Check the bulb – H412R/1 menu 5 lights
circuit for bulb tail light
Check cabling be-
right (H421R).
and the component
173 Transistor has been Left direction Check bulb. D797-R/K1:29 LIGHTS, 9.6.6 Direction
triggered due to short indicator rear Check the bulb – H426/1 menu 8 indicators
Check cabling be-
indicator left rear
(H426).
and the component
174 Transistor has been Right direction Check bulb. D797-R/K1:39 LIGHTS, 9.6.6 Direction
triggered due to short indicator rear Check the bulb – H427/1 menu 8 indicators
Check cabling be-
indicator right rear
(H426).
and the component


and menu
components
175 Different signal from Overload sys- Check sensor D797-R/K1:11 OP, menu 1 8.2.1.4 Sen-
Sensor, steering axle tem indicates adjustment. – B7221L/C sor, steering
load (B7221L and overload. Check the sensor. D797-R/K1:12 axle load
B722R) for more than – B7221R/C
10 seconds.
178 Transistor has been Unloading of Check cabling be- D797-R/K1:40 BOOM, 7.3.8 Valve
triggered due to short hydraulic oil tween the control unit – Y6062/1 menu 2 block pump
circuit or open circuit in pumps at boom and the component unloading
circuit for Solenoid not working. with diagnostic menu.
valve pump unloading Check the solenoid
(Y6062). valve.
183 Faulty signal from sen- Overload sys- Check cabling be- D797-R/K1:21 OP, menu 4 8.2.1.5 Sensor
sor boom angle (771). tem not work- tween the control unit – B771/3 boom angle
Signal voltage under ing. All lift and the component
0.2 V or over 4.8 V. functions oper- with diagnostic menu.
ate at reduced Check the sensor.
speed. Error
code 150 acti-
vated.
184 Faulty signal from sen- Overload sys- Check cabling be- D797-R/K1:22 OP, menu 4 8.2.1.6 Sensor
sor length (777). Signal tem not work- tween the control unit – B777/3 boom length
voltage under 0.2 V or ing. All lift and the component
over 4.8 V. functions oper- with diagnostic menu.
ate at reduced Check the sensor.
speed. Error
code 150
activated.
191 Transistor has been Air conditioning Check cabling be- D797-R/K1:11 CLIMATE, 9.4.8
triggered due to short not working. tween the control unit – M645/1 menu 6 Compressor
192 D797-R/K1:26
circuit for magnetic with diagnostic menu.
– M645/1
clutch on AC Check the
compressor (M677). component.
NOTE! Error code 191
and 192 apply to the
same user.
193 Only engine alternative Starter motor Check cabling be- D797-R/K1:36 ENGINE, 1 Engine
Cummins QSM11: not working. tween the control unit – K360/86 menu 5
Transistor has been and the component
triggered due to short with diagnostic menu.
circuit or open circuit in Check the
circuit for relay starter component.
motor (K360).


and menu
components
197 High temperature hy- No limitation. Check that cooling fan D797-R/K2:13 HYD, menu 1 10.6 Temper-
draulic oil. is working. – B776/1 ature control,
Check that the radia- cleaning and
tor is not clogged. hydraulic oil
Check the sensor.
198 Incorrect signal from Incorrect tem- Check the sensor. D797-R/K2:13 HYD, menu 1 10.6.4 Sensor
Sensor, hydraulic oil perature Check cabling be- – B776/1 hydraulic oil
temperature (B776). display. tween the control unit temperature
and the component
199 Faulty signal from fuel Incorrect dis- Check the sensor. D797-R/K2:15 CAB, menu 7 1.2.2 Sensor
level sensor (B757). play of fuel vol- Check cabling be- – B757 fuel level
Resistance over ume (empty tween the control unit
180 . or full). and the component
201 Redundant voltage - Check cabling be- D797-O/K2:7 CAN/POW- 11.5.1.2 Re-
trol unit option (D797- and the component age feed of
O) does not reach with diagnostic menu. Control units
202 Redundant voltage - Check cabling be- D797-O/K2:8 CAN/POW- 11.5.1.2 Re-
feed right to frame tween the control unit ER, menu 12 dundant volt-
control unit option and the component age feed of
(D797-O) does not with diagnostic menu. Control units
reach destination. Check the control unit.
203 Incorrect power supply - Check fuse F58-2/4, D797-O/K2:10 CAN/POW- 11.5.1.3
to control unit frame replace if necessary. – F58-2/4:1 ER, menu 12 Ignition
option (D797-O). Volt- Check cabling be- voltage (15)
age under 18 V or tween the control unit
over 32 V. and the component
204 Incorrect control break- Functions nor- Check fuse F58-3/4, D797-O/K2:11 CAN/POW- 11.5.1.4
er voltage to Control mally supplied replace if necessary. – F58-3/4:1 ER, menu 12 Emergency
unit, frame option emergency Check cabling be- stop switch
(D797-O). stop switch tween the control unit voltage
voltage have and the component
no feed. All hy- with diagnostic menu.
draulic func-
tions blocked.


and menu
components
211 The transistor has Hydraulic slid- Check cabling be- D797-O/K1:2 – SLIDING 9.10.4.3 Con-
been triggered due to ing cab or lifta- tween the control unit Y6016/1 CAB, menu 3 trol valve op-
short circuit in the cir- ble cab do not and the component tion frame
cuit for Solenoid valve work. with diagnostic menu. 9.10.5.2 Con-
cab forward/up Check the solenoid trol valve op-
(Y6016). valve. tion frame
212 The transistor has Hydraulic slid- Check cabling be- D797-O/K1:3 – SLIDING 9.10.4.3 Con-
been triggered due to ing cab or lifta- tween the control unit Y6017/1 CAB, menu 4 trol valve op-
short circuit in the cir- ble cab do not and the component tion frame
cuit for Solenoid valve work. with diagnostic menu. 9.10.5.2 Con-
cab rear/down Check the solenoid trol valve op-
(Y6017). valve. tion frame
213 The transistor has Joystick control Check cabling be- D797-O/K1:4 – EL-STEER- 5.2.10 Control
been triggered due to or mini-wheel tween the control unit Y636L1/1 ING, menu 4 valve joystick
short circuit in the cir- not working. and the component steering/
cuit for Solenoid valve with diagnostic menu. mini-wheel
steering left (Y636L). Check the solenoid
valve.
214 The transistor has Joystick control Check cabling be- D797-O/K1:5 – EL-STEER- 5.2.10 Control
been triggered due to or mini-wheel tween the control unit Y636R1/1 ING, menu 5 valve joystick
short circuit in the cir- not working. and the component steering/
cuit for Solenoid valve with diagnostic menu. mini-wheel
steering right (Y636R). Check the solenoid
valve.
215 Transistor has been Support jacks Check cabling be- D797-O/K1:30 SUPPORT- 7.10.1.2 Con-
triggered due to short do not work. tween the control unit – Y6063/1 JACKS, trol valve op-
circuit or open circuit in and the component menu 3 tion frame
valve support jacks up Check the solenoid
(Y6053). valve.
216 Transistor has been Support jacks Check cabling be- D797-O/K1:31 SUPPORT- 7.10.1.2 Con-
triggered due to short do not work. tween the control unit – Y6064/1 JACKS, trol valve op-
circuit or open circuit in and the component menu 3 tion frame
valve support jacks Check the solenoid
down (Y6064). valve.
217 Solenoid valve cab Tiltable cab Check cabling be- D797-O/K1:32 SLIDING MISSING
tilt up (Y6047). does not work. tween the control unit – Y6047/1 CAB, menu 3
and the component
Check the solenoid
valve.


and menu
components
218 Solenoid valve cab tilt Tiltable cab Check cabling be- D797-O/K1:33 SLIDING MISSING
down (Y6048). does not work. tween the control unit – Y6048/1 CAB, menu 4
and the component
Check the solenoid
valve.
219 Solenoid valve disen- Disengaging Check cabling be- D797-O/K1:7 – HYD, menu 6 MISSING
gaging hydraulic oil hydraulic oil tween the control unit Y6057/1
pumps (Y6057). pump when and the component
lowering tilta- with diagnostic menu.
ble cab does Check the solenoid
not work. valve.
220 Incorrect 24 V refer- Indicator sup- Check cabling be- D797-O/K1:9 – SUPPORT- 7.10.1.5 Sen-
ence voltage to Posi- port jacks up tween the control unit B7222L, JACKS, sor, raised
tion sensor support not working. and the component B7222R, menu 2 support jacks
jacks (B7222L, Gear cannot be with diagnostic menu. B7223L, 7.10.1.6 Sen-
B7222R, B7223L and selected to op- Check the sensor. B7223R sor, lowered
B7223R). erate machine. support jacks
221 Incorrect 24 V refer- Indicator low- Check cabling be- D797-O/K1:10 SLIDING- 9.10.5.8 Sen-
ence voltage to Posi- ered cab not tween the control unit – B777-2/1 CAB, menu 4 sor lowered
tion sensor cab lift working. Door and the component cab
(B777-2). must be closed with diagnostic menu.
for the boom to Check the sensor.
be lowered.
Speed limita-
tion is
activated.
237 Faulty signal from sole- Hydraulic slid- Check cabling be- D797-O/K1:16 SLIDING 9.10.4.3 Con-
noid valve cab forward/ ing cab or lifta- tween the control unit – Y6016/2 CAB, menu 3 trol valve op-
up (Y6016). Return ble cab do not and the component tion frame
current does not match work. with diagnostic menu. 9.10.5.2 Con-
control current. Check the solenoid trol valve op-
valve. tion frame
238 Faulty signal from sole- Hydraulic slid- Check cabling be- D797-O/K1:17 SLIDING 9.10.4.3 Con-
noid valve cab back- ing cab or lifta- tween the control unit – Y6017/2 CAB, menu 4 trol valve op-
ward/down (Y6017). ble cab do not and the component tion frame
Return current does work. with diagnostic menu. 9.10.5.2 Con-
not match control Check the solenoid trol valve op-
current. valve. tion frame


and menu
components
239 Faulty signal from sole- Joystick control Check cabling be- D797-O/K1:18 EL-STEER- 5.2.10 Control
noid valve steering left or mini-wheel tween the control unit – Y636L/2 ING, menu 4 valve joystick
(Y636L). Return cur- not working. and the component steering/
rent does not match with diagnostic menu. mini-wheel
valve.
240 Faulty signal from sole- Joystick control Check cabling be- D797-O/K1:19 EL-STEER- 5.2.10 Control
noid valve steering or mini-wheel tween the control unit – Y636R/2 ING, menu 5 valve joystick
right (Y636R). Return not working. and the component steering/
current does not match with diagnostic menu. mini-wheel
valve.
251 Redundant voltage - Check cabling be- D791-1/K2:7 CAN/POW- 11.5.1.2 Re-
feed left to attachment tween the control unit ER, menu 16 dundant volt-
control unit (D791-1) and the component age feed of
destination.
control unit (D791-1) and the component age feed of
destination.
253 Incorrect power supply Functions nor- Check fuse F58-3/1, D791-1/K2:1/9/ CAN/POW- 11.5.1.4
to attachment control mally supplied replace if necessary. 10 – F52-1 – ER, menu 16 Emergency
unit (D791-1). Voltage emergency Check fuse F52-1, re- F58-3/1:1 stop switch
under 18 V or over stop switch place if necessary. voltage
32 V. voltage have
Check cabling be-
no feed. No at-
tachment
and the component
functions
operational.
254 Incorrect emergency Functions nor- Check fuse F58-3/1, D791-1/K2:11 – CAN/POW- 11.5.1.4
stop switch voltage to mally supplied replace if necessary. F58-3/1 ER, menu 16 Emergency
Control unit, emergency Check fuse F52-1, re- stop switch
attachment (D791-1). stop switch place if necessary. voltage
voltage have
Check cabling be-
no feed. No at-
tachment
and the component
functions
operational.


and menu
components
257 Transistor has been Work light at- Check bulb. D791-1/K1:1 – LIGHTS, 9.6.11 Work
triggered due to short tachment right Check the bulb E406R menu 2 light
circuit or open circuit in not working. holder. attachment
light attachment right Check cabling be-
(E406R). tween the control unit
and the component
258 Transistor has been Work light at- Check bulb. D791-1/K1:15 – LIGHTS, 9.6.11 Work
triggered due to short tachment left Check the bulb E406L menu 2 light
circuit or open circuit in not working. holder. attachment
light attachment left Check cabling be-
(E406L). tween the control unit
and the component
259 Transistor has been Automatic Check cabling be- D791-1/K1:28 – ATTACH, 7.5 Spreading
triggered due to short spreading tween the control unit H9003/1 menu 15
circuit or open circuit in 20'-40' not and the component
circuit for buzzer, auto- working. with diagnostic menu.
matic spreading 20'-40' Check the
(H4009). component.
260 Transistor has been Extra work light Check bulb. D791-1/K1:42 – LIGHTS, 9.6.11 Work
triggered due to short attachment not Check the bulb E404-4L, menu 2 light
circuit or open circuit in working. holder. E404-4R attachment
circuit for bulb extra
work light attachment Check cabling be-
right (E404-4L and tween the control unit
E404-4R). and the component
261 The transistor has Rotation of at- Check cabling be- D791-1/K1:2 – ATTACH, 7.6.3 Control
been triggered due to tachment not tween the control unit Y6008/1 menu 11 valve
short circuit in the cir- working. and the component attachment
cuit for Solenoid valve, with diagnostic menu.
rotation clockwise Check the solenoid
(Y6008). valve.
262 The transistor has Rotation of at- Check cabling be- D791-1/K1:3 – ATTACH, 7.6.3 Control
been triggered due to tachment not tween the control unit Y6009/1 menu 12 valve
short circuit in the cir- working. and the component attachment
rotation counter- Check the solenoid
clock-wise (Y6009). valve.


and menu
components
263 The transistor has Spreading not Check cabling be- D791-1/K1:4 – ATTACH, 7.5.3 Control
been triggered due to working. tween the control unit Y6018/1 menu 13 valve
short circuit in the cir- and the component attachment
spreading out (Y6018). Check the solenoid
valve.
264 The transistor has Spreading not Check cabling be- D791-1/K1:5 – ATTACH, 7.5.3 Control
cuit for Solenoid valve with diagnostic menu.
spreading in (Y6019). Check the solenoid
valve.
265 Transistor has been Side shift of at- Check cabling be- D791-1/K1:30 – ATTACH, 7.4.3 Control
triggered due to short tachment not tween the control unit Y6021/1 menu 8 valve
circuit or open circuit in working. and the component attachment
valve sideshift right Check the solenoid
(Y6021). valve.
266 Transistor has been Side shift of at- Check cabling be- D791-1/K1:31 – ATTACH, 7.4.3 Control
triggered due to short tachment not tween the control unit Y6020/1 menu 8 valve
circuit or open circuit in working. and the component attachment
valve sideshift left Check the solenoid
(Y6020). valve.
267 Transistor has been Twistlock not Check cabling be- D791-1/K1:32 – ATTACH, 7.9.1.3 Con-
triggered due to short working. tween the control unit Y6040/1 menu 9 trol valve
circuit or open circuit in and the component attachment
valve lock twistlock Check the solenoid
(Y6040). valve.
268 Transistor has been Twistlock not Check cabling be- D791-1/K1:33 – ATTACH, 7.9.1.3 Con-
triggered due to short working. tween the control unit Y6039/1 menu 9 trol valve
circuit or open circuit in and the component attachment
valve open twistlock Check the solenoid
(Y6039). valve.
269 Transistor has been Tilt locked, tilt Check cabling be- D791-1/K1:7 – ATTACH, 7.7.4 Lock
triggered due to short damping and tween the control unit Y6012-1/1 menu 15 valve tilt
circuit or open circuit in controllable tilt and the component
valve tilt lock 1 Check the solenoid
(Y6012-1). valve.


and menu
components
270 Transistor has been Tilt locked, tilt Check cabling be- D791-1/K1:9 – ATTACH, 7.7.4 Lock
triggered due to short damping and tween the control unit Y6012-2/1 menu 15 valve tilt
circuit or open circuit in controllable tilt and the component
valve tilt lock 2 Check the solenoid
(Y6012-2). valve.
271 The transistor has Twistlocks, ro- Check cabling be- D791-1/K1:10 – ATTACH, 7.5.10 Posi-
been triggered due to tation stop, and tween the control unit B769/A, B777- menu 5, 6, 7, tion sensor,
short circuit or open cir- spreading not and the component 2/A, B7225/A, 21 spreading
cuit in circuit for Volt- working. with diagnostic menu. B7202R/A, 7.6.10 Sensor
age feed, position Check the sensor. B7204R/A, rotation stop
sensor attachment. B7205R/A,
B7203R/A, 7.9.1.8 Sensor
B7202L/A, alignment
B7204L/A, 7.9.1.9 Sensor
B7205L/A, twistlocks
B7203L/A, 8.2.1.6 Sen-
B7224/A sor, boom
length (posi-
tion sensor)
272 The transistor has Indicator light, Check bulb. D791-1/K1:25 – ATTACH, 7.9.1 Twist-
been triggered due to open twistlock Check the bulb H562/1 menu 10 locks
short circuit or open cir- not working. holder.
cuit in the circuit for In-
Check cabling be-
dicator light, open
twistlocks (H562).
and the component
273 The transistor has Indicator light, Check bulb. D791-1/K1:29 – ATTACH, 7.9.1
been triggered due to alignment Check the bulb H564/1 menu 10 Twistlocks
short circuit or open cir- twistlock not holder.
cuit in circuit for Indica- working.
Check cabling be-
tor light, alignment
(H564).
and the component
274 The transistor has Indicator light, Check bulb. D791-1/K1:39 – ATTACH, 7.9.1
been triggered due to locked twist- Check the bulb H563/1 menu 10 Twistlocks
short circuit or open cir- lock not holder.
cuit in the circuit for In- working.
Check cabling be-
dicator light, locked
twistlock (H563).
and the component


and menu
components
287 Faulty signal from sole- Rotation of at- Check cabling be- D791-1/K1:16 – ATTACH, 7.6.3 Control
noid valve rotation tachment not tween the control unit Y6008/2 menu 11 valve
clockwise (Y6008). Re- working. and the component attachment
turn current does not with diagnostic menu.
match control current. Check the solenoid
valve.
288 Faulty signal from sole- Rotation of at- Check cabling be- D791-1/K1:17 – ATTACH, 7.6.3 Control
noid valve rotation tachment not tween the control unit Y6009/2 menu 12 valve
counter.clockwise working. and the component attachment
(Y6009). Return cur- with diagnostic menu.
rent does not match Check the solenoid
control current. valve.
289 Faulty signal from sole- Spreading not Check cabling be- D791-1/K1:18 – ATTACH, 7.5.3 Control
noid valve spreading working. tween the control unit Y6018/2 menu 13 valve
out (Y6018). Return and the component attachment
current does not match with diagnostic menu.
valve.
290 Faulty signal from sole- Spreading not Check cabling be- D791-1/K1:19 – ATTACH, 7.5.3 Control
noid valve spreading in working. tween the control unit Y6019/2 menu 14 valve
(Y6019). Return cur- and the component attachment
rent does not match with diagnostic menu.
valve.
298 Sensor, twistlock indi- Lift and exten- Check that Sensors, - ATTACH, 7.9.1.9 Sensor
cates that left twistlock sion not twistlock, are clean menu 7 twistlocks
is between open and working. and correctly
locked position. adjusted.
Check cabling be-
and the component
299 Sensor, twistlock indi- Lift and exten- Check that Sensors, - ATTACH, 7.9.1.9 Sensor
cates that right twist- sion not twistlock, are clean menu 7 twistlocks
lock is between open working. and correctly
and locked position. adjusted.
Check cabling be-
and the component


and menu
components
300 Sensor, alignment, in- Twistlock not Check that Sensors, - ATTACH, 7.9.1.8 Sensor
dicates unreasonable working. alignment, are clean menu 6 alignment
distance. and correctly
adjusted.
Check that the con-
tact pin runs
smoothly.
Check cabling be-
and the component
(D791-2) does not with diagnostic menu. Control units
(D791-2) does not with diagnostic menu. Control units
303 Incorrect power supply Levelling, tilt, Check fuse F58-3/1 D791-2/K2:1, CAN/POW- 11.5.1.4
to attachment control and special and F52-1, replace if K2:9, K2:10 – ER, menu 17 Emergency
unit option (D791-2). function not necessary. F52-1 – stop switch
Voltage under 18 V or working. Check cabling be- F58-3/1 voltage
over 32 V. tween the control unit
and the component
304 Incorrect emergency Functions sup- Check fuse F58-3/1 D791-2/K2:11 – CAN/POW- 11.5.1.4
stop switch voltage to plied with con- and F52-1, replace if F52-1 – ER, menu 17 Emergency
Control unit, attach- trol breaker necessary. F58-3/1 stop switch
ment option (D791-2). voltage have Check cabling be- voltage
no feed. Level- tween the control unit
ling, tilt, and and the component
special func- with diagnostic menu.
tion not
working.
311 The transistor has Levelling not Check cabling be- D791-2/K1:2 – ATTACH, 7.8.3 Control
levelling right (Y6035). Check the solenoid
valve.


and menu
components
levelling left (Y6036). Check the solenoid
valve.
313 The transistor has Controllable tilt Check cabling be- D791-2/K1:4 – ATTACH, 7.7.5 Control
been triggered due to not working. tween the control unit Y6010/1 menu 16 valve
tilt out (Y6010). Check the solenoid
valve.
tilt in (Y6011). Check the solenoid
valve.
315 Transistor has been Levelling is Check cabling be- D791-2/K1:30 – ATTACH, 7.8.6 Valve
triggered due to short locked, control- tween the control unit Y6034-1/1 menu 18 block levelling
circuit or open circuit in lable levelling and the component cylinders
circuit for Solenoid lev- and float mode with diagnostic menu.
elling lock (Y6034-1). do not work. Check the solenoid
valve.
triggered due to short locked, control- tween the control unit Y6034-2/1 menu 18 block levelling
circuit or open circuit in lable levelling and the component cylinders
circuit for Solenoid and float mode with diagnostic menu.
valve levelling lock do not work. Check the solenoid
(Y6034-2). valve.
317 Incorrect output signal WARNING D791-2/K1:32

special function.

special function.

special function.

special function.

special function.

special function.


and menu
components
337 Faulty signal from sole- Levelling not Check cabling be- D791-2/K1:16 – ATTACH, 7.8.3 Control
noid valve levelling working. tween the control unit Y6035/2 menu 17 valve
right (Y6035). Return and the component attachment
valve.
noid valve levelling left working. tween the control unit Y6036/2 menu 18 valve
valve.
339 Faulty signal from sole- Controllable tilt Check cabling be- D791-2/K1:18 – ATTACH, 7.7.5 Control
noid valve for tilt out not working. tween the control unit Y6010/2 menu 14 valve
valve.
noid valve for tilt in not working. tween the control unit Y6011/2 menu 15 valve attach-
(Y6011). Return cur- and the component ment
valve.
control unit left jack and the component age feed of
pair (D791-3) does not with diagnostic menu. Control units
control unit right jack and the component age feed of
353 Incorrect power supply Left lift jacks Check fuse F58-3/1 D791-3/K2:1 – CAN/POW- 11.5.1.4
to attachment control not working. and F52-2, replace if F52-2 – ER, menu 18 Emergency
unit left jack pair necessary. F58-3/1 stop switch
(D791-3). Voltage un- Check cabling be- voltage
der 18 V or over 32 V. tween the control unit
and the component


and menu
components
354 Incorrect control break- Functions sup- Check fuse F58-3/1 D791-3/K2:11 – CAN/POW- 11.5.1.4
er voltage to Control plied with con- and F52-2, replace if F52-2 – ER, menu 18 Emergency
unit, attachment left trol breaker necessary. F58-3/1 stop switch
jack pair (D791-3). voltage do not Check cabling be- voltage
have supply. tween the control unit
Left lift jacks and the component
not working. with diagnostic menu.
357 Transistor has been Work lights left Check bulb. D791-3/K1:1 – - 9.6.11 Work
triggered due to short lift jacks not Check the bulb E404-6L/1 light
circuit or open circuit in working. holder. attachment
circuit for work light lift
Check cabling be-
jacks left (E404-6L).
and the component
triggered due to short locked, control- tween the control unit Y6034-1/1, menu 18 block levelling
circuit or open circuit in lable levelling and the component Y6034-2/1 cylinders
circuit for Solenoid lev- and float mode with diagnostic menu.
elling lock (Y6034-1) do not work. Check the solenoid
and Solenoid valve lev- valve.
elling lock (Y6034-2).
360 Transistor has been Left lift jacks Check cabling be- D791-3/K1:42 – COMBI, 7.9.2.5 Valve,
triggered due to short not working. tween the control unit Y6053L/1 menu 16 operating
circuit or open circuit in and the component position
valve operating posi- Check the solenoid
tion (Y6053L). valve.
levelling right (Y6035). Check the solenoid
valve.
levelling left (Y6036). Check the solenoid
valve.


and menu
components
363 Transistor has been Left lift jacks Check cabling be- D791-3/K1:4 – COMBI, 7.9.2.3 Con-
triggered due to short not working. tween the control unit Y6057L/1 menu 11 trol valve, lift
circuit or open circuit in and the component jacks
valve front knee in Check the solenoid
(Y6057L). valve.
valve front knee out Check the solenoid
(Y6056L). valve.
valve rear knee in Check the solenoid
(Y6059L). valve.
valve rear knee out Check the solenoid
(Y6058L). valve.
valve front jack down Check the solenoid
(Y6013L). valve.
valve front jack up Check the solenoid
(Y6060L). valve.
valve rear jack down Check the solenoid
(Y6014L). valve.


and menu
components
valve rear jack up Check the solenoid
(Y6061L). valve.
371 The transistor has Indicator light Check bulb. D791-3/K1:10 – COMBI, 7.9.2 Lift jacks
been triggered due to alignment lift Check the bulb H566R/1 menu 7
short circuit or open cir- jacks right front holder.
cuit in circuit for Indica- does not work.
Check cabling be-
tor light (H566R).
and the component
been triggered due to alignment lift Check the bulb H567R/1 menu 7
short circuit or open cir- jacks right rear holder.
tor light (H567R). Check cabling be-
and the component
been triggered due to alignment lift Check the bulb H566L/1 menu 7
short circuit or open cir- jacks left front holder.
Check cabling be-
tor light (H556L).
and the component
been triggered due to alignment lift Check the bulb H567L/1 menu 7
short circuit or open cir- jacks left rear holder.
Check cabling be-
tor light (H556L).
and the component
valve clamp in Check the solenoid
(Y6054L). valve.


and menu
components
valve clamp out Check the solenoid
(Y6055L). valve.
377 The transistor has Left lift jacks Check cabling be- D791-3/K1:26 – COMBI, 7.9.2.9 Sen-
been triggered due to not working. tween the control unit B7212L/A, menu 2, 3, 4, sor, operating
short circuit or open cir- and the component B7213L/A, 5, 6 position
cuit in circuit for voltage with diagnostic menu. B7214L/A, 7.9.2.10 Sen-
feed position sensor Check the sensor. B7215L/A, sor knee
left jack pair. B7216L/A,
B7217L/A, 7.9.2.13 Sen-
B7218L/A, sor lift jacks
B7219L/A, 7.9.2.15 Sen-
B7220L/A sor alignment
7.9.2.16 Sen-
sor clamping
position
noid valve levelling working. tween the control unit Y6035/2 menu 19 valve
right (Y6035). Return and the component attachment
valve.
noid valve levelling left working. tween the control unit Y6036/2 menu 20 valve
valve.


and menu
components
403 Incorrect power supply Right lift jacks Check fuse F58-3/1 D791-4/K2:1 – CAN/POW- 11.5.1.4
to attachment control and controlla- and F52-2, replace if F52-2 – ER, menu 19 Emergency
unit right jack pair ble tilt not necessary. F58-3/1 stop switch
(D791-4). Voltage un- working. Check cabling be- voltage
der 18 V or over 32 V. tween the control unit
and the component
404 Incorrect control break- Control break- Check fuse F58-3/1 D791-4/K2:11 – CAN/POW- 11.5.1.4
er voltage to Control er cannot be and F52-2, replace if F52-2 – ER, menu 19 Emergency
unit, attachment right disengaged. necessary. F58-3/1 stop switch
jack pair (D791-4). Right lift jacks Check cabling be- voltage
and controlla- tween the control unit
ble tilt not and the component
working. with diagnostic menu.
407 Transistor has been Work lights left Check bulb. D791-4/K1:1 – - 9.1.11 Work
triggered due to short lift jacks not Check the bulb E404-6R light
circuit or open circuit in working. holder. attachment
circuit for work light lift
Check cabling be-
jacks left (E404-6R).
and the component
410 Transistor has been Right lift jacks Check cabling be- D791-4/K1:42 – COMBI, 7.9.2.5 Valve,
triggered due to short not working. tween the control unit Y6053R/1 menu 16 operating
circuit or open circuit in and the component position
valve operating posi- Check the solenoid
tion (Y6053R). valve.
tilt out (Y6010). Check the solenoid
valve.
tilt in (Y6010). Check the solenoid
valve.


and menu
components
413 Transistor has been Right lift jacks Check cabling be- D791-4/K1:4 – COMBI, 7.9.2.3 Con-
triggered due to short not working. tween the control unit Y6057R/1 menu 11 trol valve, lift
valve front knee in Check the solenoid
(Y6057R). valve.
valve front knee out Check the solenoid
(Y6056R). valve.
valve rear knee in Check the solenoid
(Y6059R). valve.
circuit in circuit for So- and the component jacks
lenoid valve rear knee with diagnostic menu.
out (Y6058L). Check the solenoid
valve.
valve front jack down Check the solenoid
(Y6013R). valve.
valve front jack up Check the solenoid
(Y6060R). valve.
valve rear jack down Check the solenoid
(Y6014R). valve.


and menu
components
valve rear jack up Check the solenoid
(Y6061R). valve.
been triggered due to front jacks up Check the bulb H580/1 menu 9
short circuit or open cir- not working. holder.
cuit in circuit for Indica-
tor light (H580). Check cabling be-
and the component
been triggered due to front jacks Check the bulb H581/1 menu 9
short circuit or open cir- down not holder.
cuit in circuit for Indica- working.
and the component
been triggered due to clamping posi- Check the bulb H578/1 menu 8
short circuit or open cir- tion lift jacks holder.
cuit in circuit for Indica- front not
working.
and the component
been triggered due to clamping posi- Check the bulb H579/1 menu 8
short circuit or open cir- tion lift jacks holder.
cuit in circuit for Indica- rear not
working.
and the component
425 Transistor has been Right lift jacks D791-4/K1:2 – COMBI, 7.9.2.3 Con-
triggered due to short not working. Y6054R menu 15 trol valve, lift
circuit or open circuit in jacks
circuit for Solenoid
valve clamp in
(Y6054R).


and menu
components
426 Transistor has been Right lift jacks D791-4/K1:3 – COMBI, 7.9.2.3 Con-
triggered due to short not working. Y6055R menu 15 trol valve, lift
circuit or open circuit in jacks
circuit for Solenoid
valve clamp out
(Y6055R).
427 The transistor has Right lift jacks Check cabling be- D791-4/K1:26 – COMBI, 7.9.2.9 Sen-
been triggered due to not working. tween the control unit B7212R/A, menu 2, 3, 4, sor, operating
short circuit or open cir- and the component B7213R/A, 5, 6 position
cuit in circuit for voltage with diagnostic menu. B7214R/A, 7.9.2.10 Sen-
feed position sensor Check the sensor. B7215R/A, sor knee
right jack pair. B7216R/A,
7.9.2.13 Sen-
B7217R/A,
sor lift jacks
B7218R/A,
B7219R/A, 7.9.2.15 Sen-
B7220R/A sor alignment
7.9.2.16 Sen-
sor clamping
position
noid valve for tilt out not working. tween the control unit Y6010/2 menu 16 valve
valve.
noid valve for tilt in not working. tween the control unit Y6011/2 menu 17 valve
valve.
451 Redundant voltage - Check cabling be- 795/K1:7 CAN/POW- 11.5.1.2 Re-
feed left to Control unit tween the control unit ER, menu 14 dundant volt-
KID (D795) does not and the component age feed of
reach destination. with diagnostic menu. Control units
452 Redundant voltage - Check cabling be- 795/K1:8 CAN/POW- 11.5.1.2 Re-
feed right to Control tween the control unit ER, menu 14 dundant volt-
unit KID (D795) does and the component age feed of
not reach destination. with diagnostic menu. Control units
460 No messages received Incorrect val- Use diagnostic menu D795/K1:10, CAN/POW- 11.6.2 Redun-
on CAN buffer 1. ues in operat- to check the CAN bus K1:11, K1:12, ER, menu 1, dant CAN bus
ing menus. K1:13 2, 21


and menu
components
461 No messages received Error codes Use diagnostic menu D795/K1:5, CAN/POW- 11.6.2 Redun-
on CAN buffer 2. from other to check the CAN bus K1:6 ER, menu 1, dant CAN bus
Control units 2, 21
cannot be
shown.
500 Time for service. - Check that service - - 8.2.6 Service

has been performed. indicator
If servicing has been
performed following
the Cargotec service
schedule, reset the
service indicator; see
section 8 Control sys-
tem, group 8.2.6 Serv-
ice indicator.

E Diagrams 1
E Diagrams
Table of Contents E Diagrams

mm mm mm mm mm mm
10 Common hydraulics....................................................................................... 3
Hydraulic diagrams, compilation ............................................................................ 3
Hydraulic diagram base machine (Dana/Rexroth) ................................................. 4
Hydraulic diagram base machine (Dana/Sauer-Danfoss) ...................................... 6
Hydraulic diagram base machine (ZF/Rexroth) ...................................................... 8
Hydraulic diagram joystick steering/control (Dana/Rexroth) ................................ 10
Hydraulic diagram joystick steering/control (Dana/Sauer-Danfoss) ..................... 12
Hydraulic diagram joystick steering/control (ZF/Rexroth) ..................................... 14
Hydraulic diagram top lift (Dana/Rexroth) ............................................................ 16
Hydraulic diagram top lift (Dana/Sauer-Danfoss) ................................................. 18
Hydraulic diagram top lift (ZF/Rexroth) ................................................................ 20
Hydraulic diagram top lift, tilt lock, and controllable tilt (Dana/Rexroth) ............... 22
Hydraulic diagram top lift, tilt lock, and controllable tilt (Dana/Sauer-Danfoss) .... 24
Hydraulic diagram top lift, tilt lock, and controllable tilt (ZF/Rexroth) ................... 26
Hydraulic diagram top lift, tilt lock, controllable tilt, and hydraulic levelling
(Dana/Rexroth) ..................................................................................................... 28
(Dana/Sauer-Danfoss) ......................................................................................... 30
(ZF/Rexroth) ......................................................................................................... 32
Hydraulic diagram combi yoke (part 1 of 3) (Dana/Rexroth) ................................ 34
Hydraulic diagram combi yoke (part 1 of 3) (Dana/Sauer-Danfoss) ..................... 36
Hydraulic diagram combi yoke (part 2 of 3) (Dana/Rexroth/Sauer-Danfoss) ....... 38
Hydraulic diagram combi yoke (part 3 of 3) (Dana/Rexroth/Sauer-Danfoss) ....... 40
Hydraulic diagram combi yoke (ZF/Rexroth) ........................................................ 42
Hydraulic diagram sliding cab (Dana/Rexroth) ..................................................... 44
Hydraulic diagram sliding cab (Dana/Sauer-Danfoss) ......................................... 46
Hydraulic diagram sliding cab (ZF/Rexroth) ......................................................... 48
Hydraulic diagram cab lift and support jacks (Dana/Rexroth) .............................. 50
Hydraulic diagram cab lift and support jacks (Dana/Sauer-Danfoss) ................... 52
Hydraulic diagram cab lift and support jacks (ZF/Rexroth) .................................. 54
Hydraulic diagram sliding cab and support jacks (Dana/Rexroth) ........................ 56
Hydraulic diagram sliding cab and support jacks (Dana/Sauer-Danfoss) ............ 58
Hydraulic diagram sliding cab and support jacks (ZF/Rexroth) ............................ 60
11 Common electrics ........................................................................................ 62
Circuit diagram, description ................................................................................. 62
Component designations ...................................................................................... 64
Circuit diagrams, compilation ............................................................................... 64

2 E Diagrams

E Diagrams – 10 Common hydraulics 3
mm mm mm mm mm mm
Hydraulic diagrams, compilation

page
–
Designation Drawing number

Hydraulic diagram base machine (Dana/Rexroth) page 4 A40740.0100
Hydraulic diagram base machine (Dana/Sauer-Danfoss) page 6 A40740.0400
Hydraulic diagram base machine (ZF/Rexroth) page 8 A40740.0500
Hydraulic diagram joystick steering/control (Dana/Rexroth) page 10 A40856.0100
Hydraulic diagram joystick steering/control (Dana/Sauer-Danfoss) page 12 -
Hydraulic diagram joystick steering/control (ZF/Rexroth) page 14 -
Hydraulic diagram top lift (Dana/Rexroth) page 16 A40853.0100
Hydraulic diagram top lift (Dana/Sauer-Danfoss) page 18 -
Hydraulic diagram top lift (ZF/Rexroth) page 20 -
Hydraulic diagram top lift, tilt lock, and controllable tilt (Dana/Rexroth) page 22 A40853.0200
Hydraulic diagram top lift, tilt lock, and controllable tilt (Dana/Sauer-Danfoss) page 24 -
Hydraulic diagram top lift, tilt lock, and controllable tilt (ZF/Rexroth) page 26 -
Hydraulic diagram top lift, tilt lock, controllable tilt, and hydraulic levelling (Dana/Rexroth) page 28 A43123.0100
Hydraulic diagram top lift, tilt lock, controllable tilt, and hydraulic levelling (Dana/Sauer-Danfoss) -
page 30
Hydraulic diagram top lift, tilt lock, controllable tilt, and hydraulic levelling (ZF/Rexroth) page 32 -
Hydraulic diagram combi yoke (part 1 of 3) (Dana/Rexroth) page 34 A41791.0100
Hydraulic diagram combi yoke (part 1 of 3) (Dana/Sauer-Danfoss) page 36 -
Hydraulic diagram combi yoke (part 2 of 3) (Dana/Rexroth/Sauer-Danfoss) page 38 A41791.0100
Hydraulic diagram combi yoke (part 3 of 3) (Dana/Rexroth/Sauer-Danfoss) page 40 A41791.0100
Hydraulic diagram combi yoke (ZF/Rexroth) page 42 A41791.0200
Hydraulic diagram sliding cab (Dana/Rexroth) page 44 A40855.0100
Hydraulic diagram sliding cab (Dana/Sauer-Danfoss) page 46 A54505.0100
Hydraulic diagram sliding cab (ZF/Rexroth) page 48 -
Hydraulic diagram cab lift and support jacks (Dana/Rexroth) page 50 A43276.0100
Hydraulic diagram cab lift and support jacks (Dana/Sauer-Danfoss) page 52 -
Hydraulic diagram cab lift and support jacks (ZF/Rexroth) page 54 -
Hydraulic diagram sliding cab and support jacks (Dana/Rexroth) page 56 A40854.0100
Hydraulic diagram sliding cab and support jacks (Dana/Sauer-Danfoss) page 58 -
Hydraulic diagram sliding cab and support jacks (ZF/Rexroth) page 60 A40854.0300

–
page
4
1 3 4 5
C+ C-
VDRF03.03GB
C+ 2 C- C+ 6 C-
8
B
PT
7
11
9 10
VA VA D VB
VA D T VA D T
ACC B 16 H
17 15 14
12
45 47 B1 A1 B2 A2 M
44 A
13
P H
46 PP
T H
10
11
LS
25
28
P M T
T T 29
P P
D
24
18
Workshop manual DRF 400–450

PSS PS
E Diagrams – 10 Common hydraulics
27 26 L R
34 30
(Dana/Rexroth)
43 40 36
33 23
39
20
33 33 33 19
X1 X2 X1
33 X2
T P
38 31 LS CF EF LS
42 21
T PP
B1 B2 B1 B2
P
37 32
22
S L1 L2 L4 L3 S L1 L2 L4 L3
41 35
010869 (A40740.0100 ver. 8)
Hydraulic diagram base machine
1. Lift cylinder 25. Oil return from attachment

2. Valve block lift cylinder 26. Oil filter brake system
3. Extension cylinder 27. Hydraulic oil filter
4. Valve block extension cylinder 28. Cooler hydraulic oil
5. Lift cylinder 29. Bypass valve, hydraulic oil cooler
6. Valve block lift cylinder 30. Fine filter hydraulic oil
7. Accumulator brake pressure 31. Priority valve
8. Brake valve 32. Pump cooling and filtration of hydraulic oil
9. Parking brake caliper 33. Non-return valve
10. Brake cylinder 34. Pressure supply to attachment
11. Wheel brakes 35. Hydraulic oil pumps 3 and 4
12. Drive axle block 36. Shuttle valve
13. NO (normally open) switch, disengagement 37. Oil pump brake system
14. Make-contact (closing switch) brake lights 38. Valve block top lift hydraulics
15. NO (normally open) switch, parking brake 39. Shuttle valve
16. Accumulator charging valve 40. Relief valve, attachment
17. Break contact (opening switch) brake pressure 41. Hydraulic oil pumps 1 and 2
18. Cooler brake system 42. Pressure limiting valve
19. Thermal bypass valve 43. Valve block pump unloading
20. Breather filter, brake oil tank 44. Pressure reducer
21. Oil tank brake system 45. Accumulator servo pressure
22. Breather filter hydraulic oil tank 46. Servo filter
23. Steering valve 47. Control valve lifting/lowering and extension

–
page
6
VDRF03.03GB
1 2 3 4 5 6
C+ C-
C+ C- C+ C- 8
11
9 10
VA VA D VB
VA D T VB D T
17 ACC B 16 H
15 14
45 12
B1 A1 B2 A2 M
44 A
P H 46 PP 13
47
T H 10
11
LS
25
28
P M T
T T 29
P P
D 26

48 24
48 PSS PS 18
27
40 36 34 30
2 1
3 23
33 392 1 20
43 3
33 X1 X1
19
33
38 LS CF EF T P
42 LS
B1 B1
T PP 21
P
37 32 31
35 22
41
S L2 L1 S L2 L1
012445 [A40470.0400 ver 01]


6. Valve block lift cylinder 30. Fine filter hydraulic oil
7. Accumulator brake pressure 31. Priority valve
8. Brake valve 32. Oil pump brake system
9. Parking brake caliper 33. Non-return valve
10. Brake cylinder 34. Pressure supply to attachment
11. Wheel brakes 35. Hydraulic oil pump 2
13. NO (normally open) switch, disengagement 37. Pump cooling and filtration of hydraulic oil
15. NO (normally open) switch, parking brake 39. Shuttle valve
16. Accumulator charging valve 40. Relief valve, attachment
17. Break contact (opening switch) brake pressure 41. Hydraulic oil pump 1
18. Cooler brake system 42. Pressure limiting valve
24. Steering cylinder 48. High-pressure filter

–
page
8
VDRF03.03GB
1 2 3 4 5 6
C+ C-
C+ C- C+ C- 8
11
9 10
VA VA D VB
VA D T VB D T
17 ACC B 16 H
15 14
45 12
B1 A1 B2 A2 M
44 A
P H 46 PP 13
47
T H 10
11
LS
25
28
P M T
T T 29
P P
D 26

(ZF/Rexroth)
48 24
48 PSS PS 18
27
40 36 34 30
2 1
3 23
33 392 1 20
43 3
33 X1 X1
19
33 T P
38 LS CF EF
42 LS
B1 B1
T PP 21
P
37 32 31
35 22
41
S L2 L1 S L2 L1
012445 [A40470.0400 ver 01]


6. Valve block lift cylinder 30. High-pressure filter
7. Accumulator brake pressure 31. Fine filter hydraulic oil
8. Brake valve 32. Priority valve
9. Parking brake caliper 33. Pressure supply to attachment
10. Brake cylinder 34. Non-return valve
11. Wheel brakes 35. Hydraulic oil pump 2
13. NO (normally open) switch, disengagement 37. Relief valve, attachment
15. NO (normally open) switch parking brake 39. Oil pump brake system
16. Accumulator charging valve 40. Hydraulic oil pump 1
17. Break contact (opening switch) brake pressure 41. Pump cooling and filtration of hydraulic oil
18. Cooler brake system 42. Hydraulic oil tank
24. Steering cylinder 48. Hydraulic oil filter

10 E Diagrams – 10 Common hydraulics
Hydraulic diagram joystick steering/

page
–
control (Dana/Rexroth)
LS
R
T
2
P
L
LS
T
4
TP
EF
P
CF
PP
A
B
6
LS
L3
X2
1
L4
P
T1
7
B2
L2
X1
010516 (A40856.0100 ver. 2)

L1
S
B1

1. Control valve option frame

3. Steering valve
4. Priority valve
5. Shuttle valve
6. Shuttle valve joystick control
7. Hydraulic oil pumps 3 and 4


page
–
control (Dana/Sauer-Danfoss)
LS
R
T
2
P
L
LS
T
4
TP
EF
P
CF
PP
A
B
6
LS
1
P
T1
L1
X1
L2
S
B1
7
013012


3. Steering valve
4. Priority valve
5. Shuttle valve
7. Non-return valve


page
–
control (ZF/Rexroth)
LS
R
T
2
P
L
LS
T
4
TP
EF
P
CF
PP
A
B
7
6
LS
1
P
T1
015282


3. Steering valve
4. Priority valve
5. Shuttle valve
7. Load signal to hydraulic oil pump
8. Pressure supply to hydraulic oil pump

–
page
16
VDRF03.03GB
2
3 3 5 6
P C1- C2+ C1+ C2- T 8 8
B A
1 1 7
4 5
P PP T T
Rexroth)
11

B A B A B A B A PS
TPB
T1
12
13 B
C P2B
A
X1 X2
10
B1 B2
T2B
14 T3B
P1 LSPB
S L1 L2 L4 L3 9
010512 (A40853.0100 ver. 4)

Hydraulic diagram top lift (Dana/
1. Tilt cylinder
2. Damping block
4. Valve block rotation motor
5. Sideshift cylinders
6. Spreader motor
7. Valve block spreader motor
8. Twistlock cylinders
9. Control valve, attachment
10. Filter hydraulic oil
11. Filter hydraulic oil (high-pressure filter)

12. Solenoid valve, cut-in of hydraulic pressure
13. Shuttle valve

Hydraulic diagram top lift (Dana/

page
–
8 Sauer-Danfoss)
TPB
P2B
T2B
T3B
8
PS
LSPB
7
A
6
B
A
9
B
5
A
B
4
3
A
B
3
P1
T1
11
10
1
A
T
T
12
2
14
C2-
13
L1
X1
L2
C2+ C1+
2
S
PP
15
B1
C1-
15
16
P
P
012496
1

1. Tilt cylinder
2. Damping block
6. Spreader motor

13. Shuttle valve
14. Relief valve, attachment

Hydraulic diagram top lift (ZF/

page
–
8 Rexroth)
TPB
P2B
T2B
T3B
8
PS
LSPB
7
A
6
B
A
9
B
5
A
B
4
3
A
B
3
P1
T1
12 11
P
10
T
1
A
T
T
C2-
C2+ C1+
2
T
PP
C1-
P
P
014398
1

1. Tilt cylinder
2. Damping block
6. Spreader motor
11. From hydraulic oil pump
12. Return to hydraulic oil tank

Hydraulic diagram top lift, tilt lock,

page
–
and controllable tilt (Dana/Rexroth)
TPB
P2B
T2B
T3B
8
PS
LSPB
8
A
B
7
A
6
9
A
5
5
B
A
B
4
3
A
3
P1
T1
10
11
1
12
A
13
T
L3
X2
C1+ C2-
L4
T
2
C2+
B2
010514 (A40853.0200 ver. 5)

PP
L2
X1
S L1
C1-
B1
P
P
B
14
1

1. Tilt cylinder
2. Damping block
6. Spreader motor

13. Shuttle valve


page
–
and controllable tilt (Dana/

Sauer-Danfoss)
TPB
P2B
T2B
T3B
8
PS
LSPB
8
A
B
7
A
6
9
A
5
5
B
A
B
4
3
A
3
P1
T1
10
11
1
A
T
12
C1+ C2-
13 2
14
T
L2 L1
X1
2
C2+
PP
S
C1-
15
B1
15
16
P
P
B
013010
1

1. Tilt cylinder
2. Damping block
6. Spreader motor

13. Shuttle valve


page
–
and controllable tilt (ZF/Rexroth)
TPB
P2B
T2B
T3B
8
PS
LSPB
8
A
B
7
A
6
9
A
5
5
B
A
B
4
3
A
3
P1
T1
12 11
P
10
T
1
A
T
T
C1+ C2-
T
2
C2+
PP
C1-
P
P
B
014399
1

1. Tilt cylinder
2. Damping block
6. Spreader motor


page
–
controllable tilt, and hydraulic

levelling (Dana/Rexroth)
T3
TP
T2
PS
8
8
A
7
B
6
A
5
14
B
5
15
16
A
3
B
3
9
14
A
B
1
A
T
T
C2-
A
C1+
T
C2+
2
PP
B
C1-
P
P
A
1
P1
T1
12
10
11
L4 L3
X2
010515 (A431213.0100 ver. 3)

13
B2
L1 L2
X1
S
B1

1. Tilt cylinder
2. Damping block
6. Spreader motor
11. Shuttle valve
12. Hydraulic oil filter
14. Levelling cylinders
15. Valve block levelling cylinders
16. Overcentre valve levelling


page
–

levelling (Dana/Sauer-Danfoss)
T3
TP
T2
PS
8
8
A
7
B
6
A
5
B
5
9
10
11
A
3
B
3
12
9
A
B
1
A
T
T
C2-
A
C1+
T
C2+
2
PP
B
C1-
P
P
A
1
P1
T1
13
1
14
2
15
L1
X1
L2
S
17
18
B1
16
013011
17

1. Tilt cylinder
2. Damping block
6. Spreader motor
15. Shuttle valve


page
–

levelling (ZF/Rexroth)
T3
TP
T2
PS
8
8
A
7
B
6
A
5
B
5
9
10
11
A
3
B
3
12
9
A
B
1
A
T
T
C2-
A
C1+
T
C2+
2
PP
B
C1-
P
P
A
1
P1
T1
14 13
T
P
014400

1. Tilt cylinder
2. Damping block
6. Spreader motor
11. Shuttle valve

–
page
34
010526:A 010532:D
2C1+
VDRF03.03GB
P C1- C2+ C2- T
B A
3
1 1
5 6 8
4 7
P PP T T
9 9
10
11

010526:B 010526:C
010532 :E
B A B A B A B A B A B A PS
1413
TP
15 X1 X2
T1
P2
B1 B2
(part 1 of 3) (Dana/Rexroth)
010532:F
T2
Hydraulic diagram combi yoke
S L1 L2 T3
L4 L3
P1
12
010520 (A41791.0100 ver. 1 - part 1/3)
1. Tilt cylinder
2. Damping block
6. Spreader motor
14. Shuttle valve

–
page
36
010526:A 010532:D
VDRF03.03GB
2C1+
P C1- C2+ C2- T 3
B A
1 1 5 6
8
7
4
P PP T T
010526:C
010526:B
9 9
10
11

010532 :E
B A B A B A B A B A B A PS
15 14 2
1
3 TP
15
X1 T1
13 P2
B1
16 010532:F
T2
T3
S L2 L1
P1
12
(part 1 of 3) (Dana/Sauer-Danfoss)
013016
1. Tilt cylinder
2. Damping block
6. Spreader motor
14. Shuttle valve


page
–
(part 2 of 3) (Dana/Rexroth/
Sauer-Danfoss)
Rexroth: 010520:A
1 TP P2 T2 T3 Sauer-Danfoss: 013016:A
A
3
A
5
A
P T
B
6
A
7
B
8
B
9
010526 (A41791.0100 ver. 2 - part 2/3)
10
P1
Rexroth: 010520:B Rexroth: 010520:C

Sauer-Danfoss: 013016B Sauer-Danfoss: 013016:C

1. Control valve lift jacks left

2. Lowering cylinder front lift jacks
3. Valve block lowering front lift jacks
4. Valve block extension front lift jacks
5. Clamping cylinder front lift jacks
6. Valve block operating position front lift jacks
7. Clamping cylinder rear lift jacks
8. Valve block extension rear lift jacks
9. Valve block lowering rear lift jacks
10. Lowering cylinder rear lift jacks


page
–
(part 3 of 3) (Dana/Rexroth/
Sauer-Danfoss)
Rexroth: 010520:D
Sauer-Danfoss: 013016:D T3 T2 P2 TP
1
A 3
A
5
B
6
A
7
B
8
B
9
010532 (A41791.0100 ver. 1 - part 3/3)
10
P1
T1
Rexroth: 010520:E Rexroth: 010520:F

Sauer-Danfoss: 013016:E Sauer-Danfoss: 013016:F

1. Control valve lift jacks right


Hydraulic diagram combi yoke (ZF/

page
–
Rexroth)
28 29
31
30
26
34
27
33
32
25
8
7
6
5
9
10
11
5
4
3
12
9
1
2
1413
015278 (A41791.0200 ver. 1)

15
22
19 18
23
17
16
20
24
21

1. Tilt cylinder
2. Damping block
6. Spreader motor
14. Shuttle valve
15. Control valve lift jacks left
25. Control valve lift jacks right

Hydraulic diagram sliding cab

page
–
(Dana/Rexroth)
2
TP
A
B
3
4
5
LS
1
L3
X2
L4
P
T1
6
B2
L2
X1
L1
010517 (A40855.0100 ver. 1)

S
B1


4. Shuttle valve
5. Shuttle valve option

Hydraulic diagram sliding cab

page
–
3
1
L1
013013 (A54505.0100 ver. 1)

L2
S
7


4. Shuttle valve
7. Non-return valve

Hydraulic diagram sliding cab (ZF/

page
–
Rexroth)
2
1
3
4
015283


3. Load signal to hydraulic oil pump
4. Pressure supply to hydraulic oil pump

Hydraulic diagram cab lift and

page
–
support jacks (Dana/Rexroth)
4
3
3
2
65
TP
T3
A
B
A
7
B
10
9
LS
L3
1
X2
L4
P
T1
11
B2
L2
010518 (A43276.0100 ver. 1)

X1
L1
S
B1


2. Accumulator
3. Hydraulic cylinder support jacks
4. Valve block support jacks
5. Load control valve
6. Hydraulic cylinder vertically adjustable cab
7. Restriction
9. Shuttle valve
10. Shuttle valve option frame


page
–
support jacks (Dana/Sauer-Danfoss)
4
3
3
2
65
TP
T3
A
B
A
7
B
9
LS
L1
1
L2
P
T1
S
10
11
013014


2. Accumulator
8. Shuttle valve
9. Shuttle valve option frame


page
–
support jacks (ZF/Rexroth)
4
3
3
2
65
TP
T3
A
B
A
B
LS
7
1
8
P
T1
014814


2. Accumulator
7. Load signal
8. Pressure feed from hydraulic oil pump
9. Tank return

Hydraulic diagram sliding cab and

page
–
support jacks (Dana/Rexroth)
3
2
2
4
P
A
B
A
5
B
6
7
8
LS
L4 L3
X2
1
P
T1
9
B2
010519 (A40854.0100 ver.1)

L1 L2
X1
S
B1


3. Overcentre valve support jacks
5. Restriction
7. Shuttle valve


page
–
support jacks (Dana/Sauer-Danfoss)
3
2
2
4
P
A
B
A
5
B
7
LS
L1
1
L2
P
T1
S
8
013015


6. Shuttle valve
8. Non-return valve


page
–
support jacks (ZF/Rexroth)
3
2
2
4
657
8
1
015276 (A40854.0300 ver.1)


6. Shuttle valve
8. Non-return valve

62 E Diagrams – 11 Common electrics
11 Common electrics
mm mm mm mm mm mm
Circuit diagram, description

page
–
A circuit diagram is divided into circuit names (drawing numbers) and

consists of a set of numbered pages.
The circuits and their contents are governed by the following set of
rules:
• 20015.0001 circuit drawings-post designations K-standard.
• K-standard 1: norms, rules
• K-standard 2: cables, general physical
• K-standard 5: Designation and marking system, item designations
circuit drawings
The following is an explanation of symbols and texts in a circuit
diagram:
Connectors
Connectors in the wiring start with an X followed by a number and end
-XM674m -XM674f
2 2 with f = female or m = male. If a connector is connected to a compo-
nent then the component number is inherited into the connector’s
number, e.g. XB72002Rm which is the connector for Sensor align-
ment front right (B7202R).
Under the connector’s number the pin is specified with numbers or let-
013017
-X37-201 ters depending on the connector.

• X000-X199: In the cab.
• X200-X299: On the frame.
• X300-X399: On the boom.
• X400-: On the attachment.
• X37-: All grounding points start with X37, e.g. X37-201, which is a
grounding point on the frame.
X37-A, X37-B, X37-C and X37-D are grounding points in electron-
ic box, cab.
Zero references are in the control units.
Components
Components are described with component number (S220-2) and a
short descriptive text. Components (sensors, switches, etc.) are
shown in standby mode i.e. de-energised mode or not mechanical
standby mode.
• S indicates the type of component, see Component designations
page 64.
• 220 is component number and indicates the function the compo-
nent has.
• -2 indicates that it is the second component of this type for the
specific diagram.

E Diagrams – 11 Common electrics 63
Cable marking
A01012 0525 W212D

All cables are either white (ground signal) or grey (other wiring) and la-
belled with numbers.
Cable numbering is interpreted as follows:
A01011 0524 W212C
• 0525: the number on a cable can usually be traced to a pin in a
connector, in this example, connector X052 pin 5.
A01010 0523 W212B
• W212: cables that start with W and serial number cannot be
traced directly to a connector.
A01016 0527 W212E
• A01012: cables that start with A are in the electronic box in
the cab.
013019
W212A
• W212D: cables that end with a capital letter are jointed in the wir-
ing from a main cable with the same number. Each joint will have
its own letter.
References
0 An arrow symbol means that the circuit continues on another page in
the circuit diagram at the specified coordinates. Sometimes there are
1
00816 also references for components that can then be part of a component
/4.0_1.B1 5 1
013020
00816
whose other parts are on a different diagram. In some cases there is
/9.10_1.A2 also a help text where the cable connects.
Example: /11.5_1.D3 means page 11.5_1 coordinate D3.
Connection to control unit

Connections to control units are described as a table with two fields;
the upper one shows the type of connection, the lower one has a ref-
-X411
21 K1:21 Analog In 0-5V +BOOM erence to the compilation of the control unit’s connections. Together
/0.0_4.D5 -D791-1 with this there are descriptive texts that specify control unit and signal.
013021
MEASUREPOINT SCALE For more information about the different connection types on the con-
trol units, see section 11 Common electrics, group 11.5.5 Wiring.
Fuses
Fuse boxes always start with F5. Example: F58-3 means fuse box 3
with 8 fuses.
For most fuse boxes there is also a table and an explanation of the cir-
cuits that the various fuses protect.

Component designations
page
–
The components in circuit diagrams have a prefix and number, the

prefix describes the type of component, the number which component.
Component list with component number, prefix and designation is pro-
vided as an appendix after the circuit diagrams.
Prefix Description
B Converter from non-electric to electric signals or vice versa. Example: inductive sensor.
D Binary element, delay unit, memory. Example: control unit.
E White light. Example: work light.
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.
M Motor. Example: electric motor.
P Measuring instrument, test equipment. Example: operating hour gauge.
R Resistor. Example: potentiometer.
S Electric switch for control circuit, selector. Example: switch.
X Outlet/socket, connecting device Example: connection terminal.
Y Electrically controlled mechanical device: Example: solenoid valve, hydraulic valve.
Circuit diagrams, compilation

page
–
Circuit diagrams are attached as an appendix in the following order.
Sheet Designation
0.0-1 Circuit Cross references
0.0-2 Circuit Cross references
0.0-3 Circuit Cross references Opt
0.0-4 Circuit Cross references Att
0.0-5 Circuit Cross references Att
0.0-6 Circuit Cross references Att Combi
1.0-1 Circuit Engine 1240&1250
1.0-2 Circuit Engine Cummins
1.0-3 Circuit Engine Cummins
1.0-4 Circuit Engine Volvo
1.1-1 Circuit drivetrain
2.0-1 Circuit Dana TE32

Sheet Designation
2.0-1A1 Circuit Dana TE 32FF
2.0-1B1 Circuit diagram, circuit gearshifting ZF
2.0-2 Circuit Dana TE 32
2.0-3 Circuit Dana TE 32
2.1-1 Circuit drivetrain
4.0-1 Circuit, brake system
4.0-2 Circuit, brake system
5.2-1 Circuit Steering joystick/mini-wheel
5.2-2 Circuit Steering joystick/mini-wheel
5.2-3 Circuit Steering joystick/mini-wheel and Combi att
5.2-4 Circuit Steering joystick/mini-wheel and Combi att
5.2-5 Circuit Steering joystick/mini-wheel EHPS
7.1-1 Circuit Joystick
7.2-1 Circuit Boom Up/Down
7.3-1 Circuit Boom In/Out
7.5-1 Circuit Spreading Valves
7.5-2 Circuit Spreading Auto
7.5-3 Circuit Spreading Sensor
7.6-1 Circuit Rotation
7.7-1 Circuit Tilt lock
7.7-2 Circuit Tilt + Levelling
7.7-3 Circuit Tilt + Levelling
7.9-1 Circuit Twistlocks
7.9-2 Circuit Twistlocks
7.9-3 Circuit Combi Att

Sheet Designation
7.9-15 Circuit Over Height
7.9-16 Circuit Over Height
7.9-18 Circuit fork attachment
7.10-1 Circuit Hyd Support jacks
7.10-2 Circuit Hyd Support jacks
7.10-3 Circuit Printer
8.2-1 Circuit OP + Scale
8.2-2 Circuit OP + Scale
8.2-3 Circuit, Bypassing
8.2-4 Circuit RMI
9.1-1 Circuit Extra Sensor Instr.
9.1-2 Circuit, Optional equipment
9.1-4 Circuit Sensor Instr.
9.1-5 Circuit Option Cab
9.1-6 Circuit, Optional equipment Boom nose
9.3-1 Circuit, Cab Operator’s seat
9.3-2 Circuit, Cab Operator’s seat
9.4-1 Circuit Climate system
9.5-1 Circuit Wipers
9.6-1 Circuit Work lights
9.6-2 Circuit Extra Work Light Att
9.6-3 Circuit Extra Wor.li. Boom
9.6-5 Circuit Lighting

Sheet Designation
9.6-9 Circuit Entry lighting
9.6-10 Circuit Extra Wor.li. Frame
9.7-1 Circuit Alarm, Audible signals
9.7-2 Circuit Alarm, Audible signals
9.7-3 Circuit Direction indicators, Hazard flashers
9.7-4 Circuit Back-up alarm
9.8-1 Circuit Radio
9.9-9 Circuit Camera
9.10-1 Circuit Sliding/Vertically adjustable Cab
9.10-2 Circuit Tiltable cab
9.14–1 Circuit Central lubrication
10.0-1 Circuit Hydraulics
11.5-1 Circuit Current
11.5-5 Circuit Current Att
11.5-6 Circuit Current KDU OPT
11.5-7 Circuit 24V
11.5-8 Circuit 12V + Comm. Radio
11.5-9 Circuit Current Att
11.5-10 Circuit Current Inverter
11.6-3 Circuit CAN BUS opt. Frame KDU
11.6-4 Circuit CAN BUS ATT
Power mirrors
1 Circuit diagram Mirrors
Cab tilt
1 Circuit diagram Cab tilt


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Training Rs Kalmar

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Training Rs Kalmar

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A Foreword

9 Frame, body, cab and accessories

G Terminologi och Index

Table of Contents A Foreword

Workshop manual DRF 400-450 VDRF03.03GB

VDRF03.03GB Workshop manual DRF 400-450

About the Workshop Manual

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

The instructions are based on the use of generally available standard

About machine version

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

Extreme hazard to personal health and risk of proper-

Only use equipment that is approved by Cargotec.

Workshop manual DRF 400-450 VDRF03.03GB

Warnings provide information about potential dangers that, if the warn-

Important information is denoted with NOTE and is intended to facili-

Read operator’s manual

Read the operator’s manual

Read the Maintenance manual

Read the Maintenance manual

VDRF03.03GB Workshop manual DRF 400-450

The workshop manual’s contents

The Workshop Manual contains information to facilitate maintenance

B Safety Keep in mind for your safety.

C Preventive maintenance Reference to maintenance manual: Preventive maintenance.

E Diagrams Wiring diagrams, hydraulic diagrams and list of electrical components.

Workshop manual DRF 400-450 VDRF03.03GB

Function group structure

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

VDRF03.03GB Workshop manual DRF 400-450

References between different information types

The maintenance manual and workshop manual are mainly divided

Function descriptions Hydraulic diagrams

Component descriptions Error codes

Diagnostics Wiring diagrams

• From Function description to Component description, to enable

Workshop manual DRF 400-450 VDRF03.03GB

Product alternatives and optional equipment

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

Optional equipment refers to options that can be added to standard

VDRF03.03GB Workshop manual DRF 400-450

The function descriptions are schematic overviews that describe

2 4 Bromsar – 4.3 Servobromssystem

1. Bromsoljepump 8. Slutkontakt bromsljus (S216) 5

3. Ackumulatorladdningsventil 10. Reglerenhet ram fram (D797-F)

4. Ackumulatorer 11. Reglerenhet ram bak (D797-R)

5. Bromsventil 12. Bromsljus (H411L & H411R)

6. Bromscylindrar 13. Reglerenhet KIT (D790-2), Varningslampa bromstryck

UDRF03.01S Underhållsmanual DRF 400–450

Example of function description

Workshop manual DRF 400-450 VDRF03.03GB

1. Hydraulic force (solid double line)

VDRF03.03GB Workshop manual DRF 400-450

Symbol explanation function descriptions

D790-1 13. Bulb

Workshop manual DRF 400-450 VDRF03.03GB

About the documentation

The documentation for the machine consists of the following parts:

Documentation is ordered from your Cargotec dealer.

VDRF03.03GB Workshop manual DRF 400-450

Cargotec’s ambition is that you who work with maintenance of Kalmar

To: Cargotec Sweden AB

Date: .................................... - .................. - ..................

Section / page number: .......................................................................................................................