Documentos de Académico
Documentos de Profesional
Documentos de Cultura
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
10 Common hydraulics
11 Common electrics
12 Common pneumatics
D Error codes
E Schematics
F Technical data
A Foreword
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 ..................................................................................................... 9
Function descriptions ...................................................................................... 10
About the documentation ......................................................................... 13
The documentation’s parts .............................................................................. 13
Ordering documentation .................................................................................. 13
Feedback .................................................................................................. 14
Form for copying ............................................................................................. 14
Foreword
mm mm mm mm mm mm
Conditions
page
–
Storage
page
–
NOTE
The workshop manual should be accessible to service personnel.
DANGER
External equipment may only be used if it 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.
Reading instructions
Warning information
page
–
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
–
NOTE
Important information not related to safety.
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
The symbol to the left is used in certain cases on the machine and re-
fers to important information in the Maintenance manual.
001128
A Foreword General information about the workshop manual’s purpose, contents and reading in-
structions as well as survey for feedback of views and any inaccuracies.
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. Con-
sequently, common components are described in several places, but in general un-
6 Suspension der the first function to use the component.
7 Load handling Together with the general description is a detailed description of what is unique
about the specific subfunction. The next subfunction to use the same component
8 Control system
only has a description what is unique for the new function.
9 Frame, body, cab and
Work instructions for corrective maintenance (replacement of components).
accessories
10 Common hydraulics
11 Common electrics
12 Common pneumatics
D Error codes Error code information and instructions for reading error code information.
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 sections.
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
Machine card
page
–
NOTE
If the machine has been modified after delivery, information on
the machine card may be incomplete or incorrect.
IMPORTANT
Changes made on the machine must be reported to
Cargotec so that the machine card can be updated. A
new updated machine card is sent on the request of
the customer.
NOTE
All documents that accompany the machine are non-registered
documents and there will be no notification of changes.
Function descriptions
page
–
7.5 Spridning
Spridning, funktionsbeskrivning
Twistlocks/L sklaffar Ol sta eller f rbi- Twistlocks, beskrivning sida 65 eller Lyftkrok, beskrivning sida 77
koppling aktiverad Flik 8 Styr- och vervakningssystem, grupp 8.2.2 F rbikoppling
1
D1
1b
1a
2
D790-1
D3 10,19 11,20
C
P1 12
4
T1 15
D15
A B A B 21
D16
2
9 5 15 16
C
6 13,22 14,22
7
8
3
009345
1b Man verspak (S815-T1.1 och Spridning: US815-T4 = 24 V Man verspak, beskrivning sida 6
S815-T1.2) s nder sp nningssignal D1: Diagnosmeny, se flik 8 Styr- och vervak-
Ut: US815-T1.2 = 24 V
till Reglerenhet hytt (D790-1). ningssystem, grupp 8.4.9.2 ATTACH, meny 3
In: US815-T1.1 = 24V
2 Reglerenhet hytt (D790-1) s nder Kontrolleras av styr- och Flik 11 Gemensam el, grupp 11.5.3.1 Regle-
7 spridning in eller ut p CAN-bussen. vervakningssystemet, fel renhet hytt (D790-1) 4
visas med felkod.
6
010058
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 with 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
–
Feedback
Form for copying
page
–
From:
Company / Sender: .........................................................................................................................................
Phone: ............................................................................................................................................................
E-mail: ............................................................................................................................................................
Manual
information Name / Publication number: ............................................................................................................................
Suggestions,
views, ........................................................................................................................................................................
remarks, etc.
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
B Safety
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 ......................................................... 8
Working under the machine .............................................................................. 9
Lifting heavy components ................................................................................. 9
Vibration .......................................................................................................... 10
Noise ............................................................................................................... 10
Dissolvent ........................................................................................................ 11
Fire and explosion risk .................................................................................... 12
Fluid or gas under pressure ............................................................................ 14
Coolant ............................................................................................................ 15
Refrigerant ...................................................................................................... 15
Air pollution ..................................................................................................... 16
Tensioned springs ........................................................................................... 18
Electric motors ................................................................................................. 18
Rotating components and tools ....................................................................... 18
Tyres and rims ................................................................................................. 19
Lifting equipment ............................................................................................. 20
Spare parts ........................................................................................................... 21
Non-ionised radiation ........................................................................................... 22
Environment ............................................................................................. 23
General ........................................................................................................... 23
Safety
mm mm mm mm mm mm
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!
Kalmar Industries has in this publication documented and warned for
situations and risks that may occur in connection with using as well as
service/repairs of the machine during normal circumstances.
That’s why it’s important that all who work with the machine or repair/
service the machine read and follow the information in the mainte-
nance manual and operator’s manual.
Safety instructions
General
page
–
Read and observe the following safety instructions below before start-
ing to work with the machine:
• Service position page 5
• Hydraulic and brake systems, depressurising page 5
• Oils page 7
• Fuel system page 8
• Clothing, etc. page 9
• Several mechanics on the same machine page 9
• Working under the machine page 10
• Lifting heavy components page 10
• Vibration page 11
• Noise page 11
• Dissolvent page 12
• Fire and explosion risk page 13
• 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 19
• Tyres and rims page 19
• Lifting equipment page 20
Service position
page
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General
Service position is used for service, maintenance and other situations
when the machine needs to be secured.
Service position entails:
• The machine is parked, i.e. parking brake applied.
• Trolley and attachment in totally lowered position
• Engine off.
• Main electric power voltage turned off (with the battery
disconnector).
009797
NOTE
Keep the accumulator drain valve open as long as work is in
progress.
NOTE
After the work has been finished, close the drain valve and
tighten the lock ring.
005648
CAUTION
Hydraulic oil may be directed the wrong way.
Oils
page
–
The following safety instructions must be followed for work when han-
dling oils.
WARNING
Hot and pressurised oil.
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.
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.
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.
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.
Clothing, etc.
page
–
WARNING
Be extra careful if several mechanics work on the
same vehicle, 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.
Risks
Mechanical or hydraulic tools and lifting devices may fall over or acci-
dentally lower due to malfunctions or incorrect use.
Safety precautions
Use axle stands and supports that stand securely.
Lifting tools should be inspected and type approved for use.
WARNING
Careless handling of heavy components may lead to
serious personal injury and material damage.
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.
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
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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
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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.
DANGER
In the event of fire the operator’s safety must not be
compromised.
DANGER
Smoke can be extremely toxic.
DANGER
Tyres are flammable and can cause fire with explosive
development.
Extreme danger!
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
into a sloping plane, or down in a grease pit, where welding flames,
grinding sparks or cigarette embers may cause an explosion. Evapo-
rated gasoline explodes very forcefully.
Special cases
Diesel fuel oil with added gasoline has a lower ignition point. Risk of
explosion already at room temperature. The explosion risk for warmed
diesel fuel oil is higher than for gasoline.
When changing 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 protec-
tion 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 machines
that have been exposed to intense heat or fire.
Safety precautions
DANGER
Residue from fuel, oils, grease or other flammable
materials on the engine or in the engine compartment
is a fire hazard.
Fire hazard!
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.
• First open the cooling system’s cap for the filling point, to release
the high pressure. Hot steam and coolant may otherwise
spray out.
Coolant
page
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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
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Risks
The air conditioning operates at high pressure. Escaping refrigerant
can cause frostbite.
Refrigerant that is heated (e.g. when repairing leaking climate/AC sys-
tem), generates gases that are very dangerous to inhale.
Safety precautions
• Use special instructions and equipment for refrigerant according
to the manual when working on the air conditioning system. Spe-
cial certification and authorisation is often required of the person
who may do the work. (Note national legislation and local regula-
tions!)
• 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
–
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.
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.
DANGER
Tyres should be regarded as pressurised containers.
They constitute fatal danger if handled incorrectly.
Risks
Dismantling wheels: Tyres, rims or lock rings may be ejected.
Inflating wheels: Tyres, rims or lock rings may be ejected.
Safety precautions
• 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, carriage and attachment.
Always make a habit of lowering the carriage to its lowest position be-
fore 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
• Do not start work until the carriage is completely lowered. If by na-
ture the work requires a raised carriage, this must be secured.
Spare parts
page
–
WARNING
For safety reasons, the following spare parts may
only be replaced with genuine spare parts:
• Brake valve
• Drive axle
• Steering axle
• Steering cylinder
• Rim
• Mast, carriage
• Lifting chains
• Lift cylinder
• Tilt cylinder
• Emergency stop
• Accumulator
• Tilt valve
page
–
Non-ionised radiation
WARNING
Optional equipment such as two-way radio, RMI, tele-
phone, etc. may emit non-ionising radiation.
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.
Environment
General
page
–
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 Kalmar Industries, the machine can be recy-
cled to more than 90% by weight.
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.
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, then refrigerant of the
type R134a is used, in an amount between 1-3 kg.
C Preventive maintenance
C Preventive maintenance
mm mm mm mm mm mm
Preventive maintenance
page
–
0 Complete machine
Complete machine
mm mm mm mm mm mm
that sits on a mast. Load handling is divided into the functions lifting/
lowering, tilt, side shift, spreading, levelling and load securing. Lifting/
1. Counterweight
lowering is a function for raising and lowering the lifting carriage. Side
2. Steering axle
shift is moving the side lifting attachment laterally along the lifting car-
3. Cab
riage. Spreading is adjusting the width between Twistlock or lifting
4. Tank
hooks of the side lifting attachment. Tilt is angling the load in the lon-
5. Drive axle
gitudinal direction of the truck with the help of the mast. Levelling is an-
6. Tilt cylinder
gling the side lifting attachment in the lateral direction of the truck.
7. Fork carriage
Load securing is locking the load onto the side lifting attachment.
8. Mast
9. Side lifting attachment 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 bears the machine. The frame houses the engine, trans-
mission, drive axle and steering axle. The sides of the frame house the
fuel and hydraulic oil tanks. The cab can be tilted as an option.
The hydraulic system is fed by four hydraulic oil pumps, which are
mounted together to form two pump banks, which in turn are mounted
on the gearbox’ power-take off. Three variable pumps feed load han-
dling, steering and other hydraulic functions. A fixed pump feeds the
brake system’s the brake and cooling circuits across an accumulator
charging valve. The hydraulic oil tank sits on the right side of the ma-
chine. The hydraulic oil filter is a return filter housed inside the hydrau-
lic oil tank.
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
• 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 7.
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 as in
checkpoint for measuring outlet, D for diagnostic menu).
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 9.
For hydraulic hoses, see Troubleshooting hydraulic hoses
page 10.
6 If the cables or hoses between the components seem to be intact,
then check the component that receives the signal.
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.
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 9.
For hydraulic hoses, see Troubleshooting hydraulic hoses
page 10.
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.
Connections
Diagnostic Function
Code Description Limitation Action and
menu group
components
34 Signal error from Parking brake Check cabling be- D790-1/K8:5 HYD, menu 5 4.1.2 Parking
parking brake cannot be tween the control - S107, K8:13 brake control
switch, indi- released. unit and the compo- - S107
cates released nent with diagnos-
and applied at tic menu.
same time or Check component.
nothing at all.
NOTE
Perform troubleshooting for all cables in the same way to avoid
damage to control units, components or measuring equipment.
CAUTION
Wipe and re-grease the connectors.
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.
WARNING
Hot and pressurised oil!
1 Engine
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 .................................................................................. 26
1.6 Air intake and exhaust outlet .................................................................... 27
1.6.1 Air cleaning system .............................................................................. 27
1.6.3 Exhaust system ................................................................................... 27
1.6.4 Intercooler ............................................................................................ 28
1.7 Cooling system ......................................................................................... 29
1.7.4 Radiator and expansion tank ............................................................... 30
1.7.5 Cooling fan ........................................................................................... 31
1.7.7 Coolant ................................................................................................ 33
1.7.8 NO (normally open) switch, coolant level ............................................ 38
1.7.10 Engine heater ...................................................................................... 38
1.9 Control system, engine ............................................................................. 39
1.9.1 Engine control unit ............................................................................... 39
1.11 Start/stop .................................................................................................. 40
1.11.1 Starter motor ........................................................................................ 40
1.11.2 Stopping device ................................................................................... 40
1 Engine
mm mm mm mm mm mm
Engine, general
page
–
Engine alternative
The machine is equipped with the following engine alternative:
• Volvo TAD760VE (step III as per directive 97/68/EU)
• Cummins QSB6.7 (step III as per directive 97/68/EU)
If there are differences between different engine alternatives, this is
written in brackets after headings or under figures in order to clarify
what is being shown.
˚C
. bar
0 rpm
P I kph
II
III
D5
<˚
1,5
10
D10
D1
D14 D11
3,12,14,23 11,22 2,6
D794 D790-1 D790-2
D7
D793 D797-1 D795
D19 20 17 15,18,21
D16
D12
19 D4 H2O
SENSORS D8
4 13 16
9
7 009685
8 M
2 Cab control unit KIT (D790-2) sends Checked by control sys- See section 11 Common electrics,
ignition on via the CAN bus. If the tem, error shown with er- group 11.5.3.11 Control unit KIT (D790-2)
key is turned to the preheating posi- ror code.
tion, then preheating is also sent on
the CAN bus.
4 The preheating coils (E800-1) warm - D4: Diagnostic menu, see section 8 Control sys-
each cylinder with a glow plug. tem, group 8.4.6.5 ENGINE, menu 5
5 The ignition switch (S150) sends a U = 24 V Ignition key lock, description page 23
voltage signal to the KIT control unit D5: Diagnostic menu, see section 8 Control sys-
(D790-2) when the start key is tem, group 8.4.6.4 ENGINE menu 4
turned to start position.
7 The starter motor (M654) is control- U = 24 V Starter motor, description (engine alternative
led by the engine control unit (D794) Volvo) page 40
through starter relays and receives D7: Diagnostic menu, see section 8 Control sys-
signals from the cab control unit tem, group 8.4.6.5 ENGINE, menu 5
(D790-1) via the CAN bus.
8 The starter motor (M654) cranks the - Starter motor, description (engine alternative
engine. Volvo) page 40
D8: Diagnostic menu, see section 8 Control sys-
tem, group 8.4.6.5 ENGINE, menu 5
9 The engine’s sensor sends signals - Se Control unit, engine, general page 39
to Control unit, engine (D794) that
controls the injectors so the engine
starts.
11 Control unit, cab (D790-1) sends a Checked by control sys- See section 11 Common electrics,
message with the rpm request on tem, error shown with er- group 11.5.3.1 Cab control unit (D790-1)
the CAN bus. ror code. D11: Diagnostic menu, see section 8 Control
system, group 8.4.6.1 ENGINE, menu 1
12 Control unit, engine (D794) increas- - Se Control unit, engine, general page 39
es the engine speed. D12: Diagnostic menu, see section 8 Control
system, group 8.4.6.1 ENGINE, menu 1
14 Control unit, engine (D794) sends Checked by control sys- Se Control unit, engine, general page 39
engine data and warning messages tem, error shown with er- D14: Diagnostic menu, see section 8 Control
on the CAN bus. ror code. system, group 8.4.6.6 ENGINE, menu 6,
8.4.6.7 ENGINE, menu 7 and 8.4.6.8 ENGINE,
menu 8
15 Control unit KID (D795) shows en- - See section 11 Common electrics,
gine data via display figures. group 11.5.3.12 KID control unit (D795)
16 The fuel level sensor (B757) sends R = 0–70 ohm Sensor, fuel level, description page 26
the frame control unit (D797-1) a D16: Diagnostic menu, see section 8 Control
voltage signal proportional to the fuel system, group 8.4.3.7 CAB, menu 7
level in the tank.
17 The frame control unit (D797-1) Checked by control sys- See section 11 Common electrics,
transmits fuel level on the CAN bus. tem, error shown with er- group 11.5.3.2 Frame control unit (D797-1)
ror code.
18 The KID control unit (D795) shows - See section 11 Common electrics,
fuel level in the operating menu for group 11.5.3.12 KID control unit (D795)
engine and transmission.
20 Control unit, transmission (D793) Checked by control sys- See section 11 Common electrics,
transmits the speed on the CAN bus. tem, error shown with er- group 11.5.3.9 KIT control unit (D793)
ror code.
21 The KID control unit (D795) shows - See section 11 Common electrics,
the machine’s speed. group 11.5.3.12 KID control unit (D795)
22 If the rotation speed of the output Checked by control sys- See section 11 Common electrics,
shaft is so high that it corresponds tem, error shown with er- group 11.5.3.1 Cab control unit (D790-1)
with the limit for the machine’s speed ror code.
limitation then Control unit, cab
(D790-1) sends reduce engine
speed on the CAN bus.
23 Control unit, engine (D794) limits the - Se Control unit, engine, general page 39
engine speed.
4
3 8
2
1 9
10
11
12
13
14
15
16
17
18
010197
19
3
2
010198
1
Engine, separation
page
–
DANGER
The engine is very heavy.
Risk of crushing!
NOTE
Read the safety instructions for oil before working, see section
B Safety.
1 Machine in service position, see section B Safety.
2 Attach hoisting equipment to the engine.
3 Disconnect the requisite hoses and cables before separating en-
gine and transmission.
NOTE
Drain and collect liquids before detaching hoses.
4 Remove the radiator.
5 Use a jack to secure the transmission.
7 Remove the nuts for the flex plate through the hole under the cov-
er washer.
NOTE
Turn the engine for each nut to be removed from the flex plate.
8 Take up the slack in the hoisting equipment.
NOTE
Do not lift the engine.
NOTE
Beware of balance before the engine is lifted.
NOTE
If the flex plates are damaged during engine replacement, they
must be replaced.
12 Lift the engine away.
Assembly
13 Apply lubricating grease to the converter connection - both on the
engine and the transmission.
008301
14 Insert two studs into the flywheel housing as a guide when the en-
gine is installed.
15 Transfer the engine brackets to the new engine; tighten to
169 Nm (oiled screw).
007775
16 Centre a stud on the flywheel so that it aligns with the hole in the
flywheel housing.
007772
17 Lift the engine into place. Make sure that the studs on the fly-
wheel come into correct alignment and do not damage the flex
plate.
18 Install the bolts that affix the transmission and engine, but do not
tighten the bolts fully. Leave about a millimetre between the en-
gine and transmission to facilitate installation of the nuts for the
flex plate/flywheel.
007776 19 Fit the nuts that fix the flex plates at the flywheel in two steps. First
fit the nuts without tightening. Then rotate the flywheel one more
revolution and tighten the nuts to 40 Nm (oiled screw).
NOTE
Turn the engine for each nut to be installed to the flex plate.
007973
˚C
. bar
0 rpm
P I kph
II
III
D5
<˚
1,5
10
D10
D1
D14 D11
3,12,14,23 11,22 2,6
D794 D790-1 D790-2
D7
D793 D797-1 D795
D19 20 17 15,18,21
D16
D12
19 D4 H2O
SENSORS D8
4 13 16
9
009622
8 M 7
2 Cab control unit KIT (D790-2) sends Checked by control sys- See section 11 Common electrics,
ignition on via the CAN bus. If the tem, error shown with er- group 11.5.3.11 Control unit KIT (D790-2)
key is turned to the preheating posi- ror code.
tion, then preheating is also sent on
the CAN bus.
4 The preheating coil (E800) heats the - D4: Diagnostic menu, see section 8 Control sys-
primary air to the engine. tem, group 8.4.6.5 ENGINE, menu 5
5 The ignition switch (S150) sends a U = 24 V Ignition key lock, description page 23
voltage signal to the KIT control unit D5: Diagnostic menu, see section 8 Control sys-
(D790-2) when the start key is tem, group 8.4.6.4 ENGINE menu 4
turned to start position.
7 The starter motor (M654) is control- U = 24 V Starter motor, description (engine alternative
led by the engine control unit (D794) Cummins) page 40
through starter relays and receives D7: Diagnostic menu, see section 8 Control sys-
signals from the cab control unit tem, group 8.4.6.5 ENGINE, menu 5
KCU (D790-1) via the CAN bus.
8 The starter motor (M654) cranks the - Starter motor, description (engine alternative
engine. Cummins) page 40
D8: Diagnostic menu, see section 8 Control sys-
tem, group 8.4.6.5 ENGINE, menu 5
9 The engine’s sensor sends signals - Se Control unit, engine, general page 39
to Control unit, engine (D794) that
controls the injectors so the engine
starts.
11 The cab control unit (D790-1) sends Checked by control sys- See section 11 Common electrics,
the engine control unit (D794) an tem, error shown with er- group 11.5.3.1 Cab control unit (D790-1)
rpm request via the CAN bus. ror code. D11: Diagnostic menu, see section 8 Control
system, group 8.4.6.1 ENGINE, menu 1
12 Control unit, engine (D794) increas- - Se Control unit, engine, general page 39
es the engine speed. D12: Diagnostic menu, see section 8 Control
system, group 8.4.6.1 ENGINE, menu 1
14 Control unit, engine (D794) sends Checked by control sys- Se Control unit, engine, general page 39
engine data and warning messages tem, error shown with er- D14: Diagnostic menu, see section 8 Control
on the CAN bus. ror code. system, group 8.4.6.6 ENGINE, menu 6,
8.4.6.7 ENGINE, menu 7 and 8.4.6.8 ENGINE,
menu 8
15 Control unit KID (D795) shows en- - See section 11 Common electrics,
gine data via display figures. group 11.5.3.11 KID control unit (D795)
16 The fuel level sensor (B757) sends R = 0–70 ohm Sensor, fuel level, description page 26
the frame control unit (D797-1) a A warning message ap- D16: Diagnostic menu, see section 8 Control
voltage signal proportional to the fuel pears on the display if the system, group 8.4.3.7 CAB, menu 7
level in the tank. amount of fuel in the tank
is less than 15% for more
than 40 seconds.
17 The frame control unit (D797-1) Checked by control sys- See section 11 Common electrics,
transmits fuel level on the CAN bus. tem, error shown with er- group 11.5.3.2 Frame control unit (D797-1)
ror code.
18 The KID control unit (D795) shows - See section 11 Common electrics,
fuel level in the operating menu for group 11.5.3.12 KID control unit (D795)
engine and transmission.
20 The transmission control unit (D793) Checked by control sys- See section 11 Common electrics,
transmits speed on the CAN bus. tem, error shown with er- group 11.5.3.9 KIT control unit (D793)
ror code.
21 The KID control unit (D795) shows - See section 11 Common electrics,
the machine’s speed. group 11.5.3.12 KID control unit (D795)
22 If the rotation speed of the output Checked by control sys- See section 11 Common electrics,
shaft is so high that it corresponds tem, error shown with er- group 11.5.3.1 Cab control unit (D790-1)
with the limit for the machine’s speed ror code.
limitation then Control unit, cab
(D790-1) sends reduce engine
speed on the CAN bus.
23 Control unit, engine (D794) limits the - Se Control unit, engine, general page 39
engine speed.
Component locations
page
–
(Cummins engine)
6 7
8
9
10
11
3 12
13
14
2
15
009440
1 16
7
6
8
10
5
11
4
12
13
14
15
007396
16
Engine, replacement
page
–
(Cummins engine)
DANGER
The engine is very heavy.
Risk of crushing!
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Machine in service position, see section B Safety.
2 Attach hoisting equipment to the engine.
3 Disconnect the requisite hoses and cables before separating en-
gine and transmission.
NOTE
Drain and collect liquids before detaching hoses.
009088
6 Remove the screws holding the cover plate to the flywheel on the
left side of the engine.
008314
7 Remove the screws in the flex plate through the hole under the
cover plug.
NOTE
Rotate the engine for each bolt in the flex plate that has to be
removed.
8 Take up the slack in the hoisting equipment.
NOTE
008315
Do not lift the engine.
NOTE
008275
NOTE
If the flex plates are damaged during engine replacement, they
must be replaced.
13 Lift the engine away.
Assembly
14 Transfer the engine brackets to the new engine; tighten to
330 Nm (oiled screw).
15 Apply lubricating grease to the converter connection - both on the
engine and the transmission.
008301
16 Insert a stud into one of the nuts on the flexible plate as a guide
when the engine is installed.
007769
20 Fit the screws that fix the flex plates at the flywheel in two steps.
First fit the screws without tightening. Then rotate the flywheel
one more revolution and tighten the screws to 35 Nm (oiled
screw).
NOTE
Turn the engine for each screw to be installed in the flex plate.
NOTE
008315
The engine must be loosened from the engine mounts and sep-
arated from the transmission in order to remove a dropped bolt.
Secure the bolt in the socket when installing.
21 Fit the bolts that fasten the transmission and engine and tighten
them to 52 Nm (oiled bolt).
008275
007796
P No function.
0 Stop position. Everything turned off, the key can be removed.
I Operating position.
Voltage to all electrical functions. Engine and transmission con-
trol units are now active.
The signal can be checked from the diagnostic menu, see
section 8 Control system, group 8.4.6.4 CAN/POWER, menu 4.
II Preheating position (function applies to Volvo engines only).
When the switch is in the preheating position, the engine’s intake
air is manually heated to a suitable temperature with glow plugs
in each cylinder on Volvo engines (Cummins engines are heated
automatically with a heating coil). The preheating lamp is on dur-
ing the preheating process.
0
The signal can be checked via the diagnostic menu. See
P I section 8 Control system, group 8.4.6.4 ENGINE, menu 4.
III Start position.
Engagement of starter motor for engine start.
II
NOTE
The machine is equipped with an electric restart interlock,
000317
III
which prevents engagement of the starter motor when the
engine is rotating.
Condition for starter motor to engage is that the transmis-
sion is in neutral position and that the engine isn’t already
running.
The signal can be checked via the diagnostic menu. See
section 8 Control system, group 8.4.6.4 ENGINE, menu 4.
1.1.2 Accelerator
Accelerator pedal, replacement
page
–
1. Accelerator pedal
2. Brake pedal
The fuel tank is located on the machine’s left side and has a sensor for
fuel level. The fuel volume in the tank is shown in an operating menu
on the display in the cab. The fuel pre-filter with water trap and fuel fil-
ter is located on the engine. The water trap is equipped with electric
indication, an event menu is shown in the display when the water trap
has to be drained of water.
For component locations, see the section 1 Engine.
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.
The fuel tank is located on the left side of the machine behind the oil
tank brake system.
3
2
1
009863
The air cleaning system consists of an air cleaner with filter, filter indi-
cator, pipes and hoses. There are two filter in the air cleaner that clean
the air and a dust reservoir that collects larger particles. The dust res-
2 ervoir can be emptied without opening the air cleaner.
3
Combustion in the engine requires air. Free unobstructed flow for
fresh air and exhausts is essential for effective engine operation.
When the air filter cleans the air for engine, particles collect in the filter
material. With time, so many particles collect that the filter does not let
1
through enough air for effective combustion, then the filter has to be
replaced. The filter indication measures the vacuum pressure on the
engine side of the filter. When the filter is clogged, the vacuum pres-
008040
sure increases and the indicator indicates that it’s time to replace filter.
WARNING
2 3
Hot exhaust system!
1.6.4 Intercooler
Intercooler, description
page
–
5
3
6
1
010120
Radiator core
1. Transmission oil cooler
2. Fuel cooler
3. Radiator engine
4. Intercooler
5. Expansion tank
6. Attachment condenser (to AC)
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, located in the engine.
• Expansion tank, located in the engine compartment.
• Thermostat, located in the engine
• Cooling fan, located in front of the radiator
• Water cooler, part of cooling unit (middle).
• Engine oil cooler, located in the engine
• Transmission oil cooler, part of cooling unit (lower).
• Intercooler, part of cooling unit (upper).
• Fuel cooler, located behind the radiator
Engine cooling work as follows:
1. Coolant is circulated through the cylinder head, engine block and
oil cooler by the coolant pump.
2. The thermostat directs the heated coolant back to the coolant
pump or through the radiator.
3. When the coolant is colder than the thermostat opening 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.
Radiator for the engine is located in the cooling unit which is placed
4 behind the engine.
The function of the cooler unit is to cool:
• Engine coolant.
5
• Transmission oil (cooled in the lower part of the cooler unit), see
3
also section 2 Transmission, group 2.6.3 Oil cooler.
6
• Charge air (cooled in the upper part of the cooling unit), see also
Intercooler, description page 28.
2 See also Cooling system, description page 29.
For more information, see supplier documentation, engine.
1
010120
Radiator core
1. Transmission oil cooler
2. Fuel cooler
3. Radiator engine
4. Intercooler
5. Expansion tank
6. Attachment condenser (to AC)
1
007314
1. Drift
3 Remove the belt from the coolant pump first.
4 Install the new belt.
Let back the belt tensioner and check that the belt is positioned
correctly in the grooves, and that it is tensioned correctly.
1
007969
1. Coolant pump
016043
1.7.7 Coolant
Changing coolant and cleaning the cooling system
page
–
WARNING
The cooling system is pressurised. Steam or hot fluid
may spurt out.
WARNING
Glycol and anti-corrosion agents are hazardous to
health.
Health hazard!
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 with coolant
that has no anti-freeze properties.
NOTE
Read the safety instructions before starting work with the cooling
system, see section B Safety.
NOTE
Before draining, stop the engine and remove the filler cap.
Draining
1 Remove the filler cap from the cooling system’s expansion tank.
2 Open all drain points. Drain the coolant from the radiator and en-
gine block using the drainage hose.
The drain nipples are located under the radiator and on the en-
gine block’s right-hand side.
3 Check that all coolant drains out.
NOTE
There may be deposits inside the tap or the plug which must
be cleaned away, otherwise there is a risk that coolant may
remain and cause freezing damage.
007394
Let the drainage taps or plugs remain open and make sure that
TAD760VE 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 as necessary.
5 Insert a hose in the filler hole in the expansion tank and flush with
clean water, until the draining water is clear.
6 If impurities remain after flushing for a long time, it’s possible to
clean with coolant. Otherwise, continue with step 10.
IMPORTANT
Cleaning may not be performed if there is a risk of
freezing in the cooling system since the cleaning so-
lution does not have anti-freeze properties.
NOTE
Only use cleaning agents approved by the engine
manufacturer.
Fill the system with a radiator cleaning agent approved by the en-
gine manufacturer.
Mix the radiator cleaning agent and clean the cooling system in
accordance with the engine manufacturer’s instructions.
7 Once the cleaning is completed fill the system with recommended
new coolant, see section F Technical data.
Filling point
8 When the cooling system is completely free from impurities, close
the drain valves.
CAUTION
Different types of coolant may not be mixed.
NOTE
Only use the recommended coolant, see section F Techni-
cal data.
9 Fill coolant so that the level is between the MIN and MAX mark-
ings. The engine must not be started until the system is bled and
completely filled.
10 Start the engine.
Check that the water valve is fully open in order to bleed the heat-
ing system.
11 Stop the engine after approx. one hour and check the coolant lev-
el, top up if needed.
(Cummins engine)
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.
WARNING
Glycol and anti-corrosion agents are hazardous to
health.
Health hazard!
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 with coolant
that has no anti-freeze properties.
NOTE
Read the safety instructions for coolant before starting work, see
section B Safety.
NOTE
Before draining, stop the engine and remove the filler cap.
Draining
1 Remove the filler cap from the cooling system’s expansion tank.
2 Open all drain points.
Drain the coolant from the radiator and engine block. There is a
drain nipple under the radiator and a drain plug under the coolant
inlet on the engine block.
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.
008020 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 as necessary.
IMPORTANT
Cleaning may not be performed if there is a risk of
freezing in the cooling system since the cleaning so-
lution does not have anti-freeze properties.
NOTE
Only use cleaning agents approved by the engine
manufacturer.
Fill the system with a radiator cleaning agent approved by the en-
gine manufacturer.
Mix the radiator cleaning agent and clean the cooling system in
accordance with the engine manufacturer’s instructions.
5 Once the cleaning is completed fill the system with recommended
new coolant, see section F Technical data.
Filling point
6 When the cooling system is completely free from impurities, close
the drain valves.
CAUTION
Different types of coolant may not be mixed.
NOTE
Only use the recommended coolant, see section F Techni-
cal data.
7 Fill coolant so that the level is between the MIN and MAX mark-
ings. The engine must not be started until the system is bled and
completely filled.
8 Start the engine.
Check that the water valve is fully open in order to bleed the heat-
ing system.
9 Stop the engine after approx. one hour and check the coolant lev-
el, top up if needed.
1.11 Start/stop
1.11.1 Starter motor
Starter motor, description (engine alternative Volvo)
page
–
The starter motor cranks the engine until fuel combustion begins and
the engine starts.
The starter motor is supplied with voltage directly from the start batter-
ies. A relay on the starter motor (solenoid) is activated by the engine
control unit (D794).
The signal can be checked via the diagnostic menu. See
section 8 Control system, group 8.4.6.5 ENGINE, menu 5.
For more information, see supplier documentation, engine.
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 the frame
control unit (D797-1).
The signal can be checked via the diagnostic menu. See
section 8 Control system, group 8.4.6.5 ENGINE, menu 5.
For more information, see supplier documentation, engine.
NOTE
The battery disconnector must not be used for emergency stop!
For more information, see supplier documentation, engine.
2 Transmission
2 Transmission.................................................................................................. 3
2.1 Controls and instruments ......................................................................... 21
2.1.1 Gear selector and multi-function lever ................................................. 21
2.2 Torque converter/Clutch system .............................................................. 22
2.2.1 Flex plates ........................................................................................... 22
2.6 Lubrication system ................................................................................... 24
2.6.3 Oil cooler .............................................................................................. 27
2.7 Cooling system ......................................................................................... 28
2.7.3 Oil cooler .............................................................................................. 28
2.8 Control system, transmission ................................................................... 29
2.8.1 Transmission control unit ..................................................................... 29
2.8.2 Break contact (opening switch) declutch ............................................. 29
2.8.3 Transmission cable harness ................................................................ 30
2 Transmission
mm mm mm mm mm mm
Transmission, general
page
–
F
D27 R
22 <˚ 1
27 Pa D1
5
D5
21 6,23,28 2, 7
D794 D790-1 D790-2
4 17
11
3
009864
2 The KIT control unit (D790-2) trans- Checked by control sys- See section 11 Common electrics,
mits the selected direction of travel tem, error shown with error group 11.5.3.11 Control unit KIT (D790-2)
(forward or reverse) on the CAN bus. code.
6 Control unit, cab (D790-1) transmits Checked by control sys- See section 11 Common electrics,
the desired throttle application on tem, error shown with error group 11.5.3.1 Cab control unit (D790-1)
the CAN bus. code.
7 Control unit KIT (D790-2) sends the Checked by control sys- See section 11 Common electrics,
selected shifting program on the tem, error shown with error group 11.5.3.11 Control unit KIT (D790-2)
CAN bus. code.
8 The oil pressure sensors sends a Checked by Control unit, D8: Diagnostic menu, see section 8 Control
voltage signal to the transmission transmission, error shown system, group 8.4.7.10 TRANSM menu 10
control unit (D793) if oil pressure is with error code.
too low.
9 The engine speed and oil tempera- Checked by Control unit, D9: Diagnostic menu, See Section 8 Control
ture sensor (B758/766) sends the transmission, error shown system, group 8.4.7.6 TRANSM, menu 6 and
transmission control unit (D793) a with error code. 8.4.7.10 TRANSM, menu 10
pulse signal with frequency propor-
tional to engine speed and a voltage
signal proportional to the transmis-
sion oil temperature.
10 The transmission control unit (D793) Checked by Control unit, Control unit transmission, general page 29
supplies voltage to valve block trans- transmission, error shown
mission control to obtain desired with error code.
function.
12 Sensor, turbine speed (B751) sends Checked by Control unit, D12: Diagnostic menu, see section 8 Control
Control unit, transmission (D793) a transmission, error shown system, group 8.4.7.6 TRANSM, menu 6
pulse signal with frequency propor- with error code.
tional to turbine speed.
13 The drum sensor (B752) sends the Checked by Control unit, D13: Diagnostic menu, see section 8 Control
transmission control unit (D793) a transmission, error shown system, group 8.4.7.6 TRANSM, menu 6
pulse signal with frequency propor- with error code.
tional to drum speed.
14 The output shaft speed sensor Checked by Control unit, D14: Diagnostic menu, see section 8 Control
(B758) sends the transmission con- transmission, error shown system, group 8.4.7.6 TRANSM, menu 6
trol unit (D793) a pulse signal with with error code.
frequency proportional to output
shaft speed.
16 Control unit, transmission (D793) Checked by Control unit, Control unit transmission, general page 29
controls gear shifting according to transmission, error shown
selected shifting program. with error code.
17 The oil cooler cools the transmission - Oil cooler, description page 28
oil. A thermostat senses the oil’s
temperature and directs the oil back
to the transmission if the oil is cold.
18 Control unit, transmission (D793) Checked by control sys- Control unit transmission, general page 29
transmits temperature and speed tem, error shown with error
data on the CAN bus. code.
19 Control unit KID (D795) shows trans- Checked by control sys- See section 11 Common electrics,
mission information in operating tem, error shown with error group 11.5.3.12 KID control unit (D795)
menus. code.
20 If the signal from the output shaft - D20: Diagnostic menu, see section 8 Control
speed sensor (B758) indicates that system, group 8.4.7.6 TRANSM, menu 6
machine speed exceeds the speed
limitation, the transmission control
unit (D793) transmits a engine
speed reduction request on the CAN
bus.
22 If the clutch pedal (S220-1) is U = 24 V Section 9 Frame, body, cab and accessories,
pressed down, it sends a voltage group 9.1 Controls and instruments
signal to the cab control unit D22: Diagnostic menu, see section 8 Control
(D790-1). system, group 8.4.7.1 TRANSM, menu 1
23 Control unit, cab (D790-1) transmits Checked by control sys- See section 11 Common electrics,
declutch drive on the CAN bus. tem, error shown with error group 11.5.3.1 Cab control unit (D790-1)
code.
24 Normally closed (NC) switch, disen- Brake pressure above Break contact (opening switch) declutch, de-
gagement (S220-2) sends the frame 0.2 MPa: scription page 29
control unit (D797-1) a voltage signal Conn 1, U = 24 V D24: Diagnostic menu, see section 8 Control
if brake pressure is high enough to system, group 8.4.7.1 TRANSM, menu 1
Conn 2, U = 24 V
allow drive disengagement.
Brake pressure below
0.2 MPa:
Conn 1, U = 24 V
Conn 2, U = 0 V
26 Control unit, transmission (D793) Checked by Control unit, Control unit transmission, general page 29
supplies voltage to valve block trans- transmission, error shown
mission control so that drive is with error code.
declutched.
27 If the operator leaves the driver’s U = 24 V Section 9 Frame, body, cab and accessories,
seat, the operator-in-seat sensor group 9.3.14 Operator-in-seat sensor
(S230) sends a voltage signal to the D27: Diagnostic menu, see section 8 Control
cab control unit (D790-1). system, group 8.4.7.1 TRANSM, menu 4
28 The cab control unit (D790-1) trans- Checked by control sys- See section 11 Common electrics,
mits go to neutral on the CAN bus. tem, error shown with error group 11.5.3.1 Cab control unit (D790-1)
code.
29 The transmission control unit (D793) Checked by Control unit, Control unit transmission, general page 29
supplies voltage to valve block trans- transmission, error shown
mission control so that the drive is with error code.
put in neutral three seconds after the
operator leaves the driver’s seat.
Shifting transmission,
page
–
function description
7 9 11 13 15
RSP
25 5
Fwd 2 Rev 1/3
6
8
26 10 12 14 16
18
VFS 1/3
3 4
17
28
27
19
2
008240
29 20 21 22 23 24
2. The transmission’s oil pump 1 supplies the 92.1 l/min at 2420 rpm -
transmission with control pressure for control
of the transmission.
7. Solenoid valve neutral position (RSP) - Diagnostic menu, see section 8 Control
(Y6066) controls Valve spool neutral position. system, group 8.4.7.7 TRANSM menu 7
9. Solenoid valve drive forward (Y630) controls 0-1000 mA Diagnostic menu, see section 8 Control
Pressure booster drive forward. system, group 8.4.7.8 TRANSM, menu 8
and 8.4.7.9 TRANSM, menu 9
11. Solenoid valve gear 2 (Y6069) controls Pres- 0-1000 mA Diagnostic menu, see section 8 Control
sure booster gear 2. system, group 8.4.7.8 TRANSM, menu 8
and 8.4.7.9 TRANSM, menu 9
15. Solenoid valve 1/3 (Y6067) controls Pressure 0-1000 mA Diagnostic menu, see section 8 Control
booster gear 1/3. system, group 8.4.7.8 TRANSM, menu 8
and 8.4.7.9 TRANSM, menu 9
16. Pressure booster gear 1/3 increases the pres- 0-2000 kPa -
sure and feeds Valve spool gear
selection 1/3 as well as.
18. Solenoid valve VFS 1/3 (Y6075) controls ser- 0-1000 mA Diagnostic menu, see section 8 Control
vo pressure to Valve spool gear selection 1/3. system, group 8.4.7.7 TRANSM menu 7
25. The safety valve leads the oil back to the Opening pressure: -
sump if the pressure to the torque converter 850 kPa
becomes too high.
28. The bypass valve torque converter leads the Opening pressure: -
oil past the torque converter if the pressure 400 kPa
becomes too high.
3 4
6
2 7
14 13 12
15
8
16
9
17
10
004269
19 18 11
3 4 5
2
11
10 9b 9a 8
008057
1. Accelerator pedal (B690) 7. Declutch pedal (S220-1)
2. Multi-function lever (S162) 8. Control unit, transmission (D793)
3. Control unit KIT (D790-2) 9a. Control unit, Volvo engine (D794)
4. Control unit, KID (D795) 9b. Control unit, Cummins engine (D794)
5. Control unit, cab (D790-1) 10. Frame control unit (D797-1)
6. Sensor operator in seat (S230) 11. Switch (NC), disengagement (S220-2)
Volvo), replacement
DANGER
The transmission is very heavy.
Risk of crushing!
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Machine in service position, see section B Safety.
2 Remove the propeller shaft from the transmission.
3 Disconnect the requisite hoses and cables before separating en-
gine and transmission.
NOTE
Drain and collect liquids before detaching hoses.
5 Remove the nuts for the flex plate through the hole under the cov-
er washer.
NOTE
Turn the engine for each nut to be removed from the flex plate.
6 Attach the transmission to an overhead crane.
7 Support the engine from underneath with a jack.
NOTE
Secure the engine so that it does not tip over when the transmis-
sion is removed.
8 Remove the bolts holding the transmission to the transmission
mounting.
NOTE
Check the balance of the transmission before lifting it.
NOTE
If the flex plates are damaged during transmission replacement,
they must be replaced.
11 Remove the transmission.
007780
Assembly
12 Apply lubricating grease to the converter connection - both on the
engine and the transmission.
008301
13 Insert two studs into the flywheel housing as a guide when the
transmission is installed.
14 Transfer the transmission bracket to the new transmission;
torque-tighten to 330 Nm (oiled screw).
007775
15 Centre a stud on the flywheel so that it aligns with the hole in the
flywheel housing.
007772
16 Lift the transmission into place. Make sure that the flywheel’s
studs come into correct alignment and do not damage the flex
plate.
17 Install the bolts that affix the transmission and engine, but do not
tighten the bolts fully. Leave about a millimetre between the en-
gine and transmission to facilitate installation of the nuts for the
flex plate/flywheel.
NOTE
Make sure that the torque converter has bottomed in the fly-
007776
18 Fit the nuts that fix the flex plates at the flywheel in two steps. First
fit the nuts without tightening. Then rotate the flywheel one more
revolution and tighten the nuts to 46-50 Nm (oiled screw).
NOTE
Turn the engine for each nut to be installed to the flex plate.
page 29.
Cummins), replacement
DANGER
The transmission is very heavy.
Risk of crushing!
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Machine in service position, see section B Safety.
2 Remove the propeller shaft from the transmission.
3 Disconnect the requisite hoses and cables before separating en-
gine and transmission.
NOTE
Drain and collect liquids before detaching hoses.
4 Remove the screws holding the cover plate to the flywheel on the
left side of the engine.
008314
5 Remove the screws in the flex plate through the hole under the
cover plug.
NOTE
Rotate the engine for each bolt in the flex plate that has to be
removed.
6 Attach the transmission to an overhead crane.
7 Support the engine from underneath with a jack.
008315
NOTE
Secure the engine so that it does not tip over when the transmis-
sion is removed.
8 Remove the bolts holding the transmission to the transmission
mounting.
9 Remove the bolts holding together the transmission and engine.
10 Carefully separate the transmission and engine.
NOTE
Check the balance of the transmission before lifting it.
NOTE
008275
Assembly
12 Apply lubricating grease to the converter connection - both on the
engine and the transmission.
008301
13 Insert a stud into one of the nuts on the flexible plate as a guide
when the engine is installed.
14 Transfer the transmission bracket to the new transmission;
torque-tighten to 330 Nm (oiled screw).
007769
NOTE
008319
Make sure that the torque converter has bottomed in the fly-
wheel before tightening the nuts for the flex plate.
18 Fit the screws that fix the flex plates at the flywheel in two steps.
First fit the screws without tightening. Then rotate the flywheel
one more revolution and tighten the screws to 35 Nm (oiled
screw).
NOTE
Turn the engine for each screw to be installed in the flex plate.
NOTE
008315
The engine must be loosened from the engine mounts and sep-
arated from the transmission in order to remove a dropped bolt.
Secure the bolt in the socket when installing.
19 Torque-tighten the screws to 52 Nm (oiled screw).
008275
007973
page 29.
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 voltage by and sends signals to the KIT control
unit (D790-2).
002209
R
The signal can be checked via the diagnostic menu. See
section 8 Control system, group 8.4.7.2 TRANSM, menu 2.
4 Replace the flex plate. Tighten the screws fixing the flex plate to
the transmission to 40 Nm (oiled screws).
5 Fit the transmission, see Transmission (engine alternative
Volvo), replacement page 12.
6 Before the machine is put into operation, the transmission must
be calibrated; see Transmission, calibration page 29.
007773
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.
2 Machine in service position, see section B Safety.
3 Place a receptacle under the transmission.
4 Remove the drain plug for transmission oil and let the oil drain
into the receptacle.
NOTE
Make sure that the sealing washer stays with the drain plug.
NOTE
Make sure that the seal washer for the drain plug is fitted
as well.
004331
000356
b 14 Calibrate the transmission; see Transmission, calibration
page 29.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
The transmission oil filler pipe and dipstick (position B) is located un-
der the hood.
1 Check the oil level with the engine at idle, transmission in neutral
position and at operating temperature (approx. 82-93 C). The
dipstick has two markings, MAX and MIN. The oil level should be
at MAX.
A
Wipe off the dipstick before checking.
B
NOTE
The oil dipstick is long. Wear gloves.
2 Fill transmission oil (position B) if needed (for volume and grade,
see section F Technical data).
3 Fill – wait a moment – check the dipstick.
NOTE
008054
The transmission oil is cooled in the lower section of the cooler unit.
4 A temperature-controlled thermostat, which only acts on the transmis-
sion oil cooling circuit, is located in a pipe on the underside of the cool-
er (engine side). The thermostat closes when the oil starts to reach
5 working temperature. This means that the oil reaches normal working
3 temperature more quickly.
6 The machine must not be operated if the thermostat is removed.
For more information, see supplier documentation, transmission.
2
1
010120
Radiator core
1. Transmission oil cooler
2. Fuel cooler
3. Radiator engine
4. Intercooler
5. Expansion tank
6. Attachment condenser (to AC)
NOTE
Read the safety instructions for oil before working, see section B
Safety.
IMPORTANT
007447
6 Fill with transmission oil; see Oil and oil filter transmission, chang-
ing page 24.
7 Start the engine and check for leaks.
8 Check the transmission oil level, see Transmission oil level check
page 26.
1
10
2
1
3
3
4
5
5
9 6
8 7
009865
3 Driveline/axle
3 Power transmission
mm mm mm mm mm mm
DANGER
Drive axle and machine are very heavy.
Risk of crushing!
1 Remove the mast, see section 7 Load handling, group 7.2 Lifting/
lowering.
2 Park the machine with blocks behind the steering wheels.
3 Depressurise the hydraulic systems, See section B Safety.
4 Turn the start key to position 0 and switch off the main power.
NOTE
Plug all connections immediately to protect the hydraulic
system from impurities.
1
004501
2
1. Hydraulic hoses
2. Cables
7 Remove the cover (position 3) on the parking brake.
3
004505
5 NOTE
Plug all connections immediately to protect the hydraulic
4 system from impurities.
004506
4. Lock nut
5. Release screw
6. Hydraulic hose parking brake
10 Disconnect the propeller shaft from the drive axle. Secure the
propeller shaft, otherwise there is a risk that it will be pulled apart.
CAUTION
The drive axle may start to roll.
Crushing injury!
Make sure that the drive axle does not roll away
uncontrollably.
Lifting machine
14 Remove the bolts that secure the drive axle in the frame.
15 Lift away the drive axle.
CAUTION
The drive axle may start to roll.
Crushing injury!
Make sure that the drive axle does not roll away
uncontrollably.
NOTE
Plug all connections immediately to protect the hydraulic
system from impurities.
17 Transfer the couplings from the old axle to the new axle.
19 Undo the distribution block bracket and move it to the new axle.
20 Connect the hydraulic hoses from the distribution block to the
drive wheels.
21 Clean the contact surfaces on the drive axle and frame. Also
clean the bolts’ contact surface on the drive axle’s underside.
22 Remove the nuts for attaching the drive axle, blow clean and refit
the nuts.
23 Lift the drive axle into place under the frame.
CAUTION
The drive axle may start to roll.
Crushing injury!
Make sure that the drive axle does not roll away
uncontrollably.
25 Fit the new screws that fix the drive axle in the frame. Tighten to
1530 Nm (oiled screw).
26 Install the drive wheels on the new axle.
27 Rustproof the bolts with suitable paint.
4 Brakes
4 Brakes ............................................................................................................. 3
4.1 Controls and instruments ........................................................................... 3
4.1.1 Brake pedal ............................................................................................ 3
4.3 Power-assisted brake system .................................................................... 6
4.3.1 Hydraulic oil pump ................................................................................. 9
4.3.2 Hydraulic oil filter ................................................................................. 11
4.3.3 Accumulator charging valve ................................................................. 12
4.3.4 Accumulator ......................................................................................... 15
4.3.5 Brake valve .......................................................................................... 19
4.3.6 Drive axle block ................................................................................... 23
4.3.7 Break contact (opening switch) brake pressure ................................... 24
4.3.8 Make-contact (closing switch) brake lights .......................................... 25
4.3.9 Wheel brakes ....................................................................................... 27
4.3.10 Pipes and hoses .................................................................................. 29
4.5 Parking brake system ............................................................................... 30
4.5.1 Hydraulic oil pump ............................................................................... 33
4.5.2 Hydraulic oil filter ................................................................................. 33
4.5.3 Solenoid valve parking brake ............................................................... 33
4.5.4 Parking brake unit ................................................................................ 34
4.5.5 Break contact (opening switch) parking brake ..................................... 37
4.5.6 Pipes and hoses .................................................................................. 37
4.8 Temperature control, cleaning and hydraulic oil ....................................... 38
4.8.1 Hydraulic oil tank ................................................................................. 38
4.8.3 Hydraulic oil pump ............................................................................... 39
4.8.4 Accumulator charging valve ................................................................. 39
4.8.5 Drive axle block ................................................................................... 39
4.8.6 Wheel brakes ....................................................................................... 39
4.8.8 Thermal bypass valve .......................................................................... 39
4.8.9 Cooling fan ........................................................................................... 39
4.8.10 Sensor hydraulic oil temperature ......................................................... 39
4.8.11 Breather filter hydraulic oil tank ........................................................... 39
4.8.12 Hydraulic oil filter ................................................................................. 39
4.8.13 Pipes and hoses .................................................................................. 39
4.8.14 Hydraulic oil ......................................................................................... 40
4 Brakes
mm mm mm mm mm mm
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.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Switch off the engine and switch off the system voltage.
2 Depressurise the brake and hydraulic systems, see section B
Safety.
3 Detach the brake valve from the brake pedal.
Secure the brake valve on the cab’s underside and remove the
brake valve attaching bolt.
4 Remove the panel around the steering wheel shaft.
NOTE
There is a variant available with adjustable steering
wheel shaft.
NOTE
Check that the accumulator drain valve is fully closed and tighten
the lock ring.
15 Lubricate and adjust the brake pedal, see Brake pedal, checking
and adjustment page 3.
description
5
B
13 P
T
D790-2
D11
D797-1
10, 12 8 C
Pa
11
C 9 D9
D8
4 Pa
3
C ACC
7
B
P
6
2
008059
B
Pos Explanation Signal description Reference
1 The hydraulic oil pump pumps oil See the pressure plate on Hydraulic oil pump, description page 9
from the oil tank. the left-hand frame beam.
2 The hydraulic oil filter cleans the oil. - Hydraulic oil filter, description page 39
3 The accumulator charging valve di- Charge: P = 20.50.5 MPa Accumulator charging valve, description
rects oil to charging of accumula- Cooling: P < 0.1 MPa page 12
tors or through the brake system’s
cooling circuit.
4 The accumulators store oil See the pressure plate on Accumulator, description page 15
pressure. the left-hand frame beam.
6 The brake cylinders compress the See the pressure plate on Wheel brakes, description page 27
discs in the brake unit. the left-hand frame beam.
8 Make-contact (closing switch), Brake pressure above Make-contact (closing switch) brake lights, de-
brake light (S216) closes the circuit 0.2 MPa: scription page 25
when the brake cylinders are pres- Conn. 1, U = 24 V D8: Diagnostic menu, see section 8 Control
surised. system, group 8.4.5.4 HYD, menu 4
Conn. 2, U = 24 V
Brake pressure below
0.2 MPa:
Conn. 1, U = 24 V
Conn. 2, U = 0 V
9 Brake pressure NC switch (S204) Brake pressure above Brake pressure NC switch, description page 24
opens the circuit if the pressure in 11.5 MPa: D9: Diagnostic menu, see section 8 Control
the accumulators is low. Conn. 1, U = 24 V system, group 8.4.5.4 HYD, menu 4
Conn. 2, U = 24 V
Brake pressure below
11.5 MPa:
Conn. 1, U = 24 V
Conn. 2, U = 0 V
10 The frame control unit (D797-1) Controlled by control sys- Section 11 Common electrics,
transmits the brake light request on tem, error shown with error group 11.5.3.2 Frame control unit (D797-1)
the CAN bus. code.
11 The brake light lamps (H411L and U = 24 V Section 9 Frame, body, cab and accessories,
H411R) are activated by the frame group 9.6.4 Brake lights
control unit (D797-1). D11: Diagnostic menu, see section 8 Control
system, group 8.4.2.8 LIGHTS, menu 8
12 The frame control unit (D797-1) Controlled by control sys- Section 11 Common electrics,
transmits a warning about low tem, error shown with error group 11.5.3.2 Frame control unit (D797-1)
brake pressure on the CAN bus. code.
13 Control unit KIT (D790-2) activates Controlled by control sys- Section 11 Common electrics,
Warning lamp brake pressure. tem, error shown with error group 11.5.3.11 KIT control unit (D790-2)
code.
component positions
4
1 2
5 6
3 8
9
12
008061
11 10
The brake system has a gear pump with fixed displacement. The hy-
1
2 draulic oil pump sits in the rear of the right main pump. The pump gen-
erates hydraulic power, which is stored in the accumulators for brake
force to the power-assisted brake and parking brake. It also generates
the oil flow used for cleaning and cooling. The switchover between
power generation and flow is regulated by the accumulator charging
valve, see Accumulator charging valve, description page 12.
For description of how a gear pump works, see section 10 Common
hydraulics, group 10.4.1 Gear pump with fixed displacement .
3
4
009967
NOTE
Read the safety instructions for oil before working, see section B
Safety.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
During charging the pressure should increase to 20.51.0 MPa
before the accumulator charging valve switches to cooling. When
the accumulator charging valve switches to cooling, the pressure
drops.
008049
7 Check the pressure during cooling.
Close the accumulator charging valve During cooling the pressure should be max. 0.10–0.15 MPa at
max. engine rpm.
8 Turn off engine.
9 Depressurise the hydraulic systems, See section B Safety.
10 Remove the pressure gauge and fit the protective cap on the
measuring outlet.
11 Close the drain valve on the accumulator charging valve.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
16 Check that the pressure increases slowly to 20.51.0 MPa.
17 Brake repeatedly and check at which pressure the accumulator
charging valve switches to charging.
The valve must switch to charging at 15.50.5 MPa.
008049
18 Depressurise the hydraulic systems, See section B Safety.
19 Remove the pressure gauge and fit the protective cap on the
Close the accumulator charging valve
measuring outlet.
20 Close the drain valve on the accumulator charging valve.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
The hydraulic oil pump for the brake system, cooling and filtering and
the pump for load handling are replaced as a unit. See the
section 10 Common hydraulics, group 10.4.1 Gear pump with fixed
displacement.
The accumulator charging valve distributes oil from the hydraulic oil
3 4 5 6
pump between pressure storage and cooling of the wheel brakes. The
accumulator charging valve is located on the left of the frame in the
area beside the transmission.
The accumulator charging valve stores pressure by guiding the oil to
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.
The accumulator charging valve prioritises charging of the accumula-
tors before cooling. A restriction of the charging means that a small
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
storage.
The drain valve (position 11) is used to relieve the pressure in the ac-
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.
2 1 13 12 11 10 9 8 7 There is a measuring outlet for measuring accumulator pressure (po-
sition 5) and pump pressure (position 4) on the accumulator charging
valve. The pressures are individual to each machine and are on the
pressure plate on the left-hand frame beam, see section 10 Common
hydraulics. On the accumulator charging valve, there is also a parking
brake solenoid valve (position 6), switch (NC) brake pressure (position
9) and switch (NC) parking brake (position 7).
• Solenoid valve parking brake, description page 33
• Make-contact (closing switch) brake lights, description page 25
009867
NOTE
Read the safety instructions for oil before working, see section B
Safety.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Machine in service position, see section B Safety.
2 Depressurise the hydraulic systems, See section B Safety.
3 Mark up hydraulic hoses and electric cables.
4 Detach the wiring from the accumulator charging valve.
5 Detach and plug all hydraulic hoses from the accumulator charg-
ing valve.
Remove the parking brake valve for easier access.
NOTE
Plug all connections immediately to protect the brake sys-
tem from impurities.
6 Remove the accumulator charging valve.
7 Transfer the connection adapters and sensors to the new accu-
mulator charging valve.
8 Fit the new valve.
9 Connect the hoses to the accumulator charging valve in accord-
008244
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
13 Switch on the system voltage and start the engine.
Check that the hydraulic connections are sealed tightly.
14 Check the charging and switching function, see Accumulator
charging, checking and adjustment page 13.
009868
4.3.4 Accumulator
Accumulator, description
page
–
ing brake systems and for supplying the servo hydraulics’ reducing
valve (see section 4 Brakes and section 7 Load handling).
Brake system accumulators
NOTE
If the accumulator delivers low oil pressure, the pumps may be
damaged and the hydraulic functions may cease to work.
Accumulator, checking
page
–
NOTE
Read the safety instructions for oil before working, see section B
Safety.
NOTE
A special tool for checking the accumulators can be ordered from
Cargotec. The procedure without use of the special tool is de-
scribed below.
009870
1. Clamp
2. Bolt
3. Distribution block
7 Connect a pressure gauge (0–25 MPa) to the pressure check
connection for accumulator pressure on the accumulator charg-
ing valve.
8 Switch on the system voltage and start the engine.
9 Close the drain valve on the accumulator charging valve and
charge the accumulator until the accumulator charging valve
changes to cooling.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
10 Check that the plug seals properly.
11 Turn off engine.
12 Lower the pressure by means of braking carefully several times
004810
NOTE
Check that the seals are intact and are fitted correctly.
18 Switch on the system voltage and start the engine.
19 Close the drain valve on the accumulator charging valve so that
the accumulators are charged.
NOTE
Check that the accumulator drain valve is fully closed and tighten
the lock ring.
20 Check that the accumulators’ connections are sealed tightly.
21 When the accumulators are fully charged, switch off the engine
and turn the start key to position I.
22 Check that at least 8 brake applications (pedal depressions) can
be performed before the pressure drops to 10 MPa.
At 11.5 MPa the warning lamp for low brake pressure must be
switched on.
Accumulator, replacement
page
–
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Machine in service position, see section B Safety.
2 Switch off the engine and close the system voltage.
3 Depressurise the hydraulic systems, See section B Safety.
4 Detach the accumulator’s clamp and remove the bolt.
3
2 5 Detach the accumulator from the distribution block.
1
NOTE
Hold the block firmly so that the other accumulator does not
work loose.
6 Bend the clamp away and remove the accumulator.
009871
1. Clamp NOTE
2. Bolt Check that the seal is intact and in the correct position.
3. Distribution block
8 Secure the accumulator’s clamp and tighten the bolt.
9 Close the drain valve on the accumulator charging valve.
10 Switch on the system voltage and start the engine.
11 Check that the accumulator’s connection is sealed tightly.
12 Check precharging and function, see Accumulator, checking
page 15 steps 18-19.
009868
The brake valve, which is located on the underside of the cab under
3
the brake pedal, controls the hydraulic pressure to the brakes. A lever
2 transfers pedal force to the valve.
1
The brake valve is a mechanically activated proportional valve. This
means that the resistance in the brake valve increases in proportion to
brake pressure. This provides optimal pedal response and increased
safety as the operator senses if no brake pressure is being built up (no
resistance in the pedal).
009872
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Operate and warm up the machine so that the hydraulic oil reach-
es operating temperature, at least 50 C.
2 Machine in service position, see section B Safety.
3 Depressurise the hydraulic systems, See section B Safety.
4 Connect a pressure gauge (0-25 MPa) to the measuring outlet for
brake pressure on the distribution block on the front axle.
5 Close the drain valve on the accumulator charging valve.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
6 Start the machine and run it at idle until the accumulators are
charged and the accumulator charging valve changes to cooling.
7 Press down the pedal completely and read off the pressure.
Compare 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
the pressure plate and must not decrease from this value for
15 seconds.
10 Release the pedal, the brake pressure must decrease to 0 MPa
immediately. Otherwise the brake valve does not seal and can
cause the brakes to remain applied and then overheat during
operation.
Replace the brake valve if it is not sealed.
11 Depressurise the hydraulic systems, See section B Safety.
12 Remove the pressure gauge and fit the protective cap on the
measuring outlet.
13 Close the drain valve on the accumulator charging valve.
NOTE
009873
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Machine in service position, see section B Safety.
2 Depressurise the hydraulic systems, See section B Safety.
3 Mark up and detach the hydraulic hoses from the brake valve.
B
T NOTE
P Plug the connections immediately to protect the brake sys-
tem from impurities.
009875 4 Secure the brake valve under the cab.
NOTE
Remember the spacer ring.
T
NOTE
P
Check that the O-rings are intact and are installed correctly.
10 Lubricate and adjust the brake pedal, see Brake pedal, checking
and adjustment page 3.
004795
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
12 Turn on the system voltage and start the engine. Run the engine
at idle speed.
13 Test the brakes a couple of times.
14 Check that the brake valve’s connections are sealed tightly.
15 Bleed the wheel brakes’ brake cylinders, see Wheel brakes,
bleeding page 28.
009868
The drive axle block distributes oil flow and brake pressure to the right
1
10 and left wheel brakes. The drive axle block is located on a bracket
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, descrip-
tion page 25 and disengagement NO switch, see section 2 Transmis-
sion, group 2.8.2 Normally closed (NC) switch, disengagement.
009876
The brake pressure NC switch (S204) detects the pressure in the ac-
cumulators. The NC switch is located on the accumulator charging
valve on the lifting beam in front of the transmission in the engine
compartment.
When the pressure in the feed circuit is high enough to ensure braking
of the machine, the sensor closes an electric circuit. This is used to
warn for pressure-drop in the brake system. The sensor’s opening
pressure is chosen so that there is pressure for at least 8 brake appli-
cations without additional feed from the pump after the light has
gone off.
The brake pressure NC switch (S204) is supplied power by the frame
control module (D797-1). When the pressure increases above the cut-
off pressure, the voltage signal to frame control unit (D797-1) is cut off.
The signal can be checked via the diagnostic menu. See
section 8 Control system, group 8.4.5.4 HYD, menu 4.
009877
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Operate and warm up the machine until the oil reaches operating
temperature, at least 50 C.
2 Machine in service position, see section B Safety.
3 Depressurise the hydraulic systems, See section B Safety.
4 Connect a pressure gauge (0-25 MPa) to the measuring outlet for
accumulator pressure on the accumulator charging valve.
5 Close the drain valve on the accumulator charging valve.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
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 lamp for low brake
pressure comes on.
9 Read off the accumulator pressure. The pressure should be
approx. 11.5 MPa.
004810
NOTE
The setting is very sensitive, turn max. 1/4 turn at a time.
11 Repeat steps 6-10 until the warning lamp comes on at 11.5 MPa.
12 Seal the adjusting screw with locking fluid.
13 Depressurise the hydraulic systems, See section B Safety.
14 Remove the pressure gauge and fit the protective cap on the
measuring outlet.
15 Close the drain valve on the accumulator charging valve.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
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 (D797-1). When the pressure
increases above the closing pressure, a voltage signal is sent to the
frame control unit (D797-1).
The signal can be checked via the diagnostic menu. See
section 8 Control system, group 8.4.5.4 HYD, menu 4.
009878
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Operate and warm up the machine until the hydraulic oil reaches
operating temperature, at least 50 C.
2 Stop the engine and turn the start key to position I.
3 Brake and check that the brake light is switched on.
4 Depressurise the hydraulic systems, See section B Safety.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
7 Start the engine.
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.
11 Depressurise the hydraulic systems, See section B Safety.
12 Remove the pressure gauge and fit the protective cap on the
measuring outlet.
13 Close the drain valve on the accumulator charging valve.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
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.
009879
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
NOTE
Read the safety instructions for oil before working, see section B
Safety.
IMPORTANT
Both brake cylinders must be bled after work where
the brake system is opened or after work on the wheel
brake.
NOTE
The hydraulic hose between the brake pedal and brake is
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.
7 Check the oil level in the brake system, fill if necessary.
The disc assembly consists of several thin metal discs fixed alternately
to the wheel brake housing and to the hub reduction housing. The
discs are mounted on splines, which allows them to move laterally.
Oil circulates between the discs cooling them, thus the name wet disc
brake. The oil is the same as in other parts of the brake system.
Braking 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
Brake cylinder
D5
5
6 12
D790-1 D790-2
D797-1
7 11
C D8 D10
4
8
Pa 10 9
C ACC
3
H
P
T
2
008060
B
Pos Explanation Signal description Reference
1 The hydraulic oil pump pumps oil from P = 211 MPa Hydraulic oil tank, description page 38
the hydraulic oil tank. Hydraulic oil pump, description page 9
2 The hydraulic oil filter cleans dirt from - Hydraulic oil filter, description page 39
the oil.
3 The accumulator charging valve directs Charging: Accumulator charging valve, description
oil to charging of accumulators or through P = 20.50.5 MPa page 12
the brake system’s cooling circuit.
Cooling: P < 0.1 MPa
4 The accumulators store oil pressure. See pressure plate on left Accumulator, description page 15
frame beam.
5 Switch parking brake (S107) activates Switch activated: Section 9 Frame, body, cab and accesso-
the parking brake. Conn. 1, U = 24 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 Con-
plied and one for released parking brake. trol system, group 8.4.5.5 HYD, menu 5
Switch in home position:
Both signals must be correct to enable re-
lease of the parking brake. Conn. 1, U = 0 V
Conn. 7, U = 24 V
6 The cab control unit (D790-1) transmits Controlled by control sys- Section 11 Common electrics,
Activate parking brake on the CAN bus. tem, error shown with er- group 11.5.3.1 Cab control unit (D790-1)
ror code.
7 The frame control unit (D797-1) activates U = 24 V Solenoid valve parking brake, description
the parking brake solenoid valve (Y642). page 33
D7: Diagnostic menu, see section 8 Con-
trol system, group 8.4.5.5 HYD, menu 5
8 Solenoid valve parking brake (Y642) acts Pump pressure Solenoid valve parking brake, description
on the valve slide which drains pressure page 33
in the parking brake’s brake caliper to
tank.
9 The brake caliper is drained of pressure 0 MPa Parking brake unit, description page 34
and the spring applies the parking brake.
10 The parking brake NC switch (S200) Applied parking brake: Break contact (opening switch) parking
closes the circuit when the pressure Conn. 1, U = 24 V brake, description page 37
increases. D10: Diagnostic menu, see section 8 Con-
Conn. 2, U = 0 V
trol system, group 8.4.5.5 HYD, menu 5
Released parking brake:
Conn. 1, U = 24 V
Conn. 2, U = 24 V
11 The frame control unit (D797-1) transmits Controlled by control sys- Section 11 Common electrics,
Parking brake applied on the CAN bus. tem, error shown with er- group 11.5.3.2 Frame control unit
ror code. (D797-1)
12 Control unit KIT (D790-2) activates indi- Controlled by control sys- Section 9 Frame, body, cab and accesso-
cator light, parking brake (508). tem, error shown with er- ries, group 9.1 Controls and instruments
ror code.
1 4
2 5 6
12
008062
11 10 9 8
The parking brake solenoid valve (Y642) activates the parking brake.
The solenoid valve is fitted on the accumulator charging valve, which
is fitted on the lifting beam in front of the transmission in the engine
compartment, see Accumulator charging valve, description page 12.
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
009880
(D797-1) at activation.
The signal can be checked via the diagnostic menu. See
section 8 Control system, group 8.4.5.5 HYD, menu 5.
DANGER
The machine may start to roll. Risk of crushing.
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.
The parking brake unit keeps the machine stationary when parked.
3 1 2
The parking brake unit is located on the drive axle input shaft between
the propeller shaft and drive axle.
The parking brake acts on the propeller shaft via a disc mounted on
the drive axle input shaft and a brake 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 checked and re-
placed if necessary.
009881
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.
6 Remove the cover from the brake calliper and check for oil inside
the cover. Oil inside the cover indicates internal leakage.
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.
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
The brake pads consist of a metal plate with friction material (lining).
DANGER
The machine may start to roll.
Risk of crushing.
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 page 34.
The brake disc is mounted on the drive axle input shaft. The drive ax-
le’s gear ratio amplifies the braking force.
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 fitted on the lifting beam in front of the
transmission in the engine compartment, see Accumulator charging
valve, description page 12.
Break-contact parking brake (S200) senses the pressure in the park-
ing brake circuit. When the pressure is so high that the parking brake
is released, the sensor opens an electric circuit. This is used to indi-
cate that the parking brake is released.
The parking brake NC switch (S200) is supplied power by and sends
a voltage signal to the frame control unit (D797-1). When the pressure
increases above the opening pressure, the voltage signal to the frame
control unit (D797-1) is cut off.
The signal can be checked via the diagnostic menu. See
009882
NOTE
Gears cannot be engaged when the parking brake is applied.
function description
C C
4
P T
2 5
3
002611
Pos Explanation Signal description Reference
1 The hydraulic oil pump pumps oil from See pressure plate on left Hydraulic oil pump, description page 9
the hydraulic oil tank. frame beam. Section 10 Common hydraulics,
group 10.3.1 Tank
2 The hydraulic oil filter cleans the oil. - Hydraulic oil filter, description page 39
3 The accumulator charging valve directs Charging: Accumulator charging valve, description
oil to charging of accumulators or P = 20.50.5 MPa page 12
through the brake system’s cooling
Cooling: P < 0.1 MPa
circuit.
4 The oil cools the wheel brake. - Wheel brakes, description page 27
5 The bypass valve in the distribution - Drive axle block, description page 23
block leads oil past the drive axle if the
back pressure through the wheel brake
is too great.
component positions
Hydraulic oil pump, hydraulic oil filter, accumulator charg-
ing valve, drive axle block, wheel brakes
See Power-assisted brake system, component positions page 8.
5 Steering
5 Steering........................................................................................................... 3
5.2 Power assisted system ............................................................................... 3
5.2.1 Hydraulic oil pump ................................................................................. 4
5.2.2 Priority valve .......................................................................................... 6
5.2.3 Steering valve ........................................................................................ 8
5.2.4 Steering cylinder .................................................................................. 10
5.2.5 Steering axle cradle ............................................................................. 12
5.2.6 Link arm ............................................................................................... 12
5.2.7 Wheel spindle ...................................................................................... 12
5.2.8 Wheel hub ............................................................................................ 12
5.2.9 Shuttle valve ........................................................................................ 12
5.2.13 Pipes and hoses .................................................................................. 12
5 Steering
mm mm mm mm mm mm
2
PP P
C
CF LS
T
5
P
LS T L R
3
1
6
008053
Pos Explanation Signal description Reference
1 The hydraulic oil pump pumps oil to the See the pressure plate on Section 10 Common hydraulics,
priority valve. the left-hand frame beam. group 10.4.2 Axial piston pump with variable
displacement
2 The priority valve prioritises pressure Checked by control sys- Priority valve, description page 6
supply to the steering valve over the tem, error shown with er-
working hydraulics. The priority valve ror code.
also transmits a control signal to the hy-
draulic oil pump.
3 Shuttle valve control selects the strong- Checked by control sys- Section 10 Common hydraulics,
est load signal to the hydraulic oil pump tem, error shown with er- group 10.5.3 Shuttle valve
if hydraulic functions are activated at the ror code.
same 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
6 The steering cylinder turns the wheels. - Steering cylinder, description page 10
positions
4 6
5 7
1 014828
Hydraulic components
1. Hydraulic oil pump for steering and load handling 5. Steering valve
2. Shuttle valve 6.
Steering valve mini-wheel/joystick control
3. Priority valve 7. Steering axle with steering cylinder
4. Connection terminal, return oil
Steering is supplied oil by the hydraulic oil pump for steering and load
handling; see section 10 Common hydraulics, group 10.4 Pumps.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Operate and warm up the machine so that the hydraulic oil reach-
es operating temperature, 50 C.
2 Machine in service position, see section B Safety.
3 Connect the pressure gauge to the measuring outlet on the hy-
draulic oil pump for steering and load handling.
4 Start the engine and increase engine speed to approx. 1200 rpm.
009885
1 2 The priority valve separates the oil flow from the hydraulic oil pump for
steering and load handling so that there is always oil to the steering
valve. The residual flow goes to the working hydraulics or the servo
circuit.
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
3 priority valve and steering valve via a separate line.
6 4
5 The priority valve has a built-in pressure limiter on the load signal. The
pressure limiter maximises the load signal’s pressure.
009884
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Machine in service position, see section B Safety.
2 Depressurise the hydraulic systems, See section B Safety.
3 Turn the start key to position 0 and switch off the main power.
1 2 4 Mark up and detach the hydraulic hoses from the priority valve.
NOTE
Plug all connections immediately to protect the brake sys-
tem from impurities.
5 Remove the priority valve attaching bolts.
6 Disconnect the priority valve from control valve lift and lower.
NOTE
Transfer one connection at a time so that the marking is not
mixed up.
9 Connect the new priority valve to control valve lift and lower.
CAUTION
009884
The steering valve is a closed centre, non-reaction valve with load sig-
nal connection to the priority valve.
The load signal generates load-dependent control of oil flow from the
1 priority valve to the steering valve. Closed centre means that the steer-
ing valve is closed in its neutral position. This is necessary so that sig-
nal pressure can be connected to the steering valve.
2
5 The steering valve consists of a gear pump and a distribution valve.
When the steering wheel is turned, oil flows from the main pump over
4 3
the gear pump to the distribution valve, which 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.
009887
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Stop the engine and turn the start key to position I.
2 Depressurise the hydraulic systems, See section B Safety.
3 Turn the start key to position 0 and switch off the main power.
1. Water valve
2. Steering valve
NOTE
Plug all connections immediately to protect the brake sys-
tem from impurities.
6 Remove the steering valve.
7 Transfer the connection adapters to the new steering valve.
NOTE
Transfer one connection at a time so that the marking is not
mixed up.
8 Connect the hydraulic hoses to the steering valve in accordance
with the marking.
NOTE
Check that the O-rings are intact and are fitted in the correct
position.
9 Connect the new steering valve to the brake pedal.
Position the steering valve and check that the steering wheel
shaft’s splines enter straight in the steering valve’s slot. Install the
attaching bolts.
10 Turn on the main electric power and start the engine.
11 Check that the connections on the steering valve are sealed
tightly.
12 Steer very carefully a few times right - left, to bleed the steering
valve and steering cylinder.
The steering cylinder acts on the wheels via the link arms. The steer-
1 2 3 ing cylinder is a double-acting hydraulic cylinder.
4
009888
1. Steering cylinder
2. Shaft
3. Lock bolt
4. Attaching bolt (locked with locking fluid)
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Park the machine with the wheels fully turned so that the steering
cylinder can be lifted out to one side.
2 Machine in service position, see section B Safety.
3 Depressurise the brake and hydraulic systems, see section B
Safety.
4 Detach the link arms from the steering cylinder.
NOTE
Plug all connections immediately to protect the brake sys-
tem from impurities.
6 Remove the steering cylinder’s attaching bolts.
7 Change the steering cylinder. Lift aside the steering cylinder.
1. Hydraulic connection
NOTE
2. Link arm mounting The steering cylinder is heavy, use lifting equipment.
8 Support the new steering cylinder so that the holes in the attach-
ing bolts are lined up directly opposite the holes in the steering
axle.
9 Lubricate and install the steering cylinder’s attaching bolts. Tight-
en the bolts crosswise a few times with increasing torque to
680 Nm.
10 Transfer parts to the new steering cylinder.
NOTE
Check that the O-rings are intact, clean and in the correct
position.
11 Connect the link arms to the steering cylinder, lubricate the shafts
for the link arms.
12 Connect the hydraulic hoses to the steering cylinder.
NOTE
Check that the O-rings are intact, clean and in the correct
position.
13 Close the drain valve on the accumulator charging valve. See
section B Safety.
14 Start the engine and check for leaks.
The link arm transfers the lateral movement of the steering cylinder to
turning the wheel spindles.
The setting of the steering wheels cannot be adjusted. If the link arms
are deformed in a way that changes the setting of the steering wheels,
they must be replaced.
The link arms must be turned to the right direction, otherwise they can
1 be damaged by the rims with large wheel angles.
008854
1. Link arm
6 Suspension
6 Suspension..................................................................................................... 3
6.2 Suspension ................................................................................................. 3
6.2.1 Steering axle cradle ............................................................................... 4
6.2.2 Wheel spindle ........................................................................................ 6
6.2.3 Wheel hub .............................................................................................. 8
6.3 Tyres and rims .......................................................................................... 13
6.3.1 Tyres .................................................................................................... 15
6.3.2 Rim ...................................................................................................... 16
6.3.3 Nut, washer and clamp ........................................................................ 17
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!
NOTE
Do not lift so much that the wheels are off the ground.
5 Remove the pins holding the steering axle.
6 Lift the machine so that the frame is off the steering axle.
7 Support the machine under the frame.
8 Move the steering axle so that the mountings can be accessed.
NOTE
If necessary, disconnect the cable harness for the sensors
on the steering axle.
009890
010121
Steering axle
1. Wheel hub
2. Wheel spindle
3. Link arm
4. Steering axle cradle
5. Steering cylinder
6. King pin/bearing
DANGER
Steering axle and machine are very heavy.
Risk of crushing!
NOTE
Plug all connections immediately to protect the hydraulic
system from impurities.
9 Remove the pins holding the steering axle.
10 Lift the machine up so that the frame is lifted away from the axle.
11 Lift out the steering axle.
CAUTION
The steering axle may start to roll.
Crushing injury!
Make sure that the steering axle does not roll away
uncontrollably.
NOTE
Check that the O-rings are intact and that they are fitted
correctly.
18 Remove the lifting equipment from the machine.
The wheel spindle is the link between steering axle and wheel hubs
which means that the wheels can be turned.
3
2
4
5
1 6
8 7
9
009780
11 10
1. Wheel spindle
2. Seal ring
3. Bearing (upper)
4. Guard ring
5. Seal ring
6. Bearing (lower)
7. Circlip
8. Shim
9. Bearing cage
10. Bolt
11. Grease nipple
7 Remove the six screws holding the bearing cage to the wheel
spindle.
14 From underneath, tap in the outer bearing race of the upper bear-
ing into the steering axle cradle. Use a pipe of a suitable diameter
so as not to damage the bearing race.
15 Refit the three screws on the top of the steering axle cradle.
16 Fit upper bearing’s inner bearing race, seal ring, guard ring and
seal ring as well as the lower bearing’s inner bearing race and cir-
clip on the wheel spindle.
17 Fit the wheel spindle.
18 Tap the lower bearing’s outer bearing race into the bearing cage.
Use a pipe of a suitable diameter so as not to damage the
bearing race.
19 Fit the bearing cage. Use a shim to get it in the right position.
Tighten the screws.
20 Check that the wheel spindle rotates smoothly and that there is
no play in the spindle bearing arrangement. Correct with shims as
necessary.
NOTE
The correct number of shims have been used when it takes at
least 200 Nm to move the bearing arrangement to move laterally.
If it takes more than 400 Nm for the bearing arrangement to
move, it is too hard and the number of shims must be corrected.
21 Lubricate the wheel spindle bearings via the grease nipples.
22 Fit the wheel hub and wheel bearing; see Wheel bearing, re-
placement page 8.
23 Connect the link arm to the wheel spindle.
24 Fit the wheel.
25 Remove the support and lower the steering wheel.
26 Test-run the machine and test the steering. Check also that the
machine feels stable when operating straight ahead.
The wheel hub holds the wheel in place and allows the wheel to rotate.
3 2
1
4
5
6
7
8
9
10 11
008595
1. Wheel hub
2. Wheel bolt
3. Wheel nut
4. Hub cap
5. Spacer
6. Nut
7. Washer
8. Bearing
9. Bolt
10. Bearing
11. Seal ring
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.
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.
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".
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.
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.
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.
009892
Front wheels
009893
Rear wheels
Tyres, changing
page
–
DANGER
Changing tyres is complicated and dangerous work.
EXTREME DANGER!
The rims must be checked when tyres are changed. See Maintenance
manual DCF 90-100.
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
the following parts.
• Rim
• Rim bead seat
• Rim edge
• Lock ring
5
009899
1. Rims
2. Lock ring
3. Rim flange
4. Rim bead seat taper
5. Wheel nut
6. Wheel bolt
5
009899
1. Rims
2. Lock ring
3. Rim flange
4. Rim bead seat taper
5. Wheel nut
6. Wheel bolt
7 Load handling
7 Load handling................................................................................................. 3
7.1 Controls and instruments ........................................................................... 5
7.1.1 Control levers ......................................................................................... 5
7.1.2 Switch, lock twistlock/lock tongue .......................................................... 7
7.1.3 Switch, spreading 20'-40' ....................................................................... 7
7.1.4 Switch, stop at 30' .................................................................................. 8
7.1.13 Switch, automatic spreading .................................................................. 8
7.2 Lift and lower .............................................................................................. 9
7.2.1 Hydraulic oil pump ............................................................................... 12
7.2.2 Servo filter ............................................................................................ 12
7.2.3 Pressure reducer ................................................................................. 13
7.2.4 Accumulator servo circuit ..................................................................... 14
7.2.5 Control valve, lift and tilt ....................................................................... 15
7.2.6 Shuttle valve ........................................................................................ 17
7.2.7 Lift cylinder ........................................................................................... 17
7.2.8 Sensor hydraulic pressure lift cylinder ................................................. 17
7.2.9 Mast ..................................................................................................... 19
7.2.10 Mast position sensor ............................................................................ 28
7.2.11 Trolley .................................................................................................. 29
7.2.12 Valve block quick-lift ............................................................................ 36
7.2.13 Pipes and hoses .................................................................................. 36
7.4 Side shift ................................................................................................... 37
7.4.1 Hydraulic oil pump ............................................................................... 39
7.4.2 Control valve, attachment .................................................................... 39
7.4.3 Side shift cylinder ................................................................................. 44
7.4.4 Shuttle valve ........................................................................................ 44
7.4.5 Trolley .................................................................................................. 44
7.4.6 Valve block, main pump relief .............................................................. 48
7.4.7 Relief valve, attachment ...................................................................... 48
7.4.8 Pipes and hoses .................................................................................. 48
7.5 Spreading (positioning) ............................................................................ 49
7.5.1 Hydraulic oil pump ............................................................................... 56
7.5.2 Control valve, attachment .................................................................... 57
7.5.3 Spreading cylinder ............................................................................... 58
7.5.4 Spreader beam .................................................................................... 59
7.5.5 Main beam, side lift attachment ........................................................... 64
7.5.6 Position sensor, spreading .................................................................. 74
7.5.7 Buzzer, automatic spread 20’-40’ ........................................................ 75
7.5.8 Pipes and hoses .................................................................................. 75
7.7 Tilt ............................................................................................................. 76
7.7.1 Hydraulic oil pump ............................................................................... 78
7.7.2 Accumulator ......................................................................................... 78
7.7.3 Pressure reducer ................................................................................. 78
7.7.4 Servo filter ............................................................................................ 78
7 Load handling
mm mm mm mm mm mm
Position sensor
page
–
3
1
4
009906
The illustration depicts a machine with a twistlock attachment
1. Sensor, hydraulic pressure in the lift cylinder (B768-L1), see Sen-
sor hydraulic pressure lift cylinder, description page 17.
2. Mast position sensor (B7211-2), see Position sensor, adjusting
page 4.
3. Sensor alignment
(Twistlock B7203L and B7203R), see Alignment sensor, checking
and adjusting page 95,
(Lifting hook B7203LL, B7203LU-2, B7203RL and B7203RU-2),
see Alignment sensor, checking and adjusting page 108.
4. Sensor, locked twistlocks/lock tongues (B7205LL and B7205RL),
see Twistlocks sensor, checking and adjusting page 97 or Lock
tongue sensor, checking and adjusting page 110.
5. Detection sensor, upper container (ultrasound) for attachment
with lifting hook (B7203LU and B7203RU), see Detection sensor,
upper container, checking page 109.
6. Damping sensor (B769L, B769R, B777L and B777R), see Posi-
tion sensor, adjusting page 4.
C-C
3 Check that the distance between the sensor and the indicator is
5±1 mm
51 mm.
4 Adjust if necessary.
009632
5±1 mm
d. Levelling (R8075-1-P5) .
RIGHT side up - push lever forwards.
LEFT side up - pull lever backwards.
e. Emergency stop switch
f. Opening of locked twistlocks/lock tongues, attachment (S1002)
Pull the switch sideways.
f
008110
The control lever (S815) is used to control the mast and attachment.
2 3
1 The lever sends voltage signals to the cab control unit (D790-1).
4 The control lever has four potentiometer-controlled functions and six
on/off functions.
5
Lift and lower
6
Lifting and lowering are controlled by moving the control lever forward
7 (lower - position 10) or rearward (lift - position 12). See Lifting/lower-
ing, function description page 9.
8
The signal can be checked from the diagnostic menu, see
12 9 section 8 Control system, group 8.4.8.1 ELSERV, menu 1.
Spreading (positioning)
009711
Tilt
Tilt is controlled by moving the lever to the right (tilt out - position 10)
or the left (tilt in - position 12). See Tilt, function description page 76.
The signal can be checked from the diagnostic menu, see
section 8 Control system, group 8.4.8.1 ELSERV, menu 1.
action.
Twistlocks are opened with the switch on the control lever, see Control
levers for electric servo, description page 5.
The switch is supplied power by and sends a voltage signal to the cab
control unit (D790-1).
The signal can be checked from the diagnostic menu, see
section 8 Control system, group 8.4.9.3 ATTACH, menu 5.
Switch (green) for spreading 20’ to 40’ (S1012). The spreader remains
in the position it held when the switch was released. The switch has a
return spring.
This function is used to adapt the attachment to the width of the
containers.
009910
The switch (green) for spreading stop for the attachment at 30’
(S1004) activates the 30-foot stop. When the switch is depressed, the
35 function changes from spreading from 20’–40’ to stop at 30’.
30-
The switch is supplied power by and sends a voltage signal to the cab
control unit (D790-1).
009909
The signal can be checked from the diagnostic menu, see
section 8 Control system, group 8.4.9.2 ATTACH, menu 3.
Switch (green) for automatic spreading between 20’ and 40’ (S1004).
When the switch is depressed, spreading automatically goes to the
next position (20, 30 or 40 feet) if spreading is activated with the con-
trol lever.
This switch is used to activate automatic spreading.
009908
WARNING
Risk of crushing and damage to the product!
Twistlocks/lock Locked or unlocked, not in- Twistlocks, description page 85 or Lifting hook, description page 98
tongues termediate position
Alignment Mast down: no contact Sensor, alignment, description page 94 or Alignment and detection
sensor, description page 108
Bypassed or lift height lower Section 8 Control system, group 8.2.4 Height limitation
Height limitation
than height limitation
2,4 5
D790-1 D794
D1
D21 D15
D797-1
3,16,22
˚<
21
1b 1a
D16 6 6
D3
7
LS
15
17 P
A2
13 B2
14 P PS
8,20,23
12
C
P EF
9
LS
11
19 C C
009367
18 10
1b The control lever (S815-P1) sends US815-P1 = 0.5-4.5 V Control lever, description page 6
the cab control unit (D790-1) a volt- Lower: US815-P1 = <2.5 V D1: Diagnostic menu, see section 8 Control
age signal proportional to lever system, group 8.4.8.1 ELSERV, menu 1
movement. Lift: US815-P1 = >2.5 V
2 The cab control unit (D790-1) Checked by control system, Section 11 Common electrics,
sends the frame control unit error shown with error code. group 11.5.3.1 Cab control unit (D790-1)
(D797-1) a lift/lower request via the
CAN bus.
4 Control unit, cab (D790-1) trans- Checked by control system, Section 11 Common electrics,
mits a request for increased engine error shown with error code. group 11.5.3.1 Cab control unit (D790-1)
speed on the CAN bus.
5 Control unit, engine (D794) in- Checked by control system, Section 11 Common electrics,
creases the engine speed. error shown with error code. group 11.5.3.10 Engine control unit (D794)
6 The lift solenoid valve (Y6005) or - Control valve, lift and tilt, description
the lower solenoid valve (Y6004) page 15
pressurises the control valve’s lift
spool with servo pressure.
7 The control valve’s lift spool chang- - Control valve, lift and tilt, description
es position and pressurises the lift page 15
cylinders and sends a load signal to
the hydraulic oil pumps.
10 The steering hydraulic oil pump and See the pressure plate on the Section 10 Common hydraulics,
load handling pump oil from the hy- left-hand frame beam. group 10.4.2 Axial piston pump with varia-
draulic oil tank to the priority valve ble displacement
and pressure reducer.
11 The priority valve leads feed pres- - Section 5 Steering, group 5.2.2 Priority
sure to Control valve, lifting/ valve.
lowering.
12 The pressure reducer reduces the See the pressure plate on the Pressure reducer, description page 13
oil pressure from the steering hy- left-hand frame beam.
draulic pump and load handling to
servo pressure for the control
valve.
13 The accumulator stores servo pres- See the pressure plate on the Accumulator servo circuit, description
sure. The non-return valve in the left-hand frame beam. page 14
pressure reducer makes it possible
to store the pressure when the en-
gine is turned off.
14 The servo filter cleans the servo oil - Servo filter, description page 12
before Control valve lift and lower.
22 The frame control unit (D797-1) de- - Section 11 Common electrics, group
activates quick-lift and reduces the 11.5.3.2 Frame control unit (D797-1)
control current to the lift solenoid D3: Diagnostic menu, see section 8 Control
valve (Y6005) or the lower solenoid system, group 8.4.5.6 HYD, menu 6
valve (Y6004).
The servo filter prevents the control valve’s servo circuits from contam-
inants. The servo filter sits on the hydraulic plate in front of the trans-
mission, to the right of the servo pressure accumulator.
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 great the insert is
pressed down so that the oil passes by the insert. This occurs if the oil
009161
The pressure reducer reduces the pressure from the hydraulic oil
1
pump which supplies the servo circuit for control valve servo pressure.
2 The pressure reducer is located on the hydraulic plate in front of the
3 transmission, mounted together with the servo pressure accumulator.
Servo pressure is stored in an accumulator for quicker start-up and for
emergency reduction of load. An integrated non-return valve prevents
pressure leakage from the accumulator when the machine is not in
use.
7
6
5
4 009911
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Operate and warm up the machine so that the hydraulic oil is at
operating temperature, at least 50 C. As an alternative, operate
until the cooling fan is activated.
2 Machine in service position, see section B Safety.
3 Depressurise the hydraulic systems, See section B Safety.
4 Connect a pressure gauge (0–25 MPa) to the test outlet on the
pressure reducer.
009912
5 Start the engine and check the servo pressure. Compare with the
pressure plate.
M Pa 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.
6 If the pressure does not match the value specified on the pres-
sure plate, adjust the servo pressure adjusting screw until the
right pressure is obtained; see Pressure reducer, description
page 13. Slacken the lock nut and turn the adjusting screw.
NOTE
If the servo pressure is too high, a load handling function
009913 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.
7 Depressurise the hydraulic systems, See section B Safety.
8 Remove the pressure gauge and fit the protective cap on the
measuring outlet.
The accumulator stores pressurised oil and ensures that there is servo
pressure for activating control valve functions. The accumulator sits on
the hydraulic plate in front of the transmission, on top of the pressure
reducer.
The accumulator is a diaphragm type and is divided into two spaces
by a diaphragm. One side of the diaphragm is pressurised with nitro-
gen gas. The other side is pressurised by hydraulic oil which compacts
the nitrogen gas.
Furthest up on the accumulator is a test outlet for checking gas pres-
sure and filling gas.
009914
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Depressurise the hydraulic systems, See section B Safety.
2 Machine in service position, see section B Safety.
3 Detach the accumulator from its mounting.
4 Replace the accumulator.
5 Fit in the reverse order.
6 Check the oil level and fill with hydraulic oil as necessary.
4 7
3
8
2
5
1 6
14 11
13 12 10
009915
1 Solenoid valve, lift (Y6005) 8 Connection, rod side, right lift cylinder (B1)
2 Solenoid valve, lower (Y6004) 9 Connection, piston side, tilt cylinder (A1)
3 Connection, piston side, left lift cylinder (A2) 10 Connection, rod side, tilt cylinder (B1)
4 Connection, rod side, left lift cylinder (B2) 11 Connection return to tank (T)
5 Connection, feed from hydraulic oil pump (P) 12 Connection, piston side, tilt cylinder (A1)
6 Connection, feed from priority valve (P) 13 Solenoid valve, tilt out (Y6010)
7 Connection, piston side, right lift cylinder (A1) 14 Solenoid valve, tilt in (Y6011)
The control valve controls speed and direction of lift and tilt. The con-
trol valve is located on the hydraulic plate in front of the transmission.
The valve has two sections - one for the lift function and one for the tilt
function. The sections have many similarities, but are described sep-
arately under the respective function. For tilt, see Control valve, lift and
tilt, description page 78. Electric control valves control the flow from
the valve.
The control valve is proportionally controlled by solenoid valves. This
means that both volume and direction of the flow from the valve can
be adjusted and that the valve can also send a control signal to the
variable pumps.
Electrically controlled pressure reducing valves (solenoid valves) con-
vert electrical current into a low hydraulic pressure that is proportional
to the current, known as servo pressure. The servo pressure acts on
the spring-centred control slides 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.
Lift slide
The lift slide controls the direction and flow of the oil to the lift cylinder.
The lift cylinders lift and lower the inner mast, which runs inside the
outer mast. The lower parts of the lift cylinders are fixed to the outer
mast, while their upper parts are fixed to the inner mast - one on the
right and one on the left of the mast.
A sensor that measures hydraulic pressure in the lift cylinder is situat-
ed on the left lift cylinder.
The lift cylinder is fastened in the mast with nuts in the bottom and a
washer and screw in the top.
The lift cylinders are connected in parallel and fed from lift and tilt con-
trol valve, see Control valve, lift and tilt, description page 15.
009916
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Machine in service position, see section B Safety.
2 Depressurise the hydraulic systems, See 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
Plug all connections immediately to protect the hydraulic
system from impurities.
5 Fit the new sensor.
NOTE
Check that the O-rings are intact and in the correct position.
6 Connect the cable harness to the sensor for hydraulic pressure.
009188
CAUTION
Air in the hydraulic system may cavitate and result in
product damage.
11 Check the oil level in the hydraulic oil tank with the attachment ful-
ly lowered and the mast tilted in. The oil level should be at the top
of the level glass. Top up as necessary.
CAUTION
Overfilling of oil.
12 Check pressure and signals with the diagnostic menu; see sec-
tion 8 Control system, group 8.4.5.3 HYD, menu 3 or
group 8.4.10.1 OLS, menu 1.
7.2.9 Mast
Mast, description
page
–
The mast, which is a free-view mast, lifts the load. The trolley runs
1 along the mast. This, in turn, holds the side lift attachment.
The lower part of the mast is fixed to the frame by two shafts in two
double lugs on the front of the frame. The mast is also fixed to the
2
frame by two tilt cylinders.
The mast consists of an outer mast and an inner mast, made from high
strength steel, with a minimum number of welds for highest strength.
3 The inner mast runs inside the outer mast, and is lifted and lowered by
the lift cylinders. Mast wheels and slide plates between the inner and
outer masts guide the inner mast in the outer mast and reduce friction
between the two parts of the mast.
4 The lower parts of the lift cylinders are fixed to the outer mast, while
their upper sections are fixed to the inner mast. When oil is forced into
the lift cylinders, the piston rods in the cylinders are forced out and the
inner mast is lifted. The chain which is fixed to the carriage (and the
outer mast), runs over sprockets at the top of the inner mast. This also
lifts the carriage at the same time as the inner mast.
Hydraulic hoses and cables for the trolley and side lift attachment func-
tions run along the left side.
009918
1. Inner mast
2. Lifting eye
3. Outer mast
4. Lift cylinder
Mast, removing
page
–
NOTE
Read the safety instructions for oil before working, see section B
Safety.
NOTE
It is possible to remove the trolley and the side lift attachment as
a unit.
1 Remove the side lift attachment; see Side lift attachment, remov-
ing page 64.
2 Remove the trolley; see Trolley, removing page 30.
3 Connect the lifting equipment to the lifting lugs at the top of the
mast in a secure manner.
4 Start the engine and tilt the mast forwards as far as possible.
5 Turn off engine.
6 Turn the start key to position I and activate the hydraulic functions
to depressurise the hydraulic system.
7 Turn the start key to position 0 and switch off the main power.
009974
NOTE
Plug all connections immediately to protect the hydraulic
system from impurities.
9 Mark up and detach the electrical connections of the mast.
009980
NOTE
Plug all connections immediately to protect the hydraulic
system from impurities.
009981
14 Undo the nuts and bolts and remove the shafts which fix the mast
to the frame.
009979
WARNING
The mast can swing out when it is released from the
machine.
009983
17 Place the mast on the ground and detach the lifting equipment
(overhead crane).
009975
Mast, installing
page
–
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Turn off engine.
2 Turn the start key to position I and activate the hydraulic functions
to depressurise the hydraulic system.
3 Turn the start key to position 0 and switch off the main power.
4 Connect lifting equipment to the mast in a secure manner so the
mast does not tip when lifted.
009975
NOTE
The mast is attached to the machine’s frame with strong
shafts which run in maintenance-free bearings.
It is most important that bearing surfaces are absolutely
clean when the mast is installed.
009977
7 Suspend the mast vertically. Align the mast and position the
shafts in the mast mountings.
009978
13 Lift the tilt cylinders with lifting equipment (overhead crane) and
align the tilt cylinders with the mast.
009982
15 Grease the connectors with contact grease and join them up.
16 Remove the plugs and connect the mast’s hydraulic hoses on the
machine’s front panel.
009981
17 Remove the plugs and connect the hydraulic hoses to the lift
cylinders.
18 Turn on the power supply and start the engine.
19 Check that the hydraulic connections are sealed tightly.
20 Check the mast functions.
21 Fit the trolley; see Trolley, installing page 31.
22 Fit the side lift attachment; see Side lift attachment, installing
page 67.
009980
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Machine in service position, see section B Safety.
2 Remove the trolley; see Trolley, removing page 30.
3 Removing the mast, please refer to Mast, removing page 20.
4 Separate the outer and inner mast.
5 Clean the mast components.
6 Grind the affected surfaces with a band grinder until the surface
is smooth and bare. Start with grain size 36-40 and finish with
60-80.
Grind in the longitudinal direction of the beam.
250 mm
7 Apply a thin layer of slide grease to the sliding surfaces of the out-
er mast and reassemble the inner and outer masts.
Mast beam size 250 mm. 8 Apply a thin layer of slide grease to the sliding surfaces of the in-
ner mast and fit the mast on the machine; see Mast, installing
page 23.
9 Fit the trolley; see Trolley, installing page 31.
10 Lift and lower the mast as follows to check its function.
Lift and lower the mast 20 times with 50% of the maximum load
at the right centre of gravity distance.
Lift and lower the mast 20 times with 75% of the maximum load
at the right centre of gravity distance.
Lift and lower the mast 20 times with the maximum load at the
right centre of gravity distance.
11 Check that contact surfaces look normal. If not, contact Kalmar
Industries.
NOTE
If the slide plate extends less than 3 mm from the holder, replace
it.
1 Lubricate the inner sliding surfaces of the outer mast with a thin
layer of slide grease.
2 Lift the inner mast 200 mm.
3 Adjust the slide plate in the bottom part of the outer mast so that
it lies against or has no more than 0.5 mm play to the outer mast.
Use a suitable number of shims in the rear and front of the slide
plate so that the slide plate lies evenly against the entire sliding
surface.
4 Raise the mast to its end position and check that the slide plates
do not pinch too hard against the sliding surface.
010152
NOTE
If the slide plate extends less than 3 mm from the holder,
replace it.
1 Lubricate the outer sliding surfaces of the inner mast with a thin
layer of slide grease.
2 Lower the inner mast to its bottom position.
3 Lift the inner mast 200 mm.
4 Adjust the slide plate in the top part of the outer mast so that it lies
against or has no more than 0.5 mm play to the inner mast.
Use a suitable number of shims in the rear and front of the slide
plate so that the slide plate lies evenly against the entire sliding
surface.
5 Raise the mast to its end position and check that the slide plates
do not pinch too hard against the sliding surface.
010130
4
NOTE
5 Rotate the mast wheel while tightening the clamping screw.
3 Slacken the clamping screw until the wheel can be rotated some-
what sluggishly. Turn the clamping screw to engage the spring
6 pin in the closest hole.
7
NOTE
Check that there is clearance between the mast wheel and the
mast beam.
4 Lock the clamping screw with the spring pin.
010126
1. Impeller
2. Circlip
3. Cover washer
4. Spring pin
5. Clamping screw
6. Inner bearing
7. Outer bearing
The mast position sensor (B7211-2) activates damping during lift. The
position sensor is used to deactivate the hydraulic oil pump for quick-
lift so that lifting is decelerated when the mast approaches its upper
end position.
For checking and adjusting, see Position sensor, adjusting page 4.
The position sensor sends a signal to the frame control unit (D797-1).
The signal can be checked from the diagnostic menu; see
section 8 Control system, group 8.4.8.15 ELSERV, menu 15.
7.2.11 Trolley
Trolley, description
page
–
The trolley holds via hydraulic cylinders in the side lift attachment and
runs along the inner mast with slide plates and mast wheels.
2 The following functions are controlled via the trolley cylinders:
• Side shift - the attachment can be shifted to the side 600 mm.
1
• Mechanical levelling - the attachment can be levelled 3°.
3
Trolley
1. Side shift cylinder
2. Control valve attachment
3. Slide plates
4. Mast wheels
5. Levelling cylinders
1 2
3
5 4
5
014791
Trolley, removing
page
–
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Remove the side lift attachment; see Side lift attachment, remov-
ing page 64.
2 Connect lifting equipment to the trolley in a secure manner.
3 Disconnect the main power supply.
4 Disconnect the trolley cable by undoing the lock plate screws.
Undo the connectors and protect the terminals by lubricating
them with contact grease. Then loosely insert the connectors.
009995
NOTE
Plug all connections immediately to protect the hydraulic
system from impurities.
6 Raise the carriage with the lifting equipment (overhead crane) to
slacken the chains.
009987
009986
Trolley with levelling
Trolley, installing
page
–
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Park the machine with the mast vertical.
2 Raise the mast high enough to position the carriage in the inner
mast and lift it into place.
3 Lower the mast so that the carriage fastens in the inner mast.
Stop the mast in a position where the chains can be fastened to
the carriage. Fit the chain tensioners and adjust and fasten with
the nuts.
4 Lower the carriage as far as possible.
5 Turn off engine.
6 Turn the start key to position I and activate the hydraulic functions
to depressurise the hydraulic system.
7 Turn the start key to position 0 and switch off the main power.
013591
009986
8 Remove the plugs and connect the mast’s hydraulic hoses and
the carriage wiring.
009987
replacing
1 Remove the trolley; see Trolley, removing page 30.
NOTE
Minor adjustment to the clearance between the trolley and inner
mast is possible without removing the trolley.
2 If the slide plate extends less than 3 mm from the holder,
A replace it.
3 Use a gauge in the centre of the beam to measure the interior
width of the inner mast.
B
013593
D
013648
NOTE
Minor adjustment to the clearance between the trolley and inner
mast is possible without removing the trolley.
A 2 If the slide plate extends less than 3 mm from the holder,
replace it.
3 Use a gauge in the centre of the beam to measure the interior
width of the inner mast.
B
010123
D
010124
1
2 6 Lubricate the inner sliding surfaces of the inner mast with a thin
1. Screws layer of slide grease.
2. Shim 7 Fit the trolley; see Trolley, installing page 31.
8 Lift the trolley all the way up and check that the slide plates do not
clamp too hard against the sliding surfaces.
For mast wheel adjustment, see Mast wheel, adjusting page 28.
1b 1a D1
2
D790-1
D797-1 D791-1
3 8 D8
D3 11
9
C
P1 A
4
T1 B
10
5
C
6
7
014798
Pos Explanation Signal description Reference
1a The side shift control lever U = 0.5-4.5 V Control levers for electric servo, description
(R8073-P3) sends the cab control Left: U = <2.5 V page 5
unit (D790-1) a voltage signal propor- D1: Diagnostic menu, see section 8 Control
Right: U >2.5 V
tional to lever movement. system, group 8.4.9.1 ATTACH, menu 1
0.5 V is the highest speed
for side shift left and 4.5 V
is the highest speed for
side shift right. Voltage
lower than 0.5 V and high-
er than 4.5 V is used to de-
tect defects in cable
harnesses and controls.
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 error group 11.5.3.1 Cab control unit (D790-1)
code.
4 The solenoid valve for main pump re- - Valve block, main pump relief, description
lief (Y6062-2) routes a relieved con- page 48
stant pressure to the hydraulic oil
pump for load handling. This serves
as a load signal.
6 The cab tilt shuttle valve sends the - Section 10 Common hydraulics,
load signal on to the hydraulic oil group 10.5.3 Shuttle valve
pump for load handling.
7 The hydraulic oil pump for load han- See the pressure plate on Section 10 Common hydraulics,
dling pumps oil from the hydraulic oil the left-hand frame beam. group 10.4.2 Axial piston pump with variable
tank. displacement
9 The solenoid valve for side shift left - Attachment control valve, description page 39
(Y6020) or the solenoid valve for side
shift right (Y6021) pressurises the
side shift spool in the attachment
control valve.
11 The side shift cylinders push in the - Side shift cylinder, description page 44
main beam sideways in relation to the
trolley.
1 2 3 6 9 12 16
014782
5 4 8 7 11 10 13 14 15 17
1 Connection return to tank (T) 10 Solenoid valve spreading out left (Y6018L)
2 Connection, feed from hydraulic oil pump (P) 11 Connection to spreading cylinder left
3 Solenoid valve, side shift right (Y6021) 12 Solenoid valve spreading in right (Y6019R)
4 Solenoid valve, side shift left (Y6020) 13 Solenoid valve spreading out right (Y6018R)
5 Connection to side shift cylinder 14 Connection to spreading cylinder right
6 Solenoid valve, lock twistlock (Y6040) 15 Solenoid valve, levelling right (Y6035)
7 Solenoid valve, open twistlock (Y6039) 16 Solenoid valve, levelling left (Y6036)
8 Connection to lock cylinders 17 Connection to levelling cylinders
9 Solenoid valve spreading in left (Y6019L)
• Levelling
• Spreading right extension beam
• Spreading left extension beam
• Twistlocks/lock tongues
• Side shift
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Machine in service position, see section B Safety.
2 Depressurise the hydraulic systems, See section B Safety.
3 Remove the attaching bolts and lift away the plate fitted over the
control valve.
4 Mark and disconnect the hydraulic hoses from the control valve.
NOTE
Plug all connections immediately to protect the hydraulic
system from impurities.
5 Mark and disconnect the cable harness from the control valve.
013595
6 Remove the attaching bolts and lift away the valve. Place the
valve on a clean and protected surface.
7 Transfer the connection adapters to the new control valve.
NOTE
Check that the O-rings are intact, clean and in the correct
position.
NOTE
Transfer one connection at a time so that the marking is not
013596
mixed up.
8 Mark up the solenoid valves on the new control valve.
9 Lift the valve into place and fit the attaching bolts.
10 Connect the cable harness to the control valve according to the
marking.
11 Connect the hydraulic hoses to the control valve in according to
the marking.
NOTE
Check that the O-rings are intact and in the correct position.
12 Turn on the main electric power and start the engine.
13 Check that the valve's hydraulic connections are sealed.
CAUTION
Air in the hydraulic system may cavitate and result in
product damage.
15 Check the hydraulic oil level with all hydraulic pistons fully retract-
ed. The oil level should be at the top of the level glass. Top up as
necessary.
CAUTION
Do not overfill!
pressure
NOTE
Read the safety instructions for oil before working, see section B
Safety.
Function Pressure
20.0 MPa
Levelling
Pressure check connection, control valve attachment
Twistlocks/lock tongues Same as feed pressure.
6 Remove the pressure gauge and fit the protective cap on the
measuring outlet.
The side shift cylinder sits between the trolley and the side lift attach-
ment. It shifts the main beam laterally in relation to the trolley.
013598
7.4.5 Trolley
Trolley, description
page
–
adjustment/replacement
1 Park the machine with the attachment lowered as far as possible
and spreading run all the way in.
1
2 Switch off the engine and switch off the main electric power.
3 Clean and measure the thickness of the lower slide plates.
NOTE
The thickness of the slide plate must be at least 10 mm.
4 Replace the lower slide plates, if necessary, by loosening the at-
tachment’s mounting.
5 Unload the tension from the slide plate in question.
The pressure can be relieved from the slide plates by raising the
outer edge of the side lift attachment or inserting wedges to alter
the position of the side lift attachment in the trolley.
6 Remove the slide plate and fit a new one. Repeat with the rest of
the lower slide plates (4 pcs).
3 7 Reassemble the attachment’s mounting.
2
013681
3
The illustration shows slide plates between
attachment and trolley.
1. Upper slide plates
2. Lower slide plates
3. Attachment mounting
NOTE
The thickness of the slide plate must be at least 10 mm.
9 Remove the counterhold.
10 Loosen the slide plate’s attaching bolt slightly so that the slide
4 plate releases from the carriage.
11 Insert the required number of shims to remove the play between
attachment and carriage. Alternatively replace the slide plate.
12 Refit the counterhold and tighten the attaching bolt that secures
the slide plate.
013682
13 Check the clearance between the side lift attachment and the trol-
ley. Clearance should be less than 1 mm with all slide plates
The illustration shows slide plates between fitted.
attachment and trolley. Use more shims to adjust any play.
1. Upper slide plates
2. Lower slide plates
3. Attachment mounting
NOTE
3. Screw Do not use adjustment shims that are too thick. Inadequate
clearance increases wear on the slide plates.
NOTE
Check that the attaching bolts for all slide plates are
tightened.
14 Check that the sliding surface is clean and lubricate the sliding
surface on the side lift attachment.
15 Start the machine and side shift the attachment to both of its end
positions. Check that the clearance between trolley and attach-
ment is sufficient along the whole of the attachment and that
there is no metallic contact. Adjust with shims if necessary.
adjusting/replacing
NOTE
The thickness of the slide plate should be at least 10 mm.
8 Place the slide plate in the correct position.
Check the clearance between the side lift attachment and the trol-
ley. Clearance should be less than 1 mm with all slide plates
fitted.
Use a spacer plate to adjust the clearance.
1
NOTE
2 In general, the upper slide plates on the front of the lifting
carriage and the lower slide plates on the rear of the car-
riage are adjusted with shim plates.
NOTE
009190
The valve block for the main pump relief is an electrically regulated
valve that uses relieved constant pressure as a load signal, sending it
to the hydraulic oil pump for load handling when attachment functions
are activated. The valve block sits on the hydraulic plate in front of the
transmission in the engine compartment.
When the solenoid valve is activated, pressure is routed from the hy-
draulics’ supply through a shuttle valve to the hydraulic oil pump for
load handling. A restriction before the valve block ensures that pres-
sure for control of the hydraulic oil pump does not become too high.
009955
When the solenoid valve is not activated, the load signal is drained to
the tank and the inlet from the control valve’s supply is closed.
Valve block, main pump relief
The valve is regulated electrically by the solenoid valve for main pump
relief (Y6062-2), which is activated by the frame control unit (D797-1).
The signal can be checked from the diagnostic menu, see
section 8 Control system, group 8.4.5.6 HYD, menu 6.
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 sits on the spacer block at the hydraulic oil pump for load
handling.
009961
Twistlocks/Lock tongues Unlocked or bypass Twistlocks, description page 85 or Lifting hook, description page 98
activated Section 8 Control system, group 8.2.2 Bypass
D1
1b
1a
2
D790-1
D3 10,19 11,20
C
P1 12
4 21
T1
A B A B
D15 D16
5 15 16
C
6 13,22 14,22
7
014799
1b The control lever (S815-T1.1 and Spreading (positioning): Control lever, description page 6
S815-T1.2) sends a voltage signal US815-T4 = 24 V D1: Diagnostic menu, see section 8 Control
to the cab control unit (D790-1). system, group 8.4.9.2 ATTACH, menu 3
Out: US815-T1.2 = 24 V
2 The cab control unit (D790-1) trans- Checked by control sys- Section 11 Common electrics,
mits spreading in or out on the CAN tem, error shown with error group 11.5.3.1 Cab control unit (D790-1)
bus. code.
4 The solenoid valve for main pump - Valve block, main pump relief, description
relief (Y6062-2) routes a relieved page 48
constant pressure to the hydraulic
oil pump for load handling. This
serves as a load signal.
6 The cab tilt shuttle valve sends the - Section 10 Common hydraulics,
load signal on to the hydraulic oil group 10.5.3 Shuttle valve
pump for load handling.
7 The hydraulic oil pump for load han- See the pressure plate on Section 10 Common hydraulics,
dling pumps oil from the hydraulic oil the left-hand frame beam. group 10.4.2 Axial piston pump with variable
tank to the attachment control valve. displacement
10 The solenoid valve for spreading out - Attachment control valve, description page 39
left (Y6018L) or the solenoid valve
for spreading in left (Y6019L) pres-
surises the left spreader spool in the
attachment’s control valve.
11 The solenoid valve for spreading out - Attachment control valve, description page 39
right (Y6018T) or the solenoid valve
for spreading in right (Y6019T) pres-
surises the right spreader spool in
the attachment’s control valve.
12 The control valve’s spreader spools - Attachment control valve, description page 39
change position and direct pressure
to the spreader cylinders.
15 The sensor for end position 20’-40’ Sensor directly opposite Position sensor spreading, description page 74
left (B769L) sends a voltage signal indicator plate: U > 24 V D15: Diagnostic menu, see section 8 Control
to the attachment control unit system, group 8.4.9.6 ATTACH, menu 6
(D791-1).
16 The sensor for end position 20’-40’ Sensor directly opposite Position sensor spreading, description page 74
right (B769R) sends a voltage signal indicator plate: U = 24 V D16: Diagnostic menu, see section 8 Control
to the attachment control unit system, group 8.4.9.6 ATTACH, menu 6
(D791-1).
19 The solenoid valve for spreading out - Control valve attachment, replacement
left (Y6018L) or the solenoid valve page 41
for spreading in left (Y6019L) reduc- D8: Diagnostic menu, see section 8 Control
es the pressure to the left spreader system, group 8.4.9.17 ATTACH, menu 17 and
spool in the attachment’s control 8.4.9.18 ATTACH, menu 18
valve.
20 The solenoid valve for spreading out - Control valve attachment, replacement
right (Y6018R) or the solenoid valve page 41
for spreading in right (Y6019R) re- D9: Diagnostic menu, see section 8 Control
duces the pressure to the right system, group 8.4.9.19 ATTACH, menu 19 and
spreader spool in the attachment’s 8.4.9.20 ATTACH, menu 20
control valve.
21 The control valve’s spreader spools - Attachment control valve, description page 39
change position and reduce the
pressure to the spreader cylinders.
Twistlocks/Lock tongues Unlocked or by- Twistlocks, description page 85 or Lifting hook, description page 98
pass activated Section 8 Control system, group 8.2.2 Bypass
D1 D2
2b 2a 1
35
30-
3
D790-1
D791-1
4,7,9,11 D5
D8 30' 30'
009346
014803
4,7 4,7 5 6 8 10
2b The control lever (S815-T1.2) sends a Spreading (positioning): Control lever, description page 6
voltage signal to the cab control unit US815-T4 = 24 V D2: Diagnostic menu, see section 8 Control
(D790-1). system, group 8.4.9.2 ATTACH, menu 2
Out: US815-T1.2 = 24 V
5 When the left spreader beam ap- Sensor directly opposite Position sensor spreading, description
proaches the 30’ mark, the sensor for indicator plate: page 74
30’ end position left (B777L) sends a U = 24 V D5: Diagnostic menu, see section 8 Control
voltage signal to the attachment control system, group 8.4.9.6 ATTACH, menu 6
unit (D791-1).
6 When the right spreader beam ap- Sensor directly opposite Position sensor spreading, description
proaches the 30’ mark, the sensor for indicator plate: page 74
30’ end position left (B777R) sends a U = 24 V D5: Diagnostic menu, see section 8 Control
voltage signal to the attachment control system, group 8.4.9.6 ATTACH, menu 6
unit (D791-1).
8 When the left spreader beam is at the Sensor directly opposite Position sensor spreading, description
30’ mark, the sensor for 20’-40’ end po- indicator plate: page 74
sition (B769L) sends a voltage signal to U = 24 V D8: Diagnostic menu, see section 8 Control
the attachment control unit (D791-1). system, group 8.4.9.5 ATTACH, menu 5
9 The attachment control unit (D791-1) U=0V Attachment control valve, description
cuts off the current to the solenoid valve page 39
for spreading out left (Y6018L) or the
solenoid valve for spreading in left
(Y6019L).
10 When the right spreader beam is at the Sensor directly opposite Position sensor spreading, description
30’ mark, the sensor for 20’-40’ end po- indicator plate: page 74
sition (B769R) sends a voltage signal to U = 24 V D8: Diagnostic menu, see section 8 Control
the attachment control unit (D791-1). system, group 8.4.9.5 ATTACH, menu 5
11 The attachment control unit (D791-1) U=0V Attachment control valve, description
cuts off the current to the solenoid valve page 39
for spreading out right (Y6018R) or the
solenoid valve for spreading in right
(Y6019R).
function description
Twistlocks/Lock tongues Unlocked or bypass Twistlocks, description page 85 or Lifting hook, description page 98
activated
Doors Closed Section 9 Frame, body, cab and accessories, group 9.10.2 Doors
Parking brake Released Section 4 Brakes, group 4.5 Parking brake system
2
D1 D2
1b 1a
3 7
D790-1 D795
D791-1 D9
D10 D8 D11 4, 5, 8 9 D13 D12
10 8 11 6 13 9 12
009347
D5
1b The control lever (S815-T1.1 and Spreading (positioning): Control lever, description page 6
S815-T1.2) sends a voltage signal to US815/T4 = 24 V D1: Diagnostic menu, see section 8 Control
the cab control unit (D790-1). system, 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 spreading, description
20’-40’ (S1012-2) sends a voltage US199-2/2 = 0 V page 8
signal to the cab control unit D2: Diagnostic menu, see section 8 Control
(D790-1). US199-2/5 = 24 V
system, group 8.4.9.4 ATTACH, menu 3
Switch in off position:
US199-2/2 = 24 V
US199-2/5 = 24 V
5 The attachment control unit Buzzer active: Buzzer automatic spreading 20’-40’, descrip-
(D791-1) activates the automatic U = 24 V tion page 75
spreading buzzer (H9003). D5: Diagnostic menu, see section 8 Control
system, group 8.4.9.21 ATTACH, menu 21
6 Buzzer automatic spreading Buzzer active: Buzzer automatic spreading 20’-40’, descrip-
(H9003) generates acoustic warning U = 24 V tion page 75
signal.
8 When the left spreader beam ap- Sensor directly opposite Spreading, function description page 49
indicator plate:
proaches the 20’, 30’ ( ) or 40’ 30-foot stop, function description page 52
mark, the sensor for 20’-40’ end po- U = 24 V
D8: Diagnostic menu, see section 8 Control
sition left (B769L) sends a voltage
system, group 8.4.9.6 ATTACH, menu 6
signal to the attachment control unit
(D791-1), which activates damping
for the left spreader beam the same
way as in steps 16-22 of normal
spreading.
9 When the right spreader beam ap- Sensor directly opposite Spreading, function description page 49
indicator plate:
proaches the 20’, 30’ ( ) or 40’ 30-foot stop, function description page 52
mark, the sensor for 20’-40’ end po- U = 24 V
D9: Diagnostic menu, see section 8 Control
sition right (B769R) sends a voltage
system, group 8.4.9.6 ATTACH, menu 6
signal to the attachment control unit
(D791-1), which activates damping
for the right spreader beam the
same way as in steps 16-22 of nor-
mal spreading.
10 When the left spreader beam is at Sensor directly opposite Position sensor spreading, description page 74
indicator plate: D10: Diagnostic menu, see section 8 Control
the 20’, 30’ ( ) or 40’ mark, the
sensor for end position 30’ left U = 24 V system, group 8.4.9.6 ATTACH, menu 6
(B777L) sends a voltage signal to
the attachment control unit
(D791-1).
12 When the right spreader beam is at Sensor directly opposite Position sensor spreading, description page 74
indicator plate: D12: Diagnostic menu, see section 8 Control
the 20’, 30’ ( ) or 40’ mark, the
sensor for end position 30’ right U = 24 V system, group 8.4.9.6 ATTACH, menu 6
(B777R) sends a voltage signal to
the attachment control unit
(D791-1).
Spreader slide
The valve spool controls the direction and speed of spreading. The
valve spool is controlled by a solenoid valve for spreading out and a
solenoid valve for spreading in.
The spreader cylinders pull the spreader beams in and out of the at-
tachment’s main beam. The attachment control unit (D791-1) sends a
signal to the attachment control valve, which pressurises the spreader
cylinders.
The spreader cylinders are fastened in the spreader beams and the
main beam.
Openings in the sides of the spreader beams and the attachment’s
main beam make it possible to access the spreader cylinders for main-
tenance purposes.
014816
Spreader cylinders
009925
The spreader beams are the part of the attachment that grip the con-
tainers. Two spreader beams run along the main beam. The spreader
beams are extended and retracted with hydraulic cylinders.
The spreader beam houses twistlocks, see Twistlocks, function de-
scription page 86 or Lifting hook, description page 98.
014737
Spreader beams
009926
1000 mm 013683
3 Unscrew the nuts and bolts (position 1) that secure the slide
plates.
The pressure can be relieved from the slide plates by raising the
outer edge of the spreader beam or inserting wedges to alter the
position of the spreader beam in the attachment’s main beam.
1
013684
4 Remove the slide plates and shims from the main beam
Lift the extension section slightly so that the slide the plates are
unloaded.
013685
Right side
013686
Left side
5 Refit the slide plates, add a sufficient number of shims under the
slide plates so that the play between slide plates and main beam
is 1-3 mm both laterally and vertically. This corresponds to the di-
mensions X + (1-3) mm and Y + (1-3) mm.
NOTE
Do not use adjustment shims that are too thick. Inadequate
clearance increases wear on the slide plates.
NOTE
Check that the attaching bolts for all slide plates are
tightened.
6 Start the machine and check the function of the spreader. Try lift-
ing a container and then recheck the spreader beam’s clearance
in the attachment’s main beam.
013687
Right side
013688
Left side
levelling, adjusting/replacing
2
NOTE
The thickness of the slide plate should be at least 10 mm.
8 Place the slide plate in the correct position.
Check the clearance between the spreader beam and the slide
plate. Clearance should be less than 1 mm with all slide
plates fitted.
Use a spacer plate to adjust the clearance.
009189
1 NOTE
The illustration depicts the inner slide plates on the In general, the upper slide plates on the front of the spreader
side lifting attachment’s spreader beam. beam/main beam and the lower slide plates on the rear of
1. Slide plates the spreader beam/main beam are adjusted with shim
2. Attaching bolts and guide screws for slide plates plates.
NOTE
Do not add too many shims as this increases slide plate
wear.
NOTE
Check that the attaching bolts for all slide plates are
tightened.
9 Fit the slide plate bracket.
10 Fit the slide plate’s guide screw.
11 Check that the sliding surface is clean and lubricate the sliding
surface on the spreader beam.
12 Start the machine and check the function of the spreader. Try lift-
ing a container and then recheck the spreader beam’s clearance
in the attachment’s main beam.
The side lift attachment’s main beam is fastened in the trolley with hy-
draulic cylinders. The main beam houses equipment for spreading
(spreader beams, hydraulic cylinders, slide plates and sensors).
014817
Main beam
009927
NOTE
Read the safety instructions for oil before working, see section B
Safety.
NOTE
If the trolley will also be removed, e.g. to make it possible to re-
place or service the mast, it is a good idea to remove the trolley
and the side lift attachment as a unit.
1 Park the machine with the mast vertical and the attachment in its
lowest position.
2 Turn off engine.
014819
6 Detach the side shift cylinder from the attachment.
Remove the cylinder shaft from the mounting on the trolley. If
necessary, used the threaded hole and a puller to press out the
shaft.
Start the engine and retract the cylinder so that it comes loose
from the mounting in the trolley. Switch off the engine.
Save the circlips. Refit the shaft in the cylinder.
013654
10 Mark up and detach hydraulic connections from the side lift at-
tachment and the side shift cylinder.
NOTE
Plug all connections immediately to protect the hydraulic
system from impurities.
009952
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Park the machine with the mast vertical.
2 Lower the trolley to its lowest position.
3 Turn off engine.
4 Turn the start key to position I and activate the hydraulic functions
to depressurise the hydraulic system.
5 Turn the start key to position 0 and switch off the main power.
6 Lift the side lift attachment into place.
7 Fit the lifting carriage’s front panels to fix the side lifting attach-
ment in position.
8 Check that the side lift attachment runs correctly in the trolley;
see Slide plates between trolley and attachment, adjustment/re-
placement page 45.
013680
9 Clean and apply a layer of lubricating grease to the side shift cyl-
inder shaft prior to installation.
10 Connect the side shift cylinder to the side lift attachment.
Align the side shift cylinder, press in the shaft and secure with the
circlips.
NOTE
Use an anti-recoil plastic or copper mallet.
If necessary, detach the hydraulic connections on the side shift
cylinder to make it possible to adjust cylinder length.
013654
12 Remove plugs and connect hydraulic hoses for the side lift at-
tachment and side shift cylinder using the markings as a guide.
13 Turn on the power supply and start the engine.
14 Check that the hydraulic connections are sealed tightly.
15 Check the functions of the side lift attachment.
009952
16 Check the hydraulic oil level with all hydraulic pistons fully retract-
ed. The oil level should be at the top of the level glass. Top up as
necessary.
CAUTION
Do not overfill!
NOTE
Read the safety instructions for oil before working, see section B
Safety.
NOTE
It is possible to remove the trolley and the side lift attachment as
one unit.
1 Park the machine with the mast vertical and the attachment in its
lowest position.
2 Turn off engine.
3 Connect lifting equipment (overhead crane) to the attachment in
a secure manner.
4 Start the engine and lift slightly with the lifting equipment (over-
head crane). Let the machine run with the ignition on for a little bit.
5 Turn off engine.
009998
009997 10 Mark up and detach hydraulic connections from the side lift at-
tachment and the side shift cylinder.
NOTE
Plug all connections immediately to protect the hydraulic
system from impurities.
009952
009953
13 Lift aside the side lifting attachment. Position it so that the twist-
locks/lock tongues are not damaged.
009999
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Park the machine with the mast vertical.
2 Lower the trolley to its lowest position.
3 Turn off engine.
4 Turn the start key to position I and activate the hydraulic functions
to depressurise the hydraulic system.
5 Turn the start key to position 0 and switch off the main power.
009999
7 Fit the lifting carriage’s front panels to fix the side lifting attach-
ment in position.
8 Check that the side lift attachment runs correctly in the trolley;
see Slide plates between trolley and attachment, adjustment/re-
placement page 45.
010000
9 Clean and apply a layer of lubricating grease to the side shift cyl-
inder shaft prior to installation.
10 Connect the side shift cylinder to the side lift attachment.
Align the side shift cylinder, press in the shaft and secure with the
circlips.
NOTE
Use an anti-recoil plastic or copper mallet.
If necessary, detach the hydraulic connections on the side shift
cylinder to make it possible to adjust cylinder length.
009951
12 Remove plugs and connect hydraulic hoses for the side lift at-
tachment and side shift cylinder using the markings as a guide.
13 Turn on the power supply and start the engine.
14 Check that the hydraulic connections are sealed tightly.
15 Check the functions of the side lift attachment.
009952
16 Check the hydraulic oil level with all hydraulic pistons fully retract-
ed. The oil level should be at the top of the level glass. Top up as
necessary.
CAUTION
Do not overfill!
sor. Indicator plates on the spreader units are mounted so that the
2 1
sensors generate a signal when the spreader unit passes the sensor.
1. Sensor for end position 20’ and 40’ The indicator plates and the position of the sensors are designed so
2. Sensor for end position 30’ that the distance between the spreaders becomes 20’ (30’) and 40’.
3. Indicator plate 20’ The signals can be checked from the diagnostic menu, see section 8
4. Indicator plate 30’ Control system, group 8.4.9.6 ATTACH, menu 6.
5. Indicator plate 40’
3 4 5
2
1
2
1
009928
4 3
5
The buzzer for automatic spread 20’-40’ (H9003) sits on the underside
of the trolley on machines with automatic spreading 20’-40’. The buzz-
er is activated during automatic spreader movement.
7.7 Tilt
Tilt, function description
page
–
D5
5b 5a 6
D790-1
10
D797-1 11
7
D7
8
10
11
P A1
B1
T1
P PS 9
3
4
EF
C P
1 1
009957
2 The pressure reducer reduces the pres- See the pressure plate on Pressure reducer, description page 13
sure from one of the hydraulic pumps to the left-hand frame beam.
servo pressure.
3 The accumulator stores servo pressure. See the pressure plate on Accumulator servo circuit, description
The non-return valve in the pressure re- the left-hand frame beam. page 14
ducer makes it possible to store the
pressure when the engine is turned off.
4 The servo filter cleans the oil upstream - Servo filter, description page 12
of the lift and tilt control valve.
5b The control lever (S815-P2) sends the US815-P2 = 0.5-4.5 V Control lever, description page 6
cab control unit (D790-1) a voltage sig- In: US815-P2 <2.5 V D5: Diagnostic menu, see section 8 Control
nal proportional to lever movement. system, group 8.4.8.1 ELSERV, menu 1
Out: US815-P2 = >2.5 V
6 The cab control unit (D790-1) transmits Checked by control sys- Section 11 Common electrics,
tilt in or tilt out on the CAN bus. tem, error shown with er- group 11.5.3.1 Cab control unit (D790-1)
ror code.
8 The solenoid valve for tilt in (Y6011) or - Control valve, lift and tilt, description
the solenoid valve for tilt out (Y6010) page 15
pressurises the tilt spool in the lift and tilt
control valve.
9 The control valve’s tilt spool changes - Control valve, lift and tilt, description
position and pressurises the load reten- page 78
tion valve.
10 The load retention valve opens and di- - Load holding valve, description page 79
rects the pressure on to the tilt cylinders.
11 The tilt cylinders angle the mast in rela- - Tilt cylinder, description page 79
tion to the frame. Mast, description page 19
7.7.2 Accumulator
Accumulator, description
page
–
Tilt is controlled by a separate section of the lift and tilt control valve.
See also Control valve, lift and tilt, description page 15.
For more information about tilting, see Tilt, function description
page 76.
Tilt slide
When the solenoid valves are activated, the tilt spool is pressurised
and controls the direction and flow of oil from the hydraulic oil pumps
to the tilt cylinders.
The load retention valves are mounted on the tilt cylinders, by the hy-
draulic connection to the rod side. The load retention valve prevents
the tilt cylinders from moving faster than the pressure applied from the
load handling control valve. This prevents unwanted tilting forwards,
which can occur if there is a heavy load or high lift height. The load re-
tention valve also makes the tilting movement more controlled.
009929
The tilt cylinders sit between the mast and the frame and angle the
mast in relation to the machine.
2
009930
1. Tilt cylinder
2. Mast
3. Lower mast anchorage on frame
7.7.8 Mast
Mast, description
page
–
7.8 Levelling
Mechanical levelling, function description
page
–
1b 1a
D1
2 11
+ D790-1
D797-1 D791-1
3 8 D3
D2
9 11
C
P1 A
4
T1 B
10
5
C
6
7
014800
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 Cab control unit (D790-1)
ror code.
3 The frame control unit (D797-1) acti- U = 24 V Section 11 Common electrics,
vates the solenoid valve for main group 11.5.3.2 Frame control unit (D797-1)
pump relief (Y6062-2). D3: Diagnostic menu, see section 8 Control
system, group 8.4.5.6 HYD, menu 6
4 The solenoid valve for main pump re- - Valve block, main pump relief, description
lief (Y6062-2) routes a relieved con- page 48
stant pressure to the hydraulic oil
pump for load handling. This serves
as a load signal.
5 The attachment shuttle valve sends - Section 10 Common hydraulics,
the load signal on to the hydraulic oil group 10.5.3 Shuttle valve
pump for load handling or the cab tilt
shuttle valve.
6 The cab tilt shuttle valve sends the - Section 10 Common hydraulics,
load signal on to the hydraulic oil group 10.5.3 Shuttle valve
pump for load handling.
7 The hydraulic oil pump for load han- See the pressure plate Section 10 Common hydraulics,
dling pumps oil from the hydraulic oil on the left-hand frame group 10.4.2 Axial piston pump with variable
tank. beam. displacement
8 The attachment control unit (D791-1) U = 24 V Section 11 Common electrics,
activates the solenoid valve for level- group 11.5.3.5 Attachment control unit
ling right (Y6035) or the solenoid valve (D791-1)
for levelling left (Y6036). D8: Diagnostic menu, see section 8 Control
system, group 8.4.9.13 ATTACH, menu 13
and 8.4.9.14 ATTACH, menu 14
9 The solenoid valve for levelling right - Attachment control valve, description page 39
(Y6035) or the solenoid valve for level-
ling left (Y6036) pressurises the level-
ling spool in the attachment control
valve.
10 The control valve’s levelling slide - Attachment control valve, description page 39
changes position and pressurises the
levelling cylinders.
11 The levelling cylinders push in the side - Levelling cylinder, description page 84
lifting attachments sideways in rela-
tion to the lifting carriage.
Levelling slide
The valve slide controls the direction and speed of attachment
levelling.
The valve spool is controlled by a solenoid valve for levelling right
(Y6035) and a solenoid valve for levelling left (Y6036).
The levelling cylinders sit between the lifting carriage and the side lift-
ing attachment. They change the angle of the side lifting attachment in
relation to the machine.
009924
Levelling cylinders
7.8.4 Trolley
Trolley, description
page
–
The container is held in place on the side lift attachment with two
twistlocks.
Twistlocks are controlled with the twistlock switch. A section of the at-
tachment control valve pressures two hydraulic cylinders connected in
parallel on opposite sides of the side lift attachment. Each hydraulic
cylinder actuates a linkage that rotates a twistlock. Four positions sen-
sors (two on each side of the side lift attachment) detect the position
of the linkage and indicate whether the twistlocks are open or locked.
The status of the twistlocks is shown by indicator lights on the side lift
attachment and in the cab as well as a mechanical indicator on the
side lift attachment.
A contact pin and a sensor at each twistlock indicate when the attach-
ment is in contact with the container. This is used to control when the
twistlocks can be activated. An indicator light on the side lift attach-
ment and another one in the cab indicate when the side lift attachment
has full contact. An event menu shows which twistlocks have contact
(1-2). Both twistlocks must have contact for them to be activated.
2b 1 D1
20
2a
8 7,22
D2 5,23
D790-1 D790-2 D795
D6 D20
D797-1 D791-1 D3
4,6,14, 21
9
D14
D9 19
15 D19 18 3
P1 A
D10
10 B
T1
17
16
11 18 3
19
D6
13 12
014801
2b The control lever (S815-T2) sends a voltage US815/T2 = 24 V Control lever, description page 6
signal to the cab control unit (D790-1) for D2: Diagnostic menu, see section 8 Control
twistlock opening. system, group 8.4.9.3 ATTACH, menu 3
If Switch, lock twistlocks (S1003) is in man-
ual position then no signal is required from
the control lever to open twistlocks.
3 The alignment left sensor (B7203L) and Sensor directly oppo- Sensor, alignment, description page 94
alignment right sensor (B7203R) detect po- site indicator plate: D3: Diagnostic menu, see section 8 Control
sition and send a voltage signal to the at- U = 24 V system, group 8.4.9.6 ATTACH, menu 6
tachment control unit (D791).
4 The attachment control unit (D791-1) trans- Checked by control Section 11 Common electrics,
mits alignment on the CAN bus. system, error shown group 11.5.3.5 Attachment control unit
with error code. (D791-1)
5 Control unit KID (D795) activates the event - Section 11 Common electrics,
menu for alignment. group 11.5.3.12 KID control unit (D795)
6 The attachment control module (D791) acti- U = 24 V D6: Diagnostic menu, see section 8 Control
vates the alignment indicator light on the system, group 8.4.9.10 ATTACH, menu 10
mast light panel.
7 Control unit KID (D790-2) activates the indi- - Section 11 Common electrics,
cator light for alignment on the cab’s light group 11.5.3.11 KIT control unit (D790-2)
panel.
8 Control unit, cab (D790-1) transmits "open Checked by control Section 11 Common electrics,
twistlocks" or "lock twistlocks" on the CAN system, error shown group 11.5.3.1 Cab control unit (D790-1)
bus. with error code.
10 The solenoid valve for main pump relief - Valve block, main pump relief, description
(Y6062-2) routes a relieved constant pres- page 48
sure to the hydraulic oil pump for load han- D10: Diagnostic menu, see section 8 Control
dling. This serves as a load signal. system, group 8.4.5.6 HYD, menu 6
13 The hydraulic oil pump for load handling See the pressure Section 10 Common hydraulics,
pumps oil from the hydraulic oil tank. plate on the left-hand group 10.4.2 Axial piston pump with variable
frame beam. displacement
16 The twistlock spool of the control valve - Attachment control valve, description
changes position and pressurises the lock page 39
cylinders via the overcentre valve.
18 The lock cylinders rotate the twistlocks. - Lock cylinder, description page 104
19 The "unlocked twistlocks" sensor (B7204 L Sensor directly oppo- Sensor, twistlocks, description page 96
and R) or the "locked twistlocks" sensor site indicator plate: D19: Diagnostic menu, see section 8 Control
(B7205 L and R) sends a signal to the at- U = 24 V and monitoring system,
tachment control unit (D791). group 8.4.9.7 AT-TACH, menu 7
20 The attachment control unit (D791-1) sup- U = 24 V D20: Diagnostic menu, see section 8 Control
plies voltage to the "unlocked twistlocks" in- and monitoring system,
dicator light (H562) or the "locked group 8.4.9.10 ATTACH, menu 10
twistlocks" indicator light (H563) on the
mast light panel.
21 The attachment control unit (D791-1) trans- Checked by control Section 11 Common electrics,
mits "twistlocks unlocked" or "twistlocks system, error shown group 11.5.3.5 Attachment control unit
locked" on the CAN bus. with error code. (D791-1)
014805
009931
The lock cylinder pulls the lock mechanism so that the twistlocks are
rotated. Two lock cylinders connected in parallel - one in the right and
one in the left spreader beam - actuate a linkage that twists a twistlock.
014806
014811
The lock mechanism transfers the force of the lock cylinders to the
1
twistlocks. Two lock mechanisms - one in the right and one in the left
spreader beam - actuate the twistlocks. The lock mechanism operates
3 2 in the corner box.
The lock mechanism consists of a rotary plate with a linkage bearing
at which the lock cylinder is attached. The rotary plate rotates the
twistlocks.
014807
1. Linkage bearing
2. Rotary plate
3. Lock cylinder mounting
7.9.1.6 Twistlocks
Twistlocks, description
page
–
1 2 3
WARNING
Dropped load.
Extreme danger!
5 4
1. "Unlocked twistlock" sensor Twistlocks secure the load and are located out in the corners of the
2. Sensor contact spreader beam’s longitudinal section.
3. "Locked twistlock" sensor Twistlocks are manufactured from high-strength steel according to in-
4. Lift pin ternational standards. The lift pins are marked with serial numbers.
5. Contact pin
Twistlocks are connected via a linkage system to a hydraulic cylinder
which in turn is controlled via a section in the attachment’s control
valve. Inductive sensors send signals when the twistlocks are locked
and unlocked, respectively.
Twistlock, replacement
page
–
WARNING
Dropped component.
NOTE
Remember the washer.
8 Check the positions of the parts and that the twistlock can move.
9 Tighten the screws of the clamp halves.
10 Lubricate the twistlock and lock mechanism with lubricating
grease.
11 Check that the twistlock mechanism can move.
12 Turn on the main electric power and start the machine.
13 Check that the twistlock is working.
014821
The alignment sensors (B7203L and B7203R) detect when the attach-
ment has contact with the container. Two inductive position sensors
are used to indicate contact.
The sensor senses the position of a spring pin which is pressed in
when the attachment has contact up against the container. The sensor
is located behind the pin. The position of the sensor can be adjusted
so that it gives a signal when the pin is pressed in and the head is level
with the lower edge of the spreader beam. The clearance between the
attachment and the container’s corner boxes means the sensors stop
sending signals when the attachment is lifted.
The sensors are supplied power and send a 24 V signal to the attach-
ment control unit (D791-1) when the indicator pin is pressed in.
The signal can be checked via the diagnostic menu. See
section 8 Control system, group 8.4.9.7 ATTACH, menu 7.
014813
1 2
1. Alignment pin
2. Sensor alignment
014812
1 2
1 Check that the contact pins in the corner boxes can freely move
up and down. The contact pins must spring down when they are
not loaded.
2 Check that the sensor is free of damage and dirt.
3 Turn the start key to position I and check that the LED on the sen-
sor is unlit.
4 Lower the attachment onto a container and check that the align-
ment indicator light comes on.
5 Lift the container a little bit so that the alignment indicator light
goes out.
014717
1 2
6 With the container lifted, check how much alignment pin move-
Right side ment is needed to detect contact (LED on the sensor lights). The
1. Sensor alignment movement should be 3–4 mm.
2. Alignment pin
7 If necessary, slacken the lock nut and screw the sensor in/out un-
til the distance between the sensor and the alignment pin is
51 mm.
014718
2 1
Left side
1. Sensor alignment
2. Alignment pin
1 2
1. "Locked twistlock" sensor
2. "Unlocked twistlock" sensor
014810
1 2
014719
1 2 If necessary, slacken the lock nut and screw the sensor in/out
until the distance between the sensor and the indicator plate is
Right side
51 mm.
1. "Unlocked twistlock" sensor
2. "Locked twistlock" sensor 6 Check that the "twistlocks locked" indicator light is lit.
014720
2 1
Left side
1. "Unlocked twistlock" sensor
2. "Locked twistlock" sensor
The container is held in place on the side lifting attachment with two
fixed lifting hooks that are positioned in the corner boxes of the con-
tainer (in the side holes on the long side) and two movable lock
tongues that are positioned in the corner boxes of the container (in the
side holes on the short side). These secure that side lifting attachment
to the container.
The lock tongues are controlled with the lock tongue switch. One sec-
tion in the attachment control valve pressurises two hydraulic cylinders
connected in parallel - one in each spreader boom. Each hydraulic cyl-
inder acts on a linkage that turns a lock tongue. Four position sensors
- two in each spreader boom - sense the position of the linkage and
indicate if the lock tongues are open or closed. Indicator lights on the
side lifting attachment and in the cab show the status of the lock
tongues.
The lock tongues are activated manually or automatically and can be
opened if the machine is driven at a speed below 5 km/h. If the lock
tongues are not locked when the attachment is carrying a load, the
speed of the machine’s hydraulic functions is limited and machine
speed is limited to max. 5 km/h.
Two detection sensors (one at each lifting hook) use ultrasound to de-
tect distance (and informs that system) if one or two containers will be
lifted. At each lifting hook, there is a sensor that indicates contact with
the lower container and another that indicates contacts with the upper
container.
Two indicator lights on the side lifting attachment and one in the cab
indicate when the side lifting attachment has full contact. An event
menu shows when the lifting hook has contact (1-2).
Contact by both of the lifting hooks is not required to activate the lock
tongues. But, unless there is contact and correct locking, the ma-
chine’s hydraulic functions and speed will be limited.
Alignment Full alignment or bypass activated Lifting hook, description page 107
Section 8 Control system, group 8.2.2 Bypassing
2b 1
D1
2a
8,23 21
D2 9
6
D790-1 D790-2 D795
D4 D21
D797-1 D791-1
5,7,15,22
10
D15 4
D10 16 D20 D3 19 3
P1 A
18 20
11 B
T1
17
12 19 3
C 4
14 13
014802
2b The control lever (S815-T2) sends a volt- US815/T2 = 24 V Control lever, description page 6
age signal to the cab control unit (D790-1) D2: Diagnostic menu, see section 8 Control
for lock tongue opening. system, group 8.4.9.5 ATTACH, menu 5
If the switch for locking the lock tongue
(S1003) is in the manual position, no sig-
nal is needed from the control lever to
open lock tongues.
3 The sensor for lower left alignment Sensor directly oppo- Alignment and detection sensor, description
(B7203LL), sensor for upper left alignment site indicator plate: page 108
(B7203LU-2), the sensor for lower right U = 24 V D3: Diagnostic menu, see section 8 Control
alignment (B7203RL) and the sensor for system, group 8.4.9.23 ATTACH, menu 23
upper right alignment (B7203RU-2) detect
position and send a voltage signal to the
attachment control unit (D791).
4 The sensor for upper container right detec- - Alignment and detection sensor, description
tion (B7203RU) and the sensor for upper page 108
container left detection (B7203LU) detect D4: Diagnostic menu, see section 8 Control
position and send a voltage signal to the system, group 8.4.9.22 ATTACH, menu 22
attachment control unit (D791).
5 The attachment control unit (D791-1) Checked by control Section 11 Common electrics,
transmits alignment/detection on the CAN system, error shown group 11.5.3.5 Attachment control unit
bus. with error code. (D791-1)
7 The attachment control module (D791) ac- U = 24 V D6: Diagnostic menu, see section 8 Control
tivates the alignment indicator light (H564) system, group 8.4.9.10 ATTACH, menu 10
on the mast light panel.
8 Control unit KID (D790-2) activates the in- - Section 11 Common electrics,
dicator light for alignment on the cab’s light group 11.5.3.11 KIT control unit (D790-2)
panel.
9 The cab control unit (D790-1) transmits Checked by control Section 11 Common electrics,
"open lock tongue" or "lock lock tongue" on system, error shown group 11.5.3.1 Cab control unit (D790-1)
the CAN bus. with error code.
11 The solenoid valve for main pump relief - Valve block, main pump relief, description
(Y6062-2) routes a relieved constant pres- page 48
sure to the hydraulic oil pump for load han-
dling. This serves as a load signal.
13 The cab tilt shuttle valve sends the load - Section 10 Common hydraulics,
signal on to the hydraulic oil pump for load group 10.5.3 Shuttle valve
handling.
14 The hydraulic oil pump for load handling See the pressure plate Section 10 Common hydraulics,
pumps oil from the hydraulic oil tank. on the left-hand frame group 10.4.2 Axial piston pump with variable
beam. displacement
16 The "open lock tongue" solenoid valve - Attachment control valve, description
(Y6039) or the "lock lock tongue" solenoid page 39
valve (Y6040) pressurises the lock tongue
spool with servo pressure.
17 The lock tongue spool of the control valve - Attachment control valve, description
changes position and pressurises the lock page 39
cylinders via pilot-controlled non-return
valves.
19 The lock cylinders rotate the lock tongues. - Lock cylinder, description page 104
20 The "unlocked lock tongue" sensor (B7204 Sensor directly oppo- Sensor, twistlocks, description page 96
L and R) or the "locked lock tongue" sen- site indicator plate: D20: Diagnostic menu, see section 8 Control
sor (B7205 L and R) sends a signal to the U = 24 V system, group 8.4.9.8 ATTACH, menu 8
attachment control unit (D791).
21 The attachment control unit (D791-1) sup- U = 24 V D21: Diagnostic menu, see section 8 Control
plies voltage to the "unlocked lock system, group 8.4.9.10 ATTACH, menu 10
tongues" indicator light (H562) or the
"locked lock tongues" indicator light
(H563) on the mast light panel.
description
Pilot-controlled non-return valves prevent the uncontrolled opening or
closing of the lock tongues. There is one non-return valve at each lock
cylinder on the side lifting attachment.
009938
The lock cylinder pulls the lock mechanism so that the twistlocks are
rotated. Two lock cylinders connected in parallel - one in the right and
one in the left spreader beam - each actuate a lock tongue.
009939
The lock mechanism transfers the force of the lock cylinders to the lock
2 tongues. Two lock mechanisms - one in the right and one in the left
spreader beam - actuate the lock tongues. The lock mechanism oper-
ates in the corner box.
3
The lock mechanism consists of a lock cylinder that rotates the lock
tongue, which is fastened to the corner box with a shaft bolt.
1
009940
4
WARNING
7
6 Dropped load.
5
Extreme danger!
4
3 Lock tongues together with lifting hooks hold the load
in place during load handling. It is therefore vital that
the lock tongues and lifting hooks are checked as
specified and replaced if there is any sign or damage
2
or wear whatsoever.
009941
1
1. Sensor, locked lock tongue (B7205LL/RL) The lock tongues secure the load and are located in the corners of the
2. Lock tongue spreader beam’s longitudinal part.
3. Sensor, unlocked lock tongue (B7204L/R) The lock tongues are made of high-strength steel.
4. Alignment pin for alignment sensor, lower container
The lock tongues are connected via a linkage system to a hydraulic
(B7203LL/RL)
cylinder which in turn is controlled via a section in the attachment’s
5. Lifting hook
control valve. Inductive sensors send signals when the lock tongues
6. Alignment pin for alignment sensor, upper container
are locked and unlocked, respectively.
(B7203LU-2/RU-2)
6. Detection sensor, upper container (B7203LU/RU)
1
009942
WARNING
Dropped component.
1. Lock cylinder mounting
2. Shaft bolt for lock tongue Risk of pinch injury or product damage.
NOTE
Use a new lock nut and new washers.
Apply lubricating grease to the parts before fitting.
11 Check the positions of the parts and that the lock tongues can
move.
12 Apply lubricating grease to the lock tongue’s shaft bolt and the
lock cylinder mounting.
13 Check that the lock tongue mechanism can move.
14 Turn on the main electric power and start the machine.
15 Check that the lock tongues work properly and connect with and
secure the container correctly when lifting.
WARNING
7
6 Dropped load.
5
Extreme danger!
4
3 Lock tongues together with lifting hooks hold the load
in place during load handling. It is therefore vital that
the lock tongues and lifting hooks are checked as
specified and replaced if there is any sign or damage
2
or wear whatsoever.
009941
1
1. Sensor, locked lock tongue (B7205LL/RL) The lifting hooks secure the load and are located in the corners of the
2. Lock tongue spreader beam’s longitudinal part.
3. Sensor, unlocked lock tongue (B7204L/R) The lifting hooks are manufactured from high-strength steel according
4. Alignment pin for alignment sensor, lower container to international standards. The lifting hooks are marked with serial
(B7203LL/RL) number.
5. Lifting hook
6. Alignment pin for alignment sensor, upper container
(B7203LU-2/RU-2)
7. Detection sensor, upper container (B7203LU/RU)
WARNING
1 Dropped component.
009948
2
Risk of pinch injury or product damage.
8 Place the lift pin and guide pin in the spreader beam. Place the
guide pin so that the grease cup is accessible through the holes
in the spreader beam.
NOTE
Use a new lock nut and new washers.
9 Check the positions of the parts and that the lifting hooks
can move.
10 Turn on the main electric power and start the machine.
11 Check that the lifting hooks are working.
move the sensor along the oval retaining hole and screw it into
the exact position that makes the light (B1) come on.
B2 7 Adjusting:
009375
Fix the contact pin so that the measurement (B) is 18 mm. Then
move the sensor along the oval retaining hole and screw it into
Lights on the side lifting attachment
the exact position that makes the light (B2) come on.
A Green light Lock tongues locked
3 Repeat the check from step 1 above. If the alignment event menu
remains unlit, replace the sensor.
1. Detection sensor, upper container
3
ment control unit (D791-1) when the indicator plate is in front of the
Right side sensor.
1. Detection sensor, upper container (B7203LU/RU) The signal can be checked via the diagnostic menu. See
2. Sensor, unlocked lock tongue (B7204R/L) section 8 Control system, group 8.4.9.8 ATTACH, menu 8.
3. Sensor, locked lock tongue (B7205LL/RL), lower
D1
1, 4, 7
10
D790-1 D795
D797-1 D791-1
3,6,9 D5
D2
2,8 5 009956
8 Control system
8 Control system
mm mm mm mm mm mm
The control and monitoring system’s display is divided into four fields
C where the information is shown (see figure to the left).
• 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.
The error code is shown automatically on the display.
000351
• 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
B
000389
• Engine:
XX/YY Shown with error code number XXX/YY on display.
D
NOTE
B If several error codes come from the engine, the error code
001343
level is shown for the most serious error code.
• Transmission:
XXX/YY Shown with error code number XX/YY on display.
B
001344
10 11
002058
8.2 Monitoring
8.2.1 Overload system
Overload system, function description
page
–
D790-1 5
D795
D797-2 D797-1 D3
6 4, 6, 7
Pa Pa
D2 2 3
A A A
C
P2
P1
011727
T1 B B B
2 Sensor, hydraulic pressure lift cylinder Conn 1: U = 5 V Sensor hydraulic pressure lift cylinder, de-
(B768-1) sends a voltage signal propor- Conn 2: U = 0 V scription page 8
tional to the pressure in the lift cylinders D2: Diagnostic menu, see section 8 Control
Conn 3: U = 0.5 - 4.5 V
to the Control unit, frame (D797-1). system group 8.4.10.1 OP, menu 1
3 Sensor, hydraulic pressure tilt cylinder Conn 1: U = 5 V Hydraulic pressure sensor, tilt cylinder, de-
(B768-2) sends a voltage signal propor- Conn 2: U = 0 V scription page 9
tional to the pressure in the tilt cylinders D3: Diagnostic menu, see section 8 Control
Conn 3: U = 0.5 - 4.5 V
to the Control unit, frame (D797-1). system group 8.4.10.1 OP, menu 1
4 The frame control unit (D797-1) calcu- Checked by the control Section 11 Common electrics,
lates the load based on the pressures. system, error indicated group 11.5.3.2 Frame control unit (D797-1)
If the load is high then the frame control with error code.
unit (D797-1) sends overload on the
CAN bus.
NOTE
Whatever the conditions that inter-
rupt (high load on the lift or tilt) the
system interrupts both tilt and lift.
7 If the load on tilt is high then the frame - Section 7 Load handling, group 7.7 Tilt
control unit (D797-1) interrupts tilt in.
NOTE
Whatever the conditions that inter-
rupt (high load on the lift or tilt) the
system interrupts both tilt and lift.
The sensor for hydraulic pressure, lift cylinder, measures the pressure
on the lift cylinders’ piston side. The sensor is fitted on the output for
the lift cylinders on the control valve for load handling.
The sensors are supplied with power by, and send a voltage signal
proportional to, the hydraulic oil pressure for the frame control unit
(D797-1).
The signals can be checked from the diagnostic menu, see
section 8 Control system, group 8.4.10.1 OP, menu 1.
The hydraulic pressure sensor for the tilt cylinder measures the pres-
sure on the rod side of the tilt cylinders. The sensor is fitted on the load
retention valve of the left tilt cylinder.
The sensors are supplied with power by, and send a voltage signal
proportional to, the hydraulic oil pressure for the frame control unit
(D797-1).
The signals can be checked from the diagnostic menu, see
section 8 Control system, group 8.4.10.1 OP, menu 1.
8.2.2 Bypass
Bypass, description
page
–
DANGER
Bypassing the safety systems results in a risk of tip-
ping. Use at your own risk.
is 5 km/h .
PRESENT XXXXh
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
Position sensor, mast. When Position sensor, mast indicates that the
permitted height is reached, lift is blocked. In addition, display informa-
tion for height limitation is activated.
For details about lifting and lowering, see section 7 Load handling,
group 7.2 Lifting/lowering.
The values of height limitation can be checked from the diagnostic
menu, see section 8 Control system, group 8.4.10.3 OLS, menu 3.
Height warning warns via the display menu when the set maximum lift
height is reached. The height warning can be adjusted according to
customer requirements.
8.4 Diagnostics
Diagnostic test, general
page
–
005263
OLS EXTRA
The diagnostic test is divided into the following groups:
• Voltage feed and communication for the Control system, CAN/
POWER, description page 14.
• Lighting, LIGHTS, description page 30.
• Cab functions, CAB, description page 41.
• Air conditioning, CLIMATE, description page 48.
• Hydraulic functions, HYD, description page 54.
• Engine, ENGINE, description page 61.
• Transmission, TRANSM, description page 73.
• Functions for electric servo, ELSERV, description page 84.
• Attachment functions, ATTACH, description page 98.
• Overload protection, OLS, description page 144.
• Optional functions, EXTRA, description page 146.
– Reversible driver’s seat, VBFS, menu 1 page 146.
– Mini-wheel or lever steering, EL-STEERING, menu 1
page 154.
– External attachment, EXT-ATTACH, menu 1 page 158.
– Freelift, FREELIFT, menu 1 page 163.
– Tiltable cab and sliding cab, MOVE-CAB, menu 1 page 164.
– RMI, RMI, menu 1 page 173.
Diagnostic tests show how the control units interpret input signals as
1 2 3 4
well as which signals that the control units send.
008873
FEEDBACK 0
2 Number of current menu. Every menu group consists of several menus in a loop.
(X) Total number of menus in the group. The number of menus depends on machine configuration, so the
number of menus is specified as (X) in this manual.
Variable The signal that is measured. Different signals are designated in different ways:
SWITCH: a digital input signal, e.g., a switch.
OUTPUT: a digital output signal, e.g., feed to a motor.
INPUT: an analogue input signal, e.g., from a sensor.
REFERENCE: status for an analogue output signal.
REQUIRED: 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.
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 ELSERV ATTACH
005263
OLS EXTRA
SEGMENT ERROR X
Function: 11.6.2 Redundant CAN bus
Signal value:
3 OK.
2 Segment check.
0 Error.
0 No open circuits.
005267
D795 D791-1 XX Contact:
D795: K1:10, K1:11, K1:12 and K1:13
D797-1, D797-2, D791-1: K2:2, K2:3, K2:4 and K2:5
Function: 11.5.3.2 Frame control unit (D797-1), 11.5.3.3 Frame con-
trol unit (D797-2), 11.5.3.5 Attachment control unit, 11.5.3.12 KID con-
trol unit, 11.6.2 Redundant CAN bus.
Signal value:
TRANSMISSION X
D794/1 and 2
Volvo TAD950VE: 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
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
(to either engine or transmission), then this rules out a fault in the
cable harness between the cab electronic box and the frame
electronic box.
TRANSMISSION
Description: Indicates status for transmission in drivetrain’s CAN bus.
Circuit diagram: Transmission circuit group 2.0, CAN bus circuit
group 11.6
Connection: CAN J1939 from D790-1/K13:1 and K13:2 to D793/L2
and M2
Function: 11.6.3 CAN bus drive-train
Signal value:
NOTE
The cable harness for CAN bus 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
(to either engine or transmission), then this rules out a fault in the
cable harness between the cab electronic box and the frame
electronic box.
007126
RELAY K315-2 XY
Signal value:
0 No signal.
007127
RELAY K3009-2 XY
Signal value:
0 No signal.
0 No signal.
005275
3. -
4. -
5. Circuits 4.0-1, 7.5-1, 7.9-1, 8.2-1, 9.1-1, 9.3-3, 9.10-1 and 11.5-6
6. Circuit 5-2-1
7. -
8. Circuit 9.7-1
9. Circuit 9.5-1
10. Circuit 9.5-1
Contact:
1. signal from digital out D790-1/K4:14 to M650-1/53a
2. signal from digital out D790-1/K5:1 to S100/5, S110/5, S105-1/5,
S105-2/5, S105-3/5, S143/5, S199-1/5, S199-3/5, S199-4/5,
S220-1/1
3. signal from digital out D790-1/K6:13 not connected
4. signal from digital out D790-1/K7:12 not connected
5. signal from digital out D790-1/K8:16 to S107/5, S169/3, S199-2/5,
S250/1, S1002/2, S1003/3, S1004/5, S1005/5, S1010/3,
S1012/3, S1037/5
6. signal from digital out D790-1/K9:1 to S113/5, S149-2/5, S160-2/3
7. signal from digital out D790-1/K10:1 not connected
8. signal from digital out D790-1/K11:12 to S230/2
9. signal from digital out D790-1/K12:1 to M650-2/53a
10. signal from digital out D790-1/K12:3 to M650-3/53a
Function:
1. 9.5.5 Wiper motor front
2. 2.0 Transmission, 9.3 Seat, 9.6 Lighting
3. -
4. -
5. 11.5.1.4 Emergency stop switch voltage; 4.5 Parking brake sys-
tem; 8.2.2 Bypassing; 9.10.4 Tiltable cab/Hydraulic sliding cab;
7.5 Spreading; 7.8 Levelling; 7.9.1 Twistlocks
6. 5 Steering
7. -
8. 9.3.14 Sensor operator in seat
9. 9.5.7 Wiper motor rear
10. 9.5.6 Wiper motor roof
Signal value:
1 Feed active.
0 No feed.
005277
POWER 2 X
Function: 11.5.1.3 Ignition voltage (15)
Signal value: XX.XXV = voltage on connection. The signal value
should be 22-30 V (battery voltage).
1 Feed active.
0 No feed.
1 Feed active.
0 No feed.
005279
SENSOR SUPPLY XX.XXV
Signal value: XX.XXV = voltage on the connection. The signal value
should be 22-30 V (battery voltage).
1 Feed active.
0 No feed.
1 Feed active.
0 No feed.
005281
Connection: signal from digital out D797-2/K1:7 to S720-F/2 and
S720-R/2.
Function: 9.3.9 Sensor, reversible driver’s seat
Signal value:
Not used.
005282
EME POWER 2 X
Function: 11.5.1.4 Emergency stop switch voltage (15E)
Signal value:
XX.XXV = voltage on the connection. The signal value should be
22-30 V (battery voltage).
1 Feed active.
0 No feed.
1 Feed active.
0 No feed.
005283
Connection: digital out from 791-1/K1:10 to B769-1, B777-1, B7202L,
B7202R, B7203L, B7203R, B7204L, B7204R, B7205L and B7205R
Function: 7.5.8 Spreading position sensor, 7.9.1.6 Alignment position
sensor, 7.9.1.7 Twistlocks sensor
DCF 70, DCF 80-100 with twistlock attachment
Connection: digital out from 791-1/K1:10 to B769L, B769R, B777L,
B777R, B7203L, B7203R, B7204L, B7204R, B7205L and B7205R
Function: 7.5.6 Spreading position sensor, 7.9.1.7 Alignment position
sensor, 7.9.1.8 Twistlocks sensor
DCF 80-100 with lifting hook
Connection: digital out from 791-1/K1:10 to B769L, B769R, B777L,
B777R, B7203LU-2, B7203RU-2, B7203LL, B7203RL, B7203LU,
B7203RU, B7204L, B7204R, B7205LL and B7205RL
Function: 7.5.6 Spreading position sensor, 7.9.2.8 Alignment and de-
tection sensor, 7.9.2.9 Lock tongue sensor
Signal value:
Not used.
Description: Control function from the redundant CAN bus. The cab
DIAG CAN/POWER 17(X) control unit (D790-1) performs a segment check to determine whether
REDCAN STATUS CHECK all control units have contact and are connected in the right order. The
PRESS ENTER control system indicates the fault by numbering the cables between
the control units (segments) from 1 onwards. Segment 1 is always be-
005284
SEGMENT ERROR X
tween the cab control unit (D790-1) and the next control unit in se-
quence. The last segment is always between the KID control unit
(D795) and the cab control unit (D790-1). The segments in between
vary depending on machine configuration.
Circuit diagram: Circuit CAN bus group 11.6
D790-1 D791 D797-2 D797-1 Contact: -
CAN L CAN R CAN L CAN R CAN L CAN R CAN L CAN R
D795
0 No errors.
DCF360-450CSG >0 X > 0, the number indicates incorrect segment. Use circuit di-
Segment numbering with maximum number of control agram to find the incorrect segment.
units. Control units marked with dashes are optional.
1 2
4 3
CAN R CAN L
008879
D795
DCF 280-520
Segment numbering with maximum number of control
units. Control units marked with dashes are optional.
8.4.2 LIGHTS
LIGHTS, description
page
–
OLS EXTRA
005286
Signal value:
0 No signal.
REAR LIGHTS XY
Function: 9.6.2 Running lights
Signal value:
005288
DIMMED LE/RI XY
Signal value:
0 No signal.
005289
Signal value:
0 No signal.
0 No signal.
RIGHT F/R XY
(Hazard)
Signal value:
RIGHT F/R
Description: Voltage feed to direction indicator, right-hand side.
Circuit diagram: Circuit 9.6-7
Connection: digital out from D797-1/K1:31 to H423 and H427
Function: 9.6.6 Direction indicators, 9.6.7 Flashing hazard lights
(Hazard)
Signal value:
Signal value:
0 No signal.
005292
Signal value:
0 No signal.
0 No signal.
REVERSE ALARM XY
• RI: digital out from D797-1/K1:9 to H411R
Function: 9.6.4 Brake lights
Signal value:
OUTPUT XXX
Signal value:
0 No signal.
Signal value:
005296
D797-2 C1 P42 XY
working light, attachment, 9.1.6 Switch for working light, mast
Signal value:
0 No signal.
Signal value:
005300
Contact:
output signal from D790-1/K6:1 to S117, S118, S139
output signal from D790-1/K6:2 to S105-2
output signal from D790-1/K6:3 to S105-3
output signal from D790-1/K6:4 to S110
output signal from D790-1/K6:5 to S100
output signal from D790-1/K6:6 to S143
output signal from D790-1/K6:7 to S199-4
output signal from D790-1/K6:8 to S199-3
output signal from D790-1/K6:9 to S199-1
output signal from D790-1/K6:10 to S105-1
output signal from D790-1/K8:10 to S1004
output signal from D790-1/K8:12 to S1003
output signal from D790-1/K8:13 to S107
output signal from D790-1/K8:14 to S199-2
output signal from D790-1/K8:15 to S169, S1010
output signal from D790-1/K9:2 to S160-2
Function: 9.6.11 Interior lighting
Signal value:
50 Means 4-5 V.
Signal value:
0 No signal.
8.4.3 CAB
CAB, description
page
–
OLS EXTRA
0 No signal.
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
Function: 9.5 Wiper/washer system
Signal value:
1 Long interval.
2 Normal interval.
3 Continuous operation.
Description: Signal from motor wiper front, indicates when the wiper
sweep is completed.
Circuit diagram: Circuit 9.5-1
Connection: signal from M650-1/31B to digital in D790-1/K4:13
Function: 9.5.5 Wiper motor front
Signal value:
FEEDBACK X
Function: 9.5 Wiper/washer system
Signal value:
0 No signal.
FEEDBACK X
Signal value:
0 No signal.
Description: Signal from motor wiper roof, indicates when the wiper
sweep is completed.
Circuit diagram: Circuit 9.5-1
Connection: signal from M650-3/31B to digital in D790-1/K12:4
Function: 9.5.6 Wiper motor roof
Signal value:
OUTPUT XY
Signal value:
0 No signal.
HORN, SWITCH 2
page
–
0 No signal.
HORN, OUTPUT
page
–
OP X
Signal value:
SWITCH SEAT
page
–
ALARM
page
–
OP
page
–
FUEL, PROC
page
–
005548
Signal value:
0 No signal.
8.4.4 CLIMATE
CLIMATE, description
page
–
OLS EXTRA
005549
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.
Description: Temperature of the air out from the fan. The sensor is lo-
DIAG CLIMATE 2(X) cated in the air distributor.
TEMP COIL XXX
TEMP COOLANT XXX Circuit diagram: Circuit 9.4-1
TEMP AMBIENT XXX Connection: signal from B775-2 to input D790-1/K4:10
005550
TEMP COOLANT
page
–
TEMP AMBIENT
page
–
TEMP DE-ICE
page
–
Signal value:
005552
Function: 9.4.5 Water valve
Signal value: XX.XXV = 0.50 - 4.50 V
REQ. FAN SPEED XX.XXV Connection: signal from S117/3 to analogue in D790-1/K5:8
Function: 9.4 Heating, ventilation and air conditioning
Signal value: XX.XXV 2.4 / 0 / 5.0 V = Increase / - / decrease.
013616
COMPRESSOR XY
Function: 9.4.3 cab fan.
Signal value: XXX = 0-255 = Fan speed (255 = max. fan speed).
Description: voltage feed to water valve, for opening. The valve is con-
DIAG CLIMATE 7(X) 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, so it may be difficult to determine if the valve is working
as it should.
24V
Circuit diagram: Circuit 9.4-2
Connection: digital out from D790-1/K4:1 via R3 to Y673/5 and from
D790-1/K4:2 via R4 to Y673/6
Function: 9.4.5 Water valve
M Signal value: motor runs clockwise row 1: 11 11 row 2: 00 11
Description: voltage feed to water valve, for closing. The valve is con-
nected to an H-bridge. The signal can only be diagnosed when the
valve’s position changes. The valve’s opening and closing are control-
led by the climate control unit’s software depending on desired tem-
perature, outside temperature, cab temperature and coolant
temperature, so it may be difficult to determine if the valve is working
as it should.
Circuit diagram: Circuit 9.4-2
Connection: digital out from D790-1/K4:1 via R3 to Y673/5 and from
D790-1/K4:2 via R4 to Y673/6
Function: 9.4.5 Water valve
Signal value: motor runs anticlockwise row 1: 00 11, row 2: 11 11
Description: Voltage feed to motor for the air distributor, rotation clock-
DIAG CLIMATE 8(X) 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 9.4-2
Connection: digital out from D790-1/K4:3 via R5 to Y672/5 and from
D790-1/K4:4 via R6 to Y672/6
24V
Function: 9.4.14 Air distributor
Signal value: motor runs clockwise row 1: 11 11, row 2: 00 11
Description: Voltage feed to motor for the air distributor, rotation coun-
ter-clockwise. The motor is connected to an H-bridge. Signal can only
be diagnosed when the air distributor’s position changes.
Circuit diagram: Circuit 9.4-2
Connection: digital out from D790-1/K4:3 via R5 to Y672/5 and from
D790-1/K4:4 via R6 to Y672/6
Function: 9.4.14 Air distributor
Signal value: motor runs anticlockwise row 1: 00 11, row 2: 11 11
8.4.5 HYD
HYD, description
page
–
OLS EXTRA
010070
SET OUTPUT + - X
Signal value: XXX = Temperature in tenths of degrees (200 = 20 C).
SET OUTPUT + - X
SET OUTPUT + - X
DCF-80-100 4.8.10 Hydraulic oil temperature sensor
Menu for DCF 280-520 and DCF 80-100 Signal value: XXX = Temperature in tenths of degrees (200 = 20 C).
C+
007239
Description: Pressure on the tilt cylinders’ rod side (C-). For voltage
value, see PRESENT INPUT SIGNAL, TILT CYLINDER page 144.
Circuit diagram: Circuit 8.2-2
Connection: signal from B768-2/3, analogue in D797-1/K1:22
Function: 7.7.8 Hydraulic pressure sensor, tilt cylinder
Signal value: XXX = 0-250 = Hydraulic pressure 0 - 25 MPa.
(255 = incorrect signal.)
DECLUTCH PRESSURE X
Signal value:
0 No signal.
0 No signal.
0 No signal.
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 4.0-1
007241
0 No signal.
P-BRAKE, VALVE
page
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PUMP ATTACHMENT XY
Function: 10.4.3 Vane pump with fixed displacement
Signal value:
SET OUTPUT + - X
Function: 10.4.2 Axial piston pump with variable displacement
Signal value:
0 No output signal.
OUTPUT +/-
Description: Activate or deactivate the quick-lift pump.
Circuit diagram: 10.4-1
Connection: digital out from D797-1/K1:39 to solenoid valve Y6062 is
activated or deactivated with +/-
Function: 10.4.2 Axial piston pump with variable displacement
Signal value:
0 No output signal.
VALVE
Only applies to DCF 70, DCF 80-100
DIAG HYDRAULIC 8(X)
Description: Voltage feed to solenoid valve for main pump relief (pres-
PRESENT OUTPUT SIGNAL
PRESSURE TO ATTACHM. surised attachment).
VALVE XY Circuit diagram: 10.4-1
010074
SET OUTPUT + - X
Connection: digital out from D797-1/K1:35 to solenoid valve Y6062-2
Function: 10.4.2 Axial piston pump with variable displacement
Signal value:
0 No output signal.
0 No output signal.
8.4.6 ENGINE
ENGINE, description
page
–
OLS EXTRA
Description: Required engine speed in rpm which is sent from the cab
control unit (D790-1) to the engine control unit (D794) via the CAN bus
drivetrain.
Circuit diagram: -
Contact: -
Function: 1.9 Control system, engine
Signal value: XXXX = 0-2010 rpm
Contact: -
Function: 1.9.2 Sensor engine rpm
Signal value: XXXX = active speed in rpm.
D+ X
Connection: signal from S150/19 to digital in D790-2/K2:2
Function: 1 Engine, 1.10.1 Preheating
Signal value:
0 No signal.
0 No signal.
0 No signal.
0 No output signal.
0 No output signal.
FMI XX
Function: 1.9 Control system
Signal value: XX = number of active error codes.
Description: SPN number for the first error code from Control unit, en-
gine (D794). SPN indicates the malfunction area, i.e., what component
or signal is defective. Error codes are shown using SPN/FMI in the er-
ror code menus.
Circuit diagram: -
Contact: -
Function: 8.3 Error codes
Signal value: XXXX = error code number. Use the error code list; see
section D Error codes.
Description: FMI number for the first error code from the engine control
unit (D794). FMI indicates error type, e.g., short circuit or low value. Er-
ror codes are shown with SPN/FMI in error code menus.
Circuit diagram: -
Contact: -
Function: 8.3 Error codes
Signal value: XX = fault type number. Use the error code list; see sec-
tion D Error codes.
005315
Signal value: XXX = fuel consumption in l/h.
Description: shows active alarms from the CCT system control unit
DIAG ENGINE CCT 11(X) (D797-P).
ACTIVE ALARM X
ACTIVE WARNING X Circuit diagram: -
Contact: -
011269
ACTIVE WARNING
page
–
Description: shows active warnings from the CCT system control unit
(D797-P).
Circuit diagram: -
Contact: -
Function: 1.3 Additional exhaust cleaning system
Signal value: -
0 Home position.
1 Active.
AIR PUMP
page
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0 Home position.
1 Active.
FLUSH VALVE
page
–
0 Home position.
>0 Active.
FUEL INJECTOR
page
–
0 Home position.
>0 Active.
INTERVAL TIMER
page
–
SOOT PRESSURE
page
–
ASH PRESSURE
page
–
AIR PRESSURE
page
–
SYSTEM INSTALL XXXX Connection: signal from the fuel pressure sensor in the injection block
of the CCT system control unit (D797-P).
Function: 1.3 Additional exhaust cleaning system
Signal value: XXXX = mbar (A)
CURRENT STATE
page
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SYSTEM INFO
page
–
SYSTEM INSTALL
page
–
8.4.7 TRANSM
TRANSM, description
page
–
005324
OLS EXTRA
0 No signal.
0 No signal.
005326
SHIFT MODE X
Function: 2 Transmission
Signal value:
0 No signal.
SWITCHES, REVERSE
page
–
0 No signal.
005327
GEAR X Contact: -
Function: 2.8 Control system, transmission
Signal value:
0 No output signal.
0 No output signal.
OPERATING MODE X
Function: 2.8 Control system, transmission
Signal value:
1 Automatic.
0 Manual.
1 Active error.
0 No errors.
0 Not used.
2 Not used.
3 Not used.
OLD FAULT X
Function: 2.8 Control system, transmission
Signal value:
1 Shifting in progress.
0 No activity.
0 No error codes.
5
005330
4
1. Sensor rpm drum (B752)
2. Temperature switch, torque converter (S221)
3. Sensor, engine speed and transmission tempera-
ture (B758/766)
4. Sensor rpm turbine transmission (B751)
5. Sensor rpm output shaft (B758)
OUTPUT SPEED
page
–
ENGINE SPEED
page
–
Description: Rpm signal from sensor rpm engine speed (position 3).
Circuit diagram: Circuit 2.0-2A2
Connection: signal from B758/766 to D793/H3
Function: 2.2.5 Sensor engine speed and oil temperature transmission
Signal value: XXXXHz = frequency, indicates pulses from the sensor
in Hz (pulses /second). To convert to rpm, divide frequency by number
of teeth on input shaft’s gear.
TURBINE SPEED
page
–
Description: Status high and low side for control of solenoid valve RSP
DIAG TRANSM. 7(X) Drive.
OUTPUT STATUS
RSP DRIVE X X Circuit diagram: Circuit 2.0-2A3
2/4 VFS SELECTION X Connection: signal from D793/K1 and D793/K2 to Y6066
005331
00 No signal.
1 Activated.
0 No signal.
1 Activated.
0 No signal.
1/3 SUPPLY X
transmission
Signal value:
1 Activated.
0 No signal.
REV SUPPLY
page
–
1 Activated.
0 No signal.
2/4 SUPPLY
page
–
1 Activated.
0 No signal.
1/3 SUPPLY
page
–
1 Activated.
0 No signal.
REV FEEDBACK
page
–
2/4 FEEDBACK
page
–
1/3 FEEDBACK
page
–
CONV OUT TEMP XXXXXmV Connection: signal from "pressure feedback sensor" to D793/A2
Function: 2.6.2 Sensor oil pressure
Signal value:
Description: signal from oil temperature sensor out from the transmis-
sion to the radiator. The transmission uses a temperature-sensitive
make-contact (closing switch) and two resistors in the cable harness
to generate different voltage levels.
Circuit diagram: Circuit 2.0-2A2
Connection: signal from S221 to D793/J3
Function: 2.7.4 Sensor oil temperature oil cooler
Signal value:
RADIUS
page
–
FRAME XX X XX Contact: -
Function: 8.2.3 Speed limitation
Signal value:
SPD, XX = speed in km/h.
GEAR, X = current gear.
LOG, XX = code which specifies what has caused the speed
limitation.
Description: Indicates malfunction area active error, first part of the er-
DIAG TRANSM. 13(X) 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: -
005337
TYPE
page
–
NUMBER OF OCCU.
page
–
TIME AGO
page
–
007622
Function: 2.8 Control system, transmission
Signal value: XXXX = Torque in Nm.
8.4.8 ELSERV
ELSERV, description
page
–
DIAGNOSIS
CAN/POWER LIGHTS CAB This group covers electric servo functions.
CLIMATE HYD ENGINE
Confirm selections with function key for Enter.
TRANSM ELSERV ATTACH
005400
OLS EXTRA
P3 XX.XXV
Signal value: XX.XXV = 0.50 - 4.50 V. 2.5 V in zero position.
P5 XX.XXV
Signal value: XX.XXV = 0.50 - 4.50 V. 2.5 V in zero position.
005403
FEEDBACK XXXmA machines with freelift).
Function: 7.2.5 Control valve, lift and tilt (DCF360-450CSG, DCF 70
and DCF 80-100)
7.2.6 Load handling control valve (DCF280-520)
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
FEEDBACK XXXmA
Function: 7.7.5 Control valve, lift and tilt (DCF360-450CSG, DCF 70
and DCF 80-100)
7.7.5 Load handling control valve (DCF280-520)
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
FEEDBACK XXXmA
Function: 7.7.5 Control valve, lift and tilt (DCF360-450CSG, DCF 70
and DCF 80-100)
7.7.5 Load handling control valve (DCF280-520)
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
FEEDBACK XXXmA
Function: 7.4.5 Load handling control valve (DCF280-520)
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
005408
FEEDBACK XXXmA
Function: 7.4.5 Load handling control valve (DCF280-520)
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
005409
FEEDBACK XXXmA
Function: 7.5.5 Load handling control valve (DCF280-520)
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
005410
FEEDBACK XXXmA
Function: 7.5.5 Load handling control valve (DCF280-520)
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
005411
FEEDBACK XXXmA
Function: 7.2.6 Load handling control valve (DCF280-520)
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
005412
FEEDBACK XXXmA
Function: 7.2.6 Load handling control valve (DCF280-520)
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
UNLOCK TW X
OUT: Signal from S815/16 to digital in D790-1/K7:13 (spreading
out)
0 No signal.
0 No signal.
0 No signal.
Signal value:
0 No signal.
0 No signal.
OUTPUT RIGHT XY
Signal value:
0 No signal.
OLS EXTRA
P7 XX.XXV
Function: 7.1.1 Control levers
Signal value: XX.XXV = 0.50 - 4.50 V. 2.5 V in zero position.
30/35 STOP X
(spreading in)
OUT: Signal from S1012/7 (S815/16) to digital in D790-1/K7:13
(spreading out)
Function: 7.1.3 Switch, spreading 20’-40’, 7.1.1 Control lever
Signal value:
0 No signal.
0 No signal.
0 No signal.
Signal value:
0 No signal.
LOCK LEVELLING X
Function: 7.9.1 Twistlocks
Signal value:
0 No signal.
0 No signal.
0 No signal.
30/35 STOP X
Function: 7.5.6 Position sensor spreading
Signal value:
0 No signal.
0 No signal.
Description: Signals from sensors, alignment, right front and left front.
DIAG ATTACHMENT 7(X)
Circuit diagram: Circuit 7.9-2
PRESENT INPUT SIGNALS
ALIGNMENT LE RI Contact:
FRONT X X
LE: signal from B7202L/C to digital in D791-1/K1:13
005422
REAR X X
RI: signal from B7202R/C to digital in D791-1/K1:40
Function: 7.9.1.7 Alignment sensor
Signal value:
0 No signal.
Description: Signals from sensors, alignment, right rear and left rear.
Circuit diagram: Circuit 7.9-2
Contact:
LE: signal from B7203L/B to digital in D791-1/K1:27
RI: Signal from B7203R/B to digital in D791-1/K1:26
Function: 7.9.1.7 Alignment sensor
Signal value:
0 No signal.
UNLOCKED CONT X X
RI: Signal from B7205R/B to digital in D791-1/K1:24
Function: 7.9.1.8 Sensor twistlock
Signal value:
0 No signal.
0 No signal.
013610
IND. ALIGNMENT XY
Function: 7.9.1 Twistlocks
Signal value:
FEEDBACK XXXmA
Function: 7.4.2 Control valve attachment
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
FEEDBACK XXXmA
Function: 7.4.2 Control valve attachment
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
005428
FEEDBACK XXXmA
Function: 7.5.2 Control valve attachment
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
005429
FEEDBACK XXXmA
Function: 7.5.2 Control valve attachment
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
005430
Signal value:
FEEDBACK XXXmA
Function: 7.3.2 Control valve attachment
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
FEEDBACK XXXmA
Function: 7.3.2 Control valve attachment
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
005434
FEEDBACK XXXmA
Function: 7.3.2 Control valve attachment
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
005435
FEEDBACK XXXmA
Function: 7.3.2 Control valve attachment
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
009181
Connection: digital out from D791-1/K1:28 to H9003/1
Function: 7.5 Spreading
Signal value:
OLS EXTRA
P7 XX.XXV
Function: 7.1.1 Control levers
Signal value: XX.XXV = 0.50 - 4.50 V. 2.5 V in zero position.
30/35 STOP X
(spreading in)
OUT: Signal from S1012/7 (S815/16) to digital in D790/K7:13
(spreading out)
Function: 7.1.3 Switch, spreading 20’-40’, 7.1.1 Control lever
Signal value:
0 No signal.
0 No signal.
0 No signal.
Signal value:
0 No signal.
Signal value:
0 No signal.
0 No signal.
010080
30/35 STOP X X from inductive sensor B769R to digital in D791/K1:40
Function: 7.5.6 Position sensor spreading
Signal value:
0 No signal.
Description: signal from position sensor for end position 30’ right or
left.
Circuit diagram: Circuit 5
Connection: from inductive sensor B777L to digital in D791/K1:20 or
from inductive sensor B777R to digital in D791/K1:37
Function: 7.5.6 Position sensor spreading
Signal value:
0 No signal.
LOWER X X
LE: signal from B7203RU-2 to digital in D791/K1:36
RI: Signal from B7203LU-2 to digital in D791/K1:11
Function: 7.9.2.8 Alignment and detection sensor
Signal value:
0 No signal.
Description: Signals from sensors alignment right lower and left lower.
Circuit diagram: Circuit 11B
Contact:
LE: signal from B7203LL to digital in D791/K1:27
RI: Signal from B7203RL to digital in D791/K1:26
Function: 7.9.2.8 Alignment and detection sensor
Signal value:
0 No signal.
Description: Signals from sensors locked lock tongue right and left.
DIAG ATTACHMENT 8(X)
Circuit diagram: Circuit 9
PRESENT INPUT SIGNALS
LE RI Contact:
LOCKED CONT X X
LE: signal from B7205LL to digital in D791/K1:23
010082
UNLOCKED CONT X X
RI: Signal from B7205RL to digital in D791/K1:24
Function: 7.9.2.9 Lock tongue sensor
Signal value:
0 No signal.
Description: Signals from sensors open lock tongue right and left.
Circuit diagram: Circuit 9
Contact:
LE: signal from B7204L to digital in D791-1/K1:22
RI: signal from B7204R to digital in D791-1/K1:41
Function: 7.9.2.9 Lock tongue sensor
Signal value:
0 No signal.
010083
Function: 7.4.2 Control valve attachment
Signal value:
Description: Voltage feed, indicator light for locked lock tongues - lo-
DIAG ATTACHMENT 10(X) cated on carriage.
PRESENT OUTPUT SIGNAL
IND. LOCKED CONT XY Circuit diagram: Circuit 10A
IND. UNLOCKED CONT XY Connection: digital out from D791/K1:29 to H563
010084
IND. ALIGNMENT XY
Function: 7.9.2 Lifting hook
Signal value:
Description: Voltage feed, indicator light for unlocked lock tongues - lo-
cated on carriage.
Circuit diagram: Circuit 10A
Connection: digital out from D791/K1:25 to H562
Function: 7.9.2 Lifting hook
Signal value:
FEEDBACK XXX
Function: 7.4.2 Control valve attachment
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
FEEDBACK XXX
Function: 7.4.2 Control valve attachment
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
010085
FEEDBACK XXX
Function: 7.8.2 Control valve attachment
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
010086
FEEDBACK XXX
Function: 7.8.2 Control valve attachment
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
010077
8.4.9.16 ATTACH, menu 16
Not used.
page
–
FEEDBACK XXX
Function: 7.5.2 Control valve attachment
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
FEEDBACK XXX
Function: 7.5.2 Control valve attachment
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
010091
FEEDBACK XXX
Function: 7.5.2 Control valve attachment
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
010092
FEEDBACK XXX
Function: 7.5.2 Control valve attachment
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
009181
Connection: digital out from D791/K1:28 to H9003
Function: 7.5 Spreading
Signal value:
X X
RI: Signal from B7203RU to digital in D791-1/K1:21
Function: 7.9.2.8 Alignment and detection sensor
Signal value:
0 No signal.
0 No signal.
005339
OLS EXTRA
P7 XX.XXV
Function: 7.1.1 Control levers
Signal value: XX.XXV = 0.50 - 4.50 V. 2.5 V in zero position.
005418
30/35 STOP X
(spreading in)
OUT: Signal from S1012/7 (S815/16) to digital in D790-1/K7:13
(spreading out)
Function: 7.1.3 Switch, spreading 20’-40’, 7.1.1 Control lever
Signal value:
0 No signal.
0 No signal.
0 No signal.
007130
Signal value:
0 No signal.
Signal value:
0 No signal.
0 No signal.
010080
30/35 STOP X X from inductive sensor B769R to digital in D791/K1:40
Function: 7.5.6 Position sensor spreading
Signal value:
0 No signal.
Description: signal from position sensor for end position 30’/35’ right
or left.
Circuit diagram: Circuit 5
Connection: from inductive sensor B777L to digital in D791/K1:20 or
from inductive sensor B777R to digital in D791/K1:37
Function: 7.5.6 Position sensor spreading
Signal value:
0 No signal.
0 No signal.
010082
UNLOCKED CONT X X
RI: Signal from B7205RL to digital in D791/K1:24
Function: 7.9.1.8 Twistlocks sensor
Signal value:
0 No signal.
0 No signal.
IND. ALIGNMENT XY
Function: 7.9.1 Twistlocks
Signal value:
FEEDBACK XXX
Function: 7.4.2 Control valve attachment
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
FEEDBACK XXX
Function: 7.4.2 Control valve attachment
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
FEEDBACK XXX
Function: 7.8.2 Control valve attachment
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
010086
FEEDBACK XXX
Function: 7.8.2 Control valve attachment
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
010077
8.4.9.16 ATTACH, menu 16
Not used.
page
–
FEEDBACK XXX
Function: 7.5.2 Control valve attachment
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
FEEDBACK XXX
Function: 7.5.2 Control valve attachment
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
010091
FEEDBACK XXX
Function: 7.5.2 Control valve attachment
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
FEEDBACK XXX
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
8.4.10 OLS
OLS, description
page
–
DIAGNOSIS
CAN/POWER LIGHTS CAB This group covers overload protection functions.
CLIMATE HYD ENGINE
Confirm selections with function key for Enter.
TRANSM ELSERV ATTACH
005436
OLS EXTRA
Signal value:
0 No signal.
008903
MAST POS SENSOR X
Function: 8.2.1 Overload protection
Signal value: XXXXX = Weight, kg
PRESENT LOAD
page
–
0 No signal.
Not used.
0 No signal.
8.4.11 EXTRA
EXTRA, description
page
–
005440
OLS EXTRA
• Freelift, FREELIFT
• Cab tipping, MOVE-CAB
• Auxiliary equipment, OPT
• Inputs and outputs, control units, I/O
• Remote machine interface, RMI
Confirm selections in the main menu with function key for Enter.
8.4.11.1 VBFS
VBFS, description
page
–
DIAGNOSIS EXTRA
VBFS EL-STEERING This group covers turnable operator’s station functions.
EXT-ATTACH FREELIFT
Confirm selections with function key for Enter.
MOVE-CAB OPT I/O RMI
008904
VBFS, menu 1
page
–
SWITCH CCW X
Connection: signal from S169/1 to digital in D790-1/K8:6
Function: 9.3.9 Reversible driver’s seat
Signal value:
0 No signal.
0 No signal.
VBFS, menu 2
page
–
SEAT CCW XY
Connection: digital out from D797-2/K1:29 to A798/6
Function: 9.3.9 Reversible driver’s seat
Signal value:
VBFS, menu 3
page
–
0 No signal.
0 No signal.
VBFS, menu 4
page
–
007623
REQUIRED SPD RPM XXXX
Connection: signal from B690-2/2 to analogue in D790-1/K6:12
Function: 1 Engine
Signal value: X.XXV = 0.50 - 4.50 V
Description: Required engine speed in rpm which is sent from the cab
control unit (D790-1) to the engine control unit (D794) via the CAN bus
drivetrain.
Circuit diagram: -
Contact: -
Function: 1.9 Control system, engine
Signal value: XXXX = 0-2010 rpm
VBFS, menu 5
page
–
005565
VALVE CAB REAR XY
Connection: digital out from D797-2/K1:9 to Y636-1/1
Function: 9.3.12 Directional control valve, reversible driver’s seat
Signal value:
VBFS, menu 6
page
–
005566
DIMMED LE/RI XY Connection: signal from S100/1 to digital in D790-1/K6:5
Function: 9.6.1 Headlights.
Signal value:
0 No signal.
VBFS, menu 7
page
–
FRONT LE/RI XY Connection: digital out from D797-2/K1:25 to H413L/1 and H413R/1
Function: 9.6.3 Tail lights
Signal value:
VBFS, menu 8
page
–
005568
FRONT LE XY RI XY Contact:
LE: digital out from D797-2/K1:37 to H410L/1
RI: digital out from D797-2/K1:36 to H410R/1
Function: 9.6.4 Brake lights
Signal value:
VBFS, menu 9
page
–
DAMP SPEED XY
Circuit diagram: Circuit 9.3-7
Connection: digital out from D797-2/K1:35 to Y676/1
Function: 9.3.9 Reversible driver’s seat
8.4.11.2 EL-STEERING
EL-STEERING, description
page
–
DIAGNOSIS EXTRA
VBFS EL-STEERING This group handles functions for joystick steering/mini-wheel steering.
EXT-ATTACH FREELIFT
Confirm selections with function key for Enter.
MOVE-CAB OPT I/O RMI
008911
EL-STEERING, menu 1
page
–
LOGIC X.XXV
Signal value, control lever: XX.XXV = 0.50 - 4.50 V
Signal value, mini-wheel: XX.XXV = 0 - 5 V
EL-STEERING, menu 2
page
–
SWITCHES, ON/OFF
Description: Signal from switch mini-wheel/joystick.
DIAG STEERING 2(X)
Circuit diagram: Circuit 5.2-1
SWITCHES
ON/OFF X Connection: signal from S113/1 to digital in D790-1/K9:5
FORWARD X
Function: 5.2 Power-assisted steering system
005569
REVERSE X
Signal value:
0 No signal.
SWITCHES, FORWARD
Description: Signal from mini-wheel or joystick (travel direction
selector forward).
Circuit diagram: Circuit 5.2-1
Connection: signal from S160-2/1 to digital in D790-1/K9:4
Function: 5.2 Power-assisted steering system
Signal value:
0 No signal.
SWITCHES, REVERSE
Description: Signal from mini-wheel or joystick (travel direction
selector reverse).
Circuit diagram: Circuit 5.2-1
Connection: signal from S160-2/7 to digital in D790-1/K9:3
Function: 5.2 Power-assisted steering system
Signal value:
0 No signal.
EL-STEERING, menu 3
page
–
007624
Signal value:
0 No signal.
0 No signal.
EL-STEERING, menu 4
page
–
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
EL-STEERING, menu 5
page
–
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
8.4.11.3 EXT-ATTACH
EXT-ATTACH, description
page
–
DIAGNOSIS EXTRA
VBFS EL-STEERING This group covers the external attachment functions.
EXT-ATTACH FREELIFT
Confirm selections with function key for Enter.
MOVE-CAB OPT I/O RMI
007625
EXT-ATTACH, menu 1
page
–
0 No signal.
EXT-ATTACH, menu 2
page
–
Signal value:
0 No signal.
0 No signal.
EXT-ATTACH, menu 3
page
–
Signal value:
0 No signal.
0 No signal.
EXT-ATTACH, menu 4
page
–
UNLOCKED TW X
Function: 7.10.5 Separate top lift attachment
Signal value:
0 No signal.
0 No signal.
0 No signal.
EXT-ATTACH, menu 5
page
–
Not used.
EXT-ATTACH, menu 6
page
–
SPREADING ACTIVE XY
Signal value:
EXT-ATTACH, menu 7
page
–
FEEDBACK XXX
Function 7.5.5 Solenoid valve, load handling
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
EXT-ATTACH, menu 8
page
–
FEEDBACK XXX
Function 7.5.5 Solenoid valve, load handling
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
8.4.11.4 FREELIFT
FREELIFT, description
page
–
DIAGNOSIS EXTRA
VBFS EL-STEERING This group covers freelift functions.
EXT-ATTACH FREELIFT
Confirm selections with function key for Enter.
MOVE-CAB OPT I/O RMI
008912
FREELIFT, menu 1
page
–
0 No signal.
0 No signal.
8.4.11.5 MOVE-CAB
MOVE-CAB, description
page
–
DIAGNOSIS EXTRA
VBFS EL-STEERING This group covers tiltable cap functions.
EXT-ATTACH FREELIFT
Confirm selections with function key for Enter.
MOVE-CAB OPT I/O RMI
008913
MOVE-CAB, menu 1
page
–
INPUT SWITCHES, UP
Description: Signal from switch for manual cab tilt, cab up.
DIAG MOVE-CAB 1(X) Circuit diagram: Circuit 9.10-1
INPUT SWITCHES
UP/RIGHT X Connection: signal from S1010/1 to digital in D790-1/K8:6
DOWN/LEFT X Function: 9.10.4 Cab tilt
007133
OPEN DOORS X
Signal value:
0 No signal.
0 No signal.
0 No signal.
MOVE-CAB, menu 2
page
–
Signal value:
0 No signal.
0 No signal.
MOVE-CAB, menu 3
page
–
Signal value:
0 No signal.
0 No signal.
MOVE-CAB, menu 4
page
–
005449
Signal value:
MOVE-CAB, menu 5
page
–
007134
Signal value:
MOVE-CAB, menu 6
page
–
FEEDBACK XXX
Function: 9.10.4 Hydraulic sliding cab
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
MOVE-CAB, menu 7
page
–
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
8.4.11.6 OPT
OPT, description
page
–
008914
OPT, menu 1
page
–
S199-3 X
Signal value:
0 No signal.
0 No signal.
0 No signal.
0 No signal.
OPT, menu 2
page
–
ATTACHMENT XY
Signal value:
OPT, menu 3
page
–
005490
Signal value:
OPT, menu 4
page
–
Signal value:
OPT, menu 5
page
–
Signal value:
8.4.11.7 RMI
RMI, description
page
–
007657
RMI, menu 1
page
–
MIU SW VER
Description: Software version in RMI interface.
DIAG RMI 1(X) Circuit diagram: -
MIU SW VER XXXX.XXXX
MIU TIME XX.XX.XX Contact: -
Function: 11.6.5 RMI (Remote Machine Interface)
010094
MIU TIME
Description: Date setting in RMI interface.
Circuit diagram: -
Contact: -
Function: 11.6.5 RMI (Remote Machine Interface)
Signal value: xxxx.xx.xx = Date in format YYYY.MM.DD.
RMI, menu 2
page
–
RMI, menu 3
page
–
ERROR
Description: Internal error code for the RMI interface
DIAG RMI 3(X) Circuit diagram: Circuit 8.2-4
ERROR XX.XX.XX.XX
ERR.VALID XX.XX.XX.XX Contact: -
ACT ERR XX.XX.XX.XX Function: 11.6.5 RMI (Remote Machine Interface)
007660
Signal value: XX.XX.XX.XX = Error code
ERR.VALID
Description: Internal error code for the RMI interface
Circuit diagram: Circuit 8.2-4
Contact: -
Function: 11.6.5 RMI (Remote Machine Interface)
Signal value: XX.XX.XX.XX = Error code
ACT.ERR
Description: Internal error code for the RMI interface
Circuit diagram: Circuit 8.2-4
Contact: -
Function: 11.6.5 RMI (Remote Machine Interface)
Signal value: XX.XX.XX.XX = Error code
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 ELSERVO 1(X)
START CURRENT The settings influence the functions. Adjustments
LIFT may impair the function. If in doubt, contact Cargotec
4 STORED VALUE XXXmA 3 Service.
008891
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.
START CURRENT
I [mA]
Specifies the start current to the solenoid valve for the selected func-
1 tion. The start current is the lowest current that can be actuated. In
2 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-
3
006299
rent that is triggered when the lever leaves the zero position. On
t [s] certain functions with digital activation (off/on) which are soft-started,
1. Max. current (END CURRENT) this is the current which is triggered immediately the function is
2. Damping (PROC DAMPING) activated.
3. Start current (START CURRENT)
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 DCF360-450CSG
Function Menu
INIT DRIVE-TRAIN, menu 9
1 Engine, speed limitation (limitation of engine speed
page 208
1 Engine, automatic engine speed increase for lifting INIT DRIVE-TRAIN, menu 13
page 209
2 Transmission, engine speed limit shifting forward - reverse INIT DRIVE-TRAIN, menu 3
page 206
2 Transmission, engine speed limit shifting neutral - gear INIT DRIVE-TRAIN, menu 4
page 206
Function Menu
INIT DRIVE-TRAIN, menu 10
2 Transmission, speed limitation (gear lock-out)
page 208
Function Menu
INIT DRIVE-TRAIN, menu 9
1 Engine, speed limitation (limitation of engine speed)
page 208
1 Engine, automatic engine speed increase for lifting INIT DRIVE-TRAIN, menu 13
page 209
2 Transmission, engine speed limit shifting forward - reverse INIT DRIVE-TRAIN, menu 3
page 206
2 Transmission, engine speed limit shifting neutral - gear INIT DRIVE-TRAIN, menu 4
page 206
5.2 Power-assisted steering system (product option lever steering or mini-wheel), INIT STEERING, menu 1 page 200
lever response
5.2 Power-assisted steering system (product option lever steering or mini-wheel), INIT STEERING, menu 2 page 201
speed dependent INIT STEERING, menu 3 page 201
INIT STEERING, menu 4 page 202
INIT STEERING, menu 5 page 202
INIT STEERING, menu 6 page 203
5.2 Power-assisted steering system (product option lever steering or mini-wheel), INIT STEERING, menu 7 page 203
steering angle right INIT STEERING, menu 8 page 203
5.2 Power-assisted steering system (product option lever steering or mini-wheel), INIT STEERING, menu 9 page 204
steering angle left INIT STEERING, menu 10 page 204
Function Menu
7.2 Lifting/lowering, lift trolley INIT ELSERVO, menu 13 page 188
INIT ELSERVO, menu 14 page 188
Function Menu
INIT DRIVE-TRAIN, menu 9
1 Engine, speed limitation (limitation of engine speed)
page 208
1 Engine, automatic engine speed increase for lifting INIT DRIVE-TRAIN, menu 13
page 209
2 Transmission, engine speed limit shifting forward - reverse INIT DRIVE-TRAIN, menu 3
page 206
2 Transmission, engine speed limit shifting neutral - gear INIT DRIVE-TRAIN, menu 4
page 206
Function Menu
INIT DRIVE-TRAIN, menu 9 page 208
1 Engine, speed limitation (limitation of engine speed)
1 Engine, automatic engine speed increase for lifting INIT DRIVE-TRAIN, menu 13
page 209
2 Transmission, speed limit shifting forward - reverse INIT DRIVE-TRAIN, menu 2 page 205
2 Transmission, engine speed limit shifting forward - reverse INIT DRIVE-TRAIN, menu 3 page 206
2 Transmission, engine speed limit shifting neutral - gear INIT DRIVE-TRAIN, menu 4 page 206
2 Transmission, engine speed limit kickdown to 1st INIT DRIVE-TRAIN, menu 5 page 207
000056
3 Enter the code for initiation.
Code is obtained from Cargotec Support.
1 23
4 5 NOTE
000060
RETURN the desired menus with the arrow keys (1 and 2).
5 Change the current value with the plus and minus keys.
INIT ELSERVO 1(X)
START CURRENT
LIFT NOTE
STORED VALUE XXXmA Current values can only be adjusted within specific limits.
005494
PRESENT VALUE XXXmA 6 Use the function key for Enter to store the desired current value
setting, "STORED".
The menu group for this function covers initiation of the electric servo
INITIATION functions for load handling.
ELSERVO ATTACHMENT
STEERING DRIVE-TRAIN For DCF360-450CSG, DCF 70 and DCF 80-100, settings are made
SLIDING-CAB for lift, lower, tilt in and tilt out. For other load handling functions, see
007169
RETURN INIT ATTACH page 191.
For DCF 280-520, settings are made for lift, lower, tilt in, tilt out, side
shift left, side shift right, spreading in and spreading out.
DANGER
The settings affect the functions for lift, lower, tilt,
and, for DCF370-500, spreading and side shift. Adjust-
ment can impair functionality. If in doubt, contact
Cargotec Service.
NOTE
Initiation does not need to be performed in one process but each
step can be performed separately, independently of other steps.
PRESENT VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE: indicates stored value for start current.
Function: 7.2.5 Control valve, lift and tilt (DCF360-450CSG)
7.2.6 Load handling control valve (DCF 280-520)
Component: Solenoid valve, lift mast (Y6005)
Signal value: XXXmA = 0 - 999 mA.
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.
Function: 7.2.5 Control valve, lift and tilt (DCF360-450CSG)
005496
PRESENT VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE: indicates stored value for start current.
Function: 7.2.5 Control valve, lift and tilt (DCF360-450CSG)
7.2.6 Load handling control valve (DCF 280-520)
Component: Solenoid valve, lower mast(Y6004)
Signal value: XXXmA = 0 - 999 mA.
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.
Function: 7.2.5 Control valve, lift and tilt (DCF360-450CSG)
7.2.6 Load handling control valve (DCF 280-520)
Component: Solenoid valve, stand (Y6004)
Signal value: XXXmA = 0 - 999 mA.
PRESENT VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE: indicates stored value for start current.
Function: 7.7.5 Control valve, lift and tilt (DCF360-450CSG)
7.7.6 Load handling control valve (DCF 280-520)
Component: Solenoid valve, tilt in (Y6011)
Signal value: XXXmA = 0 - 999 mA.
007140
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.
Function: 7.7.5 Control valve, lift and tilt (DCF360-450CSG)
7.7.6 Load handling control valve (DCF 280-520)
Component: Solenoid valve, tilt in (Y6011)
Signal value: XXXmA = 0 - 999 mA.
PRESENT VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE: indicates stored value for start current.
Function: 7.7.5 Control valve, lift and tilt (DCF360-450CSG)
7.7.6 Load handling control valve (DCF 280-520)
Component: Solenoid valve, tilt out (Y6010)
Signal value: XXXmA = 0 - 999 mA.
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.
Function: 7.7.5 Control valve, lift and tilt (DCF360-450CSG)
7.7.6 Load handling control valve (DCF 280-520)
Component: Solenoid valve, tilt out (Y6010)
Signal value: XXXmA = 0 - 999 mA.
007143
PRESENT VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE: indicates stored value for start current.
Function: 7.4.5 Load handling control valve (DCF 280-520)
Component: Solenoid valve for side shift left (Y6020) and solenoid
valve for side shift right (Y6021)
Signal value: XXXmA = 0 - 999 mA.
PRESENT VALUE XXXmA PRESENT VALUE: Indicates the current value for max. current. Adjust
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.
Function: 7.4.5 Load handling control valve (DCF 280-520)
Component: Solenoid valve for side shift left (Y6020) and solenoid
valve for side shift right (Y6021)
Signal value: XXXmA = 0 - 999 mA.
PRESENT VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE: indicates stored value for start current.
Function 7.5.5 Solenoid valve, load handling
Component: Solenoid valve for spreading in (Y6019) and solenoid
valve for spreading out (Y6018)
Signal value: XXXmA = 0 - 999 mA.
007146
PRESENT VALUE XXXmA PRESENT VALUE: Indicates the current value for max. current. Adjust
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.
Function 7.5.5 Solenoid valve, load handling
Component: Solenoid valve for spreading in (Y6019) and solenoid
valve for spreading out (Y6018)
Signal value: XXXmA = 0 - 999 mA.
PRESENT VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE: indicates stored value for start current.
Function 7.2.6 Solenoid valve, load handling
Component: Solenoid valve, lift carriage (Y6022)
Signal value: XXXmA = 0 - 999 mA.
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.
Function 7.2.6 Solenoid valve, load handling
Component: Solenoid valve, lift carriage (Y6022)
Signal value: XXXmA = 0 - 999 mA.
007149
PRESENT VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE: indicates stored value for start current.
Function 7.2.6 Solenoid valve, load handling
Component: Solenoid valve, lower carriage (Y6023)
Signal value: XXXmA = 0 - 999 mA.
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.
Function 7.2.6 Solenoid valve, load handling
Component: Solenoid valve, lower carriage (Y6023)
Signal value: XXXmA = 0 - 999 mA.
013612
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.
Function: -
Component: -
Signal value: XXXmA = 0 - 999 mA.
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.
Function: -
Component: -
Signal value: XXXmA = 0 - 999 mA.
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.
Function: -
Component: -
Signal value: XXXmA = 0 - 999 mA.
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.
8.5.1.2 ATTACHMENT
INIT ATTACH
page
–
DANGER
The settings affect the functions extension, side shift,
spreading, rotation and controllable levelling for
DCF360-450CSG, the functions side shift and spread-
ing for DCF 70, and the functions side shift, spreading
and controllable levelling for DCF 80-100. Adjust-
ments could impair functionality. In the event of un-
certainty, contact Cargotec Service.
NOTE
Initiation does not need to be performed in one process but each
step can be performed separately, independently of other steps.
PRESENT VALUE XXXmA PRESENT VALUE: Indicates the current value for the start current.
Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE: indicates stored value for start current.
Function: 7.3.2 Control valve attachment
Component: Solenoid valve, extend left side out (Y6046-2), Solenoid
valve, extend right side out (Y6046-4).
Signal value: XXXmA = 0 - 999 mA
005510
PRESENT VALUE XXXmA PRESENT VALUE: Indicates the current value for max. current. Adjust
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.
Function: 7.3.2 Control valve attachment
Component: Solenoid valve, extend left side out (Y6046-2), Solenoid
valve, extend right side out (Y6046-4).
Signal value: XXXmA = 0 - 999 mA
PRESENT VALUE XXXmA PRESENT VALUE: Indicates the current value for the start current.
Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE: indicates stored value for start current.
Function: 7.3.2 Control valve attachment
Component: Solenoid valve, extend left side out (Y6046-1), Solenoid
valve, extend right side out (Y6046-3).
Signal value: XXXmA = 0 - 999 mA
PRESENT VALUE XXXmA PRESENT VALUE: Indicates the current value for max. current. Adjust
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.
Function: 7.3.2 Control valve attachment
Component: Solenoid valve, extend left side out (Y6046-1), Solenoid
valve, extend right side out (Y6046-3).
Signal value: XXXmA = 0 - 999 mA
005513
PRESENT VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE: indicates stored value for start current.
Function: 7.4.2 Control valve attachment
Component: Solenoid valve for side shift left (Y6020) and solenoid
valve for side shift right (Y6021).
Signal value: XXXmA = 0 - 999 mA
PRESENT VALUE XXXmA PRESENT VALUE: Indicates the current value for max. current. Adjust
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.
Function: 7.4.2 Control valve attachment
Component: Solenoid valve for side shift left (Y6020) and solenoid
valve for side shift right (Y6021).
Signal value: XXXmA = 0 - 999 mA
PRESENT VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE: indicates stored value for start current.
Function: 7.4.2 Control valve attachment
Component: Solenoid valve for side shift left (Y6020) and solenoid
valve for side shift right (Y6021).
Signal value: XXXmA = 0 - 999 mA
PRESENT VALUE XXXmA PRESENT VALUE: Indicates the current value for max. current. Adjust
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.
Function: 7.4.2 Control valve attachment
Component: Solenoid valve for side shift left (Y6020) and solenoid
valve for side shift right (Y6021).
Signal value: XXXmA = 0 - 999 mA
010067
PRESENT VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE: indicates stored value for start current.
Function: 7.4.2 Control valve attachment
Component: Solenoid valve for levelling left (Y6036), solenoid valve
for levelling right (Y6035).
Signal value: XXXmA = 0 - 999 mA
PRESENT VALUE XXXmA PRESENT VALUE: Indicates the current value for max. current. Adjust
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.
Function: 7.4.2 Control valve attachment
Component: Solenoid valve for levelling left (Y6036), solenoid valve
for levelling right (Y6035).
Signal value: XXXmA = 0 - 999 mA
t [s] Component: Solenoid valve for spreading out left (Y6018L) and sole-
1. Max. current (END CURRENT) noid valve for spreading out right (Y6018R).
2. Damping (PROC DAMPING) Signal value: XXX = 0 - 100%. 100% means no damping i.e. max. cur-
3. Start current (START CURRENT) rent. 0% means full damping i.e. start current.
t [s] Component: Solenoid valve for spreading in left (Y6019L) and sole-
1. Max. current (END CURRENT) noid valve for spreading in right (Y6019R).
2. Damping (PROC DAMPING) Signal value: XXX = 0 - 100%. 100% means no damping i.e. max. cur-
3. Start current (START CURRENT) rent. 0% means full damping i.e. start current.
8.5.1.3 STEERING
INIT STEERING
page
–
007171
RETURN
The settings influence the functions. Adjustments
may impair the function. If in doubt, contact Cargotec
Service.
NOTE
Initiation does not need to be performed in one process but each
step can be performed separately, independently of other steps.
steering or mini-wheel)
X Component: -
U = Output signal to solenoid valve
Signal value: XX = 0-31.
X = Lever movement
005573
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 = speed setting for break point 2
BP3 = speed setting for break point 3
%BP2 = per cent of control current to solenoid
valve at BP2
%BP3 = per cent of control current to solenoid
valve at BP3
V [kph] Component: -
BP1 BP2 BP3
I [mA] = control current to solenoid valve Signal value: XX.X = speed for BP2 in km/h.
V [kph] = machine’s speed in km/h
BP1 = speed setting for break point 1
BP2 = speed setting for break point 2
BP3 = speed setting for break point 3
%BP2 = per cent of control current to solenoid
valve at BP2
%BP3 = per cent of control current to solenoid
valve at BP3
I [mA] PRESENT VALUE: indicates present speed setting for cut-off point 1.
100% Change speed with plus or minus keys. Save set speed with the Enter-
key. Go to the next menu with arrow keys. Exit initiation with the R-key.
% BP2 STORED VALUE: indicates saved speed for break point 3.
% BP3 Function: 5.2 Power-assisted steering system (product option lever
V [kph] 005575 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: XX.X = speed for BP3 in km/h.
BP1 = speed setting for break point 1
BP2 = speed setting for break point 2
BP3 = speed setting for break point 3
%BP2 = per cent of control current to solenoid
valve at BP2
%BP3 = per cent of control current to
solenoid valve at BP3
005577
V [kph] 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.
BP2 = speed setting for break point 2
BP3 = speed setting for break point 3
%BP2 = per cent of control current to solenoid
valve at BP2
%BP3 = per cent of control current to solenoid
valve at BP3
PRESENT VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R key.
STORED VALUE: indicates stored value for start current.
Function: 5.2.10 Control valve, lever steering/mini wheel
Component: Solenoid valve for steering right (Y636-3)
Signal value: XXXmA = 0 - 999 mA
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.
Function: 5.2.10 Control valve, lever steering/mini wheel
Component: Solenoid valve for steering right (Y636-3)
Signal value: XXXmA = 0 - 999 mA
005580
PRESENT VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE: indicates stored value for start current.
Function: 5.2.10 Control valve, lever steering/mini wheel
Component: Solenoid valve for steering left (Y636-4)
Signal value: XXXmA = 0 - 999 mA
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.
Function: 5.2.10 Control valve, lever steering/mini wheel
Component: Solenoid valve for steering left (Y636-4)
Signal value: XXXmA = 0 - 999 mA
8.5.1.4 DRIVE-TRAIN
INIT DRIVE-TRAIN
page
–
007172
RETURN
The settings influence the functions. Adjustments
may impair the function.
NOTE
Initiation does not need to be performed in one process but each
step can be performed separately, independently of other steps.
NOTE
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.
START IN 2ND
INIT DRIVE-TRN 1(X)
Description: Setting to get transmission to start in 2nd gear instead of
START IN 2:ND
1=YES 0=NO in 1st. Kick-down to 1st takes place as needed.
STORED VALUE XXX PRESENT VALUE: Indicates the current setting. Change the value
005525
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.
Function: 2 Transmission
Component: -
Signal value: XXX = 1= yes, XXX = 0 = no
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.
007152
PRESENT VALUE XXX NOTE
If the rpm is set too low, kick-down may take place before the ma-
chine has used the engagement on the selected gear.
If the rpm is set too high, kick-down takes place slowly or not
at all.
PRESENT VALUE: Indicates the current setting. Change the value
with the plus and minus keys. Save the set value with the Enter key.
Go to the next menu with the arrow keys. Exit initiation with the R-key.
STORED VALUE: indicates saved setting.
Function: 2 Transmission
Component: -
Signal value: XXX = engine speed (rpm)
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.
Function: 2 Transmission
Component: -
Signal value: XXX = speed (km/h)
Not used.
Not used.
005587
PRESENT VALUE XXX PRESENT VALUE: Indicates the current setting. Change the value
with the plus and minus keys. Save the set value with the Enter key.
Go to the next menu with the arrow keys. Exit initiation with the R-key.
STORED VALUE: indicates saved setting.
Function: 2 Transmission
Component: -
Signal value: XXX = speed (km/h)
PRESENT VALUE XXX PRESENT VALUE: Indicates the current setting. Change the value
with the plus and minus keys. Save the set value with the Enter key.
Go to the next menu with the arrow keys. Exit initiation with the R-key.
STORED VALUE: indicates saved setting.
Function: 1 Engine
Component: -
Signal value: XXX = time in seconds before engine shutdown.
005590
PRESENT VALUE X pedal. Engine speed drops to that set in menu 3 (see INIT DRIVE-
TRAIN, menu 3 page 206). If no value is set in menu 3, engine speed
is reduced to idling speed.
PRESENT VALUE: Indicates the current setting. Change the value
with the plus and minus keys. Save the set value with the Enter key.
Go to the next menu with the arrow keys. Exit initiation with the R-key.
STORED VALUE: indicates saved setting.
Function: 2 Transmission
Component: -
Signal value:
X = 1, activated
X = 0, deactivated
8.5.1.5 SLIDING-CAB
INIT SLIDING-CAB
page
–
007161
RETURN by means of the control current being reduced.
DANGER
The settings influence the function for hydraulic slid-
ing cab. Adjustments may impair the function. If in
doubt, contact Cargotec Service.
NOTE
Initiation does not need to be performed in one process but each
step can be performed separately, independently of other steps.
Not used.
Not used.
8.5.2 Calibration
Calibration, description
page
–
SCALE
This menu handles calibration of sensors to weight indication.
CALIBRATION
Scale, calibration page 215
SCALE STEERING
DRIVE-TRAIN RETURN
000062
STEERING
This menu handles calibration of the steering lever for lever steering,
CALIBRATION see:
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 216
000078
NOTE
Calibration does not need to be performed in one process but
each step can be performed separately, independently of other
steps.
008892
PRESENT VALUE X.XXV
LEVER CENTRE POSITION control signal affected.
1. Menu group Description: Setting the centre po- A short description of what is
2. Sequence number. Because the number of menus sition of the lever steering control calibrated and the meaning
depends on machine configuration, it is specified as (R825). of the variables.
(X) in this manual.
STORED VALUE: Gives the stored
3. Signal value
signal value for lever steering con-
4. STORED indicates stored value, PRESENT indi-
trol (R825), centre position.
cates current value of the signal to be calibrated
5. Heading of menu figure PRESENT VALUE: Gives the
present signal value for lever steer-
ing control (R825), centre position.
1 Park the machine on level ground with the mast vertical and with-
out load.
NOTE
Calibration does not need to be performed in one process but
each step can be performed separately, independently of other
steps.
To calibrate the accelerator pedal for forward driving, use steps 1-7.
To calibrate accelerator pedal 2 (with a reversible driver’s seat), use
steps 1 + 8-13.
DRIVE-TRAIN, menu 1
2 Go into the calibration menus and select DRIVE-TRAIN, menu 1,
CALIBR DRIVE-TRN 1(X) see Calibration, work instructions page 214.
ACCELERATOR,
RELEASE THE PEDAL ACCELERATOR, RELEASE THE PEDAL
STORED VALUE X.XXV Description: setting the accelerator’s pedal zero position.
005532
PRESENT VALUE X.XXV
STORED VALUE: Indicates current calibrated control value from
accelerator pedal (R690-1).
PRESENT VALUE: Indicates present signal value from Acceler-
ator pedal (B690-1).
Function: 1 Engine
Component: Accelerator pedal (B690-1).
3 Release the accelerator pedal.
4 Store the position with function key for Enter.
DRIVE-TRAIN, menu 2
5 ACCELERATOR, PRESS THE PEDAL TO FLOOR
CALIBR DRIVE-TRN 2(X) Description: Setting of full-throttle position of Accelerator pedal
ACCELERATOR, PRESS (B690-1).
THE PEDAL TO FLOOR
STORED VALUE X.XXV STORED VALUE: Indicates current calibrated control value from
PRESENT VALUE X.XXV accelerator pedal (R690-1).
00
DRIVE-TRAIN, menu 5
8
CALIBR DRIVE-TRN 5(X)
ACCELERATOR 2, Go into the calibration menus and select DRIVE-TRAIN, menu 5,
RELEASE THE PEDAL see Calibration, work instructions page 214.
STORED VALUE X.XXV
ACCELERATOR 2, RELEASE THE PEDAL
005534
DRIVE-TRAIN, menu 6
11
CALIBR DRIVE-TRN 6(X)
ACCELERATOR 2, PRESS ACCELERATOR 2, PRESS THE PEDAL TO FLOOR
THE PEDAL TO FLOOR Description: Calibration of accelerator pedal 2 for driving rear-
STORED VALUE X.XXV
ward on machines with a reversible driver’s seat. Setting of full
005535
PRESENT VALUE X.XXV
throttle position for the accelerator pedal (B690-2).
STORED VALUE: Indicates current calibrated control value from
accelerator pedal (R690-2).
PRESENT VALUE: Indicates present signal value from Acceler-
ator pedal (B690-2).
Function: 1 Engine
Component: Accelerator pedal (B690-2).
12 Press the accelerator pedal down fully and keep it down until the
position is stored.
13 Store the position with function key for Enter.
DRIVE-TRAIN, menu 7
14
CALIBR DRIVE-TRN 7(X)
CCT EMISSION CONTROL CCT EMISSION CONTROL
STEP XXX COMP. XXX Description: calibration of CCT EMISSION CONTROL.
MIN XXX MAX XXX
011645
DATA XXX STEP: specifies with text the action being performed or due to be
performed.
COMP: shows the active component
MIN: specifies MIN. value for the selected component.
MAX: specifies MAX. value for the selected component.
DATA: indicates actual value. Text is displayed to the right of the
data describing the driver’s action as described below.
15 Access the menu and press ENTER, follow the instructions in the
display:
Transmission, calibration
page
–
DANGER
Do not leave the machine during calibration. The ma-
chine may start to move.
TARGET TEMP XXX If the oil temperature is too low then go to DRIVE-TRAIN, menu 4.
A. Apply the service 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 idling speed.
D. Repeat steps B and C until the oil is hot.
NOTE
If the machine starts to move during calibration, use the
service brake to keep the machine stationary.
IMPORTANT
Calibration can be interrupted at any time by selecting
travel direction reverse.
accessories
9.1 Controls and instruments
Controls and instruments, overview
page
–
1 2 3 4 5
15
12 13 12 11 10 9 8 7 6
008108
14
Overview
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 hydraulic functions
7 Switch safety switch (S250)
8 Switch for parking brake (S107)
9 Hydraulic control
10 Driver’s seat
11 Accelerator pedal (B690)
12 Brake pedals
13 Declutch pedal (S220-1)
14 Electronic box with fuses and relays
15 Hour meter (P708)
A Joystick or mini-wheel
004394
17
16 Auxiliary work lights, carriage and attachment
Left instrument panel 21 Switch, work lights on mast (S105-3)
31 Socket 12 VDC
61 60 59 58 57 53 Ignition
54 Switch for defroster
Steering wheel panel
55 Switch, windscreen wiper roof, interval
56 Switch, windscreen wiper roof, continuous
57 Switch, interior lighting
58 Switch, windscreen wiper rear, interval
59 Switch, windscreen wiper rear, continuous
60 Control system function keys
61 Travel direction indicator, Forward Neutral Reverse
62 Shifting program A, automatic shifting
63 Shifting program 1, locked to 1st gear
64 Shifting program 2, locked to 2nd gear
69 68 Levelling (R8074)
70 69 Opening of twistlock / Opening and locking of lock tongues
(attachment) (S1002)
71
70 Switch, horn (S149)
72
73 71 Switch for twistlock/lock tongues, automatic/manual locking
74 (S1003)
75
76 72 Switch, spreading 20’-40’ (S1012)
77
73 Switch for spreader stop at 30’ or 35’ (S1004)
74 Spare
008130
77
008131
78 8 79 70
1 2 3 4
9 8 7 6
10
009174
11 12 13 14
3. Operating menu for oil temperature 10. Operating menu, code lock
4. Operating menu electrical system 11. Operating menu statistics, operating hours
5. Operating menu, container counter 12. Operating menu statistics, fuel consumption
6. Operating menu service interval 13. Operating menu statistics, driving distance
1 2 3 4
009176
1. Event menu start interlock
2. Event menu, twistlock alignment
3. Event menu twistlocks
1 2 3 4
009781
1. Event menu start interlock
2. Event menu, alignment
000338
window.
The signal can be checked from the diagnostic
menu, see section 8 Control system,
group 8.4.3.1 CAB, menu 1.
Rotation Windscreen wiper, front.
0 – No wiping front windshield. If wiper rear or
roof are active then these run at slow interval
wiping.
1 – Slow interval wiping windscreen, 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 inter-
val wiping.
The signal can be checked from the diagnostic
menu, see section 8 Control system,
group 8.4.3.2 CAB, menu 2.
The fire extinguisher sits at the entry on the left frame beam or inside
the cab. Instructions on use are found on the fire extinguisher.
The roof grating protects the operator from falling objects. This consti-
tutes protection that goes beyond the legal requirements.
9.3 Seat
Seat, general
page
–
seat)
The seat’s function is to give the operator a good sitting position and
contribute to a good work environment. The cab’s seat has several ad-
justment possibilities and meets high comfort standards.
1 2 The seat has the following equipment:
• mechanical adjustment
3
• arm rest right
• armrest left
4
• seat heating
• seat belt
• 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
Seats, description
page
–
Bege 9120 is the same as the standard seat, but is equipped with air
1 2 suspension. Air suspension automatically adjusts seat height and
springing to the operator’s weight. Air suspension is supplied by a spe-
cial compressor installed on the underside of the cab.
3
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.
4
The seat has the following equipment:
• mechanical adjustment
• air suspension (with external compressor)
5 • arm rest right
• armrest left
8 6
006826
7 • seat heating
Controls, Bege 9120 • seat belt
1. Lumber support adjustment
2. Right armrest adjustment • head rest
Seats, description
page
–
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.
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
1. Fore/aft adjustment
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
Seat, changing
page
–
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.
6 Fit in the reverse order.
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
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 14.
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 power upon warm-up of the cab
control unit (D790-1) via the seat heating relay (K383). The signal can
be checked with the diagnostic menu, see section 8 Control system,
group 8.4.3.8 CAB, menu 8.
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.
Bege 9120:
Isringhausen 6800:
Compressor air-suspension seat
• Mini-wheel
• Joystick control
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 27 C. The unit is
4 operated with controls on the instrument panel.
D
C Heating system (EHC)
The heating system (EHC) handles heating and ventilation. (The heat-
E E
ing system cannot provide cooling.)
3
The heating system uses heat from the engine’s cooling system via a
heating coil to heat ambient air. The fan forces the ambient air through
the heating coil on through ducts in the cab interior. It is then directed
to the windscreen (defroster) or the feet.
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
IMPORTANT
D. Low-pressure gas
E. Ambient air for cab ventilation On machines with ECC or AC, it is vital that the engine
F. Heated or cooled air to the cab cooling system is refilled with coolant with the correct
G. Ambient air for removal of heat concentration of antifreeze. Otherwise there is a risk
that the air conditioning system will freeze during
usage.
function description
2 1 3 26
D D 25
D
4 °C D
D
°C
6
7 D790-1 D790-2 D795
D D D797-1
16
D D794
15 D
12
M D D
14 22 23
5 °C Pa °C
M D
D 19 21
13 20 C 24
M 18
17
D
D 9
M
°C
8 11
10
007690
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
5 The outlet fan temperature sensor R = 10 k at 25 C Sensor, temperature outlet fan, description
(B775-2) sends the cab control unit page 56
(D790-1) a voltage signal proportional to D5: Diagnostic menu, see section 8 Control
temperature. system, group 8.4.4.2, CLIMATE menu 2
7 Control unit, cab (D790-1) regulates Checked by control sys- Section 11 Common electrics,
temperature and air distribution with sig- tem, error shown with er- group 11.5.3.1 Cab control unit (D790-1)
nals from sensors and controls. ror code.
9 Control unit, cab (D790-1) controls Wa- U = 0.5–4.5 V Water valve, description page 41
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.
11 Heat exchanger heat adds heat to the - Heat exchanger heat, description page 38
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 sys- tem, error shown with er- group 11.5.3.10 Engine control unit (D794)
tem on the CAN bus. ror code.
14 Control unit, cab (D790-1) controls Fan Checked by control sys- Cab fan, description page 35
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 54
Damper motor (Y672), which sets the air D15: Diagnostic menu, see section 8 Con-
distributor to the required position. trol system, group 8.4.4.8 CLIMATE, menu
The air distributor’s position is sent back 8 and 8.4.4.4 CLIMATE, menu 4
to the cab control unit (D790-1). This
gives information for controlling the air
distributor’s position.
16 The frame control unit (D797-1) controls Checked by control sys- Section 11 Common electrics, group
AC compressor engagement. tem, error shown with er- 11.5.3.3 Frame control unit (D797-1)
ror code.
20 The moisture filter absorbs any moisture - Moisture filter, description page 47
from the cooling circuit. The fluid reser-
voir stores the refrigerant.
21 The pressure switch (S246) sends a sig- U = 24 V Pressure switch, description page 48
nal to the frame control unit (D797-1) if D21: Diagnostic menu, see section 8 Con-
the pressure in the system becomes ab- trol system, group 8.4.4.3, CLIMATE
normally high or low. menu 3
22 The expansion valve adjusts the amount - Expansion valve, description page 49
of refrigerant that is let in to the evapora-
tor. If the temperature in the evapora-
tor’s outlet pipe increases, the
evaporator valve increases flow of re-
frigerant so that heat dissipation in the
evaporator increases.
25 The defroster switch on Control unit KIT Checked by control sys- Section 11 Common electrics,
(D790-2) activates the defroster pro- tem, error shown with er- group 11.5.3.11 KIT control unit (D790-2)
gram for the air conditioning for six ror code.
minutes.
26 Control unit KID (D795) shows the heat- Checked by control sys- Section 11 Common electrics,
ing and ventilation settings in the tem, error shown with er- group 11.5.3.12 KID control unit (D795)
display. ror code.
checking
1 Machine in service position, see section B Safety.
2 Navigate to the service menu and press Enter.
000056
1 23
4 5 NOTE
000060
OLS EXTRA
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
Menu 3
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
PRESENT INPUT SIGNAL
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
NOTE
Air to the round panel vents is not controlled by the air
conditioning.
Menu 5
9 Checks the switches for temperature, air distribution and fan
DIAG CLIMATE 5(8) speed.
PRESENT INPUT SIGNAL
REQUIRED TEMP 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.
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
ANTI-CLOCKWISE XY XY "CLOCKWISE 00 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
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 may affect maximum airflow.
1 004999
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 from the diagnostic menu, see
section 8 Control system, group 8.4.4.6 CLIMATE, menu 6 .
2 004999
replacement
1 Machine in service position, see section B Safety.
2 Remove the wiper arms.
3 Remove the nuts which hold the wiper motor in the protective
plate.
4 Remove the protective plate.
6 Remove the bolts which secure the arm and motor in the plate.
7 Detach the connector from the motor.
8 Replace the motor.
9 Fit in the reverse order. Tighten the wiper arm to 16-20 Nm.
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.
The signal can be checked via the diagnostic menu, section 8 Control
system, group 8.4.4.6 CLIMATE, menu 6.
1
003209
3 Remove the bolts which hold the wiper motor in the protective
plate.
4 Remove the protective plate.
7 Remove the bolts which secure the plate and cab fan.
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
WARNING
Personal injury, environmental damage
IMPORTANT
Working on the air conditioning requires special
authorisation.
12 Detach all fluid inlets and outlets from the heat exchanger.
13 Lift out the heat exchanger carefully.
14 Replace the heat exchanger.
15 Fit in the reverse order. Tighten the wiper arm to 16-20 Nm.
16 Check for leaks and refill the AC-system with refrigerant R134a,
using the intended equipment.
For volume, see section F Technical data.
IMPORTANT
Connection points for cooling hoses. Working on the air conditioning requires special
authorisation.
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.
010021
1. Water valve
2. Steering valve
9.4.7 Compressor
AC compressor, description
page
–
1 2 3 NOTE
For tightening torque of refrigerant hoses and pressure switch,
see section F Technical data.
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-
4
tromagnetic clutch, which is controlled by a thermostat.
009116
5 The signal can be checked via the diagnostic menu, section 8 Control
system, group 8.4.4.6 CLIMATE, menu 6.
The illustration depicts the compressor for Cummins
QSB 6.7
1. Rigging screw (belt tensioner)
2. Compressor
3. Connections
4. Screw and nut
5. Drive belt
Compressor, replacement
page
–
2
WARNING
Personal injury, environmental damage
7 Drain the oil from the old compressor (through the intake and out-
let connections) and the hoses. Measure the oil quantity.
8 Drain the oil from the new compressor.
9 Fill the new compressor with the same quantity of oil as was
drained from the old compressor - minimum 0.1 litre.
NOTE
Fill new oil through the compressor’s suction connection.
10 Fit the new compressor and other equipment in reverse order.
11 Check for leaks and refill the AC-system with refrigerant R134a,
using the intended equipment.
For volume, see the plate for the climate control system.
IMPORTANT
Working on the air conditioning requires special
authorisation.
006264
1. Lock ring
2. Locking washer
1. Groove
1. Electromagnetic clutch
9.4.8 Condenser
Condenser, description
page
–
NOTE
For tightening torque of refrigerant hoses and pressure switch,
see section F Technical data.
The condenser is located on the radiator in the engine compartment.
The function of the condenser is to convert the hot, high-pressure gas
from the compressor to liquid form. Pipes and cooling fins in the con-
denser battery absorb the heat, which is dissipated with a fan.
The temperature of the refrigerant in the condenser varies from ap-
prox. 50 C to 70 C and the pressure varies between 12 and 14 bar
depending on ambient temperature and airflow through the condens-
er. When the refrigerant has been condensed to liquid, it is directed on
to the fluid reservoir/filter dryer.
010023
Condenser, replacement
page
–
WARNING
Personal injury, environmental damage
IMPORTANT
Working on the air conditioning requires special
authorisation.
IMPORTANT
Working on the air conditioning requires special
authorisation.
NOTE
2 3 For tightening torque of refrigerant hoses and pressure switch,
1
see section F Technical data.
The moisture filter collects the liquid refrigerant, binds moisture, and
filters impurities. The reservoir functions as an expansion tank in the
cooling circuit.
When the refrigerant has passed through the dryer in the bottom of the
fluid reservoir, it rises through a standpipe. Through a sight glass, it is
possible to check that flow is without bubbles and that the system is
adequately filled with refrigerant.
010024
NOTE
2 3 For tightening torque of refrigerant hoses and pressure switch,
1
see section F Technical data.
The pressure switch cuts off the current to the compressor’s electro-
magnetic clutch if the pressure in the cooling circuit becomes abnor-
mally high or low.
The signal can be checked via the diagnostic menu, section 8 Control
system, group 8.4.4.3 CLIMATE, menu 3.
010024
WARNING
2 3
1 Personal injury, environmental damage
IMPORTANT
Working on the air conditioning requires special
authorisation.
010024
1. Fluid reservoir moisture filter 4 Unscrew the pressure switch from its mounting.
2. Pressure switch. 5 Replace the pressure switch.
3. Sight glass
6 Check for leaks and refill the AC-system with refrigerant R134a,
using the intended equipment.
For volume, see section F Technical data.
IMPORTANT
Working on the air conditioning requires special
authorisation.
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.
WARNING
Personal injury, environmental damage
IMPORTANT
Working on the air conditioning requires special
authorisation.
IMPORTANT
Working on the air conditioning requires special
authorisation.
1
3
005001
2
WARNING
Personal injury, environmental damage
NOTE
Requires special authorisation.
1 Machine in service position, see section B Safety.
2 Drain the AC system of refrigerant.
IMPORTANT
Working on the air conditioning requires special au-
thorisation.
IMPORTANT
Working on the air conditioning requires special
authorisation.
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
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
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
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
3 The signal can be checked via the diagnostic menu, section 8 Control
system, group 8.4.4.2 CLIMATE, menu 2.
005001
1. Instrument panel
2. Steering column adjustment
3. Lower protective cover
Sensor, cab temperature, detects the temperature of the air in the cab.
The signal can be checked via the diagnostic menu, section 8 Control
system, group 8.4.4.1 CLIMATE, menu 1
1
3
005001
007985
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
2 when the ignition is on.
3
004909
The wipers automatically switch off 2 minutes after the operator has
left the driver’s seat.
The front wiper is the parallel wiper type, i.e. the wiper blade is moved
in a constant vertical manner over the windscreen.
The rear wiper is of the type sector wiper. The wiping angle is approx.
180 degrees.
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.
The signal can be checked via the diagnostic menu. See
section 8 Control system, group 8.4.3.1 CAB, menu 1.
003619
A B
A. Washer fluid reservoir
B. Washer motors
The wiper motor drives the front windshield wiper. The wiper arm is
mounted on the motor. The motor produces the movement of the
wiper.
The signal can be checked from the diagnostic menu, see
section 8 Control system, group 8.4.3.2 CAB, menu 2.
The wiper motor drives the roof window’s wiper. The wiper arm is
mounted on the motor. The motor produces the movement of the
wiper.
The signal can be checked via the diagnostic menu. See
section 8 Control system, group 8.4.3.4 CAB, menu 4.
3 Detach the washer hose and the connector to the wiper motor.
4 Undo the lock nut securing the wiper arm and disconnect the
washer fluid hose.
5 Remove and replace the wiper motor.
6 Install in reverse order. Tighten the wiper arm with 16-20 Nm.
The wiper motor drives the rear window wiper. The wiper arm is
mounted on the motor. The motor produces the movement of the
wiper.
The signal can be checked via the diagnostic menu. See
section 8 Control system, group 8.4.3.3 CAB, menu 3.
6 Remove the screws securing the motor and the lock nut on the
motor.
7 Replace the wiper motor.
8 Fit in the reverse order. Tighten the wiper arms to 16-20 Nm.
Work lights are shut off automatically after 5 minute’s idling in order to
prevent discharge of the batteries. Auxiliary work lights are shut off af-
ter 2 minutes. Lighting is activated automatically again when the oper-
ator sits in the seat, a gear is selected or the accelerator pedal is
pressed.
NOTE
It is important that the right type of bulb is used for each area. See
section F Technical data.
1 2 3 5 4
D1 D2 D3 D5 D4 9
10
14 D15 11
6 D9
D6 18
D18 D19 15 15
D7 19 D11
7 16
17 M D16 D10
D17 D790-1 D790-2
21 8, 13 30 12 32
D22 D23 D24 D25 D26 D797-1 D797-2 D791-1
Pa 20
D27
D20 D31 D33 D34
D28
010025
D29
22 23 24 25 26 27 28 29 31 33 34
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 8.4.2.13 LIGHTS, menu 13
3 The switch for mast work lights (S105-3) sends Switch in ON position: D3: Diagnostic menu, see
a voltage signal to the cab control unit U = 24 V section 8 Control system
(D790-1). group 8.4.2.10 LIGHTS, menu 10
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
group 8.4.2.1 LIGHTS, menu 1
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
group 8.4.2.6 LIGHTS, menu 6
6 The door NC switch (S266-LE & S266-RI) Door open: U = 24 V Interior lighting cab, description page 73
sends a voltage signal to the cab control unit D6: Diagnostic menu, see
(D790-1). section 8 Control system
group 8.4.2.9 LIGHTS, menu 9
7 The switch for entry lighting (S141) sends a Switch in ON position: Entry lighting, description page 74
voltage signal to the cab control unit (D790-1). U = 24 V D7: Diagnostic menu, see
section 8 Control system,
group 8.4.2.15 LIGHTS, menu 15
8 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 Cab control unit
with error code. (D790-1)
9 Multi-function lever (S162) sends a voltage Lever in high beam po- Gear selector and multi-function lever,
signal to Control unit KIT (D790-2). sition: US162/56a = 24 V description page 11
D9: Diagnostic menu, see
section 8 Control system,
group 8.4.2.3 LIGHTS, menu 3
10 Lever, direction indicator (S161) sends a volt- Left: US161/6 = 24 V D10: Diagnostic menu, see
age signal to Control unit KIT (D790-2). section 8 Control system,
Right: US161/1 = 24 V
group 8.4.2.4 LIGHTS, menu 4
11 Switch, interior lighting on Control unit KIT Checked by control D11: 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 8.4.2.9 LIGHTS, menu 9
12 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 KIT control unit
with error code. (D790-2)
13 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 Cab control unit
with error code. (D790-1)
14 The relay for cab roof work lights (K3017-1 and UK3017/30 = 24 V Working lights, cab, description page 73
K3017-2) is activated when the cab roof work
UK3017/85 = 0 V
lights are activated. It supplies voltage to the
cab roof work lights (E406L-1 E406R-1, Cab roof work lights
E406L-2 & E406R-2). on:
UK3017/86 = 24 V
UK3017/87 = 24 V
UK3017/87 = 0 V
15 The cab roof work lights (E406L-1 E406R-1, Light on: U = 24 V Working lights, cab, description page 73
E406L-2 & E406R-2) come on when the cab D15: Diagnostic menu, see
roof work lights are activated. section 8 Control system,
group 8.4.2.12 LIGHTS, menu 12
16 Back-up lights, white (E405L & E405R) are Light on: U = 24 V Back-up lights, description page 71
switched on when reverse gear is selected. D16: Diagnostic menu, see
section 8 Control system,
group 8.4.2.8 LIGHTS, menu 8
17 Revolving beacon (H428) is switched on when Light on: U = 24 V Revolving beacon, description page 72
the revolving working light is activated. D17: Diagnostic menu, see
section 8 Control system,
group 8.4.2.6 LIGHTS, menu 6
18 Interior lighting (E434-1) comes on when a Light on: U = 24 V Interior lighting cab, description page 73
door is opened or if activated when the switch D18: Diagnostic menu, see
on the KIT control unit (D790-2). section 8 Control system,
group 8.4.2.9 LIGHTS, menu 9
19 Entry lighting (E433) comes on when activated Light on: U = 24 V Entry lighting, description page 74
with the entry lighting switch or when the inte- D19: Diagnostic menu, see
rior lighting comes on. section 8 Control system,
group 8.4.2.15 LIGHTS, menu 15
20 The brake light NO switch (S216) sends a volt- Brake pressure over Section 4 Brakes, group 4.3.8 Make-
age signal to the frame control unit (D797-1). 0.2 MPa: U = 24 V contact (closing switch) brake lights
D20: Diagnostic menu, see
section 8 Control system,
group 8.4.2.7 LIGHTS, menu 7
21 The frame control unit (D797-1) supplies volt- Checked by control Section 11 Common electrics,
age to the machine lights. system, error shown group 11.5.3.2 Frame control unit
with error code. (D797-1)
22 The direction indicators (H422, H423, H426 & Light on: U = 24 V Direction indicators, description
H427) come on when they or the warning lights page 71
are activated. D22: Diagnostic menu, see
section 8 Control system,
group 8.4.2.5 LIGHTS, menu 5
23 The running lights (H416-1, H416-2, H417-1 & Light on: U = 24 V Running lights, description page 70
H417-2) come on together with the headlights. D23: Diagnostic menu, see
section 8 Control system,
group 8.4.2.2 LIGHTS, menu 2
24 Headlights, low beam (E400L & E400R) are Light on: U = 24 V Headlights, description page 70
switched on when the headlight is activated. D24: Diagnostic menu, see
section 8 Control system,
group 8.4.2.3 LIGHTS, menu 3
25 Headlights high beam (E402L-1 & E402R-1) Light on: U = 24 V Headlights, description page 70
are lit when high beam is activated. D25: Diagnostic menu, see
section 8 Control system,
group 8.4.2.3 LIGHTS, menu 3
26 Tail lights, red (H412L & H412R) are switched Light on: U = 24 V Tail lights, description page 70
on when the headlight is activated. D26: Diagnostic menu, see
section 8 Control system,
group 8.4.2.2 LIGHTS, menu 2
27 Brake lights (H411L & H411R) are switched on Light on: U = 24 V Brake lights, description page 70
when the brake is activated. D27: Diagnostic menu, see
section 8 Control system,
group 8.4.2.8 LIGHTS, menu 8
28 The mast work lights (E404L-1 & E404R-1) Light on: U = 24 V Mast working lights, description page 72
come on when activated. D28: Diagnostic menu, see
section 8 Control system,
group 8.4.2.10 LIGHTS, menu 10
29 The auxiliary mast work lights (E404L-4 & Light on: U = 24 V Mast working lights, description page 72
E404R-4) come on when the mast work lights D29: Diagnostic menu, see
are activated. section 8 Control system,
The front wing auxiliary work lights (E404L-4 & group 8.4.2.11 LIGHTS, menu 11
E404R-4) come on when the cab roof work
lights are activated.
30 The frame control unit (D797-2) supplies volt- Checked by control Section 11 Common electrics,
age to the machine lights. system, error shown group 11.5.3.3 Frame control unit
with error code. (D797-2)
31 The auxiliary mast work lights (E404L-2 & Light on: U = 24 V Mast working lights, description page 72
E404R-2) come on when the mast work lights D31: Diagnostic menu, see
are activated. section 8 Control system,
The front wing auxiliary work lights (E404L-2 & group 8.4.2.11 LIGHTS, menu 11
E404R-2) come on when the cab roof work
lights are activated.
32 Control unit, attachment (D791-1) supplies Checked by control Section 11 Common electrics,
voltage to the attachment’s lights. system, error shown group 11.5.3.5 Attachment control unit
with error code. (D791-1)
33 The twistlock attachment work lights (E404L-3 Light on: U = 24 V Working lights, attachment, description
& E404R-3) come on when activated. page 73
The work lights for lifting hook attachment with D33: Diagnostic menu, see
lock tongues (E404UL, E404UR, E404LL and section 8 Control system,
E404LR) come on when activated. group 8.4.2.13 LIGHTS, menu 13
34 The twistlock attachment auxiliary work lights Light on: U = 24 V Working lights, attachment, description
(E404L-5 and E404R-5) come on when page 73
activated. D34: Diagnostic menu, see
section 8 Control system,
group 8.4.2.11 LIGHTS, menu 11
NOTE
It is important that the right type of bulb is used for each area. See
section F Technical data.
The machine has the following lights:
1 4 5 6 6 7 9
30 3,8,10
12
29
28
27
26
008397
22,23,24,25 21 19,20 18 17 16 15 11,13,14
1. Mast work lights (E404L-1 & E404R-1) 16. Entry lighting (E433)
2. Auxiliary mast work lights (E404L-4 & E404R-4) 17. Switches, see Controls and instruments, overview page 5
2. Relay, cab roof work lights (K3017-1 & K3017-2) 18. Switch, entry lighting (S141)
8. Auxiliary cab roof work lights (E406L-2 & E406R-2) 23. Running lights, front (H416-1 & H417-1)
9. Revolving beacon (H428) 24. Headlights, low beam (E400L & E400R)
Headlights, high beam (E402L-1 & E402R-1)
10. Control unit, cab (D790-1) 25. Auxiliary front wing work lights (E404L-4 & E404R-4)
11. Running lights, rear (H416-2 & H417-2) 26. Lifting hook attachment work lights (E404LL & E404LR)
12. Back-up lights, white (E405L & E405R) 27. Control unit, attachment (D791-1)
13. Tail lights, red (H412L & H412R) 28. Twistlock attachment work lights (E404L & E404R)
Brake lights (H411L & H411R)
14. Direction indicators, rear (H426 & H427) 29. Auxiliary carriage work lights (E404L & E404R)
15. Door NC (normally closed) switch (S266-LE & S266-RI) 30. Lifting hook attachment work lights (E404UL & E404UR)
9.6.1 Headlights
Headlights, description
page
–
Headlights are located in the front of the machine to give the operator
enhanced vision when operating in darkness, and to provide surround-
ing traffic and the environment an indication of the machine’s position.
Headlights have high beam and low beam (for meeting other traffic).
Switch between low and high beam with the gear and multi-function le-
ver. The signal goes to the cab control unit (D790-1).
The low and high beam signals can be checked from the diagnostic
menu, section 8 Control system, group 8.4.2.3 LIGHTS, menu 3.
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,
section 8 Control system, group 8.4.2.2 LIGHTS, menu 2.
Tail lights are located in the rear of the machine to provide surrounding
traffic and the environment an indication of the machine’s position, and
a limited enhancement of the view for the operator in darkness.
The tail lights are controlled by selecting with the headlight switch. The
signal goes to the cab control unit (D790-1).
The lights and their signal can be checked from the diagnostic menu,
section 8 Control system, group 8.4.2.2 LIGHTS, menu 2.
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 (D797-1), which
supplies power to the brake lights.
The lights and their signal can be checked from the diagnostic menu,
see section 8 Control system, group 8.4.2.7 LIGHTS, menu 7 and
8.4.2.8 LIGHTS, menu 8.
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 reversing lights are controlled by the direction of travel. The signal
travels via the CAN bus.
The lights and their signal can be checked from the diagnostic menu,
see section 8 Control system, group 8.4.2.7 LIGHTS, menu 7 and
8.4.2.8 LIGHTS, menu 8.
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 indicator is controlled by selecting with the switch (lever)
for direction indicators. The signal travels to the frame control unit
(D797-1).
The lights and their signal can be checked from the diagnostic menu,
see section 8 Control system, group 8.4.2.4 LIGHTS, menu 4 and
8.4.2.5 LIGHTS, menu 5.
Machines for the North American market are equipped with flashing
brake lights front and rear during operation.
Work lights on the mast provide enhanced view when load handling in
darkness.
The work lights are controlled by selecting with the mast work light
switch. The signal travels to the cab control unit (D790-1).
The lights and their signal can be checked from the diagnostic menu,
see section 8 Control system, group 8.4.2.10 LIGHTS, menu 10 and
8.4.2.11 LIGHTS, menu 11.
Xenon lights)
DANGER
Xenon lights are activated with high voltage. Always
turn off the main electric power before working on xe-
non lights.
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.
Xenon lights)
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.
The lights and their signal can be checked from the diagnostic menu,
section 8 Control system, group 8.4.2.9 LIGHTS, menu 9.
Xenon lights)
2
1
010026
2 Entry lighting
Work lights on the front wing provide enhanced view when load han-
dling 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).
The lights and their signal can be checked from the diagnostic menu,
section 8 Control system, group 8.4.2.11 LIGHTS, menu 11.
Xenon lights)
NOTE
It is important that the right type of bulb is used for each area. See
section F Technical data.
1 2 3 4
D2 D3 D17 17 6
7
D1 D4
15
16
D6
D6
D15 D13 D18
13 18
14 M
8 19
D790-1 D790-2 D795
D14 5
9
D797-1 D791-1
D10 20
D11
10 11 D21
21
010027
12
D12
2 Switch, flashing hazard lights (Haz- Switch in ON position: D2: Diagnostic menu, see section 8 Control sys-
ard) (S109) sends a voltage signal to U = 24 V tem, group 8.4.2.4 LIGHTS, menu 4
Control unit, cab (D790-1).
3 Switch, parking brake (S107) sends Switch in ON position: D3: Diagnostic menu, see section 8 Control sys-
a voltage signal to Control unit, cab U = 24 V tem group 8.4.5.4 HYD, menu 4
(D790-1).
4 The horn switch (S149-3) sends a Switch in ON position: D4: Diagnostic menu, see section 8 Control sys-
voltage signal to the cab control unit U = 24 V tem, group 8.4.3.5 CAB, menu 5
(D790-1).
5 Control unit, cab (D790-1) sends Checked by control Section 11 Common electrics, group 11.5.3.1 Cab
messages about activation on the system, error shown control unit (D790-1)
CAN bus. with error code.
6 Multi-function lever (S162) sends a Signal button pressed Gear selector and multi-function lever, description
voltage signal to Control unit KIT in: US162/H = 24 V page 11
(D790-2). D6: Diagnostic menu, see section 8 Control sys-
tem, group 8.4.3.5 CAB, menu 5
8 Control unit KIT (D790-2) sends Checked by control Section 11 Common electrics,
messages about activation on the system, error shown group 11.5.3.11 KIT control unit (D790-2)
CAN bus. with error code.
9 The frame control unit (D797-1) sup- Checked by control Section 11 Common electrics,
plies voltage to the machine lights system, error shown group 11.5.3.2 Frame control unit (D797-1)
and buzzers. with error code.
10 The direction indicators (H422, Light on: U = 24 V Direction indicators, description page 71
H423, H426 and H427) come on D10: Diagnostic menu, see section 8 Control sys-
when the warning lights are tem, group 8.4.2.5 LIGHTS, menu 5
activated.
11 The reversing lights (E405L and Light on: U = 24 V Back-up lights, description page 71
E405R) come on when reverse gear D11: Diagnostic menu, see section 8 Control sys-
is selected. tem, group 8.4.2.8 LIGHTS, menu 8
12 Back-up alarm (H965) is activated Reverse gear en- Reverse alarm, description page 79
when reverse gear is selected. gaged: U = 24 V D12: Diagnostic menu, see section 8 Control sys-
tem, group 8.4.2.8 LIGHTS, menu 8
13 Horn (H850) sounds when the horn Horn active: U = 24 V Horn, description page 78
is activated. D13: Diagnostic menu, see section 8 Control sys-
tem, group 8.4.3.5 CAB, menu 5
14 Revolving beacon (H428) is switched Light on: U = 24 V Revolving beacon, description page 72
on when the flashing hazard light is D14: Diagnostic menu, see section 8 Control sys-
activated. tem, group 8.4.2.6 LIGHTS, menu 6
UK3016/87 = 24 V
16 Loud horn (H850-1) sounds when Horn active: U = 24 V Horn, description page 78
the horn is activated.
17 Make-contact (closing switch) opera- Operator in seat: Sensor operator in seat, description page 22
tor-in-seat (S230) sends a voltage U = 24 V D17: Diagnostic menu, see section 8 Control sys-
signal to Control unit, cab (D790-1) tem, group 8.4.3.6 CAB, menu 6
when there is a load on the driver’s
seat.
19 In the event of warnings, control unit A clicking sound is au- Section 11 Common electrics,
KID (D795) activates the warning dible when then termi- group 11.5.3.12 KID control unit (D795)
lamp to draw the operator’s attention nation resistor is
to the warning message. activated.
20 The attachment control unit (D791-1) Checked by control Section 11 Common electrics, group 11.5.3.5 At-
supplies voltage to the automatic system, error shown tachment control unit (D791-1)
spreading buzzer during automatic with error code.
spreading.
21 The automatic spreading buzzer Buzzer active: U = 24 V Section 7 Load handling group 7.5.10 Buzzer, au-
(H9003) is activated when automatic tomatic spreading 20’-40’
spreading 20’-40’ is activated. D21: Diagnostic menu, see section 8 Control sys-
tem, group 8.4.9.21 ATTACH, menu 21
NOTE
On machines with side lift attachment, an audible signal can also be given with the open twistlock button (S1002) on
the panel for hydraulic functions or the open twistlock button on the joystick, provided that the "open twistlocks upon
contact" function is not active.
1 2 3 4 5 6
008395
19 18 17 16 15 14 13 12 10,11 9 8 7
9. Direction indicators, rear (H426 & H427) 19. Buzzer automatic spreading (H9003)
9.7.1 Horn
Horn, 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 22) indicates to the control system if the operator leaves the
seat.
The buzzer is located in the steering wheel panel.
The signal can be checked via the diagnostic menu. See
section 8 Control system, group 8.4.3.6 CAB, menu 6.
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.
The signal can be checked from the diagnostic menu, see
section 8 Control system, group 8.4.2.8 LIGHTS, menu 8.
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.
A E B 001512
A. Side windows
B. Windshield (front window)
C. Roof window
D. Rear window
E. Windshield (Side window front)
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
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 81.
Windscreen, replacement
page
–
NOTE
Read the handling advice for silicone adhesive before starting
work. See Silicone adhesive, handling advice page 81.
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.
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
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.
The side windows are secured in the cab and doors with decor strips.
For further details, see Glass/windows/mirrors, description page 81.
NOTE
The method describes a general procedure.
3 Remove the decor strip which runs around the whole window.
4 Carefully remove any remains of glass from the rubber strip.
7 Thread the rubber strip around the whole window; use special
tools.
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.
The cab has one rearview mirror located in the cab and external rear-
view mirrors out on the machine. The rearview mirrors give the opera-
tor a view around the machine.
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 89.
1
007425
3
1. IR-diodes
2. Camera
3. Microphone
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
BRI
4
007416
5
1. Choice of camera
2. Menu
3. Light intensity
4. Volume setting
5. On and off
3
003206
4
Cab Spirit Delta
1. Cab frame
2. Door
3. Cab suspension
4. Cab undercarriage
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
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
WARNING
If anybody goes under the tilted cab.
Extreme danger!
NOTE
Operate the cab when the machine is stationary!
The cab can be hydraulically tilted 10° along its length axis.
When the load is to be lifted high up, the cab can be tilted back to im-
prove visibility and make the working position more ergonomic.
With the automatic/manual cab tilt switch in the automatic cab tilt po-
sition, the cab will be tilted when the mast reaches a predetermined lift
height.
The cab can be tilted up or down with the manual cab tilt switch. This
switch is also operative when the cab tilt switch is in the automatic
position.
For the cab to be tilted, machine speed must not exceed 5 km/h, the
driver’s doors must be closed and the parking brake or emergency
stop switch for servo circuits must not be activated.
If the cab is not in the lowest position, machine speed is limited to not
more than second gear and 5 km/h.
Speed < 5 km/h Section 8 Control system, group 8.2.3 Speed limitation
Control breaker Disengaged Section 11 Common electrics, group 11.5.1.4 Emergency stop switch
voltage
6
3 1 4 1
0
0 2
D3 D4 D6
5 7
D790-1 D797-1
8
D797-2 12
9 D8
10
D9 12
B
T
A
TP
P LS LSPB
11
2 010028
1 The cab tilt shuttle valve sends a load P = 3.5 MPa Section 10 Common hydraulics,
signal to the hydraulic oil pumps. group 10.5.3 Shuttle valve
2 The hydraulic oil pumps pump oil from P = 190.5 MPa Hydraulic oil pump, description page 95
the hydraulic oil tank.
3 The automatic/manual cab tilt switch U = 24 V Controls and instruments, overview page 5
(S199-2) sends a voltage signal to the D3: Diagnostic menu, see section 8 Control
cab control unit (D790-1). system, group 8.4.11.5 MOVE-CAB, menu 2
4 The manual cab tilt switch (S1010) cab U = 24 V Controls and instruments, overview page 5
up/down sends a voltage signal to the
cab control unit (D790-1).
5 If manual cab tilt is selected, the cab Checked by control sys- Section 11 Common electrics,
control unit (D790-1) transmits cab up or tem, error shown with er- group 11.5.3.1 Cab control unit (D790-1)
cab down on the CAN bus. ror code.
6 If automatic cab tilt is selected, sensor U = 0-5 V Sensor for automatic cab tilt (B7211-1), de-
B7211-1 sends information to the frame scription page 99
control unit (D797-1) when the attach- D8: Diagnostic menu, see section 8 Control
ment reaches a predetermined lift system, group 8.4.11.5 MOVE-CAB, menu 2
height.
7 If automatic cab tilt is selected, the Checked by control sys- Section 11 Common electrics,
frame control unit (D797-1) transmits tem, error shown with er- group 11.5.3.2 Frame control unit (D797-1)
cab up or cab down on the CAN bus. ror code.
8 The cab up sensor (B769-1) and cab Cab up/cab down sensor, description
down sensor (B769-2) provide voltage page 99
information on cab position to the frame D10: Diagnostic menu, see section 8 Control
control unit (D797-2). system, group 8.4.11.5 MOVE-CAB, menu 3
9 The frame control unit (D797-2) acti- Checked by control sys- Section 11 Common electrics,
vates the cab up servo valve (Y6047) or tem, error shown with er- group 11.5.3.3 Frame control unit (D797-2)
the cab down servo valve. (Y6048). ror code. D11: Diagnostic menu, see section 8 Control
system, group 8.4.11.5 MOVE-CAB, menu 4
10 The servo valve for cab up (Y6047) or Cab tilt control valve, description page 95
servo valve for cab down (Y6048) pres-
surises the tilt spool in the cab tilt control
valve.
11 The control valve’s tilt slide changes po- - Cab tilt control valve, description page 95
sition and pressurises the tilt cylinders.
12 The tilt cylinders angle the cab in rela- - Cab tilt hydraulic cylinders, description
tion to the cab undercarriage. page 98
The tiltable cab is supplied pressure from a hydraulic oil pump; see
1 section 10 Common hydraulics, group 10.4.2 Axial piston pump with
variable displacement.
2
3
008082
The control valve controls the speed and direction of the cab tilt func-
tion. The control valve is located on the right on the frame, in the area
beside the gearbox.
Electrically controlled pressure reduction valves (servo valves) con-
vert electric current to a small hydraulic pressure which is proportional
1 to the current, so-called servo pressure. The servo pressure operates
a spring-centred control spool in the control valve, and thus controls
2
the main flow.
1 Tilt slide
The tilt spool controls the direction and flow of oil to the tilt cylinders.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Machine in service position, see section B Safety.
2 Depressurise the hydraulic systems, See section B Safety.
3 Mark and disconnect the hydraulic hoses from the control valve.
NOTE
Plug all connections immediately to protect the hydraulic
system from impurities.
4 Mark and disconnect the cable harness from the control valve.
5 Remove the control valve.
Remove the attaching bolts and lift away the valve. Place the
valve on a clean and protected surface.
6 Transfer parts to the new control valve.
NOTE
Check that the O-rings on the hydraulic connections are in-
tact, clean and in the correct position.
NOTE
Transfer one part 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.
9 Connect the cable harness to the control valve according to the
marking.
10 Connect the hydraulic hoses to the control valve in according to
the marking.
NOTE
Check that the O-rings are intact, clean and in the correct
position.
11 Start the engine and check for leaks.
CAUTION
Air in the hydraulic system may cavitate and result in
product damage.
13 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 at the top of the level glass. Top up as needed.
CAUTION
Do not overfill!
There are two brake valves situated between the cab tilt control valve
and the cab tilt cylinders. The brake valves are adjustable and choke
pressure to the tilt cylinders, which reduces the speed of cab tilting.
The brake valves are located on the control valve’s connections to the
hydraulic cylinders.
010032
The lower parts of the hydraulic cylinders are fixed to the cab under-
carriage and the upper parts are fixed to the cab. The hydraulic cylin-
ders lift the front edge of the cab, thereby tilting it.
010033
The cab undercarriage for cab tilt comes in two sections, the part that
holds the cab has a hinge at the trailing edge which is located on the
frame, and the hydraulic cylinders are located at the leading edge be-
tween the parts.
adjusting
Check and adjust the position sensor as follows:
1 Machine in service position, see section B Safety.
2 Check that the sensor is clean and free from dirt.
3 Check that the distance between the sensor and the indicator is
15 1 mm.
4 Adjust if necessary.
The steering wheel panel is secured to the steering column and con-
tains warning and indicator lights, display (KID), function keys (KIT)
and switches.
The left instrument panel is located in the left corner of the cab. It con-
tains rotary controls, switches, and ventilation.
The panel, which is mounted on the driver’s seat, houses switches and
controls for load handling functions and a emergency stop switch to in-
terrupt load handling functions in progress.
On machines equipped with a control lever, it is located next to the
panel .
9.11.5 Insulation
Insulation, description
page
–
Sun blinds can be chosen for the front window (windscreen) 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.
9.11.8 Reading-lamp
Reading lamp, description
page
–
The reading lamp is fitted on a jointed bracket to the right in front of the
door in the cab.
008228
9.12 Frame
Frame, description
page
–
1 2 3 4
5
010030
1 2 3
010031
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 106) 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 ( ).
The cab area has footsteps for easy access. There is a rail by the
cab area.
9.13.4 Counterweights
Counterweights, description
page
–
DANGER
The counterweights are factory fitted and are adapted
according to the machine’s properties.
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 section
F Technical data.
The central lubrication’s pause and run-time must be set after replace-
ment, the setting is unique to each machine, depending on the ma-
chine’s equipment. At replacement, the new pump unit should be set
in the same way as the old.
If the machine is not greased correctly, pause and run-time can be ad-
justed. 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.
Pause time
Pause-time is the length of the interval between greasings. The inter-
Example figure
val is adjusted in whole hours between 1 and 15 hours. Pause-time is
1. Setting pause time (red)
adjusted with the red handle (position 1)
2. Setting run time (blue)
3. Manual operation of pump
Switch position 1 2 3 4 5 6 7 8 9 A B C D E F
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
The pump unit consists of containers with stirrer, pump housing with
built-in motor, timer, pump element, filler nipple, and safety valve.
The central lubrication works with lubrication cycles (pause and run-
ning time as well as read-in time). In the pump there is a circuit board
with a timer with which one can set the pump motor’s run and pause
time.
When the central lubrication works, it greases the 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.
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
9.15 Paint/coatings
Paint/coatings, description
page
–
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.
10 Common hydraulics
10 Common hydraulics....................................................................................... 3
10.2 Safety valves .............................................................................................. 3
10.2.1 Accumulator drain valve ........................................................................ 3
10.2.2 Relief valve, attachment ........................................................................ 3
10.2.3 Pressure limiting valve ........................................................................... 4
10.2.4 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 ....................................... 9
10.4.3 Pipes and hoses .................................................................................. 18
10.5 Hoses, pipes and valves .......................................................................... 19
10.5.1 Pipes and hoses .................................................................................. 19
10.5.2 Priority valve ........................................................................................ 20
10.5.3 Shuttle valve ........................................................................................ 20
10.5.5 Collecting block, unfiltered returns ....................................................... 21
10.6 Temperature control, cleaning and hydraulic oil ....................................... 22
10.6.1 Tank heater .......................................................................................... 25
10.6.2 Cooler hydraulic oil .............................................................................. 26
10.6.3 Cooling fan ........................................................................................... 27
10.6.4 Sensor hydraulic oil temperature ......................................................... 27
10.6.5 Radiator bypass valve ......................................................................... 29
10.6.6 Breather filter hydraulic oil tank ........................................................... 30
10.6.7 Hydraulic oil filter ................................................................................. 30
10.6.8 Hydraulic oil ......................................................................................... 32
10.6.9 Fine filter hydraulic oil .......................................................................... 33
10.6.10 Pipes and hoses .................................................................................. 34
10.7 Other ........................................................................................................ 35
10.7.1 Hydraulic cylinders ............................................................................... 35
10 Common hydraulics
mm mm mm mm mm mm
009960
The relieve valve sits on the pressure supply to the attachment on hy-
draulic oil pump 2. See section 7 Load handling, group 7.4.7 Attach-
ment relief valve.
009961
The pressure limiting valve leads too high pressure in the hydraulic oil
supply to tank, protecting the hydraulic system against excessive
pressures.
The pressure limiting valve sits on the collecting block for pressure
supply from the load handling hydraulic oil pump and the quick-lift hy-
draulic oil pump on the hydraulics plate in front of the transmission.
009962
1 2 1 3 2 4 5 The hydraulic oil tank forms part of the side panel on the right side of
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
hydraulic cylinders are in the bottom position.
1
008086
008087
1. Accumulator
10.4 Pumps
10.4.1 Gear pump with fixed displacement
Gear pump with fixed displacement, description
page
–
2
3
008082
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Machine in service position, see section B Safety.
2 Depressurise the hydraulic systems, See section B Safety.
3 Mark up and release the hydraulic hoses from the gear pump.
009963
009964
6 Remove the spacer ring from the gear pump or axial piston pump.
Clean the O rings’ contact surfaces on the spacer ring.
7 Check the O-rings and replace as needed. Install the O-rings on
the spacer ring. Brush heat-resistant sealing silicone on the seal-
ing face against the gear pump, see section F Technical data.
NOTE
Only use silicon on the side facing the gear pump.
NOTE
Check that the O-rings are intact, clean and in the correct
position.
009963
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
13 Turn on the main electric power and start the engine.
14 Check that the hose connections and seal between gear pump
and axial piston pump are airtight.
008049
NOTE
If the pump is replaced due to malfunction, change the oil
and filter as well.
16 Check the brake pressure; see section 4 Brakes, group 4.3.1 Hy-
draulic oil pump.
description
The hydraulic oil pumps that supply the working hydraulics are of the
1
2 type variable axial piston pump, and are controlled by load signals de-
pending on the flow demand from each function.
Three pumps, of which two are assembled with a junction block, sup-
ply the working hydraulics. The junction block controls oil to and from
the pumps. On the junction block, there is a spacer block that contains
test connections for checking pump pressure. There are non-return
valves on the spacer block that prevent oil from being pumped around
between the pumps instead of out in the hydraulic system. On the
3 spacer block between the quick-lift hydraulic oil pump (position 2) and
4 the load handling hydraulic pump (position 1), there is a branching to
the attachment hydraulics with a separate non-return valve. The non-
009967
return valve houses the attachment relief valve; see Relief valve at-
1. Hydraulic oil pump for load handling. tachment, description page 3.
2. Hydraulic oil pump for quick-lift.
3. Hydraulic oil pump for brake system, cooling and
filtering.
4. Hydraulic oil pump for steering and load handling.
function description
D790-1 D790-2
LS (21)
D797-1 D795 P
8,12,18 P (16)
LS
D8 D12 P
6 26
C 7 P
T
PS TP
5 1
P LS LSPB
EF PP
14 2 P
CF P
9 13,17,19,22 4 T LS
LS
15,20
T
23
11
24,27
C C
009148
10 16,21 3,25,28
2 The steering shuttle valve sends the - Shuttle valve, description page 20
load signal on to the hydraulic oil pump
for steering and load handling.
3 The hydraulic oil pump for steering and See pressure plate Max. Axial piston pump with variable displace-
load handling increases the flow. pressure hydraulic oil ment, description page 9
pumps on left frame
member.
4 The priority valve prioritises pressure See pressure plate Steer- Section 5 Steering, group 5.2.2 Priority
from the hydraulic pump for steering ing pressure, on left valve.
and load handling to the steering valve frame member.
or the lever steering control valve over
the lift and tilt control valve.
6 Accumulator servo pressure stores the See pressure plate servo Section 7 Load handling, group 7.2.4 Accu-
servo pressure. pressure, on left frame mulator servo circuit
member.
7 The servo filter cleans the servo oil up- - Section 7 Load handling, group 7.2.2 Servo
stream of the lift and tilt control valve. filter
8 If the quick-lift conditions are fulfilled, U = 24 V Section 7 Load handling, group 7.2 Lifting/
the KDU frame control unit (D797-1) lowering
activates the solenoid valve for quick- D8: Diagnostic menu, see section 8 Control
lift engagement (Y6062). system, group 8.4.5.6 HYD, menu 6.
10 The quick-lift hydraulic oil pump in- See pressure plate Max. Axial piston pump with variable displace-
creases the flow. pressure hydraulic oil ment, description page 9
pumps on left frame
member.
11 The pressure limiting valve drains - Pressure limiting valve, description page 4
pressure to tank if the pressure in the
hydraulic system becomes too high.
13 The solenoid valve for main pump relief - Section 7 Load handling, group 7.4.6 Valve
(Y6062-2) routes a relieved constant block, main pump relief
pressure to the hydraulic oil pump for
load handling. This serves as a load
signal.
14 The attachment shuttle valve sends the - Shuttle valve, description page 20
load signal on to the hydraulic oil pump
for load handling.
15 The cab tilt shuttle valve sends the load - Shuttle valve, description page 20
signal on to the hydraulic oil pump for
load handling.
17 When solenoid valve for main pump re- - Section 7 Load handling, group 7.4.6 Valve
lief (Y6062-2) is not activated, the re- block, main pump relief
lieved pressure is directed to tank.
19 The solenoid valve for main pump relief - Section 7 Load handling, group 7.4.6 Valve
(Y6062-2) routes a relieved constant block, main pump relief
pressure to the hydraulic oil pump for
load handling. This serves as a load
signal.
20 The cab tilt shuttle valve sends the load - Shuttle valve, description page 20
signal on to the hydraulic oil pump for
load handling.
21 The hydraulic oil pump for load han- See pressure plate Max. Axial piston pump with variable displace-
dling increases the flow to the cab tilt pressure hydraulic oil ment, description page 9
control valve. pumps on left frame
member.
22 When solenoid valve for main pump re- - Section 7 Load handling, group 7.4.6 Valve
lief (Y6062-2) is not activated, the re- block, main pump relief
lieved pressure is directed to tank.
23 The steering valve sends a load signal - Section 5 Steering, group 5.2.3 Steering
when the steering wheel is turned. valve.
24 The shuttle valve signal cable sends a - Shuttle valve, description page 20
load signal on to the hydraulic oil pump
for steering and load handling.
25 The hydraulic oil pump for steering and See pressure plate Steer- Axial piston pump with variable displace-
load handling increases the flow. ing pressure, on left ment, description page 9
frame member.
26 For control valve for lever steering - Section 5 Steering, group 5.2.10 Control
sends a load signal to the shuttle valve valve, mini-wheel/lever steering
when a function is activated.
27 The shuttle valve signal cable sends a - Shuttle valve, description page 20
load signal to the hydraulic oil pump for
steering and load handling.
28 The hydraulic oil pump for steering and - Axial piston pump with variable displace-
load handling increases the flow. ment, description page 9
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Operate and warm up the machine so that the hydraulic oil reach-
es operating temperature, approx. 50 C.
2 Turn off engine.
3 Connect a pressure gauge to measuring outlet on hydraulic oil
pump 1.
4 Start the engine and run it at idle.
3 5 Check the stand-by pressure for one pump at a time in the follow-
2
1 ing order:
Hydraulic oil pump for steering and load handling: 3.0 MPa
Hydraulic oil pump for quick-lift: 2.8 MPa
Hydraulic oil pump for load handling: 2.6 MPa
The settings apply to standard machine, certain machines can
have higher stand-by pressure. For correct stand-by pressure,
009965
change
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Park the machine with the mast fully extended and spreading
halfway extended.
CAUTION
Make sure that the oil level in the hydraulic oil tank is
below the mouth of the axial piston pump’s suction
hose.
If there is not enough room to lift the mast, the hydraulic oil tank
must be drained; see Hydraulic oil, changing page 32.
2 Disconnect the main power supply.
3 Depressurise the hydraulic systems, See section B Safety.
4 Detach the gear pump from the hydraulic oil pump (see Gear
pump, changing page 6) in order to replace the pump for steering
and load handling.
5 Suspend the gear pump.
6 Use a plastic bag or similar to protect the connection on the gear
pump.
7 Mark the hydraulic hoses and disconnect them from the axial pis-
ton pump.
NOTE
Plug all connections immediately to protect the hydraulic
system from impurities.
009969
CAUTION
Be careful and make sure that no gasket remains fall
down into the transmission.
NOTE
Check that the O-rings are intact, clean and in the correct
position.
12 Brush sealing silicone on the axial piston pump flange facing the
transmission, see section F Technical data.
13 Fit the axial piston pump in place.
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.
NOTE
Check that the O-rings are intact, clean and in the correct
position.
009969
16 If the spacer ring is still on the axial piston pump. Remove the
spacer ring between the gear pump and axial piston pump.
If the spacer ring remains in place on the gear pump, go to
step 20.
Clean the O rings’ contact surfaces on the spacer ring.
17 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 gear pump, see section F Technical data.
NOTE
Only use silicone on one side, the side facing the brake
pump.
CAUTION
Vent the axial piston pump before starting the engine.
The illustration shows a separate pump. The oil in the axial piston pump may cavitate and
cause product damage.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
23 Turn on the main electric power and start the engine.
24 Check that the hose connections and seal between gear pump
and axial piston pump are airtight.
25 Check the pump pressures, see Hydraulic oil pump, checking
page 13.
008049
26 Check the oil level in the hydraulic oil tank. The oil level shall be
at the top of the level glass. Top up as needed.
NOTE
If the pump is replaced due to malfunction, change the oil
and filter in the hydraulic system as well.
CAUTION
Do not overfill!
venting
NOTE
Read the safety instructions for oil before working, see section B
Safety.
009970
3 Loosen the hoses to the hydraulic system’s feed from the axial
piston pump one at a time and let oil flow out. Tighten the connec-
tions when oil free of air flows out.
4 Remove the compressed air from the tank and fit the breather
filter.
5 Turn on the main electric power and start the engine.
6 Let the engine idle for at least one minute. Check that all connec-
tions seal tight.
7 Lower the mast and raise it again very slowly so that the pump
009969
NOTE
Straight coupling requires a counterhold wrench to prevent
damage to the O-ring.
7. The O-rings must not be oiled when fitted.
Hose length
C/L
Hose length is measured on a laid-out hose between the sealing sur-
faces. On angled connections, measure from the sealing surface's
centre line [C/L] according to the figure.
Cleanliness
The function and service life of hydraulic components depend to a
great extent on how clean the hydraulic oil is. Therefore, it is very im-
portant to prevent dirt from entering the brake and hydraulic system.
Some simple advice to keep the hydraulic system clean.
• Always clean the area around a component before starting to
001015
work.
C/L line for measuring hose length • Plug hose connections immediately after disconnecting. If possi-
ble, use correct plugs for the connection type. If plugs are missing,
use clean plastic bags and cable ties or tape to seal the
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.
1. Chooses between the load signal from the lift and tilt control valve
and the control signal from the attachment control valve. The shut-
tle valve sends control signals on to the steering shuttle valve or
the hydraulic oil pump for steering and load handling; see Axial
piston pump with variable displacement, description page 9.
2. Chooses between the load signal from the control valve for lifting/
lower and extension and control pressure from the control valve.
The shuttle valve sends the control signal on to control the hydrau-
lic oil pump for load handling; see Axial piston pump with variable
displacement, description page 9.
3.
Chooses between the load signal from the attachment shuttle
valve (position 1) or the cab tilt control valve to the hydraulic oil
pump for steering and load handling; see Axial piston pump with
variable displacement, description page 9.
This shuttle valve is fitted if the machine is equipped with a tiltable
cab.
The block collects several return lines from different valves and leads
these directly back to the tank.
The drain lines are very sensitive to back-pressure, if pressure builds
up in the drain lines the valves will not work properly.
The block is located on the hydraulic plate in front of the transmission.
010020
function description
The oil of the hydraulic system is cooled and cleaned through circula-
tion through the radiator and filters. The radiator has a temperature-
regulated electric fan that prevents overheating.
Temperature control consists of a hydraulic oil tank, hydraulic oil
pump, valve block, hydraulic oil cooler, cooling fan, hydraulic oil filter,
fine filter, hydraulic oil temperature sensor, and bypass valve.
The hydraulic oil pump for the brake system pumps oil (from the tank)
through the brake system’s cooling circuit to be cooled in the hydraulic
oil cooler. Some of the oil is filtered by the fine filter. An electric cooling
fan increases airflow through the cooler when a temperature reduction
is needed. When the oil is cold, a bypass valve opens and leads the
oil directly to the tank so that resistance through the cooler and filter
does not become too great. The bypass valve closes when the oil gets
hot and then instead leads the oil through the cooler and filter. The
temperature sensor regulates fan activation and temperature display.
The return oil from load handling and steering is filtered through the
hydraulic oil filter in the hydraulic oil tank.
˚C
˚C
P
P
T
EF PP
14 9, 15
P D790-2
P CF D795
LS
T LS
T D797-1
L R
8, 10, 13
16
D7 D8
11 M
P T
6
2 3 4 12
1 1 1 1
5
008090
˚C 7
2 The brake oil filter cleans the oil. - See Section 4 Brakes,
group 4.3.2 Brake oil filter
3 The accumulator charging valve directs oil Charge: See Section 4 Brakes, group 4.3.3
to charging of accumulators or through the P = 20.50.5 MPa Accumulator charging valve
brake system’s cooling circuit. Cooling: P < 0.1 MPa
4 The oil passes through the drive axle block. - See Section 4 Brakes, group 4.3.6 Drive
axle block
5 A small amount of oil is guided through the Fine filter hydraulic oil, description
fine filter and back to the hydraulic oil tank. page 33
6 The hydraulic oil cooler cools the oil. - Hydraulic oil cooler, description page 26
7 The hydraulic oil temperature sensor - Sensor, hydraulic oil temperature, de-
(B776) sends the frame control unit scription page 27
(D797-1) a voltage signal proportional to D7: Diagnostic menu, see
the hydraulic oil temperature. section 8 Control system,
group 8.4.5.1 HYD, menu 1
9 The KID control unit (D795) shows oil tem- - Section 9 Frame, body, cab and acces-
perature in the operating menu hydraulic oil sories, group 9.1 Controls and
temperature. instruments
10 If the hydraulic oil temperature is high, the U = 24 V Cooling fan, description page 27
frame control unit (D797-1) supplies volt- D8: Diagnostic menu, see
age to the cooling fan. section 8 Control system,
group 8.4.5.1 HYD, menu 1
11 The cooling fan increases the airflow - Cooling fan, description page 27
through the hydraulic oil cooler, thus in-
creasing cooling output.
12 If the pressure through the cooler is too P = 0.2 MPa Bypass valve, cooler, description
high, the thermal bypass valve opens and page 29
directs the oil past the cooler
13 If the hydraulic oil temperature is too high, Checked by the control Section 11 Common electrics, group
the frame control unit (D797-1) transmits a system; error shown with 11.5.3.2 Frame control unit (D797-1)
warning for high hydraulic oil temperature error code. D8: Diagnostic menu, see
on the CAN bus. section 8 Control system,
group 8.4.5.1 HYD, menu 1
14 The KIT control unit (D790-2) activates the - Section 9 Frame, body, cab and acces-
hydraulic oil temperature warning light. sories, group 9.1 Controls and
instruments
15 The KID control unit (D795) shows the er- Checked by the control Section 11 Common electrics,
ror code on the display. system; error shown with group 11.5.3.12 KID control unit (D795)
error code.
16 Return oil from the lift and tilt control valve - Bypass valve, cooler, description
and the attachment control valve is cleaned page 29
by the oil filters in the hydraulic oil tank.
CAUTION
The tank heater is connected to high voltage
(110 - 400 V).
High voltage.
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
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
009988
50-70 C.
009989
NOTE
Read the safety instructions for oil before working, see section B
Safety.
2 NOTE
3 Plug all connections immediately to protect the hydraulic
system from impurities.
4 Disconnect the cable harness from the cooling fan.
5 Remove the attaching bolts and lift away the cooler.
6 Transfer the cooling fan to the new cooler.
7 Fit the cooler.
8 Connect the cable harness to the cooling fan.
009990
10 Fill the hydraulic oil tank with oil; see Hydraulic oil, changing
page 32. The oil level should be visible in the sight glass.
CAUTION
Do not overfill!
The electric cooling fan is suctioning. The cooling fan is located at the
rear of the cooler. The fan draws air from the machine’s outside
through the cooler. Openings in the side cover allows air to pass
through the cooler.
The cooler is supplied voltage by the rear frame control unit (D797-1)
upon activation. The cooling fan is activated when temperature of the
oil in the hydraulic oil tank is 65 C and is deactivated when the tem-
perature is 55 C.
The signal can be checked via the diagnostic menu. See
section 8 Control system, group 8.4.5.1 HYD, menu 1.
009991
NOTE
Read the safety instructions for oil before working, see section B
Safety.
NOTE
Check that the O-rings are intact, clean and in the correct
position.
5 Connect the cable harness to the sensor.
009992
CAUTION
Do not overfill!
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.
009993
NOTE
Read the safety instructions for oil before working, see section B
Safety.
IMPORTANT
Ensure cleanliness around the filter and filling point
when working on the hydraulic 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 fitting the bypass valve.
009993
Bypass valve
6 Fill the hydraulic oil tank with oil; see Hydraulic oil, changing
page 32. The oil level should be visible in the sight glass.
IMPORTANT
Do not overfill!
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.
009994
NOTE
Read the safety instructions for oil before working, see section B
Safety.
IMPORTANT
Ensure cleanliness around the filter and filling point
when working on the hydraulic tank.
1 Switch off the engine and switch off the main electric power.
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.
NOTE
Check the hydraulic oil level with the mast fully lowered and
Magnetic rod
the side lift attachment retracted.
NOTE
Read the safety instructions for oil before working, see section F
Technical data.
IMPORTANT
Ensure cleanliness around the filter and filling point
when working on the hydraulic tank.
IMPORTANT
Do not overfill!
The fine filter sits behind the hydraulic oil tank on the right side of the
machine. The filter is connected in parallel with 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.
009968
NOTE
Read the safety instructions for oil before working, see section B
Safety.
IMPORTANT
Ensure cleanliness around the filter and filling point
when working on the hydraulic tank.
10.7 Other
10.7.1 Hydraulic cylinders
Hydraulic cylinders, repairs
page
–
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.
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:
001498
5
1. Hydraulic pressure
2. The sealing lip is pressed outward against the
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
7. O-ring
6
4
5
001499
5
1. Hydraulic pressure
2. The sealing lip is pressed outward against the
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
1
1. Hydraulic pressure
2. O-ring
3. Support ring
4. Cylinder head sealing surface
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
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
6 4
002370
5
1. Hydraulic pressure
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
002950
5 4 3 1 6 Double-acting piston seal
The double-acting seal functions with pressure from both sides, e.g. in
a steering cylinder.
All of the interior surface of the cylinder barrel is a sealing surface and
it is therefore extremely important that it is completely free from
damage.
Exercise caution when fitting the piston in the cylinder barrel, making
2
002951
sure that the seal is not damaged by the cylinder barrel threads.
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.
11 Common electrics
11 Common electrics
mm mm mm mm mm mm
IMPORTANT
Never switch off the voltage with the battery discon-
nector when the engine is running. This could dam-
age the alternator.
11.2.2 Fuses
Fuses, changing
page
–
11.3 Batteries
11.3.1 Start battery
Start battery, description
page
–
WARNING
The batteries’ electrolyte contains corrosive sulphu-
ric acid.
WARNING
Risk of explosion!
Personal injury!
WARNING
Short-circuiting of battery.
NOTE
Take great care when reconnecting the cables to prevent
short circuiting.
11.4 Alternator
11.4.1 Alternator
Alternator, description
page
–
Alternator, replacement
page
–
description
D11 D8
686800
D795 D790-2 D797-1
11 8
6, 7 10 9
D790-1 D791 D797-2
D10 D9
- +
D793 D794
D2
D1 D3 D4 D5
1 2 3 4 5
2 The interior lighting switch of the U = 24 V Section 9 Frame, body, cab and accessories,
KIT control unit (D790-2) sends a group 9.6.12 Interior lighting
voltage signal to the cab control D2: Diagnostic menu, see section 8 Control system,
unit (D790-1). group 8.4.2.13 LIGHTS, menu 13
3 Switch, flashing hazard lights U = 24 V Section 9 Frame, body, cab and accessories,
(S109) sends a voltage signal to group 9.6.7 Warning lights
Control unit, cab (D790-1). D3: Diagnostic menu, see section 8 Control system,
group 8.4.2.5 LIGHTS, menu 5
4 When the ignition switch (S150) is U = 24 V Section 9 Frame, body, cab and accessories,
turned to position I, it sends a volt- group 9.1 Controls and instruments
age signal to the cab control unit D4: Diagnostics menu, see section 8 Control system,
(D790-1). group 8.4.1.5 CAN/POWER, menu 5
6 Control unit, cab (D790-1) acti- - Cab control unit (D790-1), description page 18
vates a hold circuit, which acti-
vates the control unit’s control
logic.
7 Control unit, cab (D790-1) acti- UK11:7 = 24 V Cab control unit (D790-1), description page 18
vates a redundant voltage feed to
U K11:8 = 24 V
other control units.
UK11:9 = 24 V
The cab control unit (D790-1) has
4 outputs for redundant voltage UK11:10 = 24 V
feed while other control units have
two inputs for redundant voltage
feed. In case of a malfunction of
one voltage feed the control unit is
supplied by the other feed.
8 Control unit, cab (D790-1) sup- UK2:7 = 24 V Frame control unit (D797-1), description page 19
plies voltage to the control logic of D8: Diagnostic menu, see section 8 Control system,
UK2:8 = 24 V
the other control units via the re- group 8.4.1.10 CAN/POWER, menu 10
dundant voltage feed.
9 UK2:7 = 24 V Frame control unit (D797-2), description page 20
Redundant voltage feed Activated. Redundant voltage feed of control units, function descrip-
tion page 7
Redundant CAN bus Communication established. Redundant CAN bus, description page 40
- +
K315-2
1 2 K315-1
7 3, 6
D1 D2 D3 3
D794
D793
11 D11
4, 5
D8 D10
D790-1 D791 D797-2
2, 8 10
9
D795 D790-2 D797-1
008687
D9
2 When the ignition switch U = 24 V Section 9 Frame, body, cab and accessories,
(S150) is turned to position I, group 9.1 Controls and instruments
it sends a voltage signal to D2: Diagnostic menu, see section 8 Control system,
the cab control unit group 8.4.1.5 CAN/POWER, menu 5
(D790-1).
3 The cab control unit U = 24 V Cab control unit (D790-1), description page 18
(D790-1) supplies voltage to D3: Diagnostic menu, see section 8 Control system,
ignition voltage relay K315-1 group 8.4.1.5 CAN/POWER, menu 5
in the frame electrical distri-
bution box and ignition volt-
age relay K315-2.
7 The drive-train’s CAN-bus Checked by control sys- CAN bus drive-train, description page 43
establishes communication. tem, error shown with
error code.
8 Ignition voltage to Control UK1:2 = 24 V Cab control unit (D790-1), description page 18
unit, cab (D790-1). D8: Diagnostic menu, see section 8 Control system,
UK1:3 = 24 V
group 8.4.1.7 CAN/POWER, menu 7
UK1:4 = 24 V
9 Ignition voltage to the frame UK2:1 = 24 V Frame control unit (D797-1), description page 19
control unit (D797-1). D9: Diagnostic menu, see section 8 Control system,
UK2:9 = 24 V
group 8.4.1.10 CAN/POWER, menu 10
UK2:10 = 24 V
10 Ignition voltage to the frame UK2:1 = 24 V Frame control unit (D797-2), description page 20
control unit (D797-2). D10: Diagnostic menu, see section 8 Control system,
UK2:9 = 24 V
group 8.4.1.13 CAN/POWER, menu 13
UK2:10 = 24 V
11 Ignition voltage to Control UA1 = 24 V Transmission control unit (D793), description page 22
unit, transmission (D793). D11: Diagnostic menu, see section 8 Control system,
group 8.4.1.12 CAN/POWER, menu 12
Control breaker Not activated Section 9 Frame, body, cab and accessories, group 9.1 Controls and
instruments
D794
D793
D5
K3007
3, 4 6
K3009-1 K3009-2
- +
K3002
D4
D2
D7
D8
D790-1 D797-2 D797-1
1, 2, 5 7
8
D795 D790-2 D791
008688
Pos Explanation Signal description Reference
1 Ignition voltage is activated by the cab con- Checked by control Ignition voltage (15), function description
trol unit (D790-1) system, error shown page 9
with error code.
2 Control unit, cab (D790-1) supplies voltage UK3009-1/86 = 24 V Cab control unit (D790-1), description
to Relay, emergency stop switch voltage page 18
(K3009-1) in the frame electronic box. D2: Diagnostic menu, see section 8 Control
system, group 8.4.1.6 CAN/POWER,
menu 6
3 Relay, emergency stop switch voltage UK3009-2/87 = 24 V Electronic box frame, description page 16
(K3009-1) supplies voltage to Relay, emer-
gency stop switch voltage (K3009-2) in the
frame electronic box.
5 Control unit, cab (D790-1) activates Relay, UK3009-2/86 = 24 V Cab control unit (D790-1), description
emergency stop switch voltage (K3009-2) in page 18
the electronic box. D5: Diagnostic menu, see section 8 Control
system, group 8.4.1.6 CAN/POWER,
menu 6
6 Relay, emergency stop switch voltage UK3009-2/87 = 24 V Electronic box frame, description page 16
K3009-2 supplies voltage to the emergency
stop switch circuit.
7 The control units are supplied with emer- Emergency stop Frame control unit (D797-2), description
gency stop switch voltage as long as emer- switch in home posi- page 20
gency stop switch is not pressed in. tion: UK2:1 = 24 V D7: Diagnostic menu, see section 8 Control
The control unit on the attachment is only system , group 8.4.1.13 CAN/POWER,
supplied emergency stop switch voltage, menu 13
thus all attachment functions stop if the
8 Emergency stop Attachment control unit (D791), description
emergency stop switch is activated.
switch in home posi- page 21
If the emergency stop switch is pressed, ig- tion: UK2:1 = 24 V D8: Diagnostic menu, see section 8 Control
nition voltage to the cab control unit (D790-
Emergency stop system, group 8.4.1.15 CAN/POWER,
1) is cut off, thereby cutting off control cur-
switch in home posi- menu 15
rent to emergency stop switch voltage relay
K3009-1, emergency stop switch voltage re- tion: UK2:9 = 24 V
lay K3009-2, the tilt relay (K3002) and the Emergency stop
lift/lower relay (K3007). The power supply to switch in home posi-
the control units is cut off and the functions tion: UK2:10 = 24 V
cease.
Emergency stop
As an extra safety measure, the cab control switch in home posi-
unit (D790-1) also transmits the status of the tion: UK2:11 = 24 V
emergency stop switch the CAN bus. Thus,
functions are also cut off at the signal level.
004770
Control breaker
CAUTION
The max. output of the voltage converter is 12 V/20 A
(including the radio).
The electronic box is mounted on the rear wall of the cab, on the left.
7 Located there are:
• Control unit cab (D790-1).
6 • Circuit fuses for cab battery voltage (30), ignition voltage (15)
F58-4 and circuit fuses for cab ignition voltage (15) F58-5.
• Buzzer for alarm if, for example, the operator leaves the machine
without the parking brake being applied.
• Connectors.
• Relays.
•
Voltage converter 24 V to 12 V.
1 • Connector customer accessory. Output voltage 24 V, max. 10 A.
Connector 9-pin Universal mate-n-lock. For part number see
2
Spare parts catalogue.
NOTE
1. Control unit cab (D790-1) This connector is not fitted on the machine if the machine is
2. Diagnostic socket, machine equipped with voltage converter.
3. Diagnostic socket, CAN bus, drivetrain
4. Fuse holder for circuit fuses, cab battery
voltage (30) and ignition voltage (15) F58-4 (upper)
and circuit fuses, cab ignition voltage (15) F58-5
CAUTION
(lower).
Connector X067 is to be used to connect auxiliary
5. Voltage converter
electrical equipment. Use of other connections could
6. Termination resistor
overload the wiring and cause product damage.
7. Connector customer accessory 24V / 10A
The electronic box is fitted on the side of the machine. Also located
5 6
4 there are:
7
3 • Circuit fuses.
2
8 • Socket for communication with the engine and transmission; see
1
Communication between PC and machine, description page 44.
• Main fuses.
9
• Control unit, transmission (D793)
10
• Power relays for voltage feed to the machine’s functions.
11
12
13
007958
14
1. Circuit fuses, emergency stop switch voltage
(15E)F58-3
2. Circuit fuses, ignition voltage (15) F58-2
3. Circuit fuses, battery voltage (30) F58-1
4. Engine diagnostic socket, VODIA (Volvo engine)
5. Transmission diagnostic socket
6. Main fuses
7. Transmission control unit (D793)
8. Attachment connection terminal
9. Lift/lower relay K3007
10. Tilt in/out relay K3002
11. Ignition switch relay K315-2
12. Ignition switch power relay K315-1
13. Emergency stop switch power relay K3009-1
14. Emergency stop switch power relay K3009-2
-
1
-
2
- 1
3
-
4
5 -
-
6
007184
1. Termination resistor
1 2 3 4
009172
9 8 7 6
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 Control unit, cab has four indicator lights that indicate the control unit’s
1. Connection terminals for fan, work lights, wind- function (see illustration).
screen 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, fault indication tive. No power in system.
Green light when power electronics and 15-voltage are
supplied voltage.
The frame control unit (D797-1) processes input data from sensors
1 and sends control signals to relays and solenoid valves.
The control unit has four indicator lights that indicate the control unit’s
2
function (see illustration).
3
Lamp 1 Green light on when there is battery voltage to the unit.
4 The light is physically controlled by voltage feed to the
control unit.
The frame control unit (D797-2) processes input data from sensors
1 and sends control signals to relays and solenoid valves.
The control unit has four indicator lights that indicate the control unit’s
2
function (see illustration).
3
Lamp 1 Green light on when there is battery voltage to the unit.
4 The light is physically controlled by voltage feed to the
control unit.
The attachment control unit (D791) processes input data from sensors
1 and sends control signals to relays and solenoid valves of the side lift
attachment.
2
The control unit has four indicator lights that indicate the control unit’s
3 function (see illustration).
007959
• boost pressure
1. Connector from Cummins wiring • charge air temperature
2. Connector XD794-3 • coolant temperature
3. Connector from Cummins wiring
4. Connector XD794-3 • oil pressure
• water in fuel
• fuel pressure
• coolant level
The data gives exact information about the operating conditions and
makes it possible for the control unit to, for example, calculate the cor-
rect fuel volume and to check the condition of the engine.
CAUTION
Each control unit is individually calibrated to the en-
gine in question. Switching of control units between
engines is absolutely forbidden.
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 (2) for the control system and its
panel for warning and indicator lights (1).
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
000051
1. LCD-display
2. Series of diodes that serve as an indicator light for
serious malfunction.
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.
X061 Electronic box, cab Ground connection, Control unit, KID (D795)
Ground connection, Control unit KIT (D790-2)
X201 Electronic box frame Ground connection and power supply, Control unit, transmission
(D793)
X209 Front edge of frame Power supply, cab control unit (D790-1)
CAN bus, frame control unit (D797-1)
CAN bus, frame control unit (D797-2)
CAN bus, attachment control unit (D791)
X210 Between engine and gearbox Power supply and ground connection Control unit, engine (D794)
CAN bus, Control unit, engine (D794)
X211 Frame control unit (D797-1) 42-pin connector to frame control unit (D797-1)
X214 Front edge of frame CAN bus, frame control unit (D797-2)
CAN bus, attachment control unit (D791)
X221 Frame control unit (D797-2) 42-pin connector to frame control unit (D797-2)
X222 Frame control unit (D797-2) Power supply and ground connection, frame control unit (D797-2)
CAN bus, frame control unit (D797-2)
Emergency stop switch voltage
X252 Control unit, transmission (D793), 18-pin connector for Control unit, transmission (D793)
electronic box frame
X279 Control unit, engine (D794) Power supply and ground connection Control unit, engine (D794)
CAN bus Drive-train
X401 Attachment control unit (D791) CAN bus, attachment control unit
X421 Attachment control unit (D791) 42-pin connector for Control unit attachment (D791)
X422 Attachment control unit (D791) Power supply and earth connection, Control unit attachment (D791)
CAN bus Control unit attachment option (D791)
Emergency stop switch voltage
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.
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
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.
High side driver, Logical one (1) generates voltage out, U >= 22.5 V E.g. working lights and
5A Max. load 5 A wiper motors.
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.
Max. instantaneous current load, 70 A
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).
11.6 Communication
11.6.1 CAN bus
CAN bus, description
page
–
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
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.
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]
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).
D797-2 D797-1
D795
in a loop.
Segment numbering with optional equipment without The redundant CAN bus can handle the loss of a segment. The link is
cab tilt 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.
Redundant voltage feed Activated. Redundant voltage feed of control units, function description page 7
S1
S4
2
D791
7
014795
Pos Explanation Signal description Reference
1 Control unit, cab (D790-1) establishes Checked by control sys- Cab control unit (D790-1), description
redundant CAN bus communication by tem, error shown with er- page 18
sending a request on the CAN bus via ror code. Diagnostic menu, see section 8 Control sys-
CAN R. tem, group 8.4.1.1 CAN/POWER, menu 1
and 8.4.1.2 CAN/POWER, menu 2
2 The attachment control unit (D791) A clicking sound is audi- Attachment control unit (D791), description
sends a response back on the CAN bus ble when then termina- page 21
via CAN L and sends the request on via tion resistor is activated. Diagnostic menu, see section 8 Control sys-
CAN R. tem, group 8.4.1.1 CAN/POWER, menu 1
Termination resistors in the control and 8.4.1.2 CAN/POWER, menu 2
nodes ensure communication segment
by segment.
3 The frame control unit (D797-2) sends a A clicking sound is audi- Frame control unit (D797-2), description
response back on the CAN bus via CAN ble when then termina- page 20
L and sends the request on via CAN R. tion resistor is activated. Diagnostic menu, see section 8 Control sys-
Termination resistors in the control tem, group 8.4.1.1 CAN/POWER, menu 1
nodes ensure communication segment and 8.4.1.2 CAN/POWER, menu 2
by segment.
5 Control unit KID (D795) sends a re- A clicking sound is audi- KID control unit (D795), description page 26
sponse back on the CAN bus via CAN L ble when then termina- Diagnostic menu, see section 8 Control sys-
and sends the request on via CAN R. tion resistor is activated. tem, group 8.4.1.1 CAN/POWER, menu 1
Termination resistors in the control and 8.4.1.2 CAN/POWER, menu 2
nodes ensure communication segment
by segment.
6 The KIT control unit (D790-2) is not con- A clicking sound is audi- KIT control unit (D790-2), description
nected to the redundant CAN bus. The ble when then termina- page 25
KIT control unit (D790-2) does not com- tion resistor is activated.
municate until ignition voltage (15) is
activated.
7 If all control units have responded, the Checked by control sys- Diagnostic menu, see section 8 Control sys-
cab control unit (D790-1) deactivates tem, error shown with er- tem, group 8.4.1.1 CAN/POWER, menu 1
the segment to the attachment control ror code. and 8.4.1.2 CAN/POWER, menu 2
unit (D791).
If a control unit has not responded, then
Control unit, cab (D790-1) uses both
CAN L and CAN R to keep communica-
tion open and analyses which segment
is faulty.
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
The engine and transmission control units come from the respective
engine and transmission suppliers.
The machine uses only one model of gearbox, but there are several
engine alternatives. All engine alternatives use the standard, therefore
the messages are based on the same structure regardless of which
engine is used.
Communication with Control unit, engine (D794) and Control unit,
transmission (D793) are separate from the redundant CAN bus.
The signals can be checked from the diagnostic menu, see
section 8 Control system, group 8.4.1.4 CAN/POWER, menu 4.
000033
1 2
1. Redundant CAN bus
2. CAN bus drivetrain
3. Engine control unit (D794)
4. Engine
5. Transmission control unit (D793)
6. Transmission
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 electrical distribution box cab
(position 1) are used for programming the control units in the cab, on
the frame, and on the attachment.
Socket for drivetrain CAN bus in the electrical distribution box cab (po-
sition 2) is used for communicating with the engine and transmission
via CAN bus.
The VODIA socket in the frame electronic box (position 3) is used to
connect the Volvo’s diagnostic tool - VODIA.
The socket for transmission control unit (D793) programming in the
frame electrical distribution box (position 4) is used to program the
transmission control unit (D793).
For further details on communication between computer and machine,
3 contact Kalmar Industries AB.
4
010054
007443
the machine, antenna for communication and GPS-antenna ( ) for
positioning.
RMI-interface
The interface records the communication on the CAN-bus and sends
the information to a central RMI-server. The control unit in the machine
can sends the information via GSM, GPRS, WLAN, Radio-modem,
SMS, or e-mail in case of a malfunction.
From the RMI-server, 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.
NOTE
RMI only sends data from the machine, no data can be sent to
the machine. RMI cannot be used to control the machine.
D Error codes
Error codes
mm mm mm mm mm mm
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
The control and monitoring system’s display is divided into four fields
C where the information is shown (see figure to the left).
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.
• 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.
The error code is shown automatically on the display.
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.
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
• Transmission:
XXX/YY Shown with error code number XX/YY on display.
B
001344
10 11
002058
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.
WARNING
Risk of machine damage.
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.
000389
• The function affected by the error is shown with a symbol in
field E
The book symbol is an instruction for the operator to read the
operator’s manual.
6 Use the error code tables to find more information about the error
code.
7 After the remedial action, check that no active error codes remain
for the function in question.
1 Engine
mm mm mm mm mm mm
Code J1587
84 / 2 P084 / 2 Machine Speed Sensor Engine speed limited Check the ca- D794 ENGINE,
Circuit - Data Erratic, In- to Maximum Engine ble harness menu 2
termittent or Incorrect. Speed without VSS between con-
The ECU 794 lost the ma- parameter value. trol unit and
chine speed signal. Cruise control, Gear- component.
Down Protection, and Check the
Road Speed Gover- sensor.
nor will not work.
84 / 10 P084 / 10 Machine Speed Sensor Engine speed limited Check the ca- D794 ENGINE,
Circuit Tampering Has to Maximum Engine ble harness menu 2
Been Detected - Abnor- Speed without VSS between con-
mal Rate of Change. parameter value. trol unit and
Invalid or inappropriate Cruise control, Gear- component.
machine speed signal. Down Protection, and Check the
Signal indicates an inter- Road Speed Gover- sensor.
mittent connection or nor will not work.
VSS tampering.
91 / 0 P91 / 0 Accelerator Pedal or Le- Severe derate in - - ENGINE,
ver Position Sensor 1 - power output of the menu 1
Data Valid but Above engine. Limp home
Normal Operational power only.
Range - Most Severe
Level. A frequency of
more than 1500 Hz has
been detected at the fre-
quency throttle input to
the ECU 794.
91 / 1 P91 / 1 Accelerator Pedal or Le- Severe derate in - - ENGINE,
ver Position 1 Sensor Cir- power output of the menu 1
cuit Frequency - Data engine. Limp home
Valid but Below Normal power only.
Operational Range - Most
Severe Level. A frequen-
cy of less than 100 HZ
has been detected at the
frequency throttle input to
the ECU 794.
Code J1587
91 / 19 P91 SAE J1939 Multiplexing Engine may only idle Use diagnos- - -
Accelerator Pedal or Le- or engine will not ac- tic menu to
ver Sensor System Error - celerate to full speed. find incorrect
Received Network Data segment.
Error. The OEM machine
electronic control unit
(VECU) detected a fault
with its accelerator pedal.
91 / 2 P31 / 2 Position sensor accelera- - - ENGINE,
tor pedal menu 1
91 / 3 P091 / 3 Accelerator Pedal or Le- Severe derate in Check the ca- - ENGINE,
ver Position Sensor Cir- power output of the ble harness menu 1
cuit - Shorted High. High engine. Limp home between con-
voltage detected at accel- capability only. trol unit and
erator pedal or lever posi- component.
tion circuit. Check the
component.
91 / 4 P091 / 4 Accelerator Pedal or Le- Severe derate in Check the ca- - ENGINE,
ver Position Sensor Cir- power output of the ble harness menu 1
cuit - Voltage Below engine. Limp home between con-
Normal or Shorted to Low capability only. trol unit and
Source. Low voltage de- component.
tected at accelerator ped- Check the
al or lever position signal component.
circuit.
94 / 1 P94 / 1 Fuel pump delivery pres- Possibly hard to start; - D794 -
sure - data valid but be- low power; possible
low normal operational engine smoke. En-
range - moderately se- gine can possibly not
vere level. The ECU 794 start.
has detected the fuel
pressure in the fuel rail is
lower than the command-
ed performance.
94 / 2 P094 / 2 Injector Metering Rail 1 The ECU 794 will es- - D794 -
Pressure - Data Erratic, timate fuel pressure,
Intermittent, or Incorrect. and power is re-
The ECU 794 has detect- duced.
ed that the fuel pressure
signal is not changing.
Code J1587
94 / 18 P94 / 0 Fuel pump delivery pres- None or possible en- - D794 -
sure - data valid but gine noise associated
above normal operational with higher injection
range - moderately se- pressures (especial-
vere level. The ECU 794 ly at idle or light load).
has detected fuel pres- Engine power is
sure in the fuel rail that is reduced.
higher than the com-
manded pressure.
97 / 3 P097 / 3 Water-in-fuel indicator None on perform- Check the ca- D794 -
sensor circuit - Voltage ance. No water-in- ble harness
above normal or short fuel warning between con-
circuited to high source. available. trol unit and
High voltage detected at component.
the water-in-fuel circuit. Check the
sensor.
97 / 4 P097 / 4 Water-in-fuel indicator None on perform- Check the ca- D794 -
sensor circuit - Voltage ance. No water-in- ble harness
below normal or short fuel warning between con-
circuited to low source. available. trol unit and
Low voltage detected at component.
the water-in-fuel circuit. Check the
sensor.
97 / 15 P097 / 0 Water-in-fuel indicator - Possible white Drain water - -
Data valid but above nor- smoke, loss of power, from the fuel.
mal operational range - or hard starting.
least severe level. Water
has been detected in the
fuel filter.
100 / 1 P100 / 1 Engine Oil Rifle Pressure Progressive power Check the oil - ENGINE,
- Data Valid but Below derate increasing in level in the en- menu 6
Normal Operational severity from time af- gine; fill if
Range - Most Severe ter alert. If the Engine necessary.
Level. Oil pressure signal Protection Shutdown
indicates oil pressure is feature is enabled,
below the engine protec- engine will shut down
tion critical limit. 30 seconds after the
red STOP lamp starts
flashing.
Code J1587
100 / 2 P100 / 2 Oil Pressure Switch Sen- None on perform- Check the ca- D794 ENGINE,
sor Circuit - Data Erratic, ance. No engine pro- ble harness menu 6
Intermittent or Incorrect. tection for oil between con-
An error in the engine oil pressure. trol unit and
pressure switch signal component.
was detected by the Check the
ECU 794. sensor.
100 / 3 P100 / 3 Oil Pressure Sensor Cir- None on perform- Check the ca- D794 ENGINE,
cuit - Voltage Above Nor- ance. No engine pro- ble harness menu 6
mal, or Shorted to High tection for oil between con-
Source. High signal volt- pressure. trol unit and
age detected at the en- component.
gine oil pressure circuit. Check the
sensor.
100 / 4 P100 / 4 Oil Pressure Sensor Cir- None on perform- Check the ca- D794 ENGINE,
cuit - Voltage Below Nor- ance. No engine pro- ble harness menu 6
mal, or Shorted to Low tection for oil between con-
Source. Low signal volt- pressure. trol unit and
age detected at the en- component.
gine oil pressure circuit. Check the
sensor.
100 / 18 P100 / 1 Engine Oil Rifle Pressure None on Check the oil - ENGINE,
- Data Valid but Below performance. level in the en- menu 6
Normal Operational gine; fill if
Range - Moderately Se- necessary.
vere Level. Engine oil
pressure signal indicates
engine oil pressure is be-
low the engine protection
warning limit.
102 / 2 P102 /2 Intake Manifold Pressure Engine power derate. Check the ca- D794 ENGINE,
Sensor Circuit - Data Er- ble harness menu 6
ratic, Intermittent or Incor- between con-
rect. The ECU 794 has trol unit and
detected an intake mani- component.
fold pressure signal that Check the
is too high or low for cur- sensor.
rent engine operating
conditions.
Code J1587
102 / 2 P102 /2 Intake manifold pressure Derate in power out- Check the ca- D794 ENGINE,
sensor circuit - data incor- put of the engine. ble harness menu 6
rect. An error in the intake between con-
manifold pressure sensor trol unit and
signal was detected by component.
the ECU 794. Check the
sensor.
102 / 3 P102 / 3 Intake Manifold Pressure Derate in power out- Check the ca- D794 ENGINE,
Sensor Circuit - Voltage put of the engine. ble harness menu 6
Above Normal or Shorted between con-
to High Source. High sig- trol unit and
nal voltage detected at component.
the intake manifold pres- Check the
sure circuit. sensor.
102 / 4 P102 / 4 Intake Manifold Pressure Derate in power out- Check the ca- D794 ENGINE,
Sensor Circuit - Voltage put of the engine. ble harness menu 6
Below Normal or Shorted between con-
to Low Source. Low sig- trol unit and
nal voltage detected at component.
the intake manifold pres- Check the
sure circuit. sensor.
103 / 10 P103 / 10 Turbocharger speed - Possible-low-power Check the ca- D794 -
invalid rate of change de- estimated turbo- ble harness
tected. The turbocharger charger speed will be between con-
speed sensor has detect- used. trol unit and
ed an erroneous speed component.
value. Check the
sensor.
103 / 16 P103 / 0 Turbocharger Number 1 Engine power derate. Check the D794 -
speed high - warning lev- The ECU 794 uses component
el. High turbocharger an estimated turbo-
speed has been detected. charger speed.
103 / 18 P103 / 1 Turbocharger number 1 Engine power derate. Check the D794 -
speed low - warning level. The ECU 794 uses component
Low turbocharger speed an estimated turbo-
detected by the ECU 794. charger speed.
Code J1587
105 / 0 P105 / 0 Intake Manifold 1 Tem- Progressive power Check the - ENGINE,
perature - Data Valid but derate increasing in coolant level menu 7
Above Normal Operation- severity from time af- in the engine;
al Range - Most Severe ter alert. If the Engine fill if
Level. Intake manifold air Protection Shutdown necessary.
temperature signal indi- feature is enabled, Check that the
cates intake manifold air engine will shut down charge air
temperature above en- 30 seconds after the cooler is
gine protection critical red STOP lamp starts clean, clean if
limit. flashing. necessary.
Check that fan
belts are in-
tact. Check
the sensor.
105 / 3 P105 / 3 Intake Manifold Air Tem- Possible white Check cable D794 ENGINE,
perature Sensor Circuit - smoke. Fan will stay harness be- menu 7
Voltage Above Normal or ON if controlled by tween control
Shorted to High Source. the ECU 794. No en- unit and
High signal voltage de- gine protection for in- component.
tected at intake manifold take manifold air Check the
air temperature circuit. temperature. sensor.
105 / 4 P105 / 4 Intake Manifold Air Tem- Possible white Check cable D794 ENGINE,
perature Sensor Circuit - smoke. Fan will stay harness be- menu 7
Voltage Below Normal or ON if controlled by tween control
Shorted to Low Source. the ECU 794. No en- unit and
Low signal voltage de- gine protection for in- component.
tected at intake manifold take manifold air Check the
air temperature circuit. temperature. sensor.
105 / 15 P105 / 0 Intake Manifold Tempera- Progressive power Check the D794 ENGINE,
ture High - Data Valid but derate increasing in coolant level menu 7
Above Normal Operation- severity from time of in the engine;
al Range - Least Severe alert. fill if
Level. Intake manifold air necessary.
temperature signal indi- Check that the
cates intake manifold air charge air
temperature above en- cooler is
gine protection warning clean, clean if
limit. necessary.
Check that fan
belts are in-
tact. Check
the sensor.
Code J1587
108 / 2 P108 / 2 Barometric pressure: Engine power derate. Check cable - -
Data erratic, intermittent, harness be-
or incorrect. The ambient tween control
air pressure sensor reads unit and
an erratic value upon component.
activation. Check the
sensor.
108 / 3 P108 / 3 Barometric Pressure Engine power derate. Check cable D794 -
Sensor Circuit - Voltage harness be-
Above Normal, or Short- tween control
ed to High Source. High unit and
signal voltage detected at component.
barometric pressure Check the
circuit. sensor.
108 / 4 P108 / 4 Barometric Pressure Engine power derate. Check cable D794 -
Sensor Circuit - Voltage harness be-
Below Normal, or Shorted tween control
to Low Source. Low sig- unit and
nal voltage detected at component.
barometric pressure Check the
circuit. sensor.
110 / 0 P110 / 0 Engine Coolant Temper- Progressive power Check the - ENGINE,
ature - Data Valid but derate increasing in coolant level. menu 7
Above Normal Operation- severity from time af- Check that ra-
al Range - Most Severe ter alert. If the Engine diator is clean.
Level. Engine coolant Protection Shutdown
temperature signal indi- Check if there
feature is enabled,
cates engine coolant tem- is air in cool-
engine will shut down
perature above engine ant system.
30 seconds after the
protection critical limit. red STOP lamp starts Check the cap
flashing. on the expan-
sion tank.
Check the
sensor.
Check the
thermostat.
110 / 2 P110 / 2 Engine Coolant Temper- The ECU 794 will es- Check cable D794 ENGINE,
ature - Data Erratic, Inter- timate engine coolant harness be- menu 7
mittent, or Incorrect. The temperature. tween control
engine coolant tempera- unit and
ture reading is not component.
changed with engine op- Check the
erating conditions. sensor.
Code J1587
110 / 3 P110 / 3 Engine Coolant Temper- Possible white Check cable D794 ENGINE,
ature 1 Sensor Circuit - smoke. Fan will stay harness be- menu 7
Voltage Above Normal or ON if controlled by tween control
Shorted to High Source. ECU 794. No engine unit and
High signal voltage or protection for engine component.
open circuit detected at coolant temperature. Check the
engine coolant tempera- sensor.
ture circuit.
110 / 4 P110 / 4 Engine Coolant Temper- Possible white Check cable D794 ENGINE,
ature 1 Sensor Circuit - smoke. Fan will stay harness be- menu 7
Voltage Below Normal or ON if controlled by tween control
Shorted to Low Source. ECU 794. No engine unit and
Low signal voltage de- protection for engine component.
tected at engine coolant coolant temperature. Check the
temperature circuit. sensor.
110 / 15 P110 / 0 Engine Coolant Temper- Progressive power Check the D794 ENGINE,
ature High - Data Valid derate increasing in coolant level. menu 7
but Above Normal Opera- severity from time of Check that ra-
tional Range - Least Se- alert. diator is clean.
vere Level. Engine
coolant temperature sig- Check if there
nal indicates coolant tem- is air in cool-
ant system.
perature is above the
engine coolant tempera- Check the cap
ture engine protection on the expan-
warning limit. sion tank.
Check the
sensor.
Check the
thermostat.
Code J1587
110 / 16 P110 / 0 Engine Coolant Temper- Progressive power Check the D794 ENGINE,
ature - Data Valid but derate increasing in coolant level. menu 7
Above Normal Operation- severity from time of Check that ra-
al Range - Moderately alert. diator is clean.
Severe Level. Engine
Check if there
coolant temperature sig-
is air in cool-
nal indicates engine cool-
ant system.
ant temperature is above
engine protection warn- Check the cap
ing limit. on the expan-
sion tank.
Check the
sensor.
Check the
thermostat.
111 / 1 P111 / 1 Coolant Level - Data Val- Progressive power Check the - -
id but Below Normal Op- derate increasing in coolant level;
erational Range - Most severity from time af- fill if
Severe Level. Low engine ter alert. If the engine necessary.
coolant level detected. protection shutdown Check the
feature is enabled, sensor.
engine will shut down
30 seconds after the
red STOP lamp starts
flashing.
111 / 3 P111 / 3 Coolant Level Sensor Cir- None on Check cable D794 -
cuit - Voltage Above Nor- performance. harness be-
mal or Shorted to High tween control
Source. High signal volt- unit and
age detected at engine component.
coolant level circuit. Check the
sensor.
111 / 4 P111 / 4 Coolant Level Sensor Cir- None on Check cable D794 -
cuit - Voltage Below Nor- performance. harness be-
mal or Shorted to Low tween control
Source. Low signal volt- unit and
age detected at the en- component.
gine coolant level circuit. Check the
sensor.
Code J1587
157 / 0 P94 / 0 Injector Metering Rail None or possible en- - D794 -
Number 1 Pressure - gine noise associated
Data Valid But Above with higher injection
Normal Operating Range pressures (especial-
- Most Severe Level. The ly at idle or light load).
ECU 794 has detected Engine power is
that fuel pressure in the reduced.
rail fuel is higher than the
commanded pressure.
157 / 2 P157 / 2 Injector Metering Rail 1 The ECU 794 will es- - D794 -
Pressure - Data Erratic, timate fuel pressure,
Intermittent, or Incorrect. and power is
the ECU 794 has detect- reduced.
ed that the fuel pressure
signal is not changing.
157 / 3 P157 / 3 Injector Metering Rail Power and or speed - D794 -
Number 1 Pressure Sen- derate.
sor Circuit - Voltage
Above Normal or Shorted
to High Source. High sig-
nal voltage detected at
rail fuel pressure sensor
circuit.
157 / 4 P157 / 4 Injector Metering Rail Power and or speed - D794 -
Number 1 Pressure Sen- derate.
sor Circuit - Voltage Be-
low Normal or Shorted to
Low Source. Low signal
voltage detected at the
rail fuel pressure sensor
circuit.
157 / 16 P157 / 0 Injector Metering Rail 1 None or possible en- - D794 -
Pressure - Data Valid but gine noise associated
Above Normal Operation- with higher injection
al Range - Moderately pressures (especial-
Severe Level. The ly at idle or light load).
ECU 794 has detected Engine power is
that fuel pressure is high- reduced.
er than commanded
pressure.
Code J1587
157 / 18 P157 / 1 Fuel Pump Delivery Pres- Possibly hard to start, - D794 -
sure Low - Data Valid but low power, or engine
Below Normal Operation- smoke. Engine can
al Range - Moderately possibly not start.
Severe Level. The
ECU 794 has detected
that fuel pressure is lower
than commanded
pressure.
167 / 1 P167 / 1 Electrical Charging Sys- Warning lamp illumi- Check batter- D794 -
tem Voltage Low - Data nated until very low ies and
Valid but Below Normal battery voltage condi- alternator.
Operational Range - Most tion is corrected.
Severe Level. Very low
battery voltage detected
by the battery voltage
monitor feature.
167 / 16 P167 / 0 Electrical Charging Sys- Amber warning lamp Check fuses. D794 -
tem Voltage High - Data illuminated until high Check batter-
Valid but Above Normal battery voltage condi- ies and
Operational Range - tion is corrected. alternator.
Moderately Severe Level.
High battery voltage de-
tected by the battery volt-
age monitor feature.
167 / 18 P167 / 1 Electrical Charging Sys- Amber lamp will light Check batter- D794 -
tem Voltage Low - Data until low battery volt- ies and
Valid but Below Normal age condition is alternator.
Operational Range - corrected.
Moderately Severe Level.
Low battery voltage de-
tected by the battery volt-
age monitor feature.
168 / 16 P168 / 0 Battery 1 Voltage - Data Possible electrical Check fuses. D794 -
Valid but Above Normal damage to all electri- Check batter-
Operational Range - cal components. ies and
Moderately Severe Level. alternator.
ECU 794 supply voltage
is above the maximum
system voltage level.
Code J1587
168 / 18 S168 / 1 Battery 1 Voltage - Data Engine may stop run- Check fuses. D794 -
Valid but Below Normal ning or be difficult to Check batter-
Operational Range - start. ies and
Moderately Severe Level. alternator.
ECU 794 supply voltage
is below the minimum
system voltage level.
171 / 3 P171 / 3 Ambient temperature - D794 -
sensor, circuit fault- Ab-
normally high voltage or
short-circuit to higher
voltage.
171 / 4 P171 / 4 Ambient temperature - D794 -
sensor, circuit fault - Ab-
normally low voltage or
short-circuit to lower
voltage.
190 / 0 P190 / 0 Engine Crankshaft Fuel injection disa- Ease off the - -
Speed/Position - Data bled until engine throttle or se-
Valid but Above Normal speed fails below the lect higher
Operational Range - Most overspeed limit. gear.
Severe Level. Engine
speed signal indicates
engine speed above en-
gine protection limit.
190 / 2 P190 / 2 Engine Crankshaft Engine can exhibit Check cable D794 -
Speed/Position - Data Er- misfire as control harness be-
ratic, Intermittent, or In- switches from the pri- tween control
correct. Crankshaft mary to the backup unit and
engine speed sensor in- speed sensor. En- component.
termittent gine power is re- Check the
synchronisation. duced while the sensor.
engine operates on
the backup speed
sensor.
190 / 2 P190 / 2 Engine Crankshaft Engine can run Check cable D794 -
Speed/Position - Data Er- rough. Possibly poor harness be-
ratic, Intermittent, or In- starting capability. tween control
correct. Loss of signal Engine runs using unit and
from crankshaft sensor. backup speed sen- component.
sor. Engine power is Check the
reduced. sensor.
Code J1587
251 / 2 P251 / 2 Real-Time Clock Power None on perform- - - -
Interrupt - Data Erratic, ance. Data in the
Intermittent or Incorrect. ECU 794 will not
Real-time clock lost have accurate time
power. and date information.
441 / 3 P441 / 3 Auxiliary Temperature None on Check cable D794 -
Sensor Input 1 - Voltage performance. harness be-
Above Normal, or Short- tween control
ed to High Source. High unit and
signal voltage or open cir- component.
cuit detected at the OEM Check the
auxiliary temperature sensor.
circuit.
441 / 4 P441 / 4 Auxiliary Temperature None on Check cable D794 -
Sensor Input 1 Circuit - performance. harness be-
Voltage Below Normal, or tween control
Shorted to Low Source. unit and
Low signal voltage de- component.
tected at OEM auxiliary Check the
temperature circuit. sensor.
558 / 2 S230 / 2 Accelerator Pedal or Le- Engine only running Check cable D794 -
ver Idle Validation Circuit at idle. harness be-
- Data Erratic, Intermittent tween control
or Incorrect. Voltage de- unit and
tected simultaneously on component.
both idle validation and Check
off-idle validation component.
switches.
558 / 4 S230 / 4 Accelerator Pedal or Le- Engine only running Check cable D794 -
ver Idle Validation Circuit at idle. harness be-
- Voltage Below Normal tween control
or Shorted to Low unit and
Source. No voltage de- component.
tected simultaneously on Check
both the idle validation component.
off-idle and on-idle
circuits.
558 / 13 S230 / 13 Accelerator Pedal or Le- Engine only running Check cable D794 -
ver Idle Validation Circuit at idle. harness be-
- Out of Calibration. Volt- tween control
age at idle validation on- unit and
idle and off-idle circuit component.
does not match accelera- Check
tor pedal position. component.
Code J1587
611 / 2 P089 / 2 Auxiliary Intermediate Intermediate speed - D794 -
(PTO) Speed Switch Vali- control switch may
dation - Data Erratic, In- not operate correctly.
termittent, or Incorrect.
The position of the inter-
mediate speed control
switch 1 does not match
the position of the inter-
mediate speed control
validation switch.
611 / 3 S232 / 3 Sensor Supply Voltage 4 Engine only running - D794 -
Circuit - Voltage Above at idle.
Normal or Shorted to
High Source. High volt-
age detected at +5 volt
sensor supply circuit to
the accelerator pedal po-
sition sensor.
611 / 4 S232 / 4 Sensor Supply 3 Circuit - Possible hard starting - D794 -
Voltage Below Normal, or and rough running.
Shorted to Low Source.
Low voltage detected on
the +5 volt sensor supply
circuit to the engine
speed sensor.
611 / 4 S232 / 4 Sensor Supply Voltage 4 Engine will only die. - D794 -
Circuit - Voltage Below
Normal or Shorted to Low
Source. Low voltage de-
tected at +5 VDC sensor
supply circuit to the accel-
erator pedal position
sensor.
611 / 15 S151 / 0 Turbocharger compres- Fuel is limited in an - D794 -
sor outlet temperature - attempt to decrease
data above normal. High the calculated turbo-
turbocharger compres- charger compressor
sor outlet temperature outlet temperature.
has been calculated by
the ECU 794.
Code J1587
612 / 2 P190 / 2 Engine Magnetic Crank- Fuelling to the injec- - D794 -
shaft Speed/Position lost tors is disabled, and
both of two signals - Data the engine can not be
Erratic, Intermittent, or In- started.
correct. The ECU 794 has
detected that the primary
engine speed sensor and
the backup engine speed
sensor signals are
reversed.
627 / 2 S251 / 2 Power Lost without Igni- Possible no noticea- Check fuses. D794 -
tion Off - Data Erratic, In- ble performance ef- Check batter-
termittent or Incorrect. fects or engine dying ies and
Supply voltage to the or hard starting. Fault alternator.
ECU 794 fell below 6.2 information, trip infor-
volts momentarily, or the mation, and mainte-
ECU 794 was not allowed nance monitor data
to power down correctly can be inaccurate.
(retain battery voltage for
30 seconds after key
OFF).
627 / 2 S251 / 2 Power Supply Lost With Possible no noticea- Check fuses. D794 -
Ignition On - Data Erratic, ble performance ef- Check batter-
Intermittent or Incorrect. fects or engine dying ies and
Supply voltage to the or hard starting. Fault alternator.
ECU 794 fell below 6.2 information, trip infor-
VDC momentarily, or the mation, and mainte-
ECU 794 was not allowed nance monitor data
to power down correctly can be inaccurate.
(retain battery voltage for
30 seconds after key
OFF).
627 / 2 S254 / 12 Injector Power Supply - Possible smoke, low Check fuses. D794 -
Bad Intelligent Device or power, engine mis- Check batter-
Component. The fire, and/or engine ies and
ECU 794 measured in- will not start. alternator.
jector boost voltage is
low.
629 / 12 S254 / 12 Engine Control Module - Engine may not start. Check the D794 -
critical internal failure. Er- control unit
ror internal to the
ECU 794 related to mem-
ory hardware failures or
internal ECU 794 voltage
supply circuits.
Code J1587
629 / 12 S254 / 12 Engine Control Module No performance ef- Check the D794 -
Warning Internal Hard- fects or possible se- control unit
ware Failure - Bad Intelli- vere power derate.
gent Device or
Component.
630 / 2 S253 / 2 Engine Control Module Possible no noticea- Reprogram D794 -
Data Lost - Data Erratic, ble performance ef- the software in
Intermittent or Incorrect. fects or engine dying Control unit,
Severe loss of data from or hard starting. Fault engine
the ECU 794. information, trip infor- (D794).
mation, and mainte-
nance monitor data
can be inaccurate.
630 / 31 S240 / 11 Engine Control Module Possible no noticea- - D794 -
Calibration Program ble performance ef-
Memory (RAM) Corrup- fects or engine dying
tion - Condition Exists. or hard starting. Fault
Severe loss of data from information, trip infor-
the ECU 794. mation, and mainte-
nance monitor data
can be inaccurate.
633 / 31 S018 / 11 Fuelling Actuator Number Possible low power. - D794 -
1 Circuit Error Conditions
Exists. Fuel pump actua-
tor circuit resistance too
high or too low.
639 / 9 S231 / 9 SAE J1939 Multiplexing One or more multi- Use diagnos- - CAN/
PGN Timeout Error - Ab- plexed devices will tic menu to POWER,
normal Update Rate. The not operate properly. find incorrect menu 2
Cummins ECU 794 did One or more symp- segment.
not receive a multiplexed toms will occur.
message from an OEM
VECU within the time limit
or did not receive it at all.
639 / 13 S231 / 13 SAE J1939 Multiplexing At least one multi- Use diagnos- - CAN/
Configuration Error - Out plexed devices will tic menu to POWER,
of Calibration. The ECU not operate properly. find incorrect menu 2
794 expected information segment.
from a multiplexed device
but only received a por-
tion of the necessary
information.
Code J1587
641 / 3 S027 / 3 VGT actuator driver cir- Possible low power. - D794 -
cuit - voltage above nor- Power removed from
mal or shorted to high the turbocharger ac-
source. tuator motor.
641 / 4 S027 / 4 VGT actuator driver cir- Possible low power. - D794 -
cuit - voltage below nor- Power removed from
mal, or shorted to low the turbocharger ac-
source. tuator motor.
644 / 2 S030 / 2 External Speed Com- Primary or secondary Check cable - -
mand Input (Multiple Unit engines may be shut harness be-
Synchronisation) - Data down. tween control
Erratic, Intermittent, or In- unit and
correct. The throttle input component.
signal to the primary or Check
secondary engine for component.
multiple unit synchronisa-
tion is less than 3 percent
or more than 97 percent.
647 / 3 S033 / 3 Fan Control Circuit - Volt- The fan may stay on Check cable D794 -
age Above Normal or continuously or not harness be-
Shorted to High Source. run at all. tween control
Open circuit or high volt- unit and
age detected at the fan component.
control circuit. Check
component.
647 / 4 S033 / 4 Fan Control Circuit - Volt- The fan may stay on Check cable D794 -
age Below Normal or continuously or not harness be-
Shorted to Low Source. run at all. tween control
Low signal voltage de- unit and
tected at the fan control component.
circuit when commanded Check
on. component.
651 / 5 S001 / 5 Injector Solenoid Driver Engine can misfire or Check cable D794 -
Cylinder 1 Circuit - Cur- possibly run rough. harness be-
rent Below Normal, or tween control
Open Circuit. High resist- unit and
ance or no current detect- component.
ed at Number 1 injector Check the
DRIVER or RETURN pin. injector.
Code J1587
651 / 7 S001 / 7 Injector Solenoid Driver The engine is Check cable D794 -
Cylinder 1 - Mechanical switched off. harness be-
System Not Responding tween control
Properly or Out of Adjust- unit and
ment. Unintended fuelling component.
detected in cylinder Check the
number 1. injector.
652 / 5 S002 / 5 Injector Solenoid Driver Engine can misfire or Check cable D794 -
Cylinder 2 Circuit - Cur- possibly run rough. harness be-
rent Below Normal, or tween control
Open Circuit. High resist- unit and
ance or no current detect- component.
ed at Number 2 injector Check the
driver or return pin. injector.
652 / 7 S002 / 7 Injector Solenoid Driver The engine is Check cable D794 -
Cylinder 2 - Mechanical switched off. harness be-
System Not Responding tween control
Properly or Out of Adjust- unit and
ment. Unintended fuelling component.
detected in cylinder Check the
number 2. injector.
653 / 5 S003 / 5 Injector Solenoid Driver Engine can misfire or Check cable D794 -
Cylinder 3 Circuit - Cur- possibly run rough. harness be-
rent Below Normal, or tween control
Open Circuit. High resist- unit and
ance or no current detect- component.
ed at Number 3 injector or Check the
return pin. injector.
653 / 7 S003 / 7 Injector Solenoid Driver The engine is Check cable D794 -
Cylinder 3 - Mechanical switched off. harness be-
System Not Responding tween control
Properly or Out of Adjust- unit and
ment. Unintended fuelling component.
detected in cylinder Check the
number 3. injector.
654 / 5 S004 / 5 Injector Solenoid Driver Engine can misfire or Check cable D794 -
Cylinder 4 Circuit - Cur- possibly run rough. harness be-
rent Below Normal or tween control
Open Circuit. High resist- unit and
ance or no current detect- component.
ed at Number 1 injector Check the
driver or return pin. injector.
Code J1587
654 / 7 S004 / 7 Injector Solenoid Driver The engine is Check cable D794 -
Cylinder 4 - Mechanical switched off. harness be-
System Not Responding tween control
Properly or Out of Adjust- unit and
ment. Unintended fuelling component.
detected in cylinder Check the
number 4. injector.
655 / 5 S005 / 5 Injector Solenoid Driver Engine can misfire or Check cable D794 -
Cylinder 5 Circuit - Cur- possibly run rough. harness be-
rent Below Normal, or tween control
Open Circuit. High resist- unit and
ance or no current detect- component.
ed at Number 5 injector Check the
DRIVER or RETURN pin. injector.
655 / 7 S005 / 7 Injector Solenoid Driver The engine is Check cable D794 -
Cylinder 5 - Mechanical switched off. harness be-
System Not Responding tween control
Properly or Out of Adjust- unit and
ment. Unintended fuelling component.
detected in cylinder Check the
Number 5. injector.
656 / 5 S006 / 5 Injector Solenoid Driver Engine can misfire or Check cable D794 -
Cylinder 6 Circuit - Cur- possibly run rough. harness be-
rent Below Normal, or tween control
Open Circuit. High resist- unit and
ance or no current detect- component.
ed at Number 6 injector Check the
driver or return pin. injector.
656 / 7 S006 / 7 Injector Solenoid Driver The engine is Check cable D794 -
Cylinder 6 - Mechanical switched off. harness be-
System Not Responding tween control
Properly or Out of Adjust- unit and
ment. Unintended fuelling component.
detected in cylinder Check the
Number 6. injector.
677 / 3 S39 / 3 Starter Relay Circuit - Either the engine will Check cable D794 ENGINE,
Voltage Above Normal or not start or the engine harness be- menu 5
Shorted to High Source. will not have starter tween control
Open circuit or high volt- lockout protection. unit and
age detected at starter component.
lockout circuit. Check the
relay.
Code J1587
677 / 4 S39 / 4 Starter Relay Circuit - The engine will not Check cable D794 ENGINE,
Voltage Below Normal or have starter lockout harness be- menu 5
Shorted to Low Source. protection. tween control
Low voltage detected at unit and
starter lockout circuit. component.
Check the
relay.
697 / 3 S057 / 3 Auxiliary PWM Driver #1 - Can not control - D794 -
Voltage Above Normal or transmission.
Shorted to High Source.
High signal voltage de-
tected at the analogue
torque circuit.
697 / 4 S057 / 4 Auxiliary PWM Driver #1 - Can not control - D794 -
Voltage Below Normal or transmission.
Shorted to Low Source.
Low signal voltage de-
tected at the analogue
torque circuit.
703 / 11 S051 /11 Auxiliary Equipment Sen- Possible engine pow- Check cable D794 -
sor Input #3 (OEM er derate. harness be-
Switch) - Root Cause Not tween control
Known. unit and
component.
Check the
component.
723 / 2 S064 / 2 Backup Engine Speed/ Possible low power. Check cable D794 -
Position Sensor Number harness be-
2 - Data Erratic, Intermit- tween control
tent, or Incorrect. Cam- unit and
shaft engine speed component.
sensor intermittent Check the
synchronisation. sensor.
723 / 2 S064 / 2 Engine Speed Sensor Possible poor start- Check cable D794 -
(Camshaft) Error - Data ing. Engine power harness be-
Erratic, Intermittent, or In- derate. tween control
correct. The ECU 794 has unit and
detected an error in the component.
camshaft position sensor Check the
signal. sensor.
Code J1587
723 / 7 S064 / 7 Engine Speed Sensor/ Engine will run derat- Check cable D794 -
Position Camshaft and ed. Excessive harness be-
Crankshaft Misalignment smoke, hard start, tween control
- Mechanical System Not and rough idle unit and
Responding Properly or possible. component.
Out of Adjustment. Me- Check the
chanical misalignment sensor.
between the crankshaft
and camshaft engine
speed sensors.
729 / 3 S070 / 3 Intake Air Heater #1 Cir- The intake air heaters Check cable D794 -
cuit - Voltage Above Nor- may be ON or OFF all harness be-
mal or Shorted to High the time. tween control
Source. High voltage de- unit and
tected at the intake air component.
heater signal circuit. Check
component.
729 / 4 S070 / 4 Intake Air Heater #1 Cir- The intake air heaters Check cable D794 -
cuit - Voltage Below Nor- may be ON or OFF all harness be-
mal or Shorted to Low the time. tween control
Source. Low voltage de- unit and
tected at the intake air component.
heater signal circuit. Check
component.
974 / 3 P974 / 3 Remote Accelerator Ped- Remote accelerator Check cable D794 -
al or Lever Position Sen- will not operate. Re- harness be-
sor 1 Circuit - Voltage mote accelerator po- tween control
Above Normal, or shorted sition will be set to unit and
to High Source. High volt- zero percent. component.
age detected at remote Check
accelerator pedal position component.
circuit.
974 / 4 P974 / 4 Remote Accelerator Ped- Remote accelerator Check cable D794 -
al or Lever Position Sen- will not operate. Re- harness be-
sor 1 Circuit - Voltage mote accelerator po- tween control
Below Normal, or Shorted sition will be set to unit and
to Low Source. Low volt- zero percent. component.
age detected at remote Check
accelerator pedal position component.
signal.
Code J1587
974 / 19 P29 SAE J1939 Multiplexing The engine will not Use diagnos- - CAN/
Remote Accelerator Ped- respond to the re- tic menu to POWER,
al or Lever Data Error - mote throttle. Engine find incorrect menu 2
Received Network Data may only idle. The segment.
Error. The OEM machine primary or cab accel-
electronic control unit erator may be able to
(VECU) detected a fault be used.
with the remote
accelerator.
1043 / 3 S221 / 3 Accelerator Pedal or Le- Engine only running Check cable D794 -
ver Position Sensor Sup- at idle. harness be-
ply Voltage Circuit - tween control
Voltage Above Normal or unit and
Shorted to High Source. component.
High voltage detected at Check
sensor supply circuit for component.
the accelerator pedal or
lever position sensor.
1043 / 4 S221 / 4 Accelerator Pedal or Le- Engine will only die. Check cable D794 -
ver Position Sensor Sup- harness be-
ply Voltage Circuit - tween control
Voltage Below Normal or unit and
Shorted to Low Source. component.
Low voltage detected at Check
sensor supply circuit to component.
the accelerator pedal or
lever position sensor.
1043 / 4 S221 / 4 Engine Speed/Position Possible hard starting Check cable D794 -
Sensor (Crankshaft) Sup- and rough running. harness be-
ply Voltage Circuit - Volt- tween control
age Below Normal or unit and
Shorted to Low Source. component.
Low voltage detected on Check
the ECU 794 voltage sup- component.
ply line to engine speed
sensor.
1072 / 3 S028 / 3 Engine Brake Actuator Engine brake on cyl- Check cable D794 -
Circuit #1 - Voltage inders 1, 2, and 3 can harness be-
Above Normal or Shorted not be activated or tween control
to High Source. Open cir- exhaust brake will not unit and
cuit or high voltage de- operate. component.
tected at the engine brake Check
solenoid number 1 signal component.
circuit.
Code J1587
1072 / 4 S028 / 4 Engine Brake Actuator Engine brake on cyl- Check cable D794 -
Circuit #1 - Voltage Below inders 1, 2, and 3 can harness be-
Normal or Shorted to Low not be activated or tween control
Source. Low voltage de- exhaust brake will not unit and
tected at the engine brake operate. component.
solenoid number 1 signal Check
circuit. component.
1073 / 3 S029 / 3 Engine Brake Actuator Engine brake on cyl- Check cable D794 -
Circuit #2 - Voltage inders 4, 5, and 6 can harness be-
Above Normal or Shorted not be activated. tween control
to High Source. Open cir- unit and
cuit or high voltage de- component.
tected at the engine brake Check
solenoid number 2 signal component.
circuit.
1073 / 4 S029 / 4 Engine Brake Actuator Engine brake on cyl- Check cable D794 -
Circuit #2 - Voltage Below inders 4, 5, and 6 can harness be-
Normal or Shorted to Low not be activated. tween control
Source. Low voltage de- unit and
tected at the engine brake component.
solenoid number 2 signal Check
circuit. component.
1075 / 3 S126 / 3 Electric Lift Pump for En- Engine can be diffi- - D794 -
gine Fuel Supply Circuit - cult to start.
Voltage Above Normal, or
Shorted to High Source.
High voltage or open de-
tected at the fuel lift pump
signal circuit.
1075 / 4 S126 / 4 Electric Lift Pump for En- Engine can be diffi- - D794 -
gine Fuel Supply Circuit - cult to start.
Voltage Below Normal, or
Shorted to Low Source.
Low signal voltage de-
tected at the fuel lift pump
circuit.
1079 / 3 S212 / 3 Sensor Supply Voltage Engine power derate. Check cable D794 -
number 1 Circuit - Volt- harness be-
age Above Normal or tween control
Shorted to High Source. unit and
High voltage detected at component.
sensor supply number 1 Check the
circuit. sensor.
Code J1587
1079 / 4 S212 / 4 Sensor Supply Voltage Engine power derate. Check cable D794 -
Number 1 Circuit - Volt- harness be-
age Below Normal or tween control
Shorted to Low Source. unit and
Low voltage detected at component.
sensor supply number 1 Check the
circuit. sensor.
1080 / 3 S232 / 3 Sensor Supply 2 Circuit - Engine power derate. Check cable D794 -
Voltage Above Normal or harness be-
Shorted to High Source. tween control
High voltage detected at unit and
sensor supply number 2 component.
circuit. Check the
sensor.
1080 / 4 S232 / 4 Sensor Supply Voltage Engine power derate. Check cable D794 -
Number 2 Circuit - Volt- harness be-
age Below Normal, or tween control
Shorted to Low Source. unit and
Low voltage detected at component.
the sensor supply Check the
number 2 circuit. sensor.
1137 / 2 S114 / 2 Multiple Unit Synchroni- Multiple Unit Syn- - D794 -
sation Switch - Data Er- chronisation feature
ratic, Intermittent, or is disabled.
Incorrect. Multi-unit syn-
chronous ON/OFF switch
and multi-unit synchro-
nous complimentary ON/
OFF switch have different
values in the ECU 794.
1172 / 3 /3 Turbocharger Number 1 Engine power derate. - D794 -
Compressor Inlet Tem-
perature Sensor Circuit -
Voltage Above Normal or
Shorted to High Source.
High signal voltage de-
tected at the turbocharger
compressor inlet air tem-
perature circuit.
Code J1587
1172 / 4 /4 Turbocharger Number 1 Engine power derate. - D794 -
Compressor Inlet Tem-
perature Sensor Circuit -
Voltage Below Normal or
Shorted to Low Source.
Low signal voltage de-
tected at the turbocharger
compressor inlet air tem-
perature sensor circuit.
1347 / 3 S126 / 3 High Fuel Pressure Sole- Engine will run poorly - D794 -
noid Valve Circuit - Volt- but will be severely
age Above Normal or derated. Rail pres-
Shorted to High Source. sure will be higher
Electronic fuel control ac- than commanded.
tuator shorted high.
1347 / 4 S126 / 4 High Fuel Pressure Sole- Engine will run poorly - D794 -
noid Valve Circuit - Volt- at idle. Engine will
age Below Normal or have low power. Fuel
Shorted to Low Source. pressure will be high-
Electronic fuel control ac- er than commanded.
tuator shorted low.
1347 / 7 S126 / 7 Fuel Pump Pressurising Engine will not run or - D794 -
Assembly 1 - Mechanical possible low power.
System Not Responding
Properly or Out of Adjust-
ment. A pumping imbal-
ance between the front
and rear pumping plung-
ers has been detected.
1347 / 7 S126 / 7 Fuel Pumping Element Engine will not run or - D794 -
Number 1 (Front) - Me- possible low power.
chanical System Not Re-
sponding Properly or Out
of Adjustment.
1378 / 31 S153 / 11 Change Lubricating Oil None on perform- - D794 -
and Filter - Condition Ex- ance; maintenance
ists. Change engine oil reminder only.
and filter.
1388 / 3 P223 / 3 Auxiliary Pressure Sen- None on - D794 -
sor Input 1 Circuit - Volt- performance.
age Above Normal, or
Shorted to High Source.
High signal voltage de-
tected at the OEM pres-
sure circuit.
Code J1587
1388 / 4 P223 / 4 Auxiliary Pressure Sen- None on - D794 -
sor Input 1 Circuit - Volt- performance.
age Below Normal, or
Shorted to Low Source.
Low signal voltage or
open circuit detected at
the OEM pressure circuit.
2789 / 15 / 0 Exhaust gas temperature Derate in power out- - D794 -
- data above normal. High put of the engine in
exhaust temperature has attempt to decrease
been calculated by the the calculated ex-
electronic control system. haust gas tempera-
ture value.
94/3 3.6 PID94/3 Sensor fuel No limitation. Check the cable har- D794/B:16 -
pressure, ness between control
short-circuited unit and component.
to voltage. Check the sensor.
94/5 3.6 PID94/5 Sensor fuel No limitation. Check the cable har- D794/B:16 -
pressure, ness between control
short-circuited unit and component.
to ground or Check the sensor.
open circuit.
94/7 3.8 PID94/7 Sensor fuel No limitation. Change the fuel filter. D794/B:16 -
pressure, Change the fuel
short-circuited prefilter.
to voltage,
Check whether pres-
ground or open
sure can be built up with
circuit.
the hand pump.
97/4 2.9 PID97/4 Sensor water No limitation. Check the cable har- D794/B:8 -
in fuel short- ness between control
circuited to unit and component.
ground or open Check the sensor.
circuit.
100/3 3.1 PID100/3 Sensor oil No limitation. Check the cable har- D794/B:11 ENGINE,
pressure, ness between control menu 6
short-circuited unit and component.
to voltage. Check the sensor.
100/5 3.1 PID100/5 Sensor oil No limitation. Check the cable har- D794/B:11 ENGINE,
pressure, open ness between control menu 6
circuit. unit and component.
Check the sensor.
105/0 6.2 PID105/0 High The engine is Check that charge-air - ENGINE,
charge-air switched off. cooler is clean. menu 7
temperature. Check the sensor.
105/4 3.2 PID105/4 Sensor charge No limitation. Check the cable har- D794/A:47 ENGINE,
air tempera- ness between control menu 7
ture, cable unit and component.
short-circuited Check the sensor.
to ground.
105/5 3.3 PID105/5 Sensor charge No limitation. Check the cable har- D794/A:47 ENGINE,
air tempera- ness between control menu 7
ture, cable unit and component.
open circuit. Check the sensor.
106/0 3.5 PID106/0 High booster Reduced en- Check turbocharger. - ENGINE,
pressure. gine power. Check the sensor. menu 6
106/3 3.4 PID106/3 Sensor, boost Reduced en- Check the cable har- D794/A:22 ENGINE,
pressure, ca- gine power. ness between control menu 7
ble short- unit and component.
circuited to Check the sensor.
voltage.
108/2 - PID108/2 Incorrect sig- No limitation. Check the cable har- - ENGINE,
nal from Sen- ness between control menu 6
sor, boost unit and component.
pressure. Check the sensor.
108/3 - PID108/3 Sensor, boost No limitation. Check the cable har- D794/A:29 ENGINE,
pressure, ness between control menu 6
short-circuited unit and component.
to voltage. Check the sensor.
108/4 - PID108/4 Sensor boost No limitation. Check the cable har- D794/A:29 ENGINE,
pressure, ness between control menu 6
short-circuited unit and component.
to frame Check the sensor.
ground or open
circuit.
110/0 6.1 PID110/0 High coolant No limitation. Check the coolant level. - ENGINE,
temperature. Check that radiator is menu 7
clean.
Check the thermostat.
Check the cap on the
expansion tank.
Check if there is air in
coolant system.
Check the sensor.
110/4 3.3 PID110/4 Sensor coolant Preheating is Check the cable har- D794/B:27 ENGINE,
temperature, activated even ness between control menu 7
short-circuited if engine is unit and component.
to ground. warm. Check the sensor.
110/5 3.3 PID110/5 Sensor coolant Preheating is Check the cable har- D794/B:27 ENGINE,
temperature, activated even ness between control menu 7
cable open if engine is unit and component.
circuit. warm. Check the sensor.
111/1 2.2 PID111/1 Low coolant No limitation. Check the coolant level; - -
level. fill if necessary.
Check the sensor.
164/2 - PID164/2 Incorrect sig- Engine speed Check the cable har- D794/B:16 -
nal from Sen- limited to ness between control
sor, fuel 1100 rpm. unit and component.
pressure. Check the sensor.
164/4 - PID164/4 Sensor fuel Engine speed Check the cable har- D794/B:16 -
pressure, limited to ness between control
short-circuited 1100 rpm. unit and component.
to ground. Check the sensor.
164/5 - PID164/5 Sensor fuel Engine speed Check the cable har- D794/B:16 -
pressure, open limited to ness between control
circuit. 1100 rpm. unit and component.
Check the sensor.
190/0 2.6 PID190/0 Engine speed No limitation. Ease off throttle or se- - -
too high. lect higher gear.
626/3 5.4 PID45/3 Preheating re- Preheating Check the cable har- D794/B:25 ENGINE,
lay, short- cannot be ness between control menu 5
circuited to activated. unit and component.
voltage. White smoke Check the relay.
with cold-start.
Starting prob-
lems in cold
weather.
626/4 5.4 PID45/4 Preheating re- Preheating re- Check the cable har- D794/B:25 ENGINE,
lay, short- lay is activated ness between control menu 5
circuited to constantly. unit and component.
ground. Fuse for pre- Check the relay.
heating may
blow.
629/3 9.9 SID254/3 Engine control The engine Change the control unit. - -
unit (D794), in- does not start.
ternal error.
629/8 9.9 SID254/8 Engine control The engine Change the control unit. - -
unit (D794), in- does not start.
ternal error.
629/12 9.9 SID254/12 Engine control The engine Change the control unit. - -
unit (D794), in- does not start.
ternal error.
636/2 9.9 SID21/3 Incorrect sig- Engine takes Check the cable har- D794/A:45, -
nal from Sen- longer time to ness between control A:46
sor, camshaft start than nor- unit and component.
speed. mal. Engine Check the sensor.
runs normally
when it has
started.
636/3 2.5 SID21/3 Sensor rota- Engine takes Check the cable har- D794/A:45, -
tion speed longer time to ness between control A:46
camshaft, no start than nor- unit and component.
signal. mal. Engine Check the sensor.
runs normally
when it has
started.
636/8 2.5 SID21/8 Sensor engine Engine takes Check the cable har- D794/A:45, -
speed, cam- longer time to ness between control A:46
shaft, abnor- start than nor- unit and component.
mal frequency. mal. Engine Check the sensor.
runs normally
when it has
started.
637/3 2.4 SID22/3 Sensor engine Engine is diffi- Check the cable har- D794/A:37, ENGINE,
speed, fly- cult to start ness between control A:38 menu 2
wheel, abnor- and runs unit and component.
mal frequency. rough, if it Check the sensor.
starts.
637/8 2.4 SID22/8 Sensor engine Engine is diffi- Check the cable har- D794/A:37, ENGINE,
speed, fly- cult to start ness between control A:38 menu 2
wheel, abnor- and runs unit and component.
mal frequency. rough, if it Check that the sensor is
starts. connected correctly.
639/2 6.5 SID231/2 Communica- Engine Use diagnostic menu to D794/B:51, CAN/POW-
tion error with switched off: find incorrect segment. B:55 ER, menu 3
Control unit, engine cannot Check the cable har-
engine (D794), be started. ness between control
configuration Engine on: en- unit and component.
error. gine goes to Check the control unit.
idle and can
only be
stopped by us-
ing the emer-
gency stop.
651/3 7.1 SID1/3 Electric fail- Engine only Check the cable har- D794/A:24 -
ure, injector runs on 5 cyl- ness between control
cylinder 1. inders, sounds unit and component.
rough and has Check the injector.
reduced
power.
651/4 7.1 SID1/4 Electric fail- Engine only Check the cable har- D794/A:24 -
ure, injector runs on 5 cyl- ness between control
cylinder 1. inders, sounds unit and component.
rough and has Check the injector.
reduced
power.
651/5 7.1 SID1/5 Electric fail- Engine only Check the cable har- D794/A:24 -
ure, injector runs on 5 cyl- ness between control
cylinder 1. inders, sounds unit and component.
rough and has Check the injector.
reduced
power.
651/12 7.1 SID1/12 Electric fail- Engine only Check the cable har- D794/A:24 -
ure, injector runs on 5 cyl- ness between control
cylinder 1. inders, sounds unit and component.
rough and has Check the injector.
reduced
power.
652/3 7.2 SID2/3 Electric fail- Engine only Check the cable har- D794/A:16 -
ure, injector runs on 5 cyl- ness between control
cylinder 1. inders, sounds unit and component.
rough and has Check the injector.
reduced
power.
652/4 7.2 SID2/4 Electric fail- Engine only Check the cable har- D794/A:16 -
ure, injector runs on 5 cyl- ness between control
cylinder 1. inders, sounds unit and component.
rough and has Check the injector.
reduced
power.
652/5 7.2 SID2/5 Electric fail- Engine only Check the cable har- D794/A:16 -
ure, injector runs on 5 cyl- ness between control
cylinder 1. inders, sounds unit and component.
rough and has Check the injector.
reduced
power.
652/12 7.2 SID2/12 Electric fail- Engine only Check the cable har- D794/A:16 -
ure, injector runs on 5 cyl- ness between control
cylinder 2. inders, sounds unit and component.
rough and has Check the injector.
reduced
power.
653/3 7.3 SID3/3 Electric fail- Engine only Check the cable har- D794/A:32 -
ure, injector runs on 5 cyl- ness between control
cylinder 3. inders, sounds unit and component.
rough and has Check the injector.
reduced
power.
653/4 7.3 SID3/4 Electric fail- Engine only Check the cable har- D794/A:32 -
ure, injector runs on 5 cyl- ness between control
cylinder 3. inders, sounds unit and component.
rough and has Check the injector.
reduced
power.
653/5 7.3 SID3/5 Electric fail- Engine only Check the cable har- D794/A:32 -
ure, injector runs on 5 cyl- ness between control
cylinder 3. inders, sounds unit and component.
rough and has Check the injector.
reduced
power.
653/12 7.3 SID3/12 Electric fail- Engine only Check the cable har- D794/A:32 -
ure, injector runs on 5 cyl- ness between control
cylinder 3. inders, sounds unit and component.
rough and has Check the injector.
reduced
power.
654/3 7.4 SID4/3 Electric fail- Engine only Check the cable har- D794/A:56 -
ure, injector runs on 5 cyl- ness between control
cylinder 4. inders, sounds unit and component.
rough and has Check the injector.
reduced
power.
654/4 7.4 SID4/4 Electric fail- Engine only Check the cable har- D794/A:56 -
ure, injector runs on 5 cyl- ness between control
cylinder 4. inders, sounds unit and component.
rough and has Check the injector.
reduced
power.
654/5 7.4 SID4/5 Electric fail- Engine only Check the cable har- D794/A:56 -
ure, injector runs on 5 cyl- ness between control
cylinder 4. inders, sounds unit and component.
rough and has Check the injector.
reduced
power.
654/12 7.4 SID4/12 Electric fail- Engine only Check the cable har- D794/A:56 -
ure, injector runs on 5 cyl- ness between control
cylinder 4. inders, sounds unit and component.
rough and has Check the injector.
reduced
power.
655/3 7.5 SID5/3 Electric fail- Engine only Check the cable har- D794/A:48 -
ure, injector runs on 5 cyl- ness between control
cylinder 5. inders, sounds unit and component.
rough and has Check the injector.
reduced
power.
655/4 7.5 SID5/4 Electric fail- Engine only Check the cable har- D794/A:48 -
ure, injector runs on 5 cyl- ness between control
cylinder 5. inders, sounds unit and component.
rough and has Check the injector.
reduced
power.
655/5 7.5 SID5/5 Electric fail- Engine only Check the cable har- D794/A:48 -
ure, injector runs on 5 cyl- ness between control
cylinder 5. inders, sounds unit and component.
rough and has Check the injector.
reduced
power.
655/12 7.5 SID5/12 Electric fail- Engine only Check the cable har- D794/A:48 -
ure, injector runs on 5 cyl- ness between control
cylinder 5. inders, sounds unit and component.
rough and has Check the injector.
reduced
power.
656/3 7.6 SID6/3 Electric fail- Engine only Check the cable har- D794/A:40 -
ure, injector runs on 5 cyl- ness between control
cylinder 6. inders, sounds unit and component.
rough and has Check the injector.
reduced
power.
656/4 7.6 SID6/4 Electric fail- Engine only Check the cable har- D794/A:40 -
ure, injector runs on 5 cyl- ness between control
cylinder 6. inders, sounds unit and component.
rough and has Check the injector.
reduced
power.
656/5 7.6 SID6/5 Electric fail- Engine only Check the cable har- D794/A:40 -
ure, injector runs on 5 cyl- ness between control
cylinder 6. inders, sounds unit and component.
rough and has Check the injector.
reduced
power.
656/12 7.6 SID6/12 Electric fail- Engine only Check the cable har- D794/A:36, -
ure, injector runs on 5 cyl- ness between control A:40
cylinder 6. inders, sounds unit and component.
rough and has Check the injector.
reduced
power.
677/3 6.3 SID39/3 Starter motor The engine Check the cable har- D794/B:29 ENGINE,
1675/3 relay, short- does not start. ness between control menu 5
circuited to Engine starts unit and component.
voltage. immediately Check the relay.
when ignition
is turned on.
677/4 6.3 SID39/4 Starter motor The engine Check the cable har- D794/B:29 ENGINE,
1675/4 relay, short- does not start. ness between control menu 5
circuited to unit and component.
ground Check the relay.
677/5 6.3 SID39/5 Starter motor The engine Check the cable har- D794/B:29 ENGINE,
1675/5 relay, open does not start. ness between control menu 5
circuit. unit and component.
Check the relay.
679/0 - PSID97/0 Incorrect sig- Engine speed Check the cable har- - -
nal from con- limited to ness between control
trol Pressure 1100 rpm. unit and component.
relief valve. Reduced en- Check the component.
gine power.
679/3 - SID42/3 Pressure relief Engine speed Check the cable har- - -
valve, short- limited to ness between control
circuited to 1100 rpm. unit and component.
voltage. Check the component.
679/5 - SID43/5 Pressure relief Engine speed Check the cable har- - -
valve, open limited to ness between control
circuit. 1100 rpm. unit and component.
Check the component.
679/7 - PSID97/7 Pressure relief Engine speed Check the cable har- - -
valve, me- limited to ness between control
chanical 1100 rpm. unit and component.
defect. Reduced en- Check the component.
gine power.
679/11 - PSID97/ Pressure relief Engine speed Check the cable har- - -
11 valve, uniden- limited to ness between control
tified problem. 1100 rpm. unit and component.
Reduced en- Check the component.
gine power.
679/14 - PSID97/ Pressure relief Engine speed Check the cable har- - -
14 valve, defec- limited to ness between control
tive 1100 rpm. unit and component.
component. Reduced en- Check the component.
gine power.
729/3 - SID70/3 Sensor pre- Fuse blows. Check the cable har- D794/B:31 -
heating, short- ness between control
circuited to unit and component.
voltage. Check the component.
729/4 - SID70/4 Sensor pre- Engine difficult Check the cable har- D794/B:31 -
heating, short- to start in cold ness between control
circuited to weather. unit and component.
ground. Check the component.
729/5 - SID70/5 Sensor pre- Engine difficult Check the cable har- D794/B:31 -
heating, open to start in cold ness between control
circuit. weather. unit and component.
Check the component.
1079/4 9.3 SID 232/4 Reference No limitation. Check the cable har- D794/B:17 -
voltage 5 V no. ness between control
1 to sensor, unit and component.
short-circuited Check the sensor.
to ground.
1080/3 - SID 211/3 Reference No limitation. Check the cable har- D794/A:7 -
voltage 5 V no. ness between control
2 to sensor, unit and component.
short-circuited Check the sensor.
to voltage.
1080/4 - SID 211/4 Reference No limitation. Check the cable har- D794/A:7 -
voltage 5 V no. ness between control
2 to sensor, unit and component.
short-circuited Check the sensor.
to ground.
1239/0 - PSID 96/0 Fuel pressure Engine speed Check fuel feed. - -
too high. limited to
1100 rpm.
High engine
power. (Pow-
erful engine)
1239/1 - PSID 96/1 Fuel pressure Engine speed Check fuel filter, - -
too low limited to change if necessary.
1100 rpm. Check fuel feed.
Reduced en-
gine power.
1239/4 - PSID 96/4 Sensor fuel Engine speed Check the cable har- D794/B:16 -
pressure, limited to ness between control
short-circuited 1100 rpm. unit and component.
to ground. Reduced en- Check the sensor.
gine power.
Engine start-
ing difficulty.
1239/ - PSID 96/ Sensor fuel Engine speed Check the sensor. - -
12 12 pressure, de- limited to
fective 1100 rpm.
component. Reduced en-
gine power.
Engine start-
ing difficulty.
2791/3 - PPID19/3 Internal EGR, Internal EGR Check the cable har- D794/B:30 -
short-circuited not working. ness between control
to voltage. unit and component.
Check the component.
2791/4 - PPID19/4 Internal EGR, Internal EGR Check the cable har- D794/B:30 -
short-circuited not working. ness between control
to ground. unit and component.
Check the component.
2791/5 - PPID19/5 Internal EGR, Internal EGR Check the cable har- D794/B:30 -
open circuit. not working. ness between control
unit and component.
Check the component.
2791/7 - PPID19/7 Internal EGR, Internal EGR Check, Sensor boost D794/B:30 -
mechanical not working. pressure.
defect. Check the component.
(IEGR)
Contact Volvo Penta
workshop for more
information.
520192 6.8 PPID6/5 Sensor piston No limitation. Check the cable har- D794/B:14 -
/5 cooling pres- ness between control
sure, short- unit and component.
circuited to Check the sensor.
voltage,
ground or open
circuit.
- - PPID 435/ Low fuel pres- Engine speed Check fuel filter, - -
4 sure. limited to change if necessary.
1100 rpm. Check fuel feed.
Reduced en-
gine power.
2 Transmission
mm mm mm mm mm mm
Control unit transmission can generate two states with reduced func-
tionality to protect the transmission in the event of serious malfunc-
tions:
• "Limp-home", indicated in display with "LH".
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", indicated in display with "Sd".
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
00/50 Memory error in con- Transmission locked in - - -
trol unit transmission. neutral (shutdown).
00/51 Memory error in con- Transmission locked in - - -
trol unit transmission. neutral (shutdown).
00/52 Memory error in con- Transmission locked in - - -
trol unit transmission. neutral (shutdown).
00/53 Memory error in con- Transmission locked in - - -
trol unit transmission. neutral (shutdown).
20/60 Sensor oil pressure Transmission locked in Check the cable harness D793/A:2 - TRANSM,
(B253) indicates low neutral (shutdown). between control unit and B253 menu 10
oil pressure when component.
there should be Check the solenoid
pressure. valve.
20/61 The oil pressure sen- Transmission locked in Check the cable harness D793/A:2 - TRANSM,
sor (B253) indicates neutral (shutdown). between control unit and B253 menu 10
oil pressure when component.
there should not be Check the solenoid
pressure. valve.
21/02 Solenoid valves VFS Transmission locked in Check cabling between D793/D1 - TRANSM,
short-circuiting to volt- neutral (shutdown). the control unit and the Y6069, D793/ menu 7
age, ground, or open component with diag- F2 - Y6075
circuit. nostic menu.
Check the solenoid
valve.
Connections
Diagnostic
Description Limitation Action and
menu
components
Code
30/04 Low battery voltage. Control unit saves stored Check the cable harness - CAN/
information to flash mem- to the control unit. POWER,
ory and restarts to clear Check alternator, battery menu 12
memory. and cable harness be-
tween battery and
alternator.
30/05 High battery voltage. Control unit receives re- Check voltage feed. - CAN/
duced proportional control If auxiliary start equip- POWER,
precision depending on ment is connected, dis- menu 12
reduced PWM work cycle. connect it.
31/00 Reference voltage Control unit receives re- Check the voltage feed. - CAN/
sensor 8 V, too low. duced sensor signals. Check the control unit. POWER,
menu 12
31/01 Reference voltage Control unit receives re- Check the voltage feed. - CAN/
sensor 8 V, too high. duced sensor signals. Check the control unit. POWER,
menu 12
40/06 Incorrect direction Control unit locks trans- Check cabling to gear - TRANSM,
from gear selector. mission in neutral. selector with regards to menu 2
forward and reverse
signal.
41/06 Incorrect gear selec- Control unit doesn’t allow Check cabling to gear - TRANSM,
tion from gear change of range, howev- selector with regards to menu 2
selector. er, operation of machine signal range.
is possible.
42/04 Actual gear ratio too Control unit indicates that Check transmission with - TRANSM,
low. one or several clutches purpose to understand if menu 6
are slipping. and, if that is the case,
which clutch is slipping.
Check the set gear ratio
for the control unit.
42/05 Actual gear ratio too Control unit indicates that Check transmission with - TRANSM,
high. one or several clutches purpose to understand if menu 6
are slipping. and, if that is the case,
which clutch is slipping.
Check the set gear ratio
for the control unit.
43/03 Signal from Sensor Control unit indicates the Check the cable harness D793/H3 - TRANSM,
engine rpm and oil error. between control unit and B758/766 menu 10
temperature transmis- component.
sion (B758/766) out- Check the sensor.
side valid interval.
Connections
Diagnostic
Description Limitation Action and
menu
components
Code
43/07 Torque converter tem- Control unit indicates the Check the transmission D793/H3 - TRANSM,
perature exceeds error to make operator oil cooler, clean if B758/766 menu 10
100 C. aware of the warning’s necessary.
level. Check the thermostat in
the transmission oil
cooler.
43/08 Torque converter tem- The control unit protects Check the transmission D793/H3 - TRANSM,
perature exceeds the transmission and does oil cooler, clean if B758/766 menu 10
125 C. not allow the temperature necessary.
in the torque converter to Check the thermostat in
exceed the limit value. the transmission oil
The control unit locks the cooler.
transmission in neutral
position, the engine is re-
stricted to 50% of max.
rpm.
44/10 Faulty signal for accel- - Use diagnostic menu to - CAN/
erator pedal position find incorrect segment. POWER,
from engine control menu 4
unit (D794)
46/05 Max. torque for inch- - - - -
ing has been
exceeded.
50/00 Sensor oil pressure Transmission in Check the cable harness D793/A:2 - TRANSM,
(B253), short-circuited limp-home. between control unit and B253 menu 10
to ground. component.
Check the sensor.
50/01 Sensor oil pressure Transmission in Check the cable harness D793/A:2 - TRANSM,
(B253), not connected limp-home. between control unit and B253 menu 10
or open circuit. component.
Check the sensor.
51/00 Sensor engine rpm The control unit limits the Check the cable harness D793/H3 - TRANSM,
and oil temperature transmission’s tempera- between control unit and B758/766 menu 10
transmission (B758/ ture measurement to the component.
766) short-circuited to lowest value in its set- Check the sensor.
ground. tings, which results in
poor temperature
compensation.
Connections
Diagnostic
Description Limitation Action and
menu
components
Code
51/01 Sensor engine rpm The control unit limits the Check the cable harness D793/H3 - TRANSM,
and oil temperature transmission’s tempera- between control unit and B758/766 menu 10
transmission (B758/ ture measurement to the component.
766) not connected or highest value in its set- Check the sensor.
open circuit. tings, which results in
poor temperature
compensation.
52/00 Sensor oil tempera- The control unit limits the Check the cable harness D793/J3 - S221 TRANSM,
ture (S221) short- transmission’s tempera- between control unit and menu 10
circuited to ground. ture measurement to the component.
highest value in its set- Check the sensor.
tings, which results in
poor temperature
compensation.
52/01 Sensor oil tempera- The control unit limits the Check the cable harness D793/J3 - S221 TRANSM,
ture (S221) open transmission’s tempera- between control unit and menu 10
circuit. ture measurement to the component.
highest value in its set- Check the sensor.
tings, which results in
poor temperature
compensation.
54/00 Reference voltage - Check the cable harness - CAN/
sensor 5 V short- between control unit and POWER,
circuiting to frame component. menu 12
ground. Check the sensor.
54/01 Reference voltage - Check the cable harness - CAN/
sensor 5 V open between control unit and POWER,
circuit. component. menu 12
Check the sensor.
60/00 Sensor rpm drum When only one rpm signal Check cable between D793/C3 - TRANSM,
(B752) short-circuited that is not the engine rpm control unit and B752 menu 6
to ground. signal is incorrect, the component.
control unit calculates the Check component.
missing rpm.
If several rpm signals or if
the engine rpm signal are
defective, the control unit
activates Limp-home.
Connections
Diagnostic
Description Limitation Action and
menu
components
Code
60/01 Sensor rpm drum When only one rpm signal Check cable between D793/C3 - TRANSM,
(B752) not connected. that is not the engine rpm control unit and B752 menu 6
signal is incorrect, the component.
control unit calculates the Check component.
missing rpm.
If several rpm signals or if
the engine rpm signal are
defective, the control unit
activates Limp-home.
61/00 Sensor rpm output When only one rpm signal Check cable between D793/D3 - TRANSM,
shaft (B758) short- that is not the engine rpm control unit and B758 menu 6
circuited to ground. signal is incorrect, the component.
control unit calculates the Check component.
missing rpm.
If several rpm signals or if
the engine rpm signal are
defective, the control unit
activates Limp-home.
61/01 Sensor rpm output When only one rpm signal Check cable between D793/D3 - TRANSM,
shaft (B758) not that is not the engine rpm control unit and B758 menu 6
connected. signal is incorrect, the component.
control unit calculates the Check component.
missing rpm.
If several rpm signals or if
the engine rpm signal are
defective, the control unit
activates Limp-home.
62/00 Sensor engine rpm When only one rpm signal Check cable between D793/F3 - TRANSM,
(B758/766), short- that is not the engine rpm control unit and B758/766 menu 6
circuited to ground. signal is incorrect, the component.
control unit calculates the Check component.
missing rpm.
If several rpm signals or if
the engine rpm signal are
defective, the control unit
activates Limp-home.
Connections
Diagnostic
Description Limitation Action and
menu
components
Code
62/01 Sensor engine rpm When only one rpm signal Check cable between D793/F3 - TRANSM,
(B758/766), not con- that is not the engine rpm control unit and B758/766 menu 6
nected or has open signal is incorrect, the component.
circuit. control unit calculates the Check component.
missing rpm.
If several rpm signals or if
the engine rpm signal are
defective, the control unit
activates Limp-home.
63/00 Sensor rpm turbine When only one rpm signal Check cable between D793/R2 - TRANSM,
(B751) short-circuited that is not the engine rpm control unit and B751 menu 6
to ground. signal is incorrect, the component.
control unit calculates the Check component.
missing rpm.
If several rpm signals or if
the engine rpm signal are
defective, the control unit
activates Limp-home.
63/01 Sensor rpm turbine When only one rpm signal Check cable between D793/R2 - TRANSM,
(B751) not connected. that is not the engine rpm control unit and B751 menu 6
signal is incorrect, the component.
control unit calculates the Check component.
missing rpm.
If several rpm signals or if
the engine rpm signal are
defective, the control unit
activates Limp-home.
70/00 Solenoid valve VFS Transmission in Check the cable harness D793/B1 - TRANSM,
front (Y630), short- limp-home. between control unit and Y630, C1 - menu 8
circuited to each oth- component. Y630
er, signal cable short- Check the solenoid
circuited to voltage, or valve.
plus-cable short-
circuited to frame
ground.
70/01 Solenoid valve VFS Transmission in Check the cable harness D793/B1 - TRANSM,
forward (Y630) open limp-home. between control unit and Y630, C1 - menu 8
circuit or short- component. Y630
circuited voltage. Check the solenoid
valve.
Connections
Diagnostic
Description Limitation Action and
menu
components
Code
70/02 Solenoid valve VFS Transmission in Check the cable harness D793/B1 - TRANSM,
forward (Y630), con- limp-home. between control unit and Y630, C1 - menu 9
trol current higher than component. Y630
1400 mA. Check the solenoid
valve.
70/03 Solenoid valve VFS Transmission in Check the cable harness D793/B1 - TRANSM,
forward (Y630), con- limp-home. between control unit and Y630, C1 - menu 9
trol current outside ap- component. Y630
proved interval. Check the solenoid
Incorrect impedance. valve.
71/00 Solenoid valve VFS Transmission in Check the cable harness D793/D1 - TRANSM,
2/4 (Y6069), short- limp-home. between control unit and Y6069, E1 - menu 8
circuited to each oth- component. Y6069
er, signal cable short- Check the solenoid
circuited to voltage, or valve.
plus-cable short-
circuited to frame
ground.
71/01 Solenoid valve VFS Transmission in Check the cable harness D793/D1 - TRANSM,
2/4 (Y6069) open cir- limp-home. between control unit and Y6069, E1 - menu 8
cuit or short-circuited component. Y6069
voltage. Check the solenoid
valve.
71/02 Solenoid valve VFS Transmission in Check the cable harness D793/D1 - TRANSM,
2/4 (Y6069), control limp-home. between control unit and Y6069, E1 - menu 9
current higher than component. Y6069
1400 mA. Check the solenoid
valve.
71/03 Solenoid valve VFS Transmission in Check the cable harness D793/D1 - TRANSM,
2/4 (Y6069), control limp-home. between control unit and Y6069, E1 - menu 9
current outside ap- component. Y6069
proved interval (incor- Check the solenoid
rect impedance). valve.
72/00 Solenoid valve VFS Transmission in Check the cable harness D793/F1 - TRANSM,
reverse (Y631), ca- limp-home. between control unit and Y631, G1 - menu 8
bles short-circuited to component. Y631
each other, signal ca- Check the solenoid
ble short-circuited to valve.
voltage, or plus-cable
short-circuited to
frame ground.
Connections
Diagnostic
Description Limitation Action and
menu
components
Code
72/01 Solenoid valve VFS Transmission in Check the cable harness D793/F1 - TRANSM,
reverse (Y631) open limp-home. between control unit and Y631, G1 - menu 8
circuit or short- component. Y631
circuited voltage. Check the solenoid
valve.
72/02 Solenoid valve VFS Transmission in Check the cable harness D793/F1 - TRANSM,
reverse (Y631), con- limp-home. between control unit and Y631, G1 - menu 9
trol current higher than component. Y631
1400 mA. Check the solenoid
valve.
72/03 Solenoid valve VFS Transmission in Check the cable harness D793/F1 - TRANSM,
reverse (Y631), con- limp-home. between control unit and Y631, G1 - menu 9
trol current outside ap- component. Y631
proved interval Check the solenoid
(incorrect impedance). valve.
73/00 Solenoid valve VFS Transmission in Check the cable harness D793/H1 - TRANSM,
1/3 (Y6067), cables limp-home. between control unit and Y6067, J1 - menu 8
short-circuited to each component. Y6067
other, signal cable Check the solenoid
short-circuited to volt- valve.
age, or plus-cable
short-circuited to
frame ground.
73/01 Solenoid valve VFS Transmission in Check the cable harness D793/H1 - TRANSM,
1/3 (Y6067) open cir- limp-home. between control unit and Y6067, J1 - menu 8
cuit or short-circuited component. Y6067
voltage. Check the solenoid
valve.
73/02 Solenoid valve VFS Transmission in Check the cable harness D793/H1 - TRANSM,
1/3 (Y6067), control limp-home. between control unit and Y6067, J1 - menu 9
current higher than component. Y6067
1400 mA. Check the solenoid
valve.
73/03 Solenoid valve VFS Transmission in Check the cable harness D793/H1 - TRANSM,
1/3 (Y6067), control limp-home. between control unit and Y6067, J1 - menu 9
current outside ap- component. Y6067
proved interval (incor- Check the solenoid
rect impedance). valve.
77/02 All gear packs Transmission locked in - - -
disengaged. neutral (shutdown).
Connections
Diagnostic
Description Limitation Action and
menu
components
Code
80/00 Solenoid valve RSP Transmission locked in Check the cable harness D793/K1 - TRANSM,
Drive (Y6066), cable neutral (shutdown). between control unit and Y6066 menu 7
short-circuited to component.
frame ground. Check the solenoid
valve.
80/01 Solenoid valve RSP Transmission locked in Check the cable harness D793/K1 - TRANSM,
Drive (Y6066), cable neutral (shutdown). between control unit and Y6066 menu 7
is not connected or component.
short-circuited to Check the solenoid
voltage. valve.
81/00 Solenoid valve VFS Transmission in Check the cable harness D793/E2 - TRANSM,
2/4 (Y6074), cable limp-home. between control unit and Y6074 menu 7
short-circuited to component.
frame ground. Check the solenoid
valve.
81/01 Solenoid valve VSF Transmission in Check the cable harness D793/E2 - TRANSM,
2/4 (Y6074), cable is limp-home. between control unit and Y6074 menu 7
not connected or component.
short-circuited to volt- Check the solenoid
age. valve.
82/00 Solenoid valve VFS Transmission in Check the cable harness D793/F2 - TRANSM,
1/3 (Y6075), cable limp-home. between control unit and Y6075 menu 7
short-circuited to component.
frame ground. Check the solenoid
valve.
82/01 Solenoid valve VSF Transmission in Check the cable harness D793/F2 - TRANSM,
1/3 (Y6075), cable is limp-home. between control unit and Y6075 menu 7
not connected or component.
short-circuited to volt- Check the solenoid
age. valve.
83/00 Solenoid valve RSP Transmission locked in Check cabling to sole- D793/K2 - TRANSM,
Drive (Y6066), cable neutral (shutdown). noid valve drive. Y6066 menu 7
short-circuited to Check solenoid valve
frame ground. drive.
83/01 Solenoid valve RSP Transmission locked in Check cabling to sole- D793/K2 - TRANSM,
Drive (Y6066), cable neutral (shutdown). noid valve drive Y6066 menu 7
is not connected or Check solenoid valve
short-circuited to drive.
voltage.
90/xx - System error. Transmission locked in - D793/A:20 -
99/xx neutral (shutdown).
Connections
Diagnostic
Description Limitation Action and
menu
components
Code
95/71 Control unit cannot in- - -
terpret input data.
99/90 Incorrect software in - -
control unit
transmission.
8 Control system
mm mm mm mm mm mm
109 Transistor has Low beams Check bulb. D797-1/K1:28 – LIGHTS, 9.6.1
been triggered due not working. Check the bulb holder. E400L, E400R menu 3 Head-lights
to short circuit or
Check cabling between
open circuit in cir-
the control unit and the
cuit for low beam
component with diag-
(E400L, E400R).
nostic menu.
111 Transistor has Running Check bulb. D797-1/K1:2 – LIGHTS, 9.6.2 Running
been triggered due lights not Check the bulb holder. H416-1, menu 2 lights
to short circuit or working. H416-2,
Check cabling between
open circuit in cir- H417-1, H417-2
the control unit and the
cuit for running
component with diag-
lights (H416-1,
nostic menu.
H416-2, H417-1,
H417-2).
112 Transistor has Cooling fan Check cabling between D797-1/K1:3 – HYD, menu 2 4.8.9 Cooling
been triggered due brake oil not the control unit and the M674/1 fan
to short circuit or working. component with diag-
open circuit in cir- nostic menu.
cuit for brake oil Check the motor.
cooling fan (M674).
117 Transistor has Starter motor Check cabling between D797-1/K1:32 – ENGINE, 1.11 Start and
been triggered due not working. the control unit and the K315/85 menu 5 stop
to short circuit or component with diag-
open circuit in cir- nostic menu.
cuit for start relay Check the component.
(K315) for starter
motor.
194 Transistor has Left front Check bulb. D797-1/K1:37 – VBFS, menu 8 9.6.4 Brake
been triggered due brake light Check the bulb holder. H410L/1 light
to short circuit or not working.
open circuit in cir- Check cabling between
cuit for left front the control unit and the
component with diag-
brake light
nostic menu.
(H410L).
251 Redundant volt- - Check cabling between D791-1/K2:7 CAN/POWER, 11.5.1.2 Re-
age feed left to at- the control unit and the menu 15 dundant volt-
tachment control component with diag- age feed of
unit (D791-1) does nostic menu. Control units
not reach Check the control unit.
destination.
252 Redundant volt- - Check cabling between D791-1/K2:8 CAN/POWER, 11.5.1.2 Re-
age feed right to the control unit and the menu 15 dundant volt-
frame control unit component with diag- age feed of
(D791-1) does not nostic menu. Control units
reach destination. Check the control unit.
253 Incorrect power Functions Check fuse F58-3/1, re- D791-1/K2:1, CAN/POWER, 11.5.1.4 Emer-
supply to attach- normally sup- place if necessary. K2:9, K2:10 – menu 15 gency stop
ment control unit plied emer- Check cabling between F58-3/1:1 switch voltage
(D791-1). Voltage gency stop the control unit and the
under 18 V or over switch volt- component with diag-
32 V. age have no nostic menu.
feed. No at-
tachment
functions
operational.
287 DCF360-450CSG Extension left Check cabling between D791-1/K1:16 – ATTACH, 7.3.2 Control
Faulty signal from of attachment the control unit and the Y6046-1/2, menu 17 and valve
solenoid, extension not working. component with diag- Y6046-2/2 18 attachment
left in (Y6046-1) nostic menu.
and solenoid valve, Check the solenoid
extension left out valve.
(Y6046-2). Return
current does not
match control
current.
DCF80-100 Spreading Check cabling between D791-1/K1:16 – ATTACH, 7.3.2 Control
Faulty signal from left not the control unit and the Y6019L/2, menu 17 and valve
solenoid, spread- working. component with diag- Y6019R/2 18 attachment
ing left in (Y6019L) nostic menu.
and solenoid valve, Check the solenoid
spreading left out valve.
(Y6018L). Return
current does not
match control
current.
E Schematics
10 Common hydraulics....................................................................................... 3
Hydraulic diagrams, compilation ............................................................................ 3
Hydraulic diagram DCF 80-100, electric servo ....................................................... 4
11 Common electrics .......................................................................................... 6
Circuit diagram, description ................................................................................... 6
Component designations ........................................................................................ 7
Circuit diagrams, compilation ................................................................................. 8
10 Common hydraulics
mm mm mm mm mm mm
electric servo
26
25
25
29
24
23
17
28
20 22
21
16
19
37
6
36
27
43
18
35
34
33
4e
15
42
4d
41
14
4c
5
44
40
4b
4a
32
39
4
9
7
13
2
12
3
11
1
30
31
10
11 Common electrics
mm mm mm mm mm mm
Component designations
page
–
Prefix Description
A Unit, sub-unit. Example: amplifier with separate components
B Converter from non-electric to electric signals or vice versa. Example: inductive sensor.
C Capacitor
K Relay, contactor.
L Inductance, reactance.
T Transformer.
Z Transformer, network, hybrid, filter, equaliser, limiter. Example: cable balancing network.
Sheet Designation
0.0-1 Cross-reference list
Sheet Designation
7.2-2 Circuit, freelift sensors
Sheet Designation
9.6-1 Circuit, work lights 20’-40’
Sheet Designation
11.5-10 Circuit, option, ground
Sheet Designation
0.0_1 Cross-reference list
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H.Grp: Name Ritn.nr./ Drawing No. Utgåva/Issue
1 Nyupplägg / New design 021756 CJS 021206 Konstr/Design 6
E³ DRAWING
T=Tillk/Added U=Utgår/Deleted V=Var/Was Godk/Appr LME 021209 Klass/Class Wiring diagram attachment toplift 20-40 A44659.0100 01
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H.Grp: Name Ritn.nr./ Drawing No. Utgåva/Issue
1 Nyupplägg / New design 021756 CJS 021206 Konstr/Design 6
E³ DRAWING
T=Tillk/Added U=Utgår/Deleted V=Var/Was Godk/Appr LME 021209 Klass/Class Wiring diagram attachment toplift 20-40 A44659.0100 01
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H.Grp: Name Ritn.nr./ Drawing No. Utgåva/Issue
1 Nyupplägg / New design 021756 CJS 021206 Konstr/Design 6
E³ DRAWING
T=Tillk/Added U=Utgår/Deleted V=Var/Was Godk/Appr LME 021209 Klass/Class Wiring diagram attachment toplift 20-40 A44659.0100 01
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H.Grp: Name Ritn.nr./ Drawing No. Utgåva/Issue
1 Nyupplägg / New design 021756 CJS 021206 Konstr/Design 6
E³ DRAWING
T=Tillk/Added U=Utgår/Deleted V=Var/Was Godk/Appr LME 021209 Klass/Class Wiring diagram attachment toplift 20-40 A44659.0100 01
1 2 3 4 5 6 7 8
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BK BK 30-35_Stop
/3.D2
-X777-1m -X777-1f
BN 2 2 RD RD 8 +24V_VIA_KNAPP
-B777-1 /1.E2
BK 1 1 -XSP6
D 3 3 BU
30-35 STOP D
BU
E E
GY DAMPING
/1.E2
R
H.Grp: Name Ritn.nr./ Drawing No. Utgåva/Issue
1 Nyupplägg / New design 021756 CJS 021206 Konstr/Design 6
E³ DRAWING
T=Tillk/Added U=Utgår/Deleted V=Var/Was Godk/Appr LME 021209 Klass/Class Wiring diagram attachment toplift 20-40 A44659.0100 01
1 2 3 4 5 6 7 8
E Schema - Komponentförteckning / E Schematics - List of Components
243 S Brytkontakt tryck kylmedia AC Contact, breaking, coolant pressure (air condition)
244 S Slutkontakt hydraulik aktiverad Contact, making, hydraulics
245 S Slutkontakt hydraultryck styrning Contact, making, hydraulic pressure control
246 S Slutkontakt tryck kylmedia Contact, pressure refrigerant
250 S Manöverbrytare Operating Switch
251 S Slutkontakt vändbar förarstol Contact, making, VBFS
260 S Slutkontakt lyft steg 1 Contact, making, hoist step 1
261 S Slutkontakt lyft steg 2 Contact, making, hoist step 2
262 S Slutkontakt tilt Contact, making, tilting
263 S Slutkontakt gaffelspridning Contact, making, fork positioning
264 S Slutkontakt sidoföring Contact, making, sideshift
265 S Slutkontakt stativ in/ut Contact, making, lifting mast in-out
266 S Brytkontakt hyttdörr Contact, breaking cab door
267 S Slutkontakt bromstryck Contact, making, brake pressure
268 S Slutkontakt kompressor Contact, making, Compressor
269 S Slutkontakt sax inne Contact, making extender in
270 S Slutkontakt överlastskydd Contact, making, overload protection
271 S Slutkontakt, filter växellåda Contact, making, filter gearbox
299 S Slut/brytkontakt option Contact, making/braking option
300 K Relä hel/halvljus Relay, main/dipped beam
301 K Relä dimljus Relay, fog light
302 K Relä fjärrljus Relay, distance light
303 K Relä lastljus Relay, mast light
304 K Relä arbetsljus Relay, working light
305 K Relä backljus Relay, reversing light
306 K Relä helljus Relay, main beam
307 K Relä halvljus Relay, dipped beam
308 K Relä bromsljus Relay, brake light
309 K Relä parkeringsbroms Relay, parking light
310 K Relä körvisare vä Relay, direction indicator left
311 K Relä körvisare hö Relay, direction indicator right
312 K Relä startelement Relay,element preheater
313 K Relä vändbar förarstol Relay, rotating driver´s seat (VBFS)
314 K Relä parkeringsbroms Relay, parking brake
315 K Relä tändningslås Relay, ignition key
316 K Relä torkare Relay, wiper
317 K Relä strålkastartorkare Relay, roading lights wiper
318 K Relä AT-regulator Relay, AT-regulator
319 K Relä varningsblinkers Relay, hazard blinkers
320 K Relä elektrisk stopp Relay, electical stop
321 K Relä intervalltorkare Relay, intermittent wiper
322 K Relä kylvätskenivå Relay, coolant level
323 K Relä blinkers Relay, blinkers
324 K Relä rangespärr Relay, range interlock
325 K Relä blinkande bromsljus (back) Relay, flashing brake lights (reversing)
326 K Relä blinkande bromsljus (runt) Relay, flashing hazard brake lights
327 K Relä växel neutral Relay, gear neutral
328 K Relä växelskifte Relay, gear shift
329 K Relä växel hög/låg Relay, high/low gear
330 K Relä startspärr Relay, start interlock
331 K Relä drivning fram Relay, forward driving
332 K Relä drivning bak Relay, reversing driving
333 K Tidrelä förvärmning Time relay, automatically preheating
334 K Relä frikoppling/drivbrytning Relay, free wheel/drive disconnection
335 K Relä växelventil 1:a (diesel, gas) Relay, gear change valve 1-gear (diesel,LPG)
E Schema - Komponentförteckning / E Schematics - List of Components
F Technical data
Technical data
mm mm mm mm mm mm
Data
Power acc. to ISO 3046 (net power) 180 kW at 2200 rpm 164 kW at 2200 rpm
3 Power transmission
Drive axle, type Kessler D81
Kessler D91
4 Brakes
Parking brake Spring brake - Drive wheels
6 Suspension
Dimensions, front and rear 14.00x24
Tyre type, front and rear Air inflated. Spare and replacement tyres must be from a manufacturer approved
by Cargotec.
9. Cab Spirit Delta with Volvo TAD760VE Spirit Delta with Cummins QSB6.7
Tail lights, brake lights & LED direction - Replaced as a single unit.
indicators
fluids
Any deviation from this table must be approved in writing by Cargotec.
Coolant volume 22 l 29 l
WARNING!
Different types of coolant may not be mixed.
Risk of engine damage, if different types of coolants are mixed.
When changing and topping up coolant, the same type of coolant must be
used as was used before. See Parts Catalogue for correct part number.
Oil volume 23 l 20 l
Oil volume 37 l
7 Load handling
Oil grade See Oils and lubricants, recommendation page 7.
10 Common hydraulics
Oil grade See Oils and lubricants, recommendation page 7.
recommendation
The service intervals indicated by Cargotec in the maintenance man-
ual only apply if oils are selected in accordance with the table below.
The table indicates recommended viscosity for different oil types and
grades depending on the ambient temperature.
Any deviation from this table must be approved in writing by Cargotec,
and may mean changed service intervals.
Oil type, quality C -40 -30 -20 -10 0 +10 +20 +30 +40
SAE 75W90
7 Load handling
10 Common hydraulics
DIN 51524 Part 3 HVLP ISO VG 68
ISO VG 46 HV
ISO VG 32
WARNING
Change interval for engine oil requires that the sul-
phur content in the fuel does not exceed 0.5%.
NOTE
Oil filters shall always be changed in connection with oil change.
*) The oil in the brake system must fulfil one of the quality
requirements.
ACEA = Association des Constructeurs Européenne d’Automobiles
API = American Petroleum Institute
VDS = Volvo Drain Specification
Lubricating grease
Use a universal grease type EP according to NLGI Grade 2 (EP2) for
all lubrication points except slide plates, lifting equipment, and slide
plates.
For lifting equipment use a universal grease type EP according to
NLGI Grade 2 (EP2) with 3.5% molybdenum sulphide content.
For slide plates use a lubricant approved by Cargotec.
Order from Cargotec Spare Parts Department. 0.65 kg cartridge for
grease gun, part no. 923110.0360 and 5 kg can part no. 923595.0003
Contact grease
Use contact grease part no. 923836.0552.
Sealant silicone
Use silicone part no. 923107.0308.
Coolant
Use ready-mixed recommended coolant. Select the coolant mixture
that is adapted to the correct temperature.
CAUTION
Different types of coolant may not be mixed.
Tightening torques,
page
–
recommendations
The tightening torques in the following table are recommendations
when tightening bolts and nuts.
When torque-tightening using a machine, for example, bolt runner, the
tightening torque should be reduced by approx. 5%.
For mild surfaces (hardness below 200 HB), washer shall be used un-
der both bolt head and nut. Alternatively, use flange bolt or flange nut.
Tighten to the prescribed torque without stopping.
Recommended tightening torque may vary depending on surface
treatment. Certain combinations of nut and bolt require lubrication ac-
cording to the table below.
Condition 1 2 3 1 1
Fine M-thread
M81 27 Nm 24 Nm 30 Nm 39 Nm 46 Nm
M101.25 54 Nm 48 Nm 61 Nm 78 Nm 91 Nm
M-thread
M6 11 Nm 9.8 Nm 12.5 Nm 16 Nm 19 Nm
M8 26 Nm 24 Nm 30 Nm 38 Nm 45 Nm
M10 52 Nm 47 Nm 59 Nm 74 Nm 89 Nm
UNC-thread
3/8 44 Nm 39 Nm 50 Nm 62 Nm 73 Nm
connections
Pipe and hose fitting
6 1/4 23-25
8 5/16
33-38
10 3/8
12 1/2 51-57
14 -
15 - 80-90
16 5/8
18 3/4
120-130
20 -
22 7/8
150-170
25 1"
28 -
30 - 180-200
32 1"1/4
35 -
200-240
38 1"1/2
17 11/16 23-25
22 13/16 33-38
24 15/16 51-57
36 1 3/8 120-130
41 1 5/8 150-170
Material fitting
42x2 330
48x2 400
air conditioning
O-ring couplings cooling hoses
mm inch inch Nm
The above values should be considered guidelines and may vary de-
pending on installation.
Unit explanations
page
–
Unit Abbreviation
Newton metre Nm
Kgf/m kpm
Kilowatt kW
kilojoule kJ
Calorie ca
Inch in
Feet ft
Yard yd
Mile mile
Centimetre cm
Metre m
Kilometre km
Torque
Power (W = J/s)
Energy (J = Nm)
Horsepower/torque
Temperature
Flow factor
Unit cm m km in ft yd mile
1 mm = 0.1 cm - 1 mm = 0.001 m
Unit g kg t oz lb
Terminology
page
–
Term Description
Accumulator Reservoir that stores (accumulates) pressure for, i.e. hydraulic functions.
Anti-corrosion compound Prevents oxidation, in simple terms, rustproofing.
Attachment Part of the machine that grips the load when lifting.
Battery disconnector Cuts off power supply from battery.
Buzzer Acoustic alarm to catch the operator’s attention.
Control valve Valves that can be used to control something, for example, to release pressure and
thus lower a boom or a fork. See also control valve.
Daily inspection Actions that should be performed daily to ensure the machine’s functionality.
Decitonne Tenth of a tonne, measure of machine’s lift capacity.
Display "Window" showing digital information on steering wheel panel in the cab.
Drive axle Driving axle that receives the torque from the drive-train.
Drive-train Parts in machine involved in power transmission; engine, torque converter, trans-
mission, propeller shaft and drive axle with differential and hub reduction.
Dust reservoir The air filter collects the coarsest particles in a dust reservoir, which is emptied au-
tomatically during operation.
ECC Electric Climate Control. Air conditioning system with thermostat-controlled cooling,
dehumidification and heating.
EHC Electric Heat Control. Heater system with thermostat heating control.
Electrolyte level Fluid level in battery cells.
End position As far out or away as the object can be moved, e.g. end position for tilt cylinders.
Environmental waste Used oils, filters, etc., must be handled according to governing national laws and
regulations.
Expansion tank Coolant reservoir, with space for the fluid to change volume due to temperature
differences.
Fixed displacement Pump with fixed pump volume.
Frame member Structural members in the frame.
Hanging load Lifted load.
Hub reduction Type of final drive (often next to drive wheel) that reduces rpm and increases torque
from the drive-train.
Hydraulic oil Oil for hydraulic system. See specifications in operator’s manual.
Hydraulic oil pump Pump in hydraulic system.
Hydraulic system System that uses oil pressure to transfer power to different functions.
Indicator Mechanical "sensor", for example, shows that a filter is clogged and needs to be
changed.
LC Load centre.
Levelling Attachment is tilted, for example if load stands on uneven ground.
Term Description
Lift capacity Indicates machine’s maximal lift capacity.
Lifting point Attaching point for lift device when lifting an object.
Lock hooks Two hooks that are slide down/in into holes in the container to lock the container in
place when lifting.
Low-emission engine Engine with low emissions of hazardous substances. Manufactured according to
regulations.
Machine model Machine type. Indicated, for example: DCE 90-100. See also type designation.
Main fuse Located by battery. Cuts off current to all systems in machine.
Maintenance Periodic maintenance actions so that machine functions safely and for a long serv-
ice life.
Mast Carrier of trolley, attachment and load.
Operating time Number of hours machine has been in operation, shown on hour meter in cab.
Option Extra equipment for machine.
Pilot oil pressure A low control pressure to, for example, a valve.
Planetary gear Type of transmission with gears in constant engagement (constant mesh).
Product alternative One of several alternatives is selected for a machine, e.g. engine alternative.
Progressive steering Quick steering wheel movements give greater steering angle.
Proportional valve An electromagnetically controlled valve. If a current is applied, the valve is activated
in proportion to the current’s amplitude. In simple terms, infinitely variable valve, as
opposed to on/off valve. For example, on the transmission valve housing.
Recirculation Circulate over and over again.
Refrigerant Fluid/gas in the climate control system. Must only be handled by authorised trained
personnel.
Securing machine for transport Actions before transporting machine.
Serial number Unique machine designation. On the machine plate.
Service position How machine should be safely positioned before service may be started.
Servo Power amplifier. A small movement by the user generates great displacement, e.g.
power steering.
Servo pressure A low control pressure to control a higher pressure, for example, to a valve.
Side lift Attachment. See attachment.
Side shift Parallel sideways movement of attachment.
Solenoid valve An electro magnetically controlled valve. See also proportional valve.
Spirit Delta Enclosed type of cab.
Spreading (positioning) Widening of attachment.
Steering axle Wheel axle with steering.
Tilting The mast is tilted forwards or backwards.
Torque converter Hydraulic, variable clutch.
Transmission oil Oil for gearbox and torque converter. See specifications in operator’s manual.
Trolley Lifts the load, located on the mast.
Term Description
Twistlocks Two lock pins, one in each corner of the attachment, pushed down in corresponding
holes in container and twisted to lock the container when lifting.
Type designation Indicates machine type and capacity. See also machine model.
Valve slide Movable part in valve. Determines oil’s path.
Wet brakes Brake discs in oil bath.
Wheelbase Distance between drive axle and steering axle.
Working hydraulics All load handling functions, that is, lift and lower, tilt, side shift, spreading (exten-
sion) and levelling.
Index
page
–
ATTACH, DCF 70 and DCF 80-100 with twistlock 8 Control system 8.4.9
attachment
ATTACH, DCF 80-100 with lifting hook attachment 8 Control system 8.4.9
Brakes 4 Brakes 4
Cab structure and suspension 9 Frame, body, cab and accessories 9.10
Conditions A Foreword -
Copyright A Foreword -
Dissolvent B Safety -
Engine 1 Engine 1
Environment B Safety -
Feedback A Foreword -
Footsteps and hand rail 9 Frame, body, cab and accessories 9.13.3
Frame, body, cab and accessories 9 Frame, body, cab and accessories 9
Fresh air and recirculation damper 9 Frame, body, cab and accessories 9.4.2
Gear selector and multi-function lever 9 Frame, body, cab and accessories 9.1.1
General A Foreword -
General B Safety -
Heating, ventilation and air conditioning 9 Frame, body, cab and accessories 9.4
Instrument and control panels 9 Frame, body, cab and accessories 9.11.1
Noise B Safety -
Oils B Safety -
Refrigerant B Safety -
Safety and emergency equipment 9 Frame, body, cab and accessories 9.2
Sensor, temperature outlet fan 9 Frame, body, cab and accessories 9.4.16
Steering 5 Steering 5
Storage A Foreword -
Suspension 6 Suspension 6
Transmission 2 Transmission 2
Vibration B Safety -
Washer motor and reservoir 9 Frame, body, cab and accessories 9.5.4
Work lights, front wing 9 Frame, body, cab and accessories 9.6.14