Work Shop Manual Top Lifter Kalmar - 152578161

Empty Container Handler 8-9
tonnes
Publ. no VDCT01.02GB
Workshop Manual in original WORKSHOP MANUAL
DCT 80-90
A Foreword
B Safety
C Preventive maintenance
0 Complete machine
1 Engine
Workshop Manual
2 Transmission
DCT 80-90
3 Driveline/axle
4 Brakes
5 Steering
6 Suspension
7 Load handling
8 Control system
9 Frame, body, cab and accessories
10 Common hydraulics
11 Common electrics
12 Common pneumatics
D Error codes
E Schematics
F Technical data
G Terminology and index

A:1
A Foreword
Contents A Foreword
Foreword ............................................................................................................ A:3
About the Workshop Manual........................................................................... A:3
General ...................................................................................................... A:3
Conditions .................................................................................................. A:3
Storage....................................................................................................... A:3
About machine version............................................................................... A:3
Copyright .................................................................................................... A:3
Reading instructions ....................................................................................... A:4
Warning information ................................................................................... A:4
Important information ................................................................................. A:4
Read operator's manual ............................................................................. A:4
Read the Maintenance manual .................................................................. A:4
The workshop manual's contents............................................................... A:5
Function group structure ............................................................................ A:6
References between different information types ........................................ A:7
Product alternatives and optional equipment ............................................. A:8
Machine card.............................................................................................. A:9
Function descriptions ............................................................................... A:10
About the documentation .............................................................................. A:12
The documentation's parts ....................................................................... A:12
Ordering documentation........................................................................... A:12
Feedback ...................................................................................................... A:13
Form for copying ...................................................................................... A:13
Workshop Manual DCT 80-90 VDCT01.02GB

A:2
VDCT01.02GB Workshop Manual DCT 80-90

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

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

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

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

prohibited.

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

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

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

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

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

Function group structure

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

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

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

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

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

References between different information types

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

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

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

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

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

Product alternatives and optional equipment

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

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

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

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

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

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

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

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

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

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

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

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

Symbol explanation function descriptions

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

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

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

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

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

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

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

A:14

B:1
B Safety
Contents B Safety
Safety.................................................................................................................. B:3
General safety information.............................................................................. B:3
Safety concerns everyone!......................................................................... B:3
A near accident is a warning! ..................................................................... B:3
Safety instructions........................................................................................... B:4
General ...................................................................................................... B:4
Service position .......................................................................................... B:4
Hydraulic and brake systems, depressurising............................................ B:5
Oils ............................................................................................................. B:6
Fuel system ................................................................................................ B:7
Clothing, etc. .............................................................................................. B:8
Several mechanics on the same machine.................................................. B:8
Working under the machine ....................................................................... B:8
Lifting heavy components .......................................................................... B:9
Vibration ..................................................................................................... B:9
Noise ........................................................................................................ B:10
Dissolvent................................................................................................. B:10
Fire and explosion risk ..............................................................................B:11
Fluid or gas under pressure ..................................................................... B:13
Coolant ..................................................................................................... B:14
Refrigerant ............................................................................................... B:14
Air pollution .............................................................................................. B:15
Tensioned springs .................................................................................... B:16
Electric motors ......................................................................................... B:16
Rotating components and tools................................................................ B:16
Tyres and rims.......................................................................................... B:17
Lifting equipment ...................................................................................... B:17
Spare parts............................................................................................... B:18
Non-ionised radiation ............................................................................... B:18
Environment.................................................................................................. B:20
General .................................................................................................... B:20

B:2

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

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

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

B:4 B Safety – Safety instructions
Safety instructions
General
Read and observe the following safety instructions below before
starting to work with the machine:
• Service position, page B:4
• Hydraulic and brake systems, depressurising, page B:5
• Oils, page B:6
• Fuel system, page B:7
• Clothing, etc., page B:8
• Several mechanics on the same machine, page B:8
• Working under the machine, page B:8
• Lifting heavy components, page B:9
• Vibration, page B:9
• Noise, page B:10
• Dissolvent, page B:10
• Fire and explosion risk, page B:11
• Fluid or gas under pressure, page B:13
• Coolant, page B:14
• Refrigerant, page B:14
• Air pollution, page B:15
• Tensioned springs, page B:16
• Electric motors, page B:16
• Rotating components and tools, page B:16
• Tyres and rims, page B:17
• Lifting equipment, page B:17
• Spare parts, page B:18
• Non-ionised radiation, page B:18
Service position
General
General
Service position is used for service, maintenance and other situations

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

• The machine is parked, i.e. parking brake applied.
• Trolley and attachment in totally lowered position
• Mast tilted fully forward.
• Engine off.
• System voltage switched off (with the battery disconnector).
009797
Machine with trolley and attachment in totally lowered

position

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

1 Machine in service position, see Service position, page B:4.
2 Depressurise the hydraulic system.

Turn system voltage on, turn the starter key to position I and
activate the load handling functions several times.
3 Turn the start key to position 0 and switch off the system voltage.
4 Depressurise the brake system by opening the drain valve on the

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

5 Depressurise the attachment.

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

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

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

moving parts.
Long hair should be adequately gathered since it can easily get caught
in moving parts. Exercise caution when working with welding or an
naked flame since hair easily catches on fire.
Several mechanics on the same machine
WARNING
If several mechanics are working on the same vehicle,
extra care must be taken so that accidental movements
do not injure any other person. Communicate so that
everyone knows where everyone is, and what they are
doing.
Risks
Work with wheels or axle suspension, mountings, etc., may result in
components on the other side moving and causing damage or injury.
Operations controlled from the operator's station, e.g. all movement of

lifting equipment, may cause severe personal injury.
Safety precautions
• Make sure that the machine's lifting equipment is completely
lowered or secured in some other way.
• Move the battery disconnector to position zero and remove the key.
• Be aware of the risks when several persons are working around
the vehicle.
• Make your co-workers aware of what you are working with.
• Do not work with the drive wheels on the both sides of the machine
at the same time.
Working under the machine
Working under the frame
A raised vehicle may not, for any reason, be supported or raised in

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

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

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

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

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

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

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

Fire and explosion risk
DANGER
In the event of fire the operator's safety must not be
compromised.
If given the opportunity, take the following action at
the slightest sign of fire:
1. Stop the machine and turn the ignition key to stop
position.
2. Leave the cab.
3. Switch off the system voltage with the battery
disconnector.
4. Alert the rescue services.
5. Try to extinguish the fire.
If this is not possible, leave the machine and the
risk area.
DANGER
Smoke can be extremely toxic.
Smoke subdues, suffocates and can kill people! Smoke
can cause damage to lungs and respiratory organs
even in small quantities.
Avoid breathing fumes, do not stand in the smoke.
Use breathing apparatus for fire fighting and work with
burnt material.
Examples of fire and explosion prone substances are oils, petrol, diesel
fuel oil, organic solvents (paint, plastics, detergents), rust preventive
agents, welding gas, gas for heating (acetylene), high concentrations
of dust particles consisting of combustible materials. Rubber tyres are
flammable and can cause fire with explosive development.
Risks
Examples of the cause of ignition are welding, cutting with gas flame,
tobacco smoking, sparks when grinding with grinding machines,
contact between hot engine parts and flammable materials, heat
generation in rags soaked with oil or paint (linseed oil) and oxygen.
Oxygen containers, lines and valves must be kept clean of oil and
grease.
Fumes from e.g. fuel are heavier than air and may "run" down a slope,
or down into a grease pit, where welding flames, grinding sparks or
cigarette embers may cause an explosion. Vaporised fuel has a very
powerful explosive effect.

Special cases
Diesel fuel oil with added petrol has a lower flashpoint. Risk of
explosion even at room temperature. The explosion risk for heated
diesel fuel oil is higher than for petrol.
When changing the oil in the engine, hydraulic system and

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

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

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

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

10 cm around the welding or cutting point). Use gloves, breathing
protection and protective glasses. Also, welding work must not be
done near plastic or rubber materials without first protecting them from
the heat. Paints, plastics and rubber develop a number of substances
when heated that may be hazardous to health. Exercise caution with
machines that have been exposed to intense heat or fire.
Safety precautions
DANGER
Residue from fuel, oils, grease or other flammable
materials on the engine or in the engine compartment
is a fire hazard.
Fire hazard!
Remove residue of flammable materials in the engine
compartment as soon as they are detected. Be extra
careful on hot surfaces such as exhaust systems,
manifolds or turbochargers. If leakage of oil, fuel or
coolant is detected, the reason should be investigated
and the fault corrected before starting the engine.
• Make it a habit to make a visual inspection of the engine and

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

Fluid or gas under pressure

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

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

• Hydraulic systems (e.g., working hydraulics and brake system).
• Fuel system.
• Tyre changing.
• Air conditioning.
• Cooling system.
Safety precautions
• Use protective goggles and protective gloves.
• Never work in a pressurised system.
• Never adjust a pressure limiting valve to a higher pressure than
the manufacturer's recommendations.
• A hydraulic hose that swells, e.g. at a connection, shows evidence
that it is about to rupture. Replace it as soon as possible! Check
the connections thoroughly.
• Use fluid when checking for leaks.
• Never blow clothes clean with compressed air.
• A discarded pressure accumulator must first be depressurised and
then punctured before it is discarded (to avoid risk of explosion).
Carefully, drill a hole with 3 mm diameter after depressurising.
• Never use your hands to check for any leaks. A fine jet from a
hydraulic hose may have such high pressure that it easily cuts
through e.g. a hand and causes very severe injuries.
• First open the cooling system cap for the filling point slowly, so
that the high pressure is released. Hot steam and coolant may
otherwise spray out.

Coolant
The coolant in the machine's cooling system consists of water,
anti-corrosion compound and anti-freeze fluid, for example, ethylene
glycol.
Coolant must not be drained into the sewer system or directly onto
the ground.
Risks
The cooling system is at high pressure when the engine is warm. Hot
coolant may jet out and cause scalding in the event of leaks or when
the cap on the expansion tank (filling point) is opened.
Ingesting ethylene glycol and anti-corrosion compound is dangerous

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

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

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

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

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

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

(Generated when heating certain plastics and paints.)
Isocyanates can be released in the form of steam, dust (or present

in aerosol) when cutting, grinding or welding. May cause mucous
membrane irritation with asthma-like symptoms and impaired lung
function. Even brief exposure to high concentrations may cause
problems with persistent hypersensitivity.
Safety precautions
• Make sure of adequate ventilation with fresh air when welding,
battery charging and other work when hazardous gases are
formed.
• Use suitable protective gloves and breathing protection when there
is a risk of oil mist. Make sure that the protection is oil-resistant.
• Apply oil-resistant protective lotion to unprotected skin.
• Make sure that an eyewash station is in the immediate vicinity
when working with corrosive substances.
• Avoid unnecessary operation of the machine in the workshop.
Connect extraction equipment to the exhaust pipe so that exhausts
are routed out from the workshop.

Tensioned springs
Examples of tensioned springs:
1. Torque springs in, e.g. pedals
2. Thrust spring (cup springs) in parking brake cylinder
3. Lock rings
4. Gas springs
Risks
If a tensioned spring releases, it is shot out by the spring force and can
also take adjoining parts with it.
Small springs can cause eye injuries amongst other things.
Parking brake springs are tensioned with high force and can cause very
severe accidents if they are accidentally released in an uncontrolled
manner.
Gas springs and gas-charged shock absorbers are tensioned with high
force and can cause very severe accidents if they are accidentally
released in an uncontrolled manner.
Safety precautions
• Use protective safety glasses.
• Lock rings should be of a suitable type and in good condition.
• Follow the instructions in this and other manuals when performing
maintenance and replacing parts and components.
• Always use the tools recommended.
Electric motors
Safety precautions
Always switch off the battery disconnector when working on electric
motors.
Always block the machine's wheels, make sure that the parking brake
is activated and that the gear selector is in neutral position before
starting any work on the machine.
Rotating components and tools

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

if touched.
Drills, lathes, grinders or other machines with rotating parts can cause
severe accidents if clothing or hair gets caught and becomes wound
into the machine.

Safety precautions
• Do not use gloves when working with a drill.
• Remove loose, hanging clothing, scarf or tie.
• Never use clothing with wide sleeves or trouser legs.
• Make sure that clothing is intact and in good condition.
• Long hair should be gathered up in a hair net or similar.
• Remove large or loose hanging jewellery from hands, arms and
neck.
Tyres and rims
DANGER
Tyres should be regarded as pressure reservoirs. If
handled incorrectly, they constitute fatal danger.
Parts could be thrown out with explosive force and
cause severe injuries.
Never repair damaged tyres, wheel rims or lock rings.
Tyre changes must be performed by authorised
personnel.
Risks
Dismantling of wheels: Tyres, rims and lock rings may be ejected.
Inflating of tyres: Tyres, rims or lock rings may be ejected.
Safety precautions
• Always deflate the tyre before starting to work on the wheel.
• Check that tyres, rims and lock rings are not damaged. Never
repair damaged wheel rims or lock rings.
• Wheels shall be inflated on the machine or in a protective device,
designed and dimensioned so that it can handle or dissipate a
shock wave from a tyre explosion as well as catch the ejected
parts.
• Use protective screen and protective safety glasses.
Lifting equipment
When working on the machine in general, and with the machine's lifting
equipment in particular, the greatest caution must be exercised with
respect to securing the mast, carriage and attachment.
Always make a habit of lowering the carriage to its lowest position
before working on the machine.
Risks
If the machine's lifting equipment is not lowered or secured, there is a
risk of crushing.
Risk of crushing is particularly great when depressurising the hydraulic
system, see Hydraulic and brake systems, depressurising, page B:5.
Safety precautions
Do not begin work until the carriage has been fully lowered. If the
nature of the work requires the carriage to be raised then this must
be secured in some way.

Spare parts
WARNING
For safety reasons, the following spare parts may only
be replaced with genuine spare parts:
• Brake valve
• Drive axle
• Steering valve (Orbitrol)
• Steering valve incl. priority valve
• Steering axle
• Steering cylinder
• Rim
• Mast, carriage
• Lift cylinder incl. load control valve
• Lifting chains
• Chain tightener and shaft
• Lift cylinder
• Valve block lift
• Tilt cylinder
• Twistlock
• Control breaker (for hydraulic function)
• Emergency stop
• Accumulator
• Main valve load handling
• Accumulator charging valve
• All control units
Non-ionised radiation
WARNING
Optional equipment such as two-way radio, telephone,
etc. may emit non-ionising radiation.
Risk of interference with active or non-active medical
products.
Use two-way radio, telephone, etc. when no persons
with active or non-active medical products are in the
vicinity.

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

B:20 B Safety – Environment
Environment
General
The ever-increasing industrialisation of our world is having a significant
impact on our global environment. Nature, animals and people are
subjected daily to risks in connection with various forms of chemical
handling.
There are still no fully environmentally safe chemicals, such as oils and
coolants, available on the market. Therefore, all who handle, perform
service on or repair machines must use the tools, assisting devices and
methods necessary to protect the environment in an environmentally
sound manner.
By following the simple rules below, you will contribute to protecting

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

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

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

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

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

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

B Safety – Environment B:21
Declarations
The machine does not contain asbestos.
The machines contains lead in batteries and in electric cabling. In

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

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

B:22

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

section A Foreword.

C:2

0:1
0 Complete machine
Contents 0 Complete machine

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

0:2

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

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

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

drive axle with differential and hub reduction. Drive takes place on
the front wheels.
7 The service brakes are wet multiple disc brakes which are attached
to the drive wheel hub. The parking brake is the disc brake type and
operates on the drive axle input shaft.
Steering operates on the rear wheels with a double acting hydraulic

cylinder. The steering axle is suspended in the frame with pendulum
6
suspension.
The wheels are attached to the hubs with studs and nuts. Double
wheels are fitted on the drive axle; single wheels on the steering axle.
Load handling comprises components and functions for handling

loads. The load is lifted with the side lift attachment secured to a
trolley that sits on a mast. Load handling is divided into the functions:
lift and lower, tilt, side shift, spreading and load securing.
• Lifting/lowering is the function used to raise and lower the trolley.
014183
1 2 3 4 • Side shifting is moving the side lift attachment sideways along

the trolley.
1. Steering axle • Spreading is adjusting the width between the Twistlocks on the
2. Engine side lift attachment.
3. Frame • Tilt is used to angle the load in the longitudinal direction of the
truck with the help of the mast.
4. Drive axle
• Load securing is to lock the load to the side lift attachment.
5. Mast
6. Side lift attachment The control system consists of functions for warning the operator of
dangerous situations and faults. The control system has diagnostic
7. Cab
resources that simplify troubleshooting.
The frame carries the machine. The frame houses the engine,
transmission, drive axle and steering axle. Fuel and hydraulic oil
tanks are fitted to the side of the frame. The cab is located at the
rear of the frame.
The hydraulic system is fed by two hydraulic oil pumps. The pumps
are mounted on the transmission's power take off. One fixed pump
feeds load handling and the other fixed pump feeds the brake system,
steering and the cooling circuit over a combined priority valve and
accumulator charging valve. The hydraulic oil tank is located on the
right side of the machine. The hydraulic oil filters are return filters
fitted in the hydraulic oil tank.

0:4 0 Complete machine – Complete machine
The machine's electrical system is built around control units at strategic

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

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

functions. Certain faults can be identified directly using function
descriptions. Sections 0–12 contain descriptions of the various
functions of the machine.
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 0:6.
The error code lists contain recommended actions for every error
code. Error code lists are available in section D Error codes.
5 If there is no error code or the problem persists, use the function

description for the function affected in section 0–12.
The function description contains information on which
components are involved in the function and how these
components work together. In some cases, there is information
on what conditions are required in order for it to be possible to
activate the function. Measurement points are marked with flags
(C for measuring outlet, D for diagnostic menu).

Troubleshooting without an error code,

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

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

check the transmission of the signal (electric cables or hydraulic
hoses).
For electric cables, see Troubleshooting cable harnesses, page
0:8.
For hydraulic hoses, see Troubleshooting hydraulic hoses, page
0:9.
6 If the cables or hoses between the components seem to be intact,

then check the component that receives the signal.

Troubleshooting with an error code,

example
Error codes are indicators of malfunctions detected by the control
system. Many error codes are connected to electrical malfunctions but
there are also error codes that interpret associations between one or
several signals that indicate a non-electrical malfunction. It is important
to not draw conclusions too hastily based on an error code.
1 Read out error codes from the display, e.g. error code 34.
2 Use the error code lists and search information about the error
code, see "Example of error code information in error code list"
below.
The error code lists are available in section D Error codes.
For detailed instructions for reading out error code, see section
D Error codes.
3 Follow the instructions in the field "Action".
4 Use diagnostic menus and circuit diagrams to determine if the

input signal to the control unit is correct; see section 8 Control
system, group 8.4 Diagnostics as well as section E Schematics.
5 Use the function group to find more information if needed.

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

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

troubleshooting electric cables and hydraulic hoses.
For electric cables, see Troubleshooting cable harnesses, page
0:8.
For hydraulic hoses, see Troubleshooting hydraulic hoses, page
0:9.
8 If the wiring is not defective, then connect the cable to the control
unit.
NOTE
The system voltage must be switched off with the battery
disconnector!
9 Disconnect the cable harness from the component in question.
10 Switch on the system voltage with the battery disconnector.
11 Turn the ignition key to operating position.
12 Check that voltage reaches the component.

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

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

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

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

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

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

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

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

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

0:10

1:1
1 Engine
Contents 1 Engine
1 Engine..................................................................................................................1:3
1.1 Controls and instruments ...............................................................................1:20
1.1.1 Ignition.......................................................................................................1:20
1.1.2 Accelerator ................................................................................................1:20
1.2 Fuel system....................................................................................................1:21
1.2.1 Fuel tank ...................................................................................................1:21
1.2.2 Sensor fuel level........................................................................................1:22
1.2.5 Make-contact (closing switch) water in fuel...............................................1:22
1.6 Air intake and exhaust outlet..........................................................................1:23
1.6.1 Air cleaning system ...................................................................................1:23
1.6.3 Exhaust system .........................................................................................1:23
1.6.4 Intercooler .................................................................................................1:24
1.7 Cooling system ..............................................................................................1:25
1.7.4 Radiator and expansion tank ....................................................................1:25
1.7.5 Cooling fan ................................................................................................1:26
1.7.7 Coolant ......................................................................................................1:26
1.9 Control system, engine ..................................................................................1:30
1.9.1 Engine control unit ....................................................................................1:30
1.11 Start/stop........................................................................................................1:31
1.11.1 Starter motor .............................................................................................1:31
1.11.2 Stopping device.........................................................................................1:31

1:2

1 Engine – Engine 1:3
1 Engine
Engine, general
Engine alternative
The machine can be equipped with one of the following engine
alternatives:
• Yuchai YC6A240-30 (stage III in accordance with directive 2006/42
EC)
• Cummins QSB6.7 (stage III in accordance with directive
97/68/EC)
If there are differences between engine alternatives, this is written in

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

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

1:4 1 Engine – Engine
Engine alternative Yuchai YC6A240-30,

functional description
rpm ˚C
kph
0 . bar
P I
II
III
1, 6
11
D11 D1 D6
5, 7, 19 18, 22
D790-2 D795
D790-1 D797-1
4, 8, 17, 21
2, 12, 23
D20
D8
3, 13, 16, 24
D794 20
D3
H2O H2O
SENSORS 10 M 9
015015
15 14
Pos Explanation Signal description Reference

1 The ignition key lock sends a voltage U = 24 V Ignition key lock, description, page 1:20
signal to Control unit, cab (D790-1) when
D1: Diagnostic menu, see section 8 Control
the ignition key is turned to position 1.
system, group 8.4.1.5 CAN/POWER, menu
5 and 8.4.6.4 ENGINE, menu 4
2 Control unit, cab (D790-1) sends Ignition Checked by control Section 11 Common electrics, group
on over the CAN bus. system, error shown 11.5.3.1 Control unit, cab
with error code.
3 When required, the Control unit, engine U = 24 V Section 11 Common electrics, group Frame
(D794) activates the preheating coil. control unit (D797-1)
Status signal is also sent to Control unit,
frame (D797-1).
system, group 8.4.6.5 ENGINE menu 5
4 Control unit, frame (D797-1) sends Checked by control D3: Diagnostic menu, see section 8 Control
preheating active on the CAN bus. system, error shown system, group 8.4.6.5 ENGINE menu 5
with error code.
5 Control unit KIT (D790-2) activates - Section 11 Common electrics, group
indicator light, preheating. 11.5.3.11 Control unit, KIT
signal to Control unit KIT (D790-2) when
the ignition key is turned to start position.
7 Control unit KIT (D790-2) sends a start Checked by control Section 11 Common electrics, group
signal on the CAN bus. system, error shown 11.5.3.11 Control unit, KIT
with error code.
8 Control unit, frame (D797-1) supplies U = 24 V Section 11 Common electrics, group
voltage to Relay, starter motor (K360) on 11.5.3.2 Frame control unit
the starter motor.


9 The starter motor cranks the engine. - Starter motor, description, page 1:31
10 The engine's sensor sends signals to Checked by control Section 11 Common electrics, group
Control unit, engine (D794) that controls system, error shown 11.5.3.10 Control unit, engine
the injectors so the engine starts. with error code.
11 The accelerator pedal sends a voltage U = 0.5-4.5 V Section 9 Frame, body, cab and
signal proportional the depression to accessories, group 9.1 Controls and
Lower voltage than 0.5
Control unit, cab (D790-1). instruments
V and higher voltage
than 4.5 V is used to D11: Diagnostic menu, see section 8
detect faults in cable Control system, group 8.4.6.1 ENGINE
harnesses and controls. menu 1
12 Control unit, cab (D790-1) sends a Checked by control Section 11 Common electrics, group
message with the rpm request on the CAN system, error shown 11.5.3.1 Control unit, cab
bus. with error code.
13 Control unit, engine (D794) increases the - Section 11 Common electrics, group
engine speed. 11.5.3.10 Control unit, engine
14 Make-contact (closing switch) coolant level Low level: U = 24 V Cooling system, description, page 1:25
sends a voltage signal to Control unit frame
front (D797-F) if the coolant level is low in
the expansion tank.
15 Make-contact (closing switch) water in fuel Water in fuel: U = 0 V Make-contact (closing switch) water in
(B760) sends a ground signal to Control fuel, description (engine alternative Yuchai
unit, engine (D794) if there is too much YC6A240-30), page 1:22
water in the fuel prefilter. Control unit,
frame (D797-1) is used to supply voltage
for the signal.
16 Control unit, engine (D794) sends engine Checked by control Section 11 Common electrics, group
data and warning messages on the CAN system, error shown 11.5.3.10 Control unit, engine
D14: Diagnostic menu, see section 8
Control system, group 8.4.6.6 ENGINE,
menu 6, 8.4.6.7 ENGINE, menu 7, 8.4.6.8
ENGINE, menu 8, 8.4.6.9 ENGINE, menu
17 Control unit, frame (D797-1) sends lamp Checked by control Section 11 Common electrics, group
information on the CAN bus. system, error shown 11.5.3.2 Frame control unit
with error code.
18 Control unit KID (D795) shows engine data - Section 11 Common electrics, group
via display figures. 11.5.3.12 Control unit, KID
19 Control unit KIT (D790-2) activates warning - Section 11 Common electrics, group
lamps when necessary. 11.5.3.11 Control unit, KIT
20 Sensor fuel level (B757) sends a voltage U = 0.5-4.5 V Sensor, fuel level, description, page 1:22
signal proportional to the fuel level in the
Lower voltage than 0.5 D20: Diagnostic menu, see section 8
tank to Control unit, frame rear (D797-R).
V and higher voltage Control system, group 8.4.3.7 CAB, menu 7
than 4.5 V is used to
detect faults in cable
harnesses and controls.
21 The frame control unit (D797-1) transmits Checked by control Section 11 Common electrics, group
fuel level on the CAN bus. system, error shown 11.5.3.2 Frame control unit
with error code.
22 Control unit KID (D795) shows the fuel - Section 11 Common electrics, group
level in the operating menu for the engine. 11.5.3.12 Control unit, KID


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

Engine alternative Cummins QSB6.7 ,

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

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


7 The starter motor is controlled by the U = 24 V Starter motor, description, page 1:31
engine control unit (D794) through starter
relays and receives signals from the cab
control unit KCU (D790-1) over the CAN
bus.
8 The starter motor cranks the engine. - Starter motor, description, page 1:31
9 The engine's sensor sends signals to - Section 11 Common electrics, group
Control unit, engine (D794) that controls 11.5.3.10 Control unit, engine
the injectors so the engine starts.
10 The accelerator pedal sends a voltage U = 0.2-4.8 V Accelerator pedal, replacement, page 1:20
signal proportional the depression to
Lower voltage than 0.2 D10: Diagnostic menu, see section 8
Control unit, cab (D790-1).
V and higher voltage Control system, group 8.4.6.1 ENGINE
than 4.8 V is used to menu 1
detect malfunction in
cable harnesses and
controls.
11 Control unit, cab (D790-1) sends a Checked by control Section 11 Common electrics, group
message with the rpm request on the CAN system, error shown 11.5.3.1 Control unit, cab
Control system, group 8.4.6.1 ENGINE
menu 1
12 Control unit, engine (D794) increases the - Section 11 Common electrics, group
Control system, group 8.4.6.1 ENGINE
menu 1
13 Make-contact (closing switch) coolant level U = 24 V Cooling system, description, page 1:25
sends a voltage signal to Control unit,
engine (D794) if the coolant level is low in
the expansion tank.
14 Control unit, engine (D794) sends engine Checked by control Section 11 Common electrics, group
data and warning messages on the CAN system, error shown 11.5.3.10 Control unit, engine
Control system, group 8.4.6.6 ENGINE,
menu 6, 8.4.6.7 ENGINE, menu 7, 8.4.6.8
ENGINE, menu 8 and 8.4.6.9 ENGINE,
menu 9
15 Control unit KID (D795) shows engine data - Section 11 Common electrics, group
via display figures. 11.5.3.12 Control unit, KID
16 Sensor fuel level (B757) sends a voltage R = 0-70 ohm Sensor, fuel level, description, page 1:22
signal proportional to the fuel level in the
A warning message D16: Diagnostic menu, see section 8
tank to Control unit, frame (D797-1).
appears on the display if Control system, group 8.4.3.7 CAB, menu 7
the amount of fuel in the
tank is less than 15% for
more than 40 seconds.
17 The frame control unit (D797-1) transmits Checked by control Section 11 Common electrics, group
fuel level on the CAN bus. system, error shown 11.5.3.2 Frame control unit
with error code.
18 Control unit KID (D795) shows the fuel - Section 11 Common electrics, group
level and the machine speed in the 11.5.3.12 Control unit, KID
operating menu for the engine.


19 If the rotation speed of the output shaft is Checked by control Section 11 Common electrics, group
so high that it corresponds with the limit for system, error shown 11.5.3.1 Control unit, cab
the machine's speed limitation then Control with error code.
unit, cab (D790-1) sends reduce engine
speed on the CAN bus.
20 Control unit, engine (D794) limits the - Section 11 Common electrics, group
Engine alternative Yuchai YC6A240-30,

component placement
1 2
3
4
14
13
5
12
7
8
9
10
014622
11
Engine alternative Yuchai YC6A240-30, left-hand side (in the machine's direction of travel)
1. Make-contact (closing switch), low coolant level 8. Connection radiator inlet
(B759)
9. Oil filter
2. Expansion tank
10. Relay, starter motor (K360)
3. Thermostat housing
11. Starter motor (M654)
4. Connection radiator outlet
12. Connection exhaust system
5. Coolant pump
13. Turbocharger
6. Connection cab heating
14. Air cleaner connection
7. Drain radiator

10
014641
8 7 6
Engine alternative Yuchai YC6A240-30, right-hand side (in the machine's direction of travel)
1. Filling point engine oil 6. Control unit, engine (D794)
2. Connection intercooler 7. Fuel filter
3. Relay preheating (K312) 8. Connection intercooler
4. Preheating coil (E8000) 9. Fuel pump
5. Oil dipstick engine 10. Alternator

Engine alternative Cummins QSB6.7,

component placement
2
5
1
10
015097
9
Engine alternative Cummins QSB6.7, left side (in machine's direction of travel)
1. Oil dipstick engine 6. Connections cab heating
2. Filling point engine oil 7. Coolant inlet
3. Outlet exhaust system 8. Oil filter
4. Outlet coolant to radiator 9. Starter motor
5. Alternator 10. Crankcase ventilation

6
5
4
3
2
1
14
13
12
7
9
11
015096
10
Engine alternative Cummins QSB6.7, right side (in machine's direction of travel)
1. Alternator 8. Air inlet
2. Outlet coolant to radiator 9. Engine control unit (D794)
3. Turbo air inlet 10. Drain engine oil
4. Turbo air outlet 11. Vibration damper (rubber)
5. Oil dipstick engine 12. Fan drive
6. Filling point engine oil 13. Water pump
7. Fuel filter 14. Drive belt tensioner

Components on the machine, component

placement
0
1 2 P I 3 4 5
II
III
12
11 7
014697
10 9 8
1. Accelerator pedal (B690) 7. Control unit, transmission (D793)

2. Ignition key lock (S150) 8. Fuel tank
3. Control unit KIT (D790-2) 9. Sensor fuel level (B757)
4. Control unit, KID (D795) 10. Control unit, frame front (D797-1)
5. Control unit, cab (D790-1) 11. Water in fuel sensor (B760)
6. Diagnostic socket drive-train 12. Fuel pre-filter

Engine and transmission, separation

(engine alternative Yuchai YC6A240-30)
Separation
1 Machine in service position, see section B Safety.
2 Attach hoisting equipment to the engine.

3 Disconnect the requisite hoses and cables before separating
engine and transmission.
NOTE
Drain and collect liquids before detaching hoses.
4 Use a jack to secure the transmission.
5 Remove the cover washer on the clutch housing so that the flex
plate's attaching bolts are accessible.

6 Remove the cover washer.

7 Rotate the engine so that the bolts in the flex plate can be
removed.
8 Remove the screws for the flex plate.
The flex plate has eight fastening points against for the flywheel
on the engine.
9 Take up the slack in the hoisting equipment.
NOTE
Do not lift the engine.
10 Remove the bolts between engine and transmission.

11 Loosen the engine and transmission brackets.
12 Withdraw the engine rearwards to separate it from the
transmission.
Assembly
13 Rotate the engine so that the holes in the flywheel are just in front
of the attachment points on the flex plate.
The flex plate has eight fastening points against for the flywheel
on the engine.
14 Fit the bolts to the engine mounts and transmission brackets.

Tighten to a torque of:
Engine mount, 330 Nm.
Transmission bracket, 280 Nm.
15 Connect the engine to the transmission.
16 Fit the bolts between engine and transmission.

Tighten to a torque of:
M12: 100–120 Nm.
M14: 140–160 Nm.
17 Fit the flex plate's attaching bolts. Tighten to a torque of 40 Nm.
NOTE
The engine must be loosened from the engine mounts and
separated from the transmission to remove a dropped bolt.
Secure the bolt in the socket when installing.
18 Fit the cover plate in front of the flywheel.

19 Fit the cover plate on the clutch housing.

20 Remove the hoisting equipment from the engine.
21 Remove the jack from underneath the transmission.
22 Connect the requisite hoses and cables for the engine and
transmission. Check and fill fluids as required.

Engine, replacement (engine alternative

Cummins QSB6.7 )
Separation
2 Attach hoisting equipment to the engine.

3 Disconnect the requisite hoses and cables before separating
engine and transmission. If the engine is replaced the cooling
unit must be removed.
NOTE
Drain and collect liquids before detaching hoses.
009088
4 Remove the radiator.
5 Use a jack to secure the transmission.
6 Remove the screws holding the cover plate to the flywheel on

the left side of the engine.
008314
7 Remove the screws in the flex plate through the hole under the
cover plug.
NOTE
Turn the engine over to access each screw on the flex plate.
8 Take up the slack in the hoisting equipment.
NOTE
Do not lift the engine or transmission.
008315

9 Remove the bolts between the engine and the transmission.

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

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

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

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

1:20 1 Engine – Controls and instruments
1.1 Controls and instruments

1.1.1 Ignition
Ignition key lock, description
P No function.
0 Stop position. Everything switched off, the key can be
removed.
I Operating position.
Voltage to all electrical functions. The control units for engine
and transmission are now ready to be started.
The signal can be checked via the diagnostic menu. See
section 8 Control system, group 8.4.1.4 CAN/POWER, menu
4.
II Preheating position.
The preheating is controlled automatically by the Engine
control unit (D794).
III Start position.
Engagement of starter motor for engine start.
0
P I NOTE
The machine is equipped with an electric restart interlock,
which prevents engagement of the starter motor when the
engine is rotating.
II Condition for starter motor to engage is that the
transmission is in neutral position and that the engine isn't
already running.
000317
III
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
2 Pull one edge of the cover away to facilitate access to the

accelerator pedal.
3 Disconnect the cable harness from the connector.
4 Unscrew the connector from the accelerator pedal.
5 Replace the accelerator pedal.
6 Fit in the reverse order.
7 Calibrate the accelerator pedal. See section 8 Control system,
group 8.5.2.3 Calibrate DRIVE-TRAIN.
1. Brake pedal
2. Accelerator
Accelerator pedal, calibration

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

1 Engine – Fuel system 1:21
1.2 Fuel system

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

Fuel tank, description
The fuel tank is located on the left-hand side of the machine.
3
1
015051
1. Sensor fuel level

2. Filling point fuel
3. Fuel tank

1:22 1 Engine – Sensor fuel level
1.2.2 Sensor fuel level

Sensor, fuel level, description
Fuel tank sensor (B757) is placed on the front of the fuel tank.
3 Sensor fuel level (B757) sends a voltage signal proportional to the
fuel level in the tank to Control unit, frame (D797-1). The signal can
2 be checked via the diagnostic menu. See section 8 Control system,
group 8.4.3.7 CAB, menu 7.
1
015051
1. Sensor fuel level

2. Filling point fuel
3. Fuel tank
1.2.5 Make-contact (closing switch) water in fuel

Make-contact (closing switch) water in fuel,
description (engine alternative Yuchai YC6A240-30)
Make-contact (closing switch) water in fuel (B760) is fitted in the
bottom of the fuel prefilter and closes when it is time to drain the fuel
prefilter of water.
Make-contact (closing switch) water in fuel (B760) sends a ground

signal to Control unit, Engine (D794) when the filter should be drained.
The contact voltage is fed in parallel on the signal line of Control unit
(D797-F) across a resistor (a so-called "pull up" voltage).
014134
Make-contact (closing switch) water in fuel, (engine

alternative Yuchai YC6A240-30)

1 Engine – Air intake and exhaust outlet 1:23
1.6 Air intake and exhaust outlet

1.6.1 Air cleaning system
Air cleaning system, description
The air cleaning system consists of an air cleaner with filter, filter
indicator, pipes and hoses. There are two filters in the air cleaner that
purify the air and a dust reservoir that collects larger particles. The
2 dust reservoir can be emptied without opening the air cleaner.
3
Combustion in the engine requires air. Free unobstructed flow for
fresh air and exhaust gases is essential for efficient engine operation.
Particles are collected in the filter material when the air filters clean
the air to the engine. Over time, a great deal of particle matter is
1 collected and the filter does not let through sufficient air for efficient
combustion, the filter must then be changed. The filter indicator
measures the negative pressure on the engine side of the filter. When
008040 the filter is clogged the negative pressure is higher and the indicator
indicates that it is time to replace the filter.
As an option the machine can be equipped with a raised air intake.

Air cleaning system, overview
1. Dust reservoir
2. Air cleaner
3. Filter indicator
1.6.3 Exhaust system

Exhaust system, description
The exhaust system is mounted in the chassis. Heat protection is
fitted between the engine and exhaust system to protect cables,
etc. A flex pipe between the turbo and silencer takes up engine
1
movement. On the outside of the machine, there is heat protection
fitted over the exhaust system.
WARNING
Hot exhaust system!
Risk of burn injuries!
Never touch the turbo, silencer or catalytic converters
when the machine is running or just after it has been
turned off!
2
3
014700
1. End pipe
2. Silencer
3. Exhaust pipe

1:24 1 Engine – Intercooler
1.6.4 Intercooler
Intercooler, description
The charge air is cooled by an air-air intercooler in the upper part
of the cooling unit.
See also Cooling system, description, page 1:25.
2
4
3
014686
1. Intercooler
2. Transmission oil cooler
3. Radiator
4. Condenser AC

1 Engine – Cooling system 1:25
1.7 Cooling system

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

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

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

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

• Engine coolant.
1 • Transmission oil (cooled in its own part of the cooling unit), see
also section 2 Transmission, group 2.6.3 Oil cooler.
• Charge air (cooled in the upper part of the cooler unit), see also
2 Intercooler, description, page 1:24.
4 See also Cooling system, description, page 1:25.
3 For more information, see supplier documentation, engine.

014686
1. Intercooler
3. Radiator
4. Condenser AC

1:26 1 Engine – Cooling fan
1.7.5 Cooling fan

Cooling fan, description
The cooling fan is located on the engine water pump at the rear of
the engine. The fan is powered by the engine via the drive belts and
pushes cooling air through the cooling unit.
1.7.7 Coolant
Coolant, changing (engine alternative Yuchai
YC6A240-30)
NOTE
Read the safety instructions for coolant before starting work, see
section B Safety.
2 Open the hood.
3 Remove the cap on the expansion tank.
4 Place a receptacle under the radiator and engine. (The cooling

system holds about 40 l.)
5 Drain the cooling system.

Open the drain cock on the bottom of the radiator. Collect the
coolant in the receptacle.
014698
Drain cock coolant radiator.
6 Connect a hose to the drain cock on the engine and route the
other end to the receptacle.
7 Open the drain cock on the engine.
8 Once all the coolant has drained out, close drain cocks.
Drain cock coolant engine, the illustration shows the tap

closed.

1 Engine – Coolant 1:27
9 Fill the new premixed coolant of the correct type in the expansion
tank. For volume and quality, see section F Technical data.
A
CAUTION
Different types of coolant may not be mixed.
Risk of engine damage and damage to the cooling
system if different types of coolant are mixed.
When changing and topping up coolant, the same type
of coolant must be used as was used before.
B
10 Switch on the system voltage and start the engine.
11 Set cab heating to max.
12 Run the engine to operating temperature so the thermostat opens
and coolant is pumped around the whole system. Do not operate
the machine.
13 Check the level in the expansion tank, fill if necessary.
014191
C
14 Close the hood.
A Position for coolant reservoir (expansion tank) 15 Check the coolant level again after 10 operating hours.
B Filling point
C Sight glass, level check

1:28 1 Engine – Coolant
Coolant, replacement (engine alternative Cummins

QSB6.7 )
NOTE
Read the safety instructions for coolant before starting work, see
section B Safety.
2 Open the hood.
3 Remove the cap on the expansion tank.
4 Place a receptacle under the radiator and engine. (The cooling

system holds about 40 l.)
5 Drain the cooling system.

Open the drain cock on the bottom of the radiator. Collect the
coolant in the receptacle.
014698
6 Open the drain on the engine.

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

1 Engine – Coolant 1:29
8 Fill the new premixed coolant of the correct type in the expansion
tank. For volume and quality, see section F Technical data.
A
CAUTION
B
9 Switch on the system voltage and start the engine.
10 Set cab heating to max.
11 Run the engine to operating temperature so the thermostat opens
and coolant is pumped around the whole system.
12 Check the level in the expansion tank, fill if necessary.
014191
C 13 Close the hood.

14 Check the coolant level again after 10 operating hours.
1. Position for coolant reservoir (expansion tank)
2. Filling point
3. Sight glass, level check

1:30 1 Engine – Control system, engine
1.9 Control system, engine

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

1 Engine – Start/stop 1:31
1.11 Start/stop
1.11.1 Starter motor
Starter motor, description
The starter motor cranks the engine until fuel combustion begins and
the engine starts.
The starter motor is supplied with voltage directly from the start
batteries. A relay on the starter motor (solenoid) is activated by Control
unit, engine (D797-1R).
For more information, see supplier documentation, engine.
1.11.2 Stopping device

Stopping device, description
The engines have electrically regulated injectors that stop delivering
fuel when the voltage is cut off, which means that the engine stops.
The engine can only be stopped by turning off the ignition via the
ignition key lock.
NOTE
The battery disconnector must not be used for emergency stop!
For more information, see supplier documentation, engine.
Automatic engine shutdown is available as an option. This means

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

1:32

2:1
2 Transmission
Contents 2 Transmission
2 Transmission ......................................................................................................2:3
2.1 Controls and instruments .................................................................................2:9
2.1.1 Gear selector and multi-function lever.........................................................2:9
2.2 Torque converter/Clutch system ....................................................................2:10
2.2.1 Flex plates .................................................................................................2:10
2.6 Lubrication system .........................................................................................2:13
2.6.3 Oil cooler ...................................................................................................2:15
2.7 Cooling system ..............................................................................................2:17
2.7.3 Oil cooler ...................................................................................................2:17
2.8 Control system, transmission.........................................................................2:18
2.8.1 Transmission control unit ..........................................................................2:18
2.8.2 NO (normally open) switch, disengagement .............................................2:18
2.8.3 Transmission cable harness......................................................................2:18

2:2

2 Transmission – Transmission 2:3
2 Transmission
Transmission, general
and instructions for the transmission's components and systems, refer
to the relevant supplier documentation.

Transmission, function description
F
R
1
D 1
23 5 D 1
D 23 D 5
6,24 2,7 20
D 7 9 0 -1 D 7 9 0 -2 D 795
D 793 D 794 D 7 9 7 -F
11,17,19,21,27 22 26
D 10
D 12 D 8
8 D 9 9 10 D 25
P a
P a
25
4 16
15
3 14
18
13
013852
12

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

2:4 2 Transmission – Transmission

4 The transmission's oil filter cleans the - -
oil from impurities.
5 The accelerator pedal transmits a U = 0.5-4.5 V Section 1 Engine, group 1.1.2 Accelerator
signal to Control unit, cab (D790-1). pedal
6 Control unit, cab (D790-1) transmits Checked by control system, Section 11 Common electrics, group
the desired throttle application on the error shown with error code. 11.5.3.1 Control unit, cab
CAN bus.
7 Control unit KIT (D790-2) sends the Checked by control system, Section 11 Common electrics, group
selected shifting program on the CAN error shown with error code. 11.5.3.11 Control unit, KIT
bus.
8 Sensor, oil pressure transmission Checked by Control unit, Transmission, component location, page
(B765) sends a voltage signal transmission, error shown 2:8
proportional to the oil pressure to with error code.
Control unit, transmission (D793).
9 Sensor, turbine speed (B751) Checked by Control unit, Transmission, component location, page
sends Control unit, transmission transmission, error shown 2:8
(D793) a pulse signal with frequency with error code.
proportional to turbine speed.
10 Sensor, oil temperature (B766) sends Checked by Control unit, Transmission, component location, page
a voltage signal proportional to transmission, error shown 2:8
the transmission oil temperature to with error code.
11 Control unit, transmission (D793) Checked by Control unit, Section 11 Common electrics, group
supplies voltage to the solenoid and transmission, error shown 11.5.3.9 Control unit, transmission
servo valves in order to obtain the with error code.
desired function.
12 Solenoid valve clutch forward, (Y630) Checked by Control unit, Transmission, component location, page
or Solenoid valve clutch reverse transmission, error shown 2:8
13
(Y631) is activated to select direction with error code.
14 of travel. Solenoid valve clutch gear
See also, Actuated valves in
1 (Y6067-1), or Solenoid valve clutch
15 selected gear, page 2:5
gear 2 (Y6069).
16
Engine power is transferred to the
transmission's output shaft.
controls gear shifting according to transmission, error shown 11.5.3.9 Control unit, transmission
selected shifting program. with error code.
18 The oil cooler cools the transmission - Oil cooler, description, page 2:17
oil. A thermostat senses the oil's
temperature and directs the oil back to
the transmission if the oil is cold.
19 Control unit, transmission (D793) Checked by control system, Section 11 Common electrics, group
transmits temperature and speed data error shown with error code. 11.5.3.9 Control unit, transmission
on the CAN bus.
20 Control unit KID (D795) shows Checked by control system, Section 11 Common electrics, group
transmission information in operating error shown with error code. 11.5.3.12 Control unit, KID
menus.
21 Sensor, turbine speed (B751) - Transmission, component location, page
indicates that the machine's speed 2:8
exceeds the speed limit, sends Control
unit, transmission (D793) requests for
reduced engine speed on the CAN
bus.
22 Control unit, engine (D794) reduces - Section11 Common electrics, group
the engine speed. 11.5.3.10 Control unit, engine


23 If the declutch pedal (S220-1) is U = 24 V Section 9 Frame, body, cab and
depressed, it sends a voltage signal to accessories, group 9.1 Controls and
Control unit, cab (D790-1). instruments
Control system, group 8.4.7.1, TRANSM
menu 1
24 Control unit, cab (D790-1) transmits Checked by control system, Section 11 Common electrics, group
declutch drive on the CAN bus. error shown with error code. 11.5.3.1 Control unit, cab
25 Make-contact (closing switch) declutch Brake pressure above Make-contact (closing switch) declutch,
(S220-2) sends a voltage signal to 0.2 MPa: description, page 2:18
Control unit, frame front (D797-F) if
Conn 1, U = 24 V D25: Diagnostic menu, see section 8
the brake pressure is high enough to
Control system, group 8.4.7.1, TRANSM
allow declutch of the drive. Conn 2, U = 24 V
menu 1
Brake pressure below
0.2 MPa:
Conn 1, U = 24 V
Conn 2, U = 0 V
26 Control unit, frame front (D797-F) Checked by control system, Section 11 Common electrics, group
sends declutch approved on the CAN error shown with error code. 11.5.3.2 Control unit, frame front
bus.
supplies voltage to valve block transmission, error shown 11.5.3.9 Control unit, transmission
transmission control so that drive is with error code.
declutched.
Table Actuated valves in selected gear
Y6067-1 Y6069
Gear 1 On On
Gear 2 Off On
Gear 3 Off Off

Shifting transmission, function description
21
24 Pa
5
25 6 10
23 14 17
7 11
26
9 15 18
3 4
22
2
1 Rev
13 Fwd 1st 2nd 3rd
014699
8 12 16 19 20

1 Bottom strainer oil sump, separates particles - -
from the oil before the pumps.
2 The transmission's oil pump feeds the 30.4 l/min at 685 rpm -
transmission with control pressure for control
of the transmission.
3 The oil filter cleans the oil. - -
4 The bypass valve in the filter bracket leads Opening pressure: 410-450 kPa -
the oil past the filter if the resistance through
the filter becomes too high.
5 The pressure regulator releases pressure to Opening pressure: 2200 kPa -
the torque converter if the pressure becomes
too high.
6 When the reverse direction of travel is - Transmission, component
selected Solenoid valve, clutch reverse location, page 2:8
(Y631) is supplied with voltage. The solenoid
valve opens and directs pressure to valve
slide clutch reverse.
7 Valve slide clutch reverse pressurises drive - -
clutch reverse and modulation valve forward.
8 Drive clutch reverse locks the transmission in - -
reverse drive when the clutch is pressurised.
9 Modulation valve forward drains the pressure Drive reverse: 2200-2600 kPa -
to drive clutch forward at the same rate as
the driving clutch reverse is pressurised.
10 When the forward direction of travel is - Transmission, component
selected Solenoid valve, clutch forward location, page 2:8
(Y630) is supplied with voltage. The solenoid
valve opens and directs pressure to valve
slide clutch forward.
11 Valve slide clutch forward pressurises drive - -
clutch forward and modulation valve reverse.
12 Drive clutch forward locks the transmission in - -
forward drive when the clutch is pressurised.
13 Modulation valve reverse drains the pressure Drive reverse: 2200-2600 kPa -
to drive clutch reverse at the same rate as
the driving clutch forward is pressurised.


14 Solenoid valve gear selection 1 (Y6067-1) - Transmission, component
pressurises valve slide gear selection 1. location, page 2:8
15 Valve slide gear selection 1 pressurises drive - -
clutch gear 1 and cuts off the pressure to the
gears.
16 Drive clutch gear 1 locks the transmission in - -
gear position 1 when the clutch is pressurised.
17 Solenoid valve gear selection 2 (Y6069) - Transmission, component
pressurises valve slide gear selection 2. location, page 2:8
18 Valve slide gear selection 1 pressurises drive - -
clutch gear 1 and cuts off the pressure to the
gears.
19 Drive clutch gear 2 locks the transmission in - -
gear position 2 when the clutch is pressurised.
20 When no solenoid valve is activated, the - -
drive clutch gear 3 is pressurised and locks
the transmission in gear 3 when the clutch is
pressurised.
21 Sensor, oil pressure transmission (B765) - Transmission, component
sends a voltage signal proportional to the oil location, page 2:8
pressure in the transmission to Control unit,
transmission (D793).
22 Sensor, oil temperature (B766) sends - Transmission, component
a voltage signal proportional to the oil location, page 2:8
temperature to Control unit, transmission
(D793).
23 The safety valve leads the oil back to the Opening pressure: 900 kPa -
sump if the pressure to the torque converter
becomes too high.
24 The torque converter transmits the engine's - -
power to the transmission.
25 The transmission oil cooler cools the oil. - -
26 The oil is distributed to different lubrication - -

points in the transmission.

Transmission, component location
1 2 3
15
4
16
14 5
13 6
17
12
7
014685
11 10 9 8
1. Transmission oil cooler 10. Valve block transmission control
2. Oil pump transmission 11. Return from the transmission oil cooler
3. Oil filter transmission 12. Breather filter transmission
4. Sensor turbine speed (B751) 13. Outlet to transmission oil cooler
5. Solenoid valve clutch reverse (Y631) 14. Sensor oil temperature (B766)
6. Solenoid valve clutch gear 1 (Y6067-1) 15. Thermostat
7. Drain plug and strainer transmission oil 16. Sensor, oil pressure transmission (B765)
8. Solenoid valve clutch gear 2 (Y6069) 17. Output shaft
9. Solenoid clutch forward (Y630)

2 Transmission – Controls and instruments 2:9
1 2 3 4 5
11
10
7
9
014694
8
1. Accelerator pedal (B690) 7. Fuse transmission (F51-3)

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

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

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

• F - Forward
• N - Neutral
• R - Reverse
The switch is supplied with voltage by, and sends signals to, Control
unit KIT (D790-2).
The signal can be checked via the diagnostic menu. See section 8
Control system, group 8.4.7.2 TRANSM, menu 2.

2:10 2 Transmission – Torque converter/Clutch system
2.2 Torque converter/Clutch system

2.2.1 Flex plates
Flex plates, replacement (engine alternative Yuchai
YC6M360-30)
For further details about separating the motor and transmission, see
section 1 Engine, group 1 Engine and transmission, separating.
2 Remove the cover plate.
3 Remove the cover plate and rotate the engine so that each bolt to
the flex plate can be removed.
5 Attach the transmission to an overhead crane.
6 Remove the bolts holding together the transmission and engine.
7 Carefully separate the transmission and engine.
8 Remove the bolts holding the flex plate to the transmission.

9 Replace the flex plate. Tighten the screws fixing the flex plate to
the transmission to 40 Nm (oiled screws).
engine and the gearbox.
Insert a stud into one of the nuts on the flexible plate as a guide
11 Place the screws that secure the gearbox and engine in position
without tightening the bolts.
12 Remove the stud and replace the screws that secure the flex plate
to the flywheel in two steps. The first step fit the screws without
tightening them. Now rotate the flywheel a further turn and tighten
the screws with a torque of 35 Nm (oiled screws).
13 Fit the screws that fasten the gearbox and engine and tighten
them to 52 Nm (oiled screw).
Flex plate attachment.

2 Transmission – Flex plates 2:11
Flex plates, replacement (engine alternative Cummins

QSB6.7 )
For further details about separating the motor and transmission, see
section 1 Engine, group 1 Engine and transmission, separating.
2 Remove the cover plate.

Rotate the engine for each bolt to the flex plate that has to be
removed.
4 Attach the transmission to an overhead crane.
008314
5 Remove the bolts holding together the transmission and engine.

6 Carefully separate the transmission and engine.
008275
7 Remove the bolts holding the flex plate to the transmission.

8 Replace the flex plate. Tighten the screws fixing the flex plate to
the transmission to 40 Nm (oiled screws).
engine and the gearbox.
Insert a stud into one of the nuts on the flexible plate as a guide
Flex plate attachment.

2:12 2 Transmission – Flex plates
10 Place the screws that secure the gearbox and engine in position
without tightening the bolts.
11 Remove the stud and replace the screws that secure the flex plate
to the flywheel in two steps. The first step fit the screws without
tightening them. Now rotate the flywheel a further turn and tighten
the screws with a torque of 35 Nm (oiled screws).
NOTE
008275
12 Fit the screws that fasten the gearbox and engine and tighten
them to 52 Nm (oiled screw).

2 Transmission – Lubrication system 2:13
2.6 Lubrication system

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

transmission's valve housing to activate the clutch plates for
FORWARD or REVERSE and gear 1, 2 or 3. The clutch plates require
just a small amount of the oil flow supplied by the pump. The remainder
of the oil is pumped through the torque converter circuit to the oil cooler
and returns to the transmission for lubrication.
See also supplier documentation, transmission.
Oil and oil filter, changing
NOTE
Read the safety instructions for oil before working, see section B
Safety.
NOTE
The transmission must not be over-filled!
1 Operate and warm up the transmission oil.
3 Remove the drain plug (position 2) and and let the oil drain into
1 the receptacle.
4 Remove the strainer (position 3) and clean the strainer cloth.
If the strainer cloth has caught metal particles, the cause must be
investigated before the transmission is filled with new oil.
5 Replace the strainer gasket.
6 When the transmission oil has drained out, fit the strainer (position
3) and the drain plug (position 2).
Make sure that the washer for the drain plug is included.
2
7 Remove the filter holder (position 1) and replace the oil filter.
014693
3 Tighten until it makes contact and then another two-thirds of a turn.
1. Oil filter holder

2. Oil plug
3. Strainer

2:14 2 Transmission – Lubrication system
A B 8 Fill with new transmission oil through the oil filling orifice (position
B) to the mark for low level on the dipstick (position A).
For volume and quality, see section F Technical data.
9 Start the engine and allow it to idle for at least two minutes.
10 Check that the transmission oil drain plug is sealed.
11 Check the transmission oil level with the engine running at idle and
top up to the marking for low level.
014193
A. Oil dipstick transmission oil

B. Oil filling transmission oil
12 Operate and warm up the transmission so that the display shows

an oil temperature of approx. 85 ºC. Use the oil temperature
operating menu to check transmission oil temperature.
a
13 Check the oil level. Fill to the MAX mark.
000356
Operating menu, oil temperature

a Transmission oil temperature
b Hydraulic oil temperature
Oil level, checking
NOTE
Safety.
The transmission's oil filler pipe and dipstick are located under the
engine hood in front of the cab.

2 Transmission – Oil cooler 2:15
A B 1 Check the oil level with the engine at idle, transmission in neutral
position and at operating temperature (approx. 85 ºC in the
display). The dipstick has two markings, MAX and MIN. The oil
level should be at MAX.
Wipe off the oil dipstick before checking.
NOTE
The oil dipstick is long. Wear gloves.
2 Fill transmission oil (position B) if required (for volume and grade,

see section F Technical data).
Fill - wait a moment - check the oil dipstick.
NOTE
014193
Work carefully when filling transmission oil to prevent other
fluids or particles from contaminating the oil. Other fluids or
particles in the transmission oil means a risk of transmission
A. Oil dipstick transmission oil damage.
B. Oil filling transmission oil
2.6.3 Oil cooler

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

transmission oil cooling circuit, is located in a pipe on the underside
of the cooler (engine side). The valve closes when the oil starts to
reach operating temperature. This means that the oil reaches normal
1 operating temperature more quickly.
For more information, see supplier documentation, transmission.

2
4
3
014686
1. Intercooler
2. Radiator, transmission oil
3. Radiator, engine
4. Condenser (for AC)

2:16 2 Transmission – Oil cooler
Thermostat transmission oil cooler, replacement
NOTE
Safety.

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

the temperature bulb facing out as shown.
6 Fill with transmission oil; see Oil and oil filter, changing, page 2:13.
7 Start the engine and check for leaks.
8 Check the transmission oil level, see Oil level, checking, page
2:14.

2 Transmission – Cooling system 2:17
2.7 Cooling system

2.7.3 Oil cooler
Oil cooler, description
See Oil cooler, description, page 2:15.

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

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

Make-contact (closing switch) declutch, description
Make-contact (closing switch) declutch (S220-2) detects whether the
wheel brakes are pressurised. The make-contact (closing switch) is
located on the distribution block for the brake system above the drive
axle's differential.
The sensor can be checked via the diagnostic menu. See section 8
Control system, group 8.4.7.1 TRANSM, menu 1.
1
10
2
1
3
3
4
5
5
9 6
8 7
009865
1. Connection brake cooling, return from wheel

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

Transmission cable harness, description
See section E Schematics.

3:1
Contents 3 Power transmission

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

3:2

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

2 Clean the contact surfaces (cross-toothed) on the drive axle and

gearbox.
3 Fit the propeller shaft in position with the coupling upward.

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

3:4 3 Power transmission – Drive axle
3.3 Drive axle

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

Drive axle, replacement
DANGER
Drive axle and machine are very heavy.
Risk of crushing!
It is forbidden to go under a machine which has been
lifted by a jack etc. For machine weight, see section F
Technical data.
1 Remove the mast, see section 7 Load handling, group 7.2

Lifting/lowering.
2 Park the machine with blocks behind the steering wheels.

3 Depressurise the hydraulic systems, See section B Safety.
4 Turn the start key to position 0 and switch off the main power.
5 Insert wedges between the steering axle and the frame.

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

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

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

10 Detach the propeller shaft from the drive axle. Secure the propeller
shaft, otherwise there is a risk that it will be pulled apart.
Securing the propeller shaft.
11 Lift the machine so that the wheels are off the ground.
12 Remove the drive wheels from the drive axle.
13 Support the drive axle under the hubs.
CAUTION
The drive axle may start to roll.
Crushing injury!
Make sure that the drive axle does not roll away
uncontrollably.
Lifting machine
14 Remove the bolts that secure the drive axle in the frame.
15 Lift away the drive axle.
CAUTION
Crushing injury!
uncontrollably.
Attaching bolts drive axle

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

21 Clean the contact surfaces on the drive axle and frame. Also clean
the bolts' contact surface on the underside of the drive axle.
22 Remove the nuts for attaching the drive axle, blow clean and
refit the nuts.
23 Lift the drive axle into place under the frame.
CAUTION
Crushing injury!
uncontrollably.
24 Lower the frame toward the drive axle.
25 Insert the new screws securing the drive axle in the frame. Tighten
to 1530 Nm (oiled screw).
26 Install the drive wheels on the new axle.
27 Rustproof the bolts with suitable paint.
28 Connect hydraulic hoses (position 1) and cable harness (position

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

4:1
4 Brakes
Contents 4 Brakes
4 Brakes..................................................................................................................4:3
4.1.1 Brake pedal .................................................................................................4:3
4.3 Power-assisted brake system ..........................................................................4:5
4.3.1 Hydraulic oil pump.......................................................................................4:6
4.3.2 Brake oil filter ..............................................................................................4:6
4.3.3 Accumulator charging valve ........................................................................4:7
4.3.4 Accumulator ..............................................................................................4:10
4.3.5 Brake valve ...............................................................................................4:14
4.3.6 Drive axle block .........................................................................................4:18
4.3.7 Break contact (opening switch) brake pressure ........................................4:19
4.3.8 Make-contact (closing switch) brake lights................................................4:21
4.3.9 Wheel brakes ............................................................................................4:24
4.3.10 Pipes and hoses........................................................................................4:26
4.3.12 Valve block brake system..........................................................................4:27
4.5 Parking brake system ....................................................................................4:29
4.5.1 Hydraulic oil pump.....................................................................................4:30
4.5.2 Hydraulic oil filter .......................................................................................4:30
4.5.3 Solenoid valve parking brake ....................................................................4:31
4.5.4 Parking brake unit .....................................................................................4:32
4.5.5 Break contact (opening switch) parking brake ..........................................4:36
4.5.6 Pipes and hoses........................................................................................4:36
4.5.7 Valve block brake system..........................................................................4:36

4:2

4 Brakes – Brakes 4:3
4 Brakes
4.1.1 Brake pedal
Brake pedal, checking and adjustment
1 Clean the floor round the brake pedal and check that nothing is
obstructing the movement of the brake pedal.
2 Check that the brake pedal springs back adequately and that the
clearance between brake pedal and brake valve is 1-1.5 mm.
If necessary, adjust the brake pedal's stop screw to the correct
clearance.
3 Check that the pedal moves smoothly.
Stop screw for adjusting clearance between brake pedal

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

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

a loose brake pedal.)
Brake pedal, replacement
NOTE
Safety.
1 Switch off the engine and switch off the system voltage.
2 Depressurise the brake and hydraulic systems, see section B

Safety.
3 Detach the brake valve from the brake pedal.

Secure the brake valve on the cab's underside and remove the
brake valve attaching bolt.

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

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

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

Power-assisted brake system, function
description
14
D790-2 B
P
T
D11 D797-1
10, 13 5 9 C
Pa
11
D12 4
D9 6
C
2
12 P a LB
C ACK M 8
P P
T T
7
P 3
015034
B
1 Hydraulic oil pump for the brakes See the pressure plate on the Hydraulic oil pump, general, page 4:6
and steering pumps oil from the left-hand frame beam.
hydraulic oil tank.
2 Valve block accumulator charging - Accumulator charging valve, description, page
and priority valves direct the 4:7
pressure to the Valve block brakes
when the steering does not require
hydraulic power.
3 Valve block brakes leads the oil - Valve block brake system, description, page
on to accumulators and drive axle 4:27
block.
4 The accumulators store hydraulic See the pressure plate on the Accumulator, description, page 4:10
oil pressure. left-hand frame beam.
5 The brake valve directs pressure - Brake valve, description, page 4:14
from the accumulators to the
brake cylinder proportional to the
pressure on the pedal.
6 Drive axle block distributes the - Drive axle block, description, page 4:18
brake pressure to the wheel brakes.
7 The brake cylinder compresses the See the pressure plate on the Wheel brakes, description, page 4:24
discs in the brake unit which stops left-hand frame beam.
the machine.
8 The wheel brakes brake the - Wheel brakes, description, page 4:24
machine.

4:6 4 Brakes – Hydraulic oil pump

9 Make-contact (closing switch) Brake pressure above Make-contact (closing switch) brake lights,
brake light (S216) makes the circuit 0.2 MPa: description, page 4:21
and sends the voltage signal to the
Conn. 1, U = 24 V D8: Diagnostic menu, see section 8 Control
Frame control unit (D797-1) when
system, group 8.4.5.4 HYD, menu 4
the brake cylinders are pressurised. Conn. 2, U = 24 V
0.2 MPa:
Conn. 1, U = 24 V
Conn. 2, U = 0 V
10 The frame control unit (D797-1) Controlled by control system, Section 11 Common electrics, group 11.5.3.2
supplies power to the brake light error shown with error code. Frame control unit
lamps.
11 Brake light lamps (H411L and U = 24 V Section 9 Frame, body, cab and accessories,
H411R) come on. group 9.6.4 Brake lights
system, group 8.4.2.8 LIGHTS, menu 8
12 Break contact (opening switch) Brake pressure above Brake pressure NC switch, description, page
brake pressure (S204) breaks the 11.5 MPa: 4:19
circuit and sends the voltage signal
Conn. 1, U = 24 V D9: Diagnostic menu, see section 8 Control
to the Frame control unit (D797-1)
if the pressure in the accumulators Conn. 2, U = 24 V
is low.
11.5 MPa:
Conn. 1, U = 24 V
Conn. 2, U = 0 V
13 The frame control unit (D797-1) Controlled by control system, Section 11 Common electrics, group 11.5.3.2
transmits a warning about low error shown with error code. Frame control unit
brake pressure on the CAN bus.
14 Control unit KIT (D790-2) activates Controlled by control system, Section 11 Common electrics, group 11.5.3.11
Warning lamp brake pressure. error shown with error code. Control unit, KIT
Hydraulic diagram, see section E Schematics, group 10 Common

hydraulics, Hydraulic diagram.
4.3.1 Hydraulic oil pump

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

fixed displacement.
4.3.2 Brake oil filter

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

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

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

5 accumulators above cooling. A restriction of the charging means
that a small quantity of oil also flows to cooling during accumulator
charging. At idle the flow from the pump is so small that all oil flows
13 6 to pressure storage.
12 7 There are measuring points on the accumulator charging valve for
measuring control pressure (position 4), servo pressure (position 9),
015032
11 10 9 8 accumulator charging pressure (position 10) and pump pressure

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

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

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

M]

014619
Close the accumulator drain valve

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

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

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

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

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

The accumulator charging valve is not replaced separately, in the event
of a fault replace the complete main valve, see section 10 Common
hydraulics group 10.5.4 Main valve.
4.3.4 Accumulator
Accumulator, description
The accumulators store pressure so that there is a pressure reserve
in the event of engine or brake system malfunction. The brake
system has two parallel-connected accumulators placed on the frame
member on the left-hand side of the machine.
The accumulators are of the diaphragm type. Each accumulator

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

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

is pressed upward and the nitrogen gas pressure rises. When the
hydraulic system needs feeding from the accumulator, the diaphragm
presses back the oil to the system.
Pressurised hydraulic oil from the accumulator is used for the

service brake and parking brake systems, and for feeding the servo
009869
hydraulic's reducing valve.
Brake system accumulators NOTE

If the accumulator delivers low oil pressure, the pumps may be
damaged and the hydraulic functions may stop working.

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

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

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

4:12 4 Brakes – Accumulator

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

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

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

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

decrease immediately to 0 MPa.
If the pressure drops immediately when the engine is switched off
then the accumulator does not have any precharge pressure. This
indicates internal leakage and the accumulator must be replaced.
If the pressure can be reduced slowly to a pressure below 10
MPa then the precharge pressure is too low and the accumulator
must be replaced or handed over to authorised personnel for
maintenance.
15 Mark up and disconnect the tested accumulator. Plug the
connections. Connect the other accumulator to the distribution
block.
16 Repeat steps 6-13.
Installation and final checking
18 Connect both accumulators to the distribution blocks. If necessary,
replace or fill deficient accumulators.
NOTE
Check that the seals are intact, clean and in the correct position.

4 Brakes – Accumulator 4:13
20 Close the accumulator drain valve so that the accumulators

charge.
NOTE
21 Check that the accumulators' connections are sealed tightly.

22 When the accumulators are fully charged, switch off the engine
and turn the start key to position I.
23 Check that at least 8 brake applications (pedal depressions) can
be performed before the pressure drops to 10 MPa.
014619
At 11.5 MPa the warning lamp for low brake pressure must be
Close accumulator drain valve. switched on.
Accumulator, replacement
NOTE
Safety.
2 Switch off the engine and switch off the main electric power.
4 Detach the accumulator's clamp and remove the bolt.

3
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
7 Fit the new accumulator.
1. Clamp NOTE
2. Screw Check that the seal is intact, clean and fitted in the correct
position.
8 Secure the accumulator's clamp and tighten the bolt.
NOTE

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

4:14 4 Brakes – Brake valve
4.3.5 Brake valve

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

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

brake pressure on the distribution block on the front axle.

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

4:16 4 Brakes – Brake valve
Brake valve, replacement
NOTE
Safety.
3 Mark up and detach the hydraulic hoses from the brake valve.
B
T NOTE
P Plug all connections immediately to protect the brake system
from impurities.
009875 4 Secure the brake valve under the cab.
5 Remove the brake valve's attaching bolt.

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

B with the marking.
T NOTE
P Check that the O-rings are intact, clean and in the correct
position.
10 Lubricate and adjust the brake pedal, see Brake pedal, checking
004795
and adjustment, page 4:3.

4 Brakes – Brake valve 4:17
NOTE
12 Turn on the main electric power and start the engine. Let the
engine run at idle speed.
13 Test the brakes a couple of times.
14 Check that the brake valve's connections are sealed tightly.
15 Bleed the wheel brakes' brake cylinders, see Wheel brakes,
014619
bleeding, page 4:25.

4:18 4 Brakes – Drive axle block
4.3.6 Drive axle block

Drive axle block, description
The drive axle block distributes oil flow and brake pressure to the right
1 and left-hand wheel brakes. The drive axle block is fitted on a bracket
10
2 above the drive axle differential.
1
3 The drive axle block has a measuring outlet for brake pressure and
for measuring back pressure in the disc brake's cooling circuit.
3
4
The drive axle block has a bypass valve which leads oil directly from
5 the cooling circuit intake to the cooling circuit return if the resistance
5
in the axle becomes too great. This protects the wheel brake seals,
9 6 e.g. when the oil is cold.
8 7 There are two contacts in the drive axle block: brake light NO switch
(216), see Make-contact (closing switch) brake lights, description,
page 4:21 and disengagement NO switch, see section 2 Transmission,
group 2.8.2 Normally closed (NC) switch, disengagement.
009876
1. Connection brake cooling, return from wheel

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

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

pressure
Brake pressure NC switch, description
Break contact (opening switch) brake pressure (S204) detects the
1 2 3 pressure in the accumulators. Break contact (opening switch) located
4 on the valve block brake system on the lifting beam in front of the
gearbox in the engine compartment. See Valve block brake system,
description, page 4:27.
5 When the pressure in the feed circuit is high enough to ensure braking
of the machine, the sensor closes an electric circuit. This is used to
11 warn for pressure-drop in the brake system. The sensor's opening
6 pressure is chosen so that there is pressure for at least another 8
brake applications without additional feed from the pump after the
lamp has illuminated.
7
10 Break contact (opening switch) brake pressure (S204) voltage fed by
Frame control unit (D797-1). When the pressure increases above the
9 cut-off pressure, the voltage signal to the Frame control unit (D797-1)
8
is cut.
Control system, group 8.4.5.4 HYD, menu 4.
015018
Valve block brake system

1. Solenoid valve parking brake (Y642)
2. Accumulator drain valve
3. Pressure limiting valve
4. Connection tank return [T]
5. Switch (NO), parking brake (S200)
6. Brake pressure NC switch (S204)
7. Connection, parking brake caliper [HB]
8. Connection feed from accumulator charging and
priority valve [P]
9. Connection, accumulators [ACC]
10. Connection brake valve [P]
11. Connection brake valve [T]
Brake pressure NC switch, adjusting
NOTE
Safety.
˚C
000475

4:20 4 Brakes – Break contact (opening switch) brake pressure

pressure measuring outlet on the Valve block accumulator
014653

M]
NOTE
6 Start the engine and fully charge the accumulators (the

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

approx. 11.5 MPa.
10 If necessary, adjust the warning level by turning the adjusting
screw in the rear edge of the sensor, between the contact pins.
NOTE
The setting is very sensitive, turn max. 1/4 turn at a time.
11 Repeat steps 6-10 until the warning lamp illuminates at 11.5 MPa.
12 Seal the adjusting screw with locking fluid.
measuring outlet.

4 Brakes – Make-contact (closing switch) brake lights 4:21
NOTE
014619
4.3.8 Make-contact (closing switch) brake lights

Make-contact (closing switch) brake lights,
description
Make-contact (closing switch) brake lights controls brake light
activation when the machine brakes. The switch is fitted on the drive
axle block which is fitted on a bracket above the drive axle differential.
Make-contact (closing switch) brake light (S216) is supplied voltage

by and sends a voltage signal to Frame control unit (D797-1). When
the pressure increases above the closing pressure, a voltage signal is
sent to Frame control unit (D797-1).
009878
Make-contact (closing switch) brake light, checking
NOTE
Safety.
˚C 3 Brake and check that the brake light is switched on.
˚C
000475

4:22 4 Brakes – Make-contact (closing switch) brake lights
5 Connect a pressure gauge (0-25 MPa) to the measuring outlet for

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

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

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

4 Brakes – Make-contact (closing switch) brake lights 4:23
NOTE
014619

4:24 4 Brakes – Wheel brakes
4.3.9 Wheel brakes

Wheel brakes, description
The wheel brakes brake the machine during operation and are fitted
on the drive axle between the drive axle housing and hub reduction.
The wheel brake uses so-called Wet disc brakes (WDB). Wet disc
brakes require minimal maintenance and have a long service life due
to efficient cooling. Maintenance requirements are minimised since oil
circulates in the brake system and prevents corrosion.
015035
The wheel brakes have two main parts - disc pack and brake cylinder.
1 2 The disc pack performs the braking. The brake cylinder presses the
discs in the disc pack together during braking.
000016
Wheel hub and brake, cross-section

1. Disc pack
2. Brake cylinder

4 Brakes – Wheel brakes 4:25
Wheel brakes, bleeding
NOTE
Safety.
IMPORTANT
Both the brake cylinder and disc brake must be bled
after work which involves the brake system being
opened or after work on the wheel brake.
2 Position a ring spanner on the bleed nipple and connect a

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

Bleed nipple, brake cylinder, on top of the drive axle at
the wheel hub's inner short side (left-hand side). 6 Move the spanner and hose and repeat steps 1-5 on the other side.
7 Check the oil level in the brake system, fill if necessary.
Wheel brake, replacement

See supplier documentation, drive axle.

4:26 4 Brakes – Pipes and hoses
4.3.9.1 Disc pack
Disc pack, description

The disc pack consists of several thin coated metal discs fixed
alternately to the wheel brake housing and to the hub reduction
housing. The discs are mounted on splines, which allows them to
move laterally.
Hydraulic oil circulates between the discs cooling them, thus the
name Wet Disc Brake. Hydraulic oil is the same as in other parts of
the hydraulic system and is cooled by the cooling circuit, see Section
10 Common hydraulics, group 10.6 Temperature control, cleaning
and hydraulic oil.
Braking takes place by means of the brake cylinder pressing together

the discs. This creates friction between the discs that are fixed to the
000008 axle and those fixed to the hub reduction.
Disc pack
4.3.9.2 Brake cylinder
Brake cylinder, description

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

in the wheel brake housing. The pressure moves the metal ring
sideways and compresses the disc pack.
000007
Brake cylinder
4.3.10 Pipes and hoses

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

4 Brakes – Valve block brake system 4:27
4.3.12 Valve block brake system

Valve block brake system, description
Solenoid valve parking brake
Solenoid valve parking brake
1 2 3
See Solenoid valve parking brake, description, page 4:31
4
Accumulator drain valve
The accumulator drain valve (position 2) is located on the valve block
5
brake system and is used to drain the pressure in the accumulators to
the tank. The valve opens a connection between the accumulators
11 and the wheel brake's cooling circuit. The oil is drained through the
6 wheel brake to the tank.
See section 10 Common hydraulics group 10.2.1 Accumulator drain

7 valve.
10
Pressure limiting valve
9 8 See section 10 Common hydraulics group 10.2.4 Pressure limiting
valve.
Break contact (opening switch) parking brake
See Break contact (opening switch) parking brake, description, page
015018
4:36.

Break contact (opening switch) brake pressure
1. Solenoid valve parking brake (Y642) See Brake pressure NC switch, description, page 4:19.
priority valve [P]

4:28 4 Brakes – Valve block brake system
Valve block brake system, replacement
NOTE
Safety.
2 Mark and disconnect the cable harness from the valve block.
3 Mark up and detach the hydraulic hoses from the valve block.
4 Move the components to the new valve and assemble the valve in
the reverse order.
NOTE
014619

4 Brakes – Parking brake system 4:29
4.5 Parking brake system

Parking brake system, function description
D1
10
1
2 9
D790-1 D790-2
D797-1
3, 8 D4
D7 13
4 5
C 7
Pa GHB
C HB
ACK M P
T
P 6
12
11
015036
P
1 Switch parking brake (S107) activates Switch activated: Section 9 Frame, body, cab and
the parking brake. accessories, group 9.1 Controls and
Conn. 1, U = 24 V
instruments
The switch uses two signals, one for
Conn. 7, U = 0 V
applied and one for released parking D5: Diagnostic menu, see section 8
brake. Both signals must be correct to Switch in home position: Control system, group 8.4.5.5 HYD, menu
enable release of the parking brake. 5
Conn. 1, U = 0 V
Conn. 7, U = 24 V
2 The cab control unit (D790-1) transmits Controlled by control Section 11 Common electrics, group
Activate parking brake on the CAN bus. system, error shown with 11.5.3.1 Control unit, cab
error code.
3 The frame control unit (D797-1) activates U = 24 V Solenoid valve parking brake, description,
the parking brake solenoid valve (Y642). page 4:31
Control system, group 8.4.5.5 HYD, menu
5
4 Solenoid valve parking brake (Y642) acts - Solenoid valve parking brake, description,
on the valve slide which drains pressure page 4:31
in the parking brake's brake caliper to
tank.
5 The brake caliper is drained of pressure 0 MPa Parking brake unit, description, page 4:32
and the spring applies the parking brake.
6 Valve block brake system directs the - Valve block brake system, description,
hydraulic oil to the hydraulic oil tank. page 4:27

4:30 4 Brakes – Hydraulic oil pump

7 Break contact (opening switch) parking Applied parking brake: Break contact (opening switch) parking
brake (S200) breaks the circuit and sends brake, description, page 4:36
Conn. 1, U = 24 V
the voltage signal to the Frame control
unit (D797-1) when the pressure drops. Conn. 2, U = 0 V
Control system, group 8.4.5.5 HYD, menu
Released parking brake: 5
Conn. 1, U = 24 V
Conn. 2, U = 24 V
8 The frame control unit (D797-1) transmits Controlled by control Section 11 Common electrics, group
Parking brake applied on the CAN bus. system, error shown with 11.5.3.2 Frame control unit
error code.
9 Control unit KIT (D790-2) activates Controlled by control Section 9 Frame, body, cab and
indicator light, parking brake (508). system, error shown with accessories, group 9.1 Controls and
error code. instruments
10 Indicator light parking brake comes on. - Section 11 Common electrics, group
11.5.3.11 Control unit, KIT
11 The hydraulic oil pump pumps hydraulic See pressure plate on left Hydraulic oil pump, general, page 4:6
oil from the hydraulic oil tank. frame beam.
12 Valve block accumulator charging and See pressure plate on left Accumulator charging valve, description,
priority valve directs oil to charging of frame beam. page 4:7
the accumulators or the brake system's
cooling circuit.
13 The accumulators store the oil pressure See pressure plate on left Accumulator, description, page 4:10
used when the parking brake is released. frame beam.


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

fixed displacement.
4.5.2 Hydraulic oil filter

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

4 Brakes – Solenoid valve parking brake 4:31
4.5.3 Solenoid valve parking brake

Solenoid valve parking brake, description
Solenoid valve parking brake (Y642) activates the parking brake. The
1 2 3 solenoid valve is fitted on the valve block brake system, which is fitted
4 on the lifting beam in front of the gearbox in the engine compartment,
see Valve block brake system, description, page 4:27.
The solenoid valve opens a connection between the accumulators

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

priority valve [P]

4:32 4 Brakes – Parking brake unit
Solenoid valve parking brake, checking
DANGER
The machine may start to roll.
Risk of crushing.
Block the wheels so that the machine cannot start to
roll when the parking brake is released.
1 Start the engine and run the engine at idle until the warning lamp
for brake pressure goes out and the accumulator charging valve
changes to cooling.
2 Switch off the engine and turn the start key to position I.
3 Release the parking brake with the switch for the parking brake
and check that the parking brake's brake caliper releases. The
brake caliper should be able to move.
4 Activate the parking brake with the switch for the parking brake
and check that the parking brake's brake caliper is applied.
4.5.4 Parking brake unit

Parking brake unit, description
3 1 The parking brake unit keeps the machine stationary when parked.
2
The parking brake unit is fitted on the drive axle input shaft between
the propeller shaft and drive axle.
The parking brake acts on the universal drive shaft via a disc mounted
on the drive axle input shaft and a brake calliper with dry brake pads
mounted in a bracket on the drive axle.
NOTE
If the hydraulic pressure in the feed circuit drops, a warning is
activated before the pressure drops so low that the parking brake
is applied. If the parking brake is applied while the machine is in
motion, the brake disc and brake pads must be replaced.
009881
1. Cover
2. Parking brake caliper
3. Parking brake disc

4 Brakes – Parking brake unit 4:33
Parking brake unit, checking and adjustment
DANGER
Risk of crushing.
1 Start the engine and fully charge the accumulators (the

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

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

12 Test the function of the parking brake.

4:34 4 Brakes – Parking brake unit
4.5.4.1 Parking brake caliper

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

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

Safety.
2 Remove the cover from the brake caliper.

4 Brakes – Parking brake unit 4:35
3 Loosen the lock nut.

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

8 Clean the brake disc with methylated spirit.
9 Fit new parking brake pads.
10 Press back the attaching bolt.
11 Fit the nut and a new split pin.
12 Adjust the parking brake, see Parking brake unit, checking and
adjustment, page 4:33.
4.5.4.3 Parking brake disc
Brake disc, description

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

4:36 4 Brakes – Break contact (opening switch) parking brake
4.5.5 Break contact (opening switch) parking

brake
Break contact (opening switch) parking brake,
description
Break contact (opening switch) parking brake (S200) detects whether
1 2 3 the parking brake is applied or released. The break contact (opening
4 switch) is fitted on the valve block brake system, which is fitted on the
lifting beam in front of the transmission in the engine compartment,
see Valve block brake system, description, page 4:27.
5 Break contact (opening switch) parking brake (S200) senses the
pressure in the parking brake circuit. When the pressure is so high
11 that the parking brake is released, the sensor opens an electric circuit.
6 This is used to indicate that the parking brake is released.
Break-contact (opening switch) parking brake light (S200) is supplied

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

priority valve [P]

4.5.7 Valve block brake system

Valve block brake system, general
See Valve block brake system, description, page 4:27.

5:1
5 Steering
Contents 5 Steering
5 Steering ...............................................................................................................5:3
5.2 Power assisted system ....................................................................................5:3
5.2.1 Hydraulic oil pump.......................................................................................5:3
5.2.2 Priority valve................................................................................................5:4
5.2.3 Steering valve .............................................................................................5:7
5.2.4 Steering cylinder .........................................................................................5:9
5.2.5 Steering axle cradle .................................................................................. 5:11
5.2.6 Link arm .................................................................................................... 5:11
5.2.7 Wheel spindle............................................................................................5:12
5.2.8 Wheel hub .................................................................................................5:12
5.2.13 Pipes and hoses........................................................................................5:12

5:2

5 Steering – Steering 5:3
5 Steering
5.2 Power assisted system
Power assisted system, function description
2 C3 P
3
LS
C1 T L R
O
P
LSO
2
4
1
015017
1 Hydraulic oil pump brake and steering See the pressure plate on Section 10 Common hydraulics, group
pumps oil to the Valve block accumulator the left-hand frame beam. 10.4.1 Gear pump with fixed displacement
2 Valve block accumulator charging and Checked by control Priority valve, description, page 5:4
priority valve gives priority to the oil feed system, error shown with
to the control valve over accumulator error code.
charging and cooling to the brakes.
3 The steering wheel is turned and acts on - Steering valve, description, page 5:7
the steering valve\qs input shaft.
The control valve directs oil pressure
from the hydraulic oil pump brake and
steering to the steering cylinder.
4 The steering cylinder turns the wheels. - Steering cylinder, description, page 5:9


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

5:4 5 Steering – Priority valve
5.2.2 Priority valve

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

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

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

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

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

5 Steering – Steering valve 5:7
5.2.3 Steering valve

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

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

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

5:8 5 Steering – Steering valve

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

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

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

with the marking.
NOTE
Check that the O-rings are intact, clean and 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. Fit the
attaching bolts.

5 Steering – Steering cylinder 5:9
NOTE

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

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

5:10 5 Steering – Steering cylinder
Steering cylinder, replacement
NOTE
Safety.
1 Park the machine with the wheels fully turned so that the steering
cylinder can be lifted out to one side.
4 Detach the link arms from the steering cylinder.

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

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

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

5 Steering – Steering axle cradle 5:11
11 Fit the link arms to the steering cylinder.

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

2. Hydraulic connection
NOTE
14 Start the engine and check for leaks.

014619
Hydraulic cylinders, repairs

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

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

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

5:12 5 Steering – Wheel spindle
5.2.7 Wheel spindle

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

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


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

6:2

6 Suspension – Suspension 6:3
6 Suspension
6.2 Suspension
Bushing steering axle mounting, changing
DANGER
Steering axle and machine are very heavy.
Risk of crushing!
Technical data.
3 Support under the steering axle so that it cannot fall over.
4 Attach hoisting equipment to the rear of the machine and take up

the slack so that the steering axle's mounts are relieved.
NOTE
Do not lift so much that the wheels are off the ground.
5 Remove the 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
The illustration shows rear mounting

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

2
10 Press out the bushing.
1 11 Clean the bearing surfaces on the steering axle.
12 Press in the new bushing. Grease the bushing to facilitate
installation.
13 Fit the washers that hold the bushing in place.
14 Move the steering axle into place under the frame.
15 Lubricate and fit the pins at the steering axle's mounts.
3
16 Remove the lifting equipment from the machine.
4
010121
1. Steering axle mounting
2. Rubber bushing
3. Washers
4. Screw
6.2.1 Steering axle cradle

Steering axle cradle, description
The steering axle is pendulum suspended with a double-acting
1 2 3 4 5 6
steering cylinder. The design comprises a minimum of moving parts
to minimise service points and simplify maintenance. The frame
suspension comprises maintenance-free parts.
008047
Steering axle
1. Wheel hub
2. Wheel spindle
3. Link arm
4. Steering axle cradle
6. Spindle bolt / - bearing
Steering axle cradle, replacement
DANGER
Steering axle and machine are very heavy.
Risk of crushing!
Technical data.
1 Clean the steering axle and its surrounding area.

6 Suspension – Steering axle cradle 6:5
5 Connect the lifting equipment to the rear section of the machine.
6 Tension the lifting equipment, do not lift so much that the wheels
are off the ground.
7 Support the machine's rear section.
8 Detach the hydraulic hoses from the steering cylinder.
NOTE
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.
12 Adjust the support so that the machine is secured in the new

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

6:6 6 Suspension – Wheel spindle
6.2.2 Wheel spindle

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

2 Raise the machine under the steering axle at the wheel in

question. Support the steering axle in a safe way.
3 Remove the steering wheel in question.
4 Clean the wheel spindle and its surrounding area.
5 Detach the link arm from the wheel spindle.
6 Remove the wheel hub and wheel bearing; see Wheel bearing,

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

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

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

6:8 6 Suspension – Wheel hub
25 Remove the support and lower the steering wheel.
26 Test-operate the machine and test the steering. Check also that
the machine feels stable when driving straight ahead.
6.2.3 Wheel hub

Wheel hub, description
The wheel hub holds the wheel in place and allows the wheel to 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. Screw
10. Bearing
11. Seal ring
Wheel bearing, replacement

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

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

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

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

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

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

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

6 Suspension – Wheel hub 6:11
18 Fill the empty space in the hub with universal grease "EP2".
19 Fit the hub on the wheel spindle.
20 Install the outer bearing, protecting washer, and bearing nut.

Pack the bearing with grease and fit the bearing.
Fit the washer and hub nut with the smooth surface in towards
the hub.
21 Remove the lifting equipment.
22 Tighten the bearing nut in the following stages.

A. Lubricate the thread and the side of the nut facing the bearing
with oil (SAE 80W/140).
B. Tighten the nut to 250 Nm (oiled screw).
C. Rotate the hub 10 revolutions.
D. Angle tighten the nut 45º.
E. Rotate the hub 10 revolutions.
F. Angle tighten the nut 45º.

23 Apply grease onto the locking washer and fit it.

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

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

6 Suspension – Tyres and rims 6:13
6.3 Tyres and rims

Tyres and rims, safety
DANGER
Always block the wheels on the side of the axle that
is not going to be worked on before positioning the
jack. Always secure the jack to prevent it from sliding
out of position.
Fully deflate the tyre before removal. Otherwise the
conical ring and locking clips can loosen and shoot
out when the pressure is changed. With double wheel
fitting both tyres must be fully deflated!
The air should always be released via the valve. If this
is not possible - drill a hole in the tread to deflate.
Damaged tyres may explode.
Never stand directly in front of the wheel when deflating
or inflating. The conical ring and locking clips can
loosen and shoot out when the pressure is changed.
Never fit damaged tyres or rims.
It is prohibited to repair rims with welding.
It is prohibited to operate the machine if one of the
tyres is flat.
Wheels, tyres and rims are dimensioned and selected
for each machine type so that maximum wheel loads
and travel speeds are not exceeded. For this reason it
is not permitted to change tyre dimension, tyre make,
tyre type, rim type, or rim make without approval from
Cargotec.

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

6 Suspension – Tyres 6:15
6.3.1 Tyres
Tyres, description
The tyres are the point of contact between the machine and the
ground, and they absorb unevenness and provide suspension.
The drive axle is subject to major forces during operation. If each

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

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

6:16 6 Suspension – Rim
6.3.2 Rim
Rim, description
1 2 3 4 The rim is split to make it possible to fit a tyre. The rim consists of
the following parts.
• Rim
• Rim bead seat
• Rim edge
• Lock ring
5
009899
1. Rim
2. Lock ring
3. Rim edge
4. Tapered rim
5. Wheel nut
6. Wheel bolt

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

Nut, washer and clamp, description
1 2 3 4 The rim is attached to the wheel hub with nuts.
As an option, the rim can be equipped with nut protection.
5
009899
1. Rim
2. Lock ring
3. Rim edge
4. Tapered rim
5. Wheel nut
6. Wheel bolt

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

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

5 Replace the bolt.

7:1
7 Load handling
Contents 7 Load handling

7 Load handling .....................................................................................................7:3
7.1.1 Control levers ..............................................................................................7:4
7.1.2 Switch, lock twistlock...................................................................................7:5
7.1.3 Switch, spreading 20\q-40\q........................................................................7:6
7.1.4 Switch, stop at 30\q .....................................................................................7:6
7.1.13 Switch, automatic spreading .......................................................................7:7
7.2 Lift and lower....................................................................................................7:8
7.2.3 Pressure reducer....................................................................................... 7:11
7.2.5 Control valve, lift and tilt ............................................................................7:14
7.2.7 Lift cylinder ................................................................................................7:15
7.2.9 Mast ..........................................................................................................7:16
7.2.10 Mast position sensor .................................................................................7:25
7.2.11 Trolley........................................................................................................7:26
7.2.13 Pipes and hoses........................................................................................7:30
7.2.14 Accumulator lift..........................................................................................7:30
7.4 Side shift ........................................................................................................7:31
7.4.2 Control valve, attachment .........................................................................7:33
7.4.3 Side shift cylinder ......................................................................................7:37
7.4.5 Trolley........................................................................................................7:37
7.4.7 Relief valve, attachment ............................................................................7:39
7.4.8 Pipes and hoses........................................................................................7:39
7.4.9 Lift, tilt and attachment control valve .........................................................7:40
7.5 Spreading (positioning) ..................................................................................7:41
7.5.2 Control valve, attachment .........................................................................7:48
7.5.3 Spreading cylinder ....................................................................................7:49
7.5.4 Spreader beam .........................................................................................7:49
7.5.5 Main beam, side lift attachment.................................................................7:51
7.5.6 Position sensor, spreading ........................................................................7:56
7.5.7 Buzzer, automatic spread 20'-40' ..............................................................7:56
7.5.8 Pipes and hoses........................................................................................7:56
7.5.10 Lift, tilt and attachment control valve .........................................................7:56
7.7 Tilt ..................................................................................................................7:58
7.7.5 Control valve, lift and tilt ............................................................................7:60
7.7.6 Load retention valve ..................................................................................7:61
7.7.7 Tilt cylinder ................................................................................................7:61
7.7.8 Mast ..........................................................................................................7:62
7.7.9 Pipes and hoses........................................................................................7:62
7.8 Levelling.........................................................................................................7:63
7.9 Load carrier....................................................................................................7:64
7.9.1 Twistlocks ..................................................................................................7:64
7.10 Other functions...............................................................................................7:75
7.10.1 Container counter......................................................................................7:75

7:2

7 Load handling – Load handling 7:3
7 Load handling
Position sensor, checking and adjustment
The machine has several position sensors in the following locations.
1. Mast position sensor (B7211-2), see Mast position sensor,
2. Alignment sensors B7203L and B7203R), see Sensor, alignment,
1 description, page 7:71 and Alignment sensor, checking and
adjusting, page 7:71.
3. Locked twistlocks sensors (B7205LL and B7205RL), see
Sensor, twistlocks, description, page 7:72 and Twistlocks sensor,
checking and adjusting, page 7:73.
4. Damping sensor (B769L, B769R, B777L and B777R), see
Position sensor spreading, description, page 7:56.
4
015079
Position sensor overview
Spacing check
2 Check that the sensor in question is free of damage and dirt.

3 Check that the distance between the sensor and the indicator is
5±1 mm.
C-C
5±1 mm
4 Adjust if necessary.
009632
5±1 mm
Adjusting position sensor - indicator

7:4 7 Load handling – Controls and instruments

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

three on/off functions.
A. Side shift (S815-P3)
Side shift left is activated when the potentiometer is pushed in on
the left-hand side. Side shift right is activated when the right-hand
D side is pushed in. See Side shift, function description, page 7:31.
The signal can be checked via the diagnostic menu. See section
8 Control system, group 8.4.9.1 ATTACH, menu 1.
B. Spreading out (S815-T1.1) and Spreading in (S815-T1.2)
Pressing the right switch activates spreading out and pressing
the left switch activates spreading in. See Spreading, function
E D C 8 Control system, group 8.4.9.3 ATTACH, menu 3.
C. Lifting/lowering (S815-P1)
Lifting/lowering is controlled by moving the control lever forward
(lowering) or rearward (lifting). See Lifting/lowering, function
015080

The signal can be checked from the diagnostic menu, see section
8 Control system, group 8.4.8.1 ELSERV, menu 1.
D. Tilt (S815-P2)
Tilt is controlled by moving the control lever to the right (tilt out) or
left (tilt in). See Tilt, function description, page 7:58.
E. Lock/open the twistlocks (S815-T2) on full alignment
The twistlocks are alternately opened/locked when the switch
is activated if the conditions are met. See Twistlocks, function

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

linear levers.
The control levers are supplied voltage by and send a signal to the
cab control unit (D790-1).
C A. Lift/lower (R8071-P1).
A B
Lifting/lowering is controlled by moving the control lever forward
(lowering) or rearward (lifting). See Lifting/lowering, function
D description, page 7:8.
B. Tilt (R8072-P2).
Tilt is controlled by moving the control lever forward (tilt out) or
backward (tilt in). See Tilt, function description, page 7:58.
C. Side shift (R8073-P3).
Side shift is controlled by moving the lever forward (left) or
E backward (right). See Side shift, function description, page 7:31.
It is not possible to use side shift on the side lift attachment if the
014181
attachment is in its max or min position.

D. Emergency stop switch
E. Opening locked twistlocks, attachment (S1002).
Pull the switch sideways to open the twistlocks if the conditions
for this are met. See Twistlocks, function description, page 7:64.
7.1.2 Switch, lock twistlock

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

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

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

Control system, group 8.4.9.5 ATTACH, menu 5.

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

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

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

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

is at 40'.
Position 2 - Spreading in activated. Spreading's inner end position

is at 20'.

7.1.4 Switch, stop at 30\q

Switch stop at 30', description (linear control levers)
The switch (green) for spreading stop for the attachment at 30'
(S1004) activates the 30-foot stop. When the switch is depressed, the
35
function changes from spreading from 20'–40' to stop at 30'.
30-
009909

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

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

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

with the switch for spreading 20'-40'.
The switch is supplied with voltage from and sends a voltage signal to
the cab control unit (D790-1) when the switch is activated.
WARNING
Risk of crushing and damage to the product!
Automatic spreading is stopped by activating
spreading in the opposite direction or deactivating the
function with the switch.

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

Lifting/lowering, function description
Condition Reference value Reference
Control breaker Not activated Section 11 Common electrics, group 11.5.1.4 Emergency stop
switch voltage
Twistlocks Locked or unlocked, not Twistlocks, description, page 7:64
intermediate position
Alignment Mast down: no contact Sensor, alignment, description, page 7:71
1b 1a D3
D1
2, 3, 5 6
D790-1 D794
D797-1
7, 15
4
D7
D14 14
8
C
12, 16 12, 16
P2
9 A
10
13
015074
11

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

7 Load handling – Lift and lower 7:9

3 Cab control unit (D790-1) voltage feeds U = 24 V Section 11 Common electrics, group
the control breaker relay lifting and 11.5.3.2 Frame control unit
lowering (K3007).
CAN/POWER, menu 6
4 Control breaker relay lifting and lowering - Section 11 Common electrics, group
(K3007) makes the ground connection 11.5.1.4 Emergency stop switch
between Frame control unit (D797-1) voltage (15E)
and Solenoid valve lift (Y6005) and
Solenoid valve lower(Y6004).
5 Control unit, cab (D790-1) transmits a Checked by control system, error Section 11 Common electrics, group
request for increased engine speed on shown with error code. 11.5.3.1 Control unit, cab
the CAN bus.
6 Control unit, engine (D794) increases Checked by control system, error Section 11 Common electrics, group
the engine speed. shown with error code. 11.5.3.10 Control unit, engine
7 The frame control unit (D797-1) controls I = 380–650 mA Section 11 Common electrics, group
the current proportionally to the lever 11.5.3.2 Frame control unit
movement to the solenoid valve lift mast
(Y6005) or the Solenoid valve lower
(Y6004).
ELSERV, menu 3 and 8.4.8.4
ELSERV, menu 4
8 Solenoid valve lift (Y6005) or Solenoid - Lift, tilt and attachment control valve,
valve lower (Y6004) pressurises lift, tilt description, page 7:14
and the attachment control valve's lift
spool with servo pressure.
9 Hydraulic oil pump load handling feeds See the pressure plate on the Section 10 Common hydraulics,
the lift, tilt and attachment control valve left-hand frame beam. group 10.4.1 Gear pump
with hydraulic pressure.
10 The lift, tilt and attachment control - Lift, tilt and attachment control valve,
valve's lift spool change position and description, page 7:14
then pressurise the lift cylinders and
accumulator lifting/lowering.
11 Accumulator lift equalizes the pressure - Accumulator lift, description, page
surges that occur in the lift cylinders 7:30
when the machine is running.
12 The lift cylinders are pressurised and the - Lift cylinder, description, page 7:15
mast is lifted or lowered.
Lift
The oil is led by a non-return valve
past the restrictor to the lifting cylinders'
piston side.
Lower
The oil passes through a restrictor back
to the lift, tilt and attachment control
valve.
13 The oil filter cleans the return oil from - Section 10 Common hydraulics
the lift cylinders before it is collected in group 10.6.7 Hydraulic oil filter.
the hydraulic oil tank.
14 Damping UB771/1 = 5 V Mast position sensor, description,
page 7:25
When the mast is approx. 50 cm from its UB771/2 = 0 V
topmost position, damping is activated. Section 11 Common electrics, group
UB771/3 = 0.5-4.5 V
11.5.3.3 Frame control unit
The mast position sensor (B7211-2)
sends the frame control unit (D797-1) D14: Diagnostic menu, see section
a voltage signal proportional to the lift 8 Control system, group 8.4.8.15
height. The control unit then transmits a ELSERV, menu 15.
damping request on the CAN bus.

7:10 7 Load handling – Hydraulic oil pump

15 The frame control unit (D797-1) reduces - Section 11 Common electrics, group
the control current to the lift solenoid 11.5.3.2 Frame control unit
valve (Y6005) or the lower solenoid
valve (Y6004).
ELSERV, menu 3 and 8.4.8.4
ELSERV, menu 4
16 Lift speed decreases. - Lift cylinder, description, page 7:15

hydraulics, Hydraulic diagram

fixed displacement.

7 Load handling – Pressure reducer 7:11
7.2.3 Pressure reducer

Pressure reducer, description
The pressure reducer is located in the valve block accumulator
charging and priority valve that is part of the main valve, see section
10 Common hydraulics, group 10.5.6 Main valve. The main valve
is located on the lifting beam in front of the gearbox in the engine
compartment. The pressure reducer reduces the oil pressure from
the Hydraulic oil pump brake and steering to the servo pressure lift,
tilt and attachment control valve, see Lift, tilt and attachment control
1 valve, description, page 7:14.
2
3
4
13 6
12 7
015032
11 10 9 8
steering [P]
10. Measuring outlet accumulator pressure [ACC M]
charging [ACC]
steering [PM]

7:12 7 Load handling – Pressure reducer
Servo pressure, check
NOTE
Safety.
1 Operate and warm up the machine so that the hydraulic oil

reaches operating temperature, 50 ºC.
˚C
000475
4 Connect a pressure gauge (0-25 MPa) to the measuring outlet

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

7 Load handling – Pressure reducer 7:13
7 Check that the servo pressure corresponds with the pressure on

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

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

7:14 7 Load handling – Control valve, lift and tilt
7.2.5 Control valve, lift and tilt

Lift, tilt and attachment control valve, description
Lift slide
1 Lift, tilt and attachment control valve controls the speed and direction
of the lift and tilt and feeds pressure to the attachment control valve.
Control valve lift, tilt and attachment is a part of the main valve, see
2
section 10 Common hydraulics, group 10.5.4 Main valve. The main
valve is located on the lifting beam in front of the gearbox in the
3
engine compartment.
The valve has three sections, one for the lift function, one for the
tilt function and one to pressurise the control valve attachment.
The sections have many similarities, but are described separately
under the respective function. For tilt, see Lift, tilt and attachment
control valve, description, page 7:60, for attachment see Lift, tilt and
attachment control valve, description, page 7:40. Electric solenoid
4 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 also sends a control signal to the
015081
variable pumps.
1. Solenoid valve, lower (Y6004) Electrically controlled pressure reducing valves (solenoid valves)
convert electric current into a low hydraulic pressure that is
2. Solenoid valve, lift (Y6005)
proportional to the current, so-called servo pressure. The servo
3. Connection left lift cylinder pressure acts on the spring-centred control slide in the control valve
4. Connection right lift cylinder for the function in question and thereby controls the main flow.
The speed of the function is controlled by means of the flow being

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

7 Load handling – Lift cylinder 7:15
7.2.7 Lift cylinder

Lift cylinder, description
The lift cylinders lift and lower the inner mast which runs in the outer
mast. The lower part of the lift cylinders is fastened to the outer mast,
while its upper part is fastened to the inner mast, one on the right and
one on the left side of the mast.
The lift cylinder is fastened in the mast with nuts in the bottom and
a washer and screw in the top.
The lift cylinders are connected in parallel and are fed from one
section of the lift, tilt and attachment control valve, see Lift, tilt and
attachment control valve, description, page 7:14.
On the piston side there is a built-in load control valve. The load
control valve consists of a restrictor and a non-return valve. The
009916
non-return valve directs oil past the restrictor when lifting and forces
the oil to pass through the restrictor when lowering. This limits the
lowering speed.


7:16 7 Load handling – Mast
7.2.9 Mast
Mast, description
The mast which has a clear view design lifts the load. The trolley runs
1 in the mast, which in turn holds the side lift attachment.
The lower part of the mast is fastened to the frame with two shafts
in both of the double lugs on the front of the frame. The mast is also
2 fastened in the frame with two tilt cylinders.
The mast consists of an outer mast and an inner mast manufactured

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

to neglected maintenance, improper handling,
1. Inner mast
malfunction or damage to a mast wheel, mast or
2. Lifting eye trolley. For example, lamination or pitting could occur
3. Outer mast on the mast beam flange. This most often occurs on
the inner mast, but could also occur on the outer mast.
4. Lift cylinder
Repairs to the mast may only by performed on the
flanges on the outer and inner mast beams according
to special instructions, see Flanges on outer and inner
mast beam, repair, page 7:23.
Mast, removing
NOTE
Safety.
NOTE
It is possible to remove the trolley and the side lift attachment as
a unit.
1 Remove the side lift attachment; see Side lift attachment,

removing, page 7:52.
2 Remove the trolley; see Trolley, removing, page 7:26.

7 Load handling – Mast 7:17
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.
009974
8 Mark up and disconnect the hydraulic connections of the lift
cylinders.
NOTE
from impurities.
9 Mark up and detach the electrical connections of the mast.

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

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

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

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

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

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

Mast, installing
NOTE
Safety.
1 Turn off engine.
4 Connect lifting equipment to the mast in a secure manner so the

mast does not tip when lifted.
009975
5 The shafts and bearing surfaces must be checked before the mast
is refitted for deep grooves/scratches, fibres must not protrude
above the bearing surface. If there are signs of damage, the
shaft/bearing must be replacement.
NOTE
The mast is attached to the machine's frame with strong shafts
which run in maintenance-free bearings.
It is extremely important that bearing surfaces are absolutely
clean when the mast is installed.
The shafts and bearings mentioned above must NEVER be
009977
lubricated with oil or grease.
Check that seals are intact and clean.
6 Lift the mast into place. It is important that the lifting equipment is
connected to the mast's lifting lugs in a secure manner.
009976

7 Suspend the mast vertically. Align the mast and position the shafts
in the mast mountings.
009978
8 Fasten the shafts with bolts and lock nuts.
9 Start the engine and tilt the mast forwards as far as possible.
10 Turn off engine.
009979
13 Lift the tilt cylinders with lifting equipment (overhead crane) and
align the tilt cylinders with the mast.
009982
14 Connect the tilt cylinders to the mast.

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

15 Lubricate the connectors with contact grease and join them up.
16 Remove the plugs and connect the mast's hydraulic hoses on

the machine's front panel.
009981
17 Remove the plugs and connect the hydraulic hoses to the lift
cylinders.
18 Turn on the power supply and start the engine.
19 Check that the hydraulic connections are sealed tightly.
20 Check the mast functions.
21 Fit the trolley; see Trolley, installing, page 7:27.
22 Fit the side lift attachment; see Side lift attachment, installing,
page 7:54.
009980

Flanges on outer and inner mast beam, repair
NOTE
Safety.
If the surface of the flanges has started to break down into small
flakes, this can be repaired so that the mast can still be used. This is
rectified by first grinding down the attacked surfaces and then "run-in"
the surface.
3 Removing the mast, please refer to Mast, removing, page 7:16.
4 Separate the outer and inner mast.
5 Clean the mast components.
6 Grind the affected surfaces with a belt sander until the surface is
smooth and bright. Start with grit size 36-40 and finish with 60-80.
Grind in the longitudinal direction of the beam.
Check the internal measurement between the beam's front and
250 mm
rear flange. If the measurement exceeds 252 mm for a beam that

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

inner mast and fit the mast on the machine; see Mast, installing,
Mast beam size 250 mm. page 7:20.
9 Fit the trolley; see Trolley, installing, page 7:27.
10 Lift and lower the mast as follows to check its function.
Lift and lower the mast 20 times with 50% of the maximum load at
the right centre of gravity distance.
Lift and lower the mast 20 times with 75% of the maximum load at
the right centre of gravity distance.
Lift and lower the mast 20 times with the maximum load at the
right centre of gravity distance.
11 Check that contact surfaces look normal. If not, contact Cargotec.

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

7 Load handling – Mast position sensor 7:25
Mast wheel, adjusting

1 Use a drift to tap out the spring pin (position 4) from the inside.
1
NOTE
Check that the cover washer is centred on the clamping screw.
2
3 2 Screw in the clamping screw (position 5) so that the wheel is
completely locked.
NOTE
4
Rotate the mast wheel while tightening the clamping screw.
5
3 Loosen the clamping screw until the wheel rotates, slightly slowly.
Turn the clamping screw so that the next hole for the tubular pin
fits.
6
7 NOTE
Check that there is clearance between the mast wheel and the
mast beam.
4 Lock the clamping screw with the spring pin.

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

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

adjustment, page 7:3.

7:26 7 Load handling – Trolley
7.2.11 Trolley
Trolley, description
The trolley holds the side lift attachment and runs along the inner
mast with slide plates and mast wheels. The attachment can be
shifted sideways ±600 mm with a hydraulic cylinder that sits between
2
the attachment and trolley.
1 Also located on the trolley are the Attachment control unit (D791-1),
attachment control valve and buzzer automatic spreading 20'-40'
( )
3 See also Side shift cylinder, description, page 7:37.
4
013589
1. Side shift cylinder

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

removing, page 7:52.
2 Connect lifting equipment to the trolley in a secure manner.
3 Disconnect the main power supply.
4 Disconnect the trolley cable by undoing the lock plate screws.

009995

7 Load handling – Trolley 7:27
5 Mark up and disconnect the carriage's hydraulic connections. Let

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

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

8 Start the engine and tilt the mast rearwards.
9 Raise the mast enough for the carriage to release from the mast.
10 Lower the mast again.
11 Lift aside the trolley. Put it on blocks and supports to prevent
damage to the cylinders.
12 Undo the lifting equipment (travelling crane).
013591
Trolley, installing
NOTE
Safety.
1 Park the machine with the mast vertical.
2 Raise the mast high enough to position the carriage in the inner
mast and lift it into place.
3 Run down the mast so the trolley fastens in the inner mast. Stop
the mast in a position where the chains can be attached to the
trolley. Fit the chain tensioners and adjust and fasten with the nuts.
4 Lower the carriage as far as possible.
5 Turn off engine.
013591

8 Remove the plugs and connect the mast's hydraulic hoses and
the carriage wiring.
009987
9 Connect the trolley cable.

Lubricate the connectors with contact grease and connect them
Fasten the wiring with the lock plate.
10 Fit the side lift attachment; see Side lift attachment, installing,
page 7:54.
13 Check the trolley functions.
009995

7 Load handling – Trolley 7:29
Slide plates in trolley, adjusting and, if necessary,

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

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

slide plates (C and D).

7:30 7 Load handling – Pipes and hoses
5 Adjust trolley clearance by removing the screws and adding or

removing shims.
a. If the width at A and B is the same:
2
Adjust C and D to be equal to or max. 0.5 mm more than A.
1 b. If A is greater than B:
Adjust C to be equal to or max. 0.5 mm more than A.
Adjust D to be equal to or max. 0.5 mm more than B.
c. If A is less than B:
Adjust C to be equal to or max. 0.5 mm more than A.
Adjust D to be equal to or max. 0.5 mm less than B.
6 Lubricate the inner sliding surfaces of the inner mast with a thin
013648
1
2 7 Fit the trolley; see Trolley, installing, page 7:27.
1. Screws 8 Lift the trolley all the way up and check that the slide plates do not
clamp too hard against the sliding surfaces.
2. Shim
Mast wheel, adjusting

For mast wheel adjustment, see Mast wheel, adjusting, page 7:25.

7.2.14 Accumulator lift

Accumulator lift, description
1 2
Accumulator lift is connected in parallel with the lift cylinders and
takes up pressure surges that occur in the lift cylinder when operating.
The piston-type accumulator is located below the main valve on the
hydraulic plate in front of the transmission.
014672
1. Accumulator brake system

2. Accumulator lift

See section 10 Common hydraulics group 10.6.7 hydraulic oil filter.

7 Load handling – Side shift 7:31
7.4 Side shift

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

7:32 7 Load handling – Hydraulic oil pump

4 Solenoid valve, relief main pump - Lift, tilt and attachment control valve,
(Y6062-2) pressurises the attachment description, page 7:40
spool in the lift, tilt and attachment
control valve with servo pressure.
5 Hydraulic oil pump load handling See the pressure plate on Section 10 Common hydraulics, group 10.4.1
feeds the lift, tilt and attachment the left-hand frame beam. Gear pump with fixed displacement
control valve with hydraulic pressure.
-
6 The control valve lift, tilt and - Lift, tilt and attachment control valve,
attachment's attachment slide description, page 7:40
changes position and pressurises the
control valve attachment.
7 The attachment control unit (D791-1) U = 24 V Section 11 Common electrics, group 11.5.3.5
activates the solenoid valve for side Control unit, attachment
shift left (Y6020) or the solenoid valve
for side shift right (Y6021).
system, group 8.4.9.11 ATTACH, menu 11 and
group 8.4.9.12 ATTACH, menu 12
8 The solenoid valve for side shift left - Attachment control valve, description, page
(Y6020) or the solenoid valve for side 7:33
shift right (Y6021) pressurises the
side shift spool in the attachment
control valve.
9 The control valve's side shift slide - Attachment control valve, description, page
changes position and pressurises the 7:33
side shift cylinder.
10 The side shift cylinder pushes in the - Side shift cylinder, description, page 7:37
main beam sideways in relation to
the trolley.
11 The oil filter cleans the return oil from - Section 10 Common hydraulics group 10.6.7
the lift cylinders before it is collected Hydraulic oil filter.
in the hydraulic oil tank.


fixed displacement.

7 Load handling – Control valve, attachment 7:33
7.4.2 Control valve, attachment

Attachment control valve, description
Side shift slide
Control valve attachment controls the hydraulic functions on the
3 4
2 attachment. The control valve is located up on the trolley. Solenoid
1 valves control the flow from the valve.
The control valve is an electro-hydraulically controlled, proportional

and pressure-compensated directional control valve. Electrically
5 controlled solenoid valves convert current to servo pressure. The
servo pressure controls the spring-centred valve slides, which control
pressure and flow for the function in question. The valve slides have
10 a flow limit so that several functions can be used simultaneously. This
6 enables them to control the main flow.
The control valve has built-in supply of pilot pressure. This means that
9 the valve has built-in pressure reduction which converts feed pressure
7 to servo pressure for the various functions. Supply of pilot pressure
8 is common for all functions. This reduces pressure variations due to
long hoses and reduces the number of hoses to the valve.
The attachment control valve is fed by lift, tilt and attachment control
valve, see Lift, tilt and attachment control valve, description, page
7:40.
The control valve has the following sections:

• Side shift
015084
• Spreading right extension beam, see Attachment control valve,

description, page 7:48
1. Solenoid valve, side shift right (Y6021)
• Spreading left extension beam, see Attachment control valve,
2. Solenoid valve, lock twistlock (Y6040) description, page 7:48
3. Solenoid valve spreading in left (Y6019L) • Twistlocks, see Attachment control valve, description, page 7:67
4. Solenoid valve spreading in right (Y6019R) Side shift slide
5. Solenoid valve spreading out right (Y6018R)
The valve slide controls the direction and speed of side shift. The
6. Solenoid valve spreading out left (Y6018L)
valve spool is controlled by a solenoid valve for side shift right and a
7. Solenoid valve, open twistlock (Y6039) solenoid valve for side shift left.
8. Solenoid valve, side shift left (Y6020) Solenoid valve, side shift left
9. Connection, feed from hydraulic oil pump (P)
The solenoid valve for side shift left controls pressure to the side shift
10. Connection return to tank (T)
spool so that the side shift spool opens and pressurises the side shift
cylinder.
Solenoid valve, side shift left is controlled electrically by Solenoid

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

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

7:34 7 Load handling – Control valve, attachment
Control valve attachment, replacement
NOTE
Safety.
3 Remove the attaching bolts and lift away the plate fitted over the
control valve.
4 Mark and disconnect the hydraulic hoses from the control valve.
NOTE
from impurities.
5 Mark and disconnect the cable harness from the control valve.
013595

7 Load handling – Control valve, attachment 7:35
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
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
position.

13 Check that the valve\qs hydraulic connections are sealed.
14 Check that the attachment is working.
CAUTION
Air in the hydraulic system may cavitate and result in
product damage.
Activate the steering carefully and operate at the lowest
possible speed a couple of times to avoid cavitation.
15 Check the oil level in hydraulic oil tank with all hydraulic cylinders
in the retracted position. The oil level should be at the top of the
sight glass. Top up if necessary.
CAUTION
Do not overfill!
Leakage and environmental damage!
Check the hydraulic oil level with all hydraulic cylinders
fully retracted.

Control valve attachment, checking hydraulic

pressure
NOTE
Safety.
1 Operate and warm up the machine so that the hydraulic oil

reaches operating temperature, at least 50 ºC.
2 Turn off engine.
˚C 3 Machine in service position, see section B Safety.
˚C
Operating menu, hydraulic oil temperature 000475
4 Connect a pressure gauge (0-25 MPa) to the feed pressure

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

attachment
5 Start the engine and run at max. revs. Activate a hydraulic

function on the attachment and read the pressure gauge. The
pressure must correspond with the pressure plate.
measuring outlet.
015025

7 Load handling – Side shift cylinder 7:37
7.4.3 Side shift cylinder

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

7.4.5 Trolley
Trolley, description
See Trolley, description, page 7:26.

Slide plates between trolley and attachment,

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

attachment's mounting.
5 Unload the tension from the slide plate in question.
The pressure can be relieved from the slide plates by raising the
outer edge of the side lift attachment or inserting wedges to alter
the position of the side lift attachment in the trolley.
6 Remove the slide plate and fit a new one. Repeat with the other
lower slide plates (4 plates).
7 Reassemble the attachment's mounting.
3
2
013681
3
The illustration shows the slide plates between the
attachment and trolley.
1. Upper slide plates
2. Lower slide plates
3. Attachment's fastening

7 Load handling – Relief valve, attachment 7:39
8 Clean and measure the thickness of the upper slide plates.

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

10 Loosen the slide plate's attaching bolt slightly so that the slide
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.
13 Check the play between side lift attachment and the trolley. The
013682 play should be less than 1 mm with all slide plates fitted.
Use more shims to adjust any play.
The illustration shows the slide plates between the
trolley and attachment.
1. Upper slide plates
NOTE
Do not use too thick shims. Too little play increases wear on
2. Shim
the slide plates.
3. Counterhold
4. Screw
NOTE
Check that the attaching bolts for all slide plates are tightened.
14 Check that the sliding surface is clean and lubricate the sliding
surface on the side lift attachment.
15 Start the machine and side shift the attachment to its end positions.
Check that the play between the trolley and the attachment is
sufficient along the whole attachment and that no metallic contact
occurs. Adjust as necessary, using the shims.
7.4.7 Relief valve, attachment

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


7:40 7 Load handling – Lift, tilt and attachment control valve
7.4.9 Lift, tilt and attachment control valve

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

lift, tilt and attachment control valve. The solenoid valve hydraulic
pressure attachment (Y6062-2) is also activated when attachment
functions are activated. See also Lift, tilt and attachment control
valve, description, page 7:14.
Attachment slide
When activating the Solenoid valve hydraulic attachment (Y6062-2)
2 the attachment slide is pressurised and controls the direction and flow
of the oil from the hydraulic oil pumps to the attachment control valve.
015083
Solenoid valve hydraulic pressure attachment
1. Solenoid valve hydraulic pressure attachment Solenoid valve hydraulic pressure attachment (Y6062-2) is activated
(Y6062-2) by the frame control unit (D797-1). The solenoid valve directs servo
2. Connection feed pressure control valve, pressure to the attachment slide which is proportional to the control
attachment current to the solenoid valve.


7 Load handling – Spreading (positioning) 7:41
7.5 Spreading (positioning)

Spreading, function description
Control breaker Not activated Section 11 Common electrics, group 11.5.1.4 Emergency stop switch
voltage
Twistlocks Unlocked or bypass Twistlocks, description, page 7:64
activated
Section 8 Control system, group 8.2.2 Bypass
1b 1a
D1
2
D790-1
D797-1 D791-1
3 7, 14, 19
D3
4 D13 D8 D9
C
8, 15 9, 20
C
P2 D18
P2 10,
5 23 A 16,
6 T2 B A A B 21
13 18
015077
11, 17 12, 22

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

7:42 7 Load handling – Spreading (positioning)

6 The control valve lift, tilt and - Lift, tilt and attachment control valve,
attachment's attachment slide description, page 7:40
changes position and pressurises
the control valve attachment.
7 The attachment control unit I = 350–600 mA Section 11 Common electrics, group 11.5.3.5
(D791-1) activates the Solenoid Control unit, attachment
valve spreading out left (Y6018L)
D8–D9: Diagnostic menu, see section 8 Control
and Solenoid valve spreading
system, group 8.4.9.17 ATTACH, menu 17 –
out right (Y6018R) or Solenoid
8.4.9.20 ATTACH, menu 20
spreading in left (Y6019L) and
Solenoid valve spreading right
(Y6019R).
8 The solenoid valve for spreading - Attachment control valve, description, page
out left (Y6018L) or the solenoid 7:33
valve for spreading in left (Y6019L)
pressurises the left spreader spool
in the attachment's control valve.
9 The solenoid valve for spreading - Attachment control valve, description, page
out right (Y6018T) or the solenoid 7:33
valve for spreading in right (Y6019T)
pressurises the right spreader spool
in the attachment's control valve.
10 The control valve's spreader spools - Attachment control valve, description, page
change position and direct pressure 7:33
to the spreader cylinders.
11 Left spreader cylinder pushes left - Spreading cylinder, description, page 7:49
spreader beam in or out in the
attachment.
12 Right spreader cylinder pushes - Spreading cylinder, description, page 7:49
right spreader beam in or out in the
attachment.
13 The sensor for end position 20'-40' Sensor directly opposite Position sensor spreading, description, page
left (B769L) sends a voltage signal indicator plate: U > 24 V 7:56
to the attachment control unit
(D791-1).
14 The attachment control unit (D791-1) - Section 11 Common electrics, group 11.5.3.5
reduces the control current to the Control unit, attachment
solenoid valve for spreading out left
(Y6018L) or the solenoid valve for
spreading in left (Y6019L).
15 The solenoid valve for spreading - Control valve attachment, replacement, page
out left (Y6018L) or the solenoid 7:34
valve for spreading in left (Y6019L)
reduces the pressure to the left
spreader spool in the attachment's
control valve.
16 The control valve's spreading slide - Attachment control valve, description, page
left changes position and lowers 7:33
the pressure on the left spreading
cylinder.
17 Spreader speed decreases. - Spreading cylinder, description, page 7:49
18 The sensor for end position 20'-40' Sensor directly opposite Position sensor spreading, description, page
right (B769R) sends a voltage indicator plate: U = 24 V 7:56
signal to the attachment control unit
(D791-1).


19 The attachment control unit (D791-1) - Section 11 Common electrics, group 11.5.3.5
reduces the control current to the Control unit, attachment
solenoid valve for spreading out
right (Y6018R) or the solenoid valve
for spreading in right (Y6019R).
20 The solenoid valve for spreading out - Control valve attachment, replacement, page
right (Y6018R) or the solenoid valve 7:34
for spreading in right (Y6019R)
reduces the pressure to the right
spreader spool in the attachment's
control valve.
21 The control valve's spreading slide - Attachment control valve, description, page
right changes position and lowers 7:33
the pressure on the right spreading
cylinder.
22 Spreader speed decreases. - Spreading cylinder, description, page 7:49
23 The hydraulic oil filter cleans the - Section 10 Common hydraulics group 10.6.7
return oil from the lift cylinders Hydraulic oil filter.
before it is collected in the hydraulic
oil tank.


30-foot stop, function description

voltage
Twistlocks Unlocked or Twistlocks, description, page 7:64
bypass activated
Section 8 Control system, group 8.2.2 Bypass
D1 D2
2b 2a 1
35
30-
3
D790-1
D791-1
4,7,9,11 D5
D8 30' 30'
014803
4,7 4,7 5 6 8 10

1 The switch for stop at 30' (S1004) sends Switch in on position: Switch stop at 30', description (linear control
a voltage signal to the cab control unit levers), page 7:6
Conn. 1: U = 0 V
(D790-1).
Conn. 5: U = 24 V
Switch in off position:
Conn. 1: U = 24 V
Conn. 5: U = 24 V
2a The switch for spreading 20'-40' U = 24 V DC Switch spreading 20'-40', description (linear
(S1012) sends a voltage signal to the control levers), page 7:6
2b The control lever (S815-T1.2) sends a Spreading: US815-T4 = 24 V Control lever, description, page 7:4
voltage signal to the Cab control unit
Out: US815-T1.2 = 24 V D2: Diagnostic menu, see section 8 Control
(D790-1).
In: US815-T1.1 = 24V
3 Control unit, cab (D790-1) sends Checked by control Section 11 Common electrics, group
spreading 30' on the CAN bus. system, error shown 11.5.3.1 Control unit, cab
with error code.
4 Spreading is activated in the same way - Spreading, function description, page 7:41
as the normal spreading steps 3–14.
5 When the left spreader beam Sensor directly opposite Position sensor spreading, description, page
approaches the 30' mark, the sensor indicator plate: U = 24 V 7:56
for 30' end position left (B777L) sends a
voltage signal to the attachment control
unit (D791-1).
6 When the right spreader beam Sensor directly opposite Position sensor spreading, description, page
approaches the 30' mark, the sensor for indicator plate: U = 24 V 7:56
30' end position left (B777R) sends a
voltage signal to the attachment control
unit (D791-1).


7 The attachment control unit (D791-1) - Spreading, function description, page 7:41
dampens the speed in the same way as
in normal spreading, steps 17–22.
8 When the left spreader beam is at the Sensor directly opposite Position sensor spreading, description, page
30' mark, the sensor for 20'-40' end indicator plate: U = 24 V 7:56
position (B769L) sends a voltage signal
to the attachment control unit (D791-1).
9 The attachment control unit (D791-1) U=0V Attachment control valve, description, page
cuts off the current to the solenoid 7:33
valve for spreading out left (Y6018L) or
the solenoid valve for spreading in left
(Y6019L).
10 When the right spreader beam is at the Sensor directly opposite Position sensor spreading, description, page
30' mark, the sensor for 20'-40' end indicator plate: U = 24 V 7:56
position (B769R) sends a voltage signal
to the attachment control unit (D791-1).
11 The attachment control unit (D791-1) U=0V Attachment control valve, description, page
cuts off the current to the solenoid valve 7:33
for spreading out right (Y6018R) or the
solenoid valve for spreading in right
(Y6019R).


Automatic spreading 20-40 foot, function

description

voltage
Twistlocks Unlocked or bypass Twistlocks, description, page 7:64
activated
Doors Closed Section 9 Frame, body, cab and accessories, group 9.10.2 Doors
Parking brake Released Section 4 Brakes, group 4.5 Parking brake system
2
D1 D2
1b 1a
3 7
D790-1 D795
D791-1 D9
D10 D8 D11 4, 5, 8 9 D13 D12
10 8 11 6 13 9 12
009347
D5

1a. The switch for spreading 20'-40' U = 24 V DC Switch spreading 20'-40', description (linear
(S1012) sends a voltage signal to control levers), page 7:6
1b The control lever (S815-T1.1 and Spreading: US815/T4 = 24 V Control lever, description, page 7:4
S815-T1.2) sends a voltage signal to
Out: US815/T1.2 = 24 V D1: Diagnostic menu, see section 8 Control
In: US815/T1.1 = 24 V
2 The switch for automatic spreading Switch in on position: Switch automatic spreading, description (linear
20'-40' (S1012-2) sends a voltage control levers), page 7:7
US199-2/2 = 0 V
signal to the cab control unit
(D790-1). US199-2/5 = 24 V
Switch in off position:
US199-2/2 = 24 V
US199-2/5 = 24 V
3 The cab control unit (D790-1) Checked by control Section 11 Common electrics, group 11.5.3.1
transmits "automatic spreading out" system, error shown Control unit, cab
or "automatic spreading in" on the with error code.
CAN bus.
4 The attachment control unit (D791-1) - Spreading, function description, page 7:41
activates spreading the same way as
in steps 3-14 of normal spreading.
5 The attachment control unit (D791-1) Buzzer active: U = 24 V Buzzer automatic spreading 20'-40',
activates the automatic spreading description, page 7:56
buzzer (H9003).

7 Load handling – Hydraulic oil pump 7:47

6 Buzzer automatic spreading (H9003) Buzzer active: U = 24 V Buzzer automatic spreading 20'-40',
generates acoustic warning signal. description, page 7:56
7 When automatic spreading is active, - Section 11 Common electrics, group 11.5.3.12
the KID control unit (D795) activates Control unit, KID
the Automatic Spreading event
menu.
8 When the left spreader beam Sensor directly opposite Spreading, function description, page 7:41
approaches the 20', 30' ( ) or 40' indicator plate: U = 24 V
30-foot stop, function description, page
mark, the sensor for 20'–40' end
7:44
position left (B769L) sends a voltage
signal to the attachment control unit D8: Diagnostic menu, see section 8 Control
(D791-1), which activates damping system, group 8.4.9.6 ATTACH, menu 6
for the left spreader beam the same
way as in steps 16-22 of normal
spreading.
9 When the right spreader beam Sensor directly opposite Spreading, function description, page 7:41
approaches the 20', 30' ( ) or indicator plate: U = 24 V
30-foot stop, function description, page
40' mark, the sensor for 20'–40'
7:44
end position right (B769R) sends
a voltage signal to the attachment D9: Diagnostic menu, see section 8 Control
control unit (D791-1), which activates system, group 8.4.9.6 ATTACH, menu 6
damping for the right spreader beam
the same way as in steps 16-22 of
normal spreading.
10 When the left spreader beam is Sensor directly opposite Position sensor spreading, description, page
at the 20', 30' ( ) or 40' mark, indicator plate: U = 24 V 7:56
the sensor for end position 30' left D10: Diagnostic menu, see section 8 Control
(B777L) sends a voltage signal to system, group 8.4.9.6 ATTACH, menu 6
the attachment control unit (D791-1).
11 The attachment control unit (D791-1) I = 0 mA Section 11 Common electrics, group 11.5.3.5
cuts off the current to the solenoid Control unit, attachment
valve for spreading out left (Y6018L)
or the solenoid valve for spreading
in left (Y6019L).
12 When the right spreader beam is Sensor directly opposite Position sensor spreading, description, page
at the 20', 30' ( ) or 40' mark, indicator plate: U = 24 V 7:56
the sensor for end position 30' right D12: Diagnostic menu, see section 8 Control
(B777R) sends a voltage signal to system, group 8.4.9.6 ATTACH, menu 6
the attachment control unit (D791-1).
13 The attachment control unit (D791-1) I = 0 mA Section 11 Common electrics, group 11.5.3.5
cuts off the control current the Control unit, attachment
solenoid valve for spreading out right
D13: section 8 Control system, group 8.4.9.19
(Y6018R) or the solenoid valve for
ATTACH, menu 16 and 8.4.9.20 ATTACH,
spreading in right (Y6019R).
menu 20


fixed displacement.

7.5.2 Control valve, attachment

Spreader slide
Spreading is controlled by two identical sections in the attachment
3 4
2 control valve, one for the right spreader beam and one for the left
1 spreader beam. Both beams are controlled in the same way, which
is why they are described together below. For a more detailed
description of the valve and component locations, see Attachment
5 control valve, description, page 7:33.
Spreader slide
10 The valve slides control the direction and speed of the spreading.
Each valve slide is controlled by two solenoid valves, one for
6
spreading out and one of spreading in.
9 Solenoid valve for spreading out

7
The solenoid valves for spreading out control the pressure to the
8 spreader slides so that they open and pressurises the spreader
cylinders.
Solenoid valve, spreading out left (Y6018L) and solenoid valve,

spreading out right (Y6018R) are activated by the attachment control
unit (D791-1). The solenoid valve controls the servo pressure to
spreader slide proportionally toward the control current.
The signal can be checked with diagnostic menu.

015084
• Left: section 8 Control system, group 8.4.9.17 ATTACH, menu 17

• Right: section 8 Control system, group 8.4.9.19 ATTACH, menu
1. Solenoid valve, side shift right (Y6021)
19
2. Solenoid valve, lock twistlock (Y6040)
Solenoid valve for spreading in
3. Solenoid valve spreading in left (Y6019L)
4. Solenoid valve spreading in right (Y6019R) The solenoid valves for spreading in control the pressure to the
spreader slides so that they open and pressurises the spreader
cylinders.
Solenoid valve, spreading in left (Y6019L) and solenoid valve,
7. Solenoid valve, open twistlock (Y6039)
spreading in right (Y6019R) are activated by the attachment control
8. Solenoid valve, side shift left (Y6020) unit (D791-1). The solenoid valve controls the servo pressure to
9. Connection, feed from hydraulic oil pump (P) spreader slide proportionally toward the control current.
10. Connection return to tank (T) The signal can be checked with diagnostic menu.
• Left: section 8 Control system, group 8.4.9.18 ATTACH, menu 18
• Right: section 8 Control system, group 8.4.9.20 ATTACH, menu
20

See Control valve attachment, replacement, page 7:34.

7 Load handling – Spreading cylinder 7:49
7.5.3 Spreading cylinder

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

main beam make it possible to access the spreader cylinders for
maintenance purposes.
014816
7.5.4 Spreader beam
Spreader beam, description
The spreader beams are the part of the attachment that grips the
container Two spreader beams run in the main beam. The spreader
beams are pushed in and out by the hydraulic cylinders.
The spreader beam houses twistlocks. See Twistlocks, function

014737
Spreader beam slide plates, adjusting/replacing

1 Park the machine with the attachment lowered as far as possible
and spreading extended approx. 1000 mm.
1000 mm
013683

7:50 7 Load handling – Spreader beam
3 Unscrew the nuts and bolts (position 1) that secure the slide plates.
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

7 Load handling – Main beam, side lift attachment 7:51
5 Refit the slide plates, add a sufficient number shims under the
slide plates so that the play between the slide plates and the main
beam is 1-3 mm both laterally and vertically. This corresponds
to the measurements X + (1-3) mm and Y + (1-3) mm internally
between the slide plates.
NOTE
Do not use too thick shims. Too little play increases wear on
the slide plates.
NOTE
Check that the attaching bolts for all slide plates are tightened.
6 Start the machine and check the spreading functioning. Try to lift
a container and then check the spreader beams' play again on
the attachment's main beam.
013687
Right side
013688
Left side
7.5.5 Main beam, side lift attachment

Side lift attachment's main beam, description
The main beam side lift attachment is fastened to the trolley by the
hydraulic cylinders. The main beam contains equipment for spreading
(spreader beams, hydraulic cylinders, slide plates and sensors).
014817

7:52 7 Load handling – Main beam, side lift attachment
Side lift attachment, removing
NOTE
Safety.
NOTE
It is possible to remove the trolley and the side lift attachment as
a unit.
1 Park the machine with the mast vertical and the attachment in
its lowest position.
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 (overhead
crane). Let the machine stand with the ignition on for a while.
5 Turn off engine.
014819
6 Detach the side shift cylinder from the attachment.

Remove the cylinder's shaft from the bracket on the trolley. If
necessary, use the threaded hole and a puller to press the shaft
out.
Start the engine and retract the cylinder so that it comes loose
from the mounting in the trolley. Turn off engine.
Save the circlips. Refit the shaft in the cylinder.
013654
7 Fasten the side shift cylinder.

009997

10 Mark up and detach hydraulic connections from the side lift

attachment and the side shift cylinder.
NOTE
from impurities.
009952
11 Detach the cable harness of the attachment from the attachment
control unit.
Remove the cable harness clamping ring.
12 Loosen the attachment's mounting unit in the trolley.

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

7:54 7 Load handling – Main beam, side lift attachment
Side lift attachment, installing
NOTE
Safety.
1 Park the machine with the mast vertical.
2 Lower the trolley to its lowest position.
3 Turn off engine.
6 Lift the side lift attachment into place.
Lifting points side lift attachment
7 Fit the lifting carriage's front panels to fix the side lifting attachment
in position.
8 Check that the side lift attachment runs correctly in the trolley;
see Slide plates between trolley and attachment, adjustment,
page 7:38.
013680
9 Clean and apply a layer of lubricating grease to the side shift

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

013654
cylinder to make it possible to adjust cylinder length.

11 Attach the cable harness of the attachment to the attachment

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

7:56 7 Load handling – Position sensor, spreading
7.5.6 Position sensor, spreading

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

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

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

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


attachment.
7.5.10 Lift, tilt and attachment control valve

Lift, tilt and attachment control valve, general
See Lift, tilt and attachment control valve, description, page 7:40.

7 Load handling – Hydraulic oil filter 7:57


7:58 7 Load handling – Tilt
7.7 Tilt
Tilt, function description
voltage
1b 1a D3
D1
2, 3
D790-1
D797-1
4 5
D5
6 9
C
P2
10
7 11 A B 8 9
015075
10

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

7 Load handling – Hydraulic oil pump 7:59

4 Control breaker relay tilt (K3002) makes - Section 11 Common electrics, group 11.5.1.4
the ground connection between Frame Emergency stop switch voltage (15E)
control unit (D797-1) and to Solenoid
valve tilt in (Y6011) and Solenoid valve
tilt out (Y6010).
5 The frame control unit (D797-1) controls I = TDB mA Section 11 Common electrics, group 11.5.3.2
the current proportionally to the lever Frame control unit
movement to Solenoid valve tilt in
(Y6011) or Solenoid valve tilt out
system, group 8.4.8.5 ELSERV, menu 5 and
(Y6010).
8.4.8.6 ELSERV, menu 6
6 The solenoid valve for tilt in (Y6011) or - Lift, tilt and attachment control valve,
the solenoid valve for tilt out (Y6010) description, page 7:60
pressurises the tilt spool in the lift, tilt
and attachment control valve.
7 The hydraulic oil pumps pump oil from See the pressure plate on Section 10 Common hydraulics, group
the hydraulic oil tank. the left-hand frame beam. 10.4.1 Gear pump with fixed displacement
8 The control valve's tilt spool changes - Lift, tilt and attachment control valve,
position and pressurises the load description, page 7:60
retention valve.
9 The load retention valve opens and - Load holding valve, description, page 7:61
directs the pressure on to the tilt
cylinders.
10 The tilt cylinders angle the mast in - Tilt cylinder, description, page 7:61
relation to the frame.
Mast, description, page 7:16
the lift cylinders before it is collected in Hydraulic oil filter.


fixed displacement.

7:60 7 Load handling – Control valve, lift and tilt
7.7.5 Control valve, lift and tilt

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

control valve. See also Lift, tilt and attachment control valve,
For more information about tilting, see Tilt, function description, page
7:58.
Tilt slide
When the solenoid valves are activated, the tilt spool is pressurised
4 and controls the direction and flow of oil from the hydraulic oil pumps
to the tilt cylinders.
015082
3
Solenoid valve, tilt out
1. Solenoid valve, tilt in (Y6011)
On machines with electric servo, the solenoid valve tilt out is
2. Solenoid valve, tilt out (Y6010)
controlled electrically with Solenoid valve tilt out (Y6010) which is
3. Connection rod side tilt cylinders activated by the Frame control unit option (D797-1). The solenoid
4. Connection piston side tilt cylinders valve directs servo pressure to the tilt spool which is proportional to
the control current to the solenoid valve.
Solenoid valve, tilt in
On machines with electric servo, the solenoid valve tilt in is controlled
electrically with Solenoid valve tilt in (Y6011) which is activated by the
Frame control unit option (D797-1). The solenoid valve directs servo
pressure to the tilt spool which is proportional to the control current to
the solenoid valve.

7 Load handling – Load retention valve 7:61
7.7.6 Load retention valve

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

Tilt cylinder, description
The tilt cylinders sit between the mast and the frame and angle the
mast in relation to the machine.
2
009930
1. Tilt cylinder
2. Mast
3. Lower mast mounting in frame


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



7 Load handling – Levelling 7:63
7.8 Levelling
Mechanical levelling, function description
Mechanical levelling means that the twistlock fasteners can spring out
and adjusts the height of the twistlocks according to the incline of the
container to be lifted. This means that the machine can handle loads
on an uneven surface, up to ± 3° angle.
014021

7:64 7 Load handling – Load carrier
7.9 Load carrier

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

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

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

switch voltage
Alignment Full alignment or bypass Twistlocks, description, page 7:69
activated
Section 8 Control system, group 8.2.2 Bypassing
1
D1
2b
2a
7, 20
D2 3 6, 19
D790-1 D790-2 D795
D8 D797-1 D791-1 D5
8 5, 12, 18
9 D17
D12 17 4
C
13
C 16
P2
P2 A
10 21 A
11 T2 B
14 15 16
D17 4
17
015078
D4

7 Load handling – Twistlocks 7:65

1 The switch for locking the twistlocks U = 24 V Switch lock twistlocks, description (linear
(S1003) (automatic mode) sends a control levers), page 7:5
voltage signal to the cab control unit
(D790-1).
2a The switch for opening the twistlocks U = 24 V Switch lock twistlocks, description (linear
(S1002) sends a voltage signal to the control levers), page 7:5
cab control unit (D790-1) for twistlock
opening.
If the "lock twistlocks" switch (S1003) is
in the manual position, a signal from the
"open twistlocks" switch (S1002) is not
needed to open the twistlocks.
2b The control lever (S815-T2) sends a US815/T2 = 24 V Control lever, description, page 7:4
voltage signal to the cab control unit
(D790-1) for twistlock opening.
If Switch, lock twistlocks (S1003) is
in manual position then no signal is
required from the control lever to open
twistlocks.
3 Control unit, cab (D790-1) transmits Checked by control Section 11 Common electrics, group 11.5.3.1
"open twistlocks" or "lock twistlocks" on system, error shown with Control unit, cab.
the CAN bus. error code.
4 The alignment left sensor (B7203L) and Sensor directly opposite Sensor, alignment, description, page 7:71
alignment right sensor (B7203R) detect indicator plate: U = 24 V
position and send a voltage signal to the
attachment control unit (D791).
activates the alignment indicator light Control unit, attachment
on the mast's lamp panel and sends
alignment on the CAN bus.
6 Control unit KID (D795) activates the - Section 11 Common electrics, group
event menu for alignment. 11.5.3.12 Control unit, KID
7 Control unit KID (D790-2) activates the - Section 11 Common electrics, group
indicator light for alignment on the cab's 11.5.3.11 Control unit, KIT
light panel.
8 The frame control unit (D797-1) activates U = 24 V Section 11 Common electrics, group 11.5.3.2
the solenoid valve for main pump relief Frame control unit
(Y6062-2).
9 Solenoid valve, relief main pump - Lift, tilt and attachment control valve,
(Y6062-2) pressurises the attachment description, page 7:40
spool in the lift, tilt and attachment
control valve with servo pressure.
10 The load handling hydraulic oil pump See the pressure plate on Section 10 Common hydraulics, group 10.4.2
pumps oil from the hydraulic oil tank to the left-hand frame beam. Axial piston pump with variable displacement
the lift, tilt and attachment control valve
with hydraulic pressure.
11 The control valve lift, tilt and attachment's - Lift, tilt and attachment control valve,
attachment slide changes position and description, page 7:40
pressurises the control valve attachment.
activates the "open twistlocks" solenoid Control unit, attachment
valve (Y6039) or the "lock twistlocks"
solenoid valve (Y6040).
13 The "open twistlocks" solenoid valve - Attachment control valve, description, page
(Y6039) or the "lock twistlocks" solenoid 7:67
valve (Y6040) pressurises the twistlock
spool with servo pressure.

7:66 7 Load handling – Twistlocks

14 The twistlock spool of the control valve - Attachment control valve, description, page
changes position and pressurises the 7:67
lock cylinders via the overcentre valve.
15 The overcentre valve prevents the - Twistlock overcentre valve, description, page
uncontrolled opening or closing of the 7:68
twistlocks.
16 The lock cylinders rotate the twistlocks. - Lock cylinder, description, page 7:68
17 The "unlocked twistlocks" sensor (B7204 Sensor directly opposite Sensor, twistlocks, description, page 7:72
L and R) or the "locked twistlocks" sensor indicator plate: U = 24 V
(B7205 L and R) sends a signal to the
attachment control unit (D791-1).
voltage feeds the unlocked twistlocks Control unit, attachment
indicator light (H562) or the locked
twistlocks indicator light (H563) on
the mast's lamp panel and sends
unlocked twistlocks or locked twistlocks
information on the CAN-bus.
19 Control unit KID (D795) activates the Checked by control Section 11 Common electrics, group
event menu for twistlocks. system, error shown with 11.5.3.12 Control unit, KID
error code.
20 Control unit KIT (D790-2) supplies Checked by control Section 11 Common electrics, group
voltage to Indicator light "unlocked system, error shown with 11.5.3.11 Control unit, KIT
twistlocks" or Indicator light "locked error code.
twistlocks" on the cab lamp panel.
the lift cylinders before it is collected in Hydraulic oil filter.

7.9.1.1 Hydraulic oil pump

fixed displacement.

7.9.1.2 Control valve, attachment

Twistlocks slide, description
The twistlocks function is regulated by a separate section in the
3 4
2 attachment's control valve. For a general description of the valve
1 and component locations, see Attachment control valve, description,
page 7:33.
Twistlocks slide, description
5
The valve spool controls the direction of the lock cylinder. The valve
spool is controlled by the "lock twistlocks" solenoid valve (Y6040) and
10 the "open twistlocks" solenoid valve (Y6039).
6 "Lock twistlocks" solenoid valve, description
9 The "lock twistlocks" solenoid valve directs pressure to the twistlock

spool so that the spool opens and pressurises the lock cylinders.
7
8 Solenoid valve locked twistlocks (Y6040) is activated by the
attachment control unit (D791-1). The solenoid valve guides servo
pressure to the twistlock spool.
"Open twistlocks" solenoid valve, description
The "open twistlocks" solenoid valve directs pressure to the twistlock
015084
spool so that the spool opens and pressurises the lock cylinders.
1. Solenoid valve, side shift right (Y6021) Solenoid valve open twistlocks (Y6039) is activated by the attachment
control unit (D791-1). The solenoid valve guides servo pressure to
2. Solenoid valve, lock twistlock (Y6040)
the twistlock spool.
3. Solenoid valve spreading in left (Y6019L)
4. Solenoid valve spreading in right (Y6019R) The signal can be checked via the diagnostic menu. See section 8
7. Solenoid valve, open twistlock (Y6039)
8. Solenoid valve, side shift left (Y6020)
9. Connection, feed from hydraulic oil pump (P)
10. Connection return to tank (T)

See Control valve attachment, replacement, page 7:34.

7.9.1.3 Twistlock overcentre valve
Twistlock overcentre valve, description

The overcentre valve prevents the uncontrolled opening or closing
of the twistlocks. The valve is located to the left of the attachment
control valve on the trolley.
014805
7.9.1.4 Lock cylinder
Lock cylinder, description

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


7.9.1.5 Lock mechanism
Lock mechanism, description

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 runs in
3 the corner box.
2
The lock mechanism consists of a rotary plate with a linkage bearing
at which the lock cylinder is attached. The rotary plate rotates the
twistlocks.
014807
1. Linkages
2. Rotary plate
3. Lock cylinder mount
7.9.1.6 Twistlocks
Twistlocks, description
1 2 3
WARNING
Dropped load.
Extreme danger!
Twistlocks hold the load during load handling and
therefore it is of the utmost importance that twistlocks
are checked according to instructions and are replaced
at the slightest sign of damage or wear.
014716
5 4
Twistlocks secure the load and are located out in the corners of the
1. Unlocked twistlock sensor spreader beam's longitudinal section.
2. Sensor, alignment Twistlocks are manufactured from high-strength steel in accordance

3. Locked twistlock sensor with international standards. The lift pins are marked with serial
numbers.
4. Lift pin
5. Alignment pin Twistlocks are connected pairs via a linkage system to a hydraulic
cylinder which in turn is controlled via a section in the attachment's
control valve. Inductive sensors send signals when the twistlocks are
locked and unlocked, respectively.

Twistlocks, replacement
3 Clean the twistlocks and the surrounding area.
4 Slacken the screws on the clamp holding the twistlocks in place.

5 Hold the twistlocks while removing the clamp halves.
WARNING
Dropped component.
Risk of pinch injury or product damage.
Twistlock weighs approx. 30 kg.
014821
6 Remove the clamp halves and lift away the twistlock.

7 Fit a new twistlock and secure it with the clamp halves.
NOTE
Remember the washer.
8 Check the positions of the parts and that the twistlocks can move.
9 Tighten the screws of the clamp halves.

10 Lubricate the twistlocks and lock mechanism with lubricating
grease.
11 Check that the twistlock mechanism can move.
12 Turn on the main electric power and start the machine.
13 Check that the twistlocks are working.
014821

7.9.1.7 Sensor, alignment
Sensor, alignment, description

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

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

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

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

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

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

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

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

Twistlocks sensor, checking and adjusting

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

014720
2 1
Left side

7.9.1.10 Pipes and hoses

7.9.1.11 Relief valve, attachment

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

See Lift, tilt and attachment control valve, description, page 7:40.
7.9.1.13 Hydraulic oil filter


7 Load handling – Other functions 7:75
7.10 Other functions

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

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

switch voltage
D1
1, 4, 7
10
D790-1 D795
D797-1 D791-1
3,6,9 D5
D2
2,8 5
015086
1 The attachment is positioned over - Lifting/lowering, function description, page 7:8
a container with the functions 7.2
Side shift, function description, page 7:31
Lifting/lowering, 7.4 Side shift and 7.5
Spreading Spreading, function description, page 7:41
system, group 8.4.8.1 ELSERV, menu 1 and
8.4.8.1 ELSERV, menu 2.
2 Alignment sensors left and right (B7203L Sensor directly opposite Sensor, alignment, description, page 7:71
and B7203R) voltage signal to the indicator plate: U = 24 V
attachment control unit (D791-1).
3 Control unit, attachment (D791-1) sends Checked by control Section 11 Common electrics, group 11.5.3.5
alignment on the CAN bus. system, error shown Control unit, attachment
with error code.
4 Twistlocks are rotated to the locked - Twistlocks, function description, page 7:64
position and are closed with the 7.9.1
Twistlocks function.
5 The sensor for locked twistlocks Sensor directly opposite Sensor, twistlocks, description, page 7:72
left (B7205L) and sensor for locked indicator plate: U = 24 V
twistlocks right (B7205R) send a voltage
(D791-1).

7:76 7 Load handling – Container counter

locked twistlocks on the CAN bus. system, error shown Control unit, attachment
with error code.
7 The container is lifted with the function - Lifting/lowering, function description, page 7:8
7.2 Lifting/lowering.
8 Alignment sensors left and right (B7203L U=0V Sensor, alignment, description, page 7:71
and B7203R) make and send a voltage
(D791-1).
no alignment on the CAN bus. system, error shown Control unit, attachment
with error code.
10 If the twistlocks remain locked for 8 - Section 11 Common electrics, group 11.5.3.1
seconds then Control unit, cab (D790-1) Control unit, cab
adds one lift to the container counter.

8:1
8 Control system
Contents 8 Control system

8 Control system ...................................................................................................8:3
8.1.10 Error code menu .........................................................................................8:4
8.2 Monitoring ........................................................................................................8:7
8.2.2 Bypass ........................................................................................................8:7
8.2.3 Speed limitation...........................................................................................8:7
8.2.4 Service indicator..........................................................................................8:8
8.4 Diagnostics ......................................................................................................8:9
8.4.1 CAN/POWER ............................................................................................ 8:11
8.4.2 LIGHTS .....................................................................................................8:25
8.4.3 CAB ...........................................................................................................8:37
8.4.4 CLIMATE ...................................................................................................8:45
8.4.5 HYD...........................................................................................................8:51
8.4.6 ENGINE ....................................................................................................8:55
8.4.7 TRANSM ...................................................................................................8:62
8.4.8 ELSERV ....................................................................................................8:69
8.4.9 ATTACH ....................................................................................................8:76
8.4.10 OLS ...........................................................................................................8:89
8.4.11 EXTRA ......................................................................................................8:89
8.5 Setup..............................................................................................................8:95
8.5.1 Initiation .....................................................................................................8:95
8.5.2 Calibration ............................................................................................... 8:112

8:2

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

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

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

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

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

8:4 8 Control system – Controls and instruments

8.1.10 Error code menu
Error code menu, description
The control and monitoring system's display is divided into four fields
C where the information is shown (see figure to the left).
• Field B: Error code level is shown with a symbol.
D E
• Field C: Shows error code.
B • Field D: Shows type of error.
000389
• Field E: Indicates which function is affected by error code.
• Book symbol means that information is available in the operator's
manual.
Field B: Error code level

The control and monitoring system gives error code information in
three levels which are indicated with a symbol in the lower left corner
(B) on the display unit.
• Stop
C Indicates a serious malfunction that may jeopardise the operator's
safety or cause machine failure. The error code must be attended
D E to immediately. Stop working with the machine and contact
service immediately.
The error code is shown automatically on the display.
000350
• Warning
C Indicates malfunction in machine that should be taken care of as
soon as possible. After the finished work shift with the machine,
D E contact service as soon as possible.
000351
• Information
C Information to the operator that something should be taken care
of as soon as possible, e.g., defective light bulb. Take action to
D E fix the cause of the error code as soon as possible. See section 6
Inspection and maintenance in the operator's manual.
The error code is stored in the error code list under operating
000352
menu for service.
Field C: Error code number

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

8 Control system – Error code menu 8:5
• Transmission:
XXX/YY Shown with error code number XX/YY on display.
001344
Field D: Type of error
1 2 3
1. Temperature too high/too low.
2. Incorrect signal to solenoid valve.
3. Incorrect hydraulic pressure.
4. Incorrect sensor signal.
4 5 6
5. Incorrect signal from control.
6. Incorrect signal to bulb.
7. Incorrect signal, for example, open circuit.
7
000396

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

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

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

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

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

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

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

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

Service indicator, resetting
2 Navigate first to the service menu and press Enter.
000056
3 Enter the code to reset the service indicator.
Code is obtained from Cargotec Support.
1 23
4 5 NOTE
000060
The code determines which service menu is activated (Service,

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

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

8 Control system – Diagnostics 8:9
8.4 Diagnostics
Diagnostic test, general
The machine has built-in functions for troubleshooting called diagnostic
test. The diagnostic test consists of several menus shown on the
display. The menus are grouped for faster access. The following
pages describe the content of the menu figures and which functions
can be controlled.
The diagnostic test is divided into the following groups:

• Voltage feed and communication for the Control system,
CAN/POWER, description, page 8:11.
• Lighting, LIGHTS, description, page 8:25.
• Cab functions, CAB, description, page 8:37.
• Air conditioning, CLIMATE, description, page 8:45.
• Hydraulic functions, HYD, description, page 8:51.
• Engine ENGINE, description, page 8:55.
• Transmission, TRANSM, description, page 8:62.
• Functions for electric servo, ELSERV, description, page 8:69.
• Attachment functions, ATTACH, description, page 8:76.
• Optional functions, EXTRA, description, page 8:89
– Optional functions, OPT, description, page 8:90

8:10 8 Control system – Diagnostics
Diagnostic menu, description

Diagnostic tests show how the control units interpret input signals as
well as which signals that the control units send.
DIAG Indicates that diagnostic tests are selected.

CAB Indicates which menu group is selected, these groups are:
CAN/POWER, description, page 8:11.
LIGHTS, description, page 8:25.
CAB, description, page 8:37.
CLIMATE, description, page 8:45.
HYD, description, page 8:51.
ENGINE, description, page 8:55.
TRANSM, description, page 8:62.
ELSERV, description, page 8:69.
ATTACH, description, page 8:76.
OLS, description, page 8:89.
EXTRA, description, page 8:89.
2 Number of current menu. Every menu group consists of several menus in a loop.
(X) Total number of menus in the group. The number of menus depends on the equipment fitted to the
machine. For this reason, number of menus is indicated with (X) in this manual.
Variable The signal that is measured. Different signals are designated in different ways:
SWITCH: a digital input signal, e.g. a switch.
OUTPUT: a digital output signal, e.g. feed to a motor.
INPUT: an analogue input signal, e.g. from a sensor.
REFERENCE: status for an analogue output signal.
REQUIRED: triggered output signal for a control current
FEEDBACK: either feedback signal from a motor or measured current on the minus side for an analogue
output signal.
Signal value Measurement value or status for the signal for variable. On the same row there are different types
that are interpreted in different ways.
SWITCH: 1 or 0 where 1 means closed circuit.
OUTPUT: two characters where the first number is 1 if the output signal is active. The second number is
status for the circuit, 1=circuit OK, 0=open circuit or short circuit.
INPUT: numerical value corresponding to the signal.
REFERENCE: two characters where the first number is 1 if the input signal is active. The second number
is status for the circuit, 1=circuit OK, 0=open circuit or short circuit.
REQUIRED: numerical value corresponding to the signal.
FEEDBACK: numerical value corresponding to the signal.
Menu heading Description of the function for which the menu reads signals.

8 Control system – CAN/POWER 8:11
8.4.1 CAN/POWER
CAN/POWER, description
This group handles redundant voltage feed to control units and CAN
DIAGNOSIS bus communication.
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE Confirm selections with function key for Enter.
TRANSM ELSERV ATTACH
005263
OLS EXTRA
8.4.1.1 CAN/POWER, menu 1
PRESENT REDCAN STATUS, COMMUNICATION

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

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

nodes depends on installed options.

8:12 8 Control system – CAN/POWER
PRESENT REDCAN STATUS, SEGMENT ERROR

Description: Indicates if there is open circuit on the redundant CAN
DIAG CAN/POWER 1(X) bus and if there is, where the first open circuit is. If there is open
PRESENT REDCAN STATUS circuit, it is indicated with a number that corresponds to the defective
COMMUNICATION MODE X segment on the redundant CAN bus.
NUMBERS OF UNITS X
005266
SEGMENT ERROR X Circuit diagram: Circuit CANBUS ground group 11.6_1
Contact: -
Signal value:
0 No open circuits.
>0 If X is separated from 0, the first segment is indicated
as missing contact. A 1 means that the first segment is
defective, that is, that contact between first and second
control unit is cut off.
To see which control units are installed on the
machine along with their order, use diagnostic menu
CAN/POWER, menu 2, see PRESENT REDCAN
STATUS, CONNECTED CITIES, page 8:12.
PRESENT REDCAN STATUS, CONNECTED CITIES

Description: Indicates which control units are in contact with the cab
DIAG CAN/POWER 2(X) control unit (D790-1) via the redundant CAN bus.
PRESENT REDCAN STATUS
CONNECTED CITIES Circuit diagram: Circuit CANBUS ground group 11.6_1, Attachment
D797-1 D797-2 XX DCF90-100/45E 11.6_1
005267
D795 D791-1 XX Contact:

D795: K1:10, K1:11, K1:12 and K1:13
D797-1, D791-1: K2:2, K2:3, K2:4 and K2:5
Function: 11.5.3.2 Frame control unit (D797-1), 11.5.3.5 Attachment

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

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

PRESENT OPTION KDU

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

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

Description: Indicates status for engine in the drive-train's CAN bus.
DIAG CAN/POWER 4(X)
PRESENT DRIVE-TRAIN Circuit diagram: Circuit CANBUS ground group 11.6_1, Circuit
CAN BUS STATUS Attachment DCF90-100/45E group 11.6_1, Circuit engine QSB6.7
ENGINE X group 1.0_2E1, Circuit Yuchai YC6A240-30 group 1.0_1A1
005269
TRANSMISSION X Contact:
Cummins QSB6.7 : CAN J1939 from D790-1/K13:1 and K13:2
to D794/46 and 37
Yuchai YC6A240-30: CAN J1939 from D790-1/K13:1 and K13:2
to D794/1:34 and 1:35
Function: 11.6.3 CAN bus drive-train
Signal value:

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

PRESENT DRIVE-TRAIN CAN BUS STATUS,

TRANSMISSION
Description: Indicates status for transmission in the drive-train's CAN
DIAG CAN/POWER 4(X) bus.
PRESENT DRIVE-TRAIN
CAN BUS STATUS Circuit diagram: Circuit CAN-BUS ground group 11.6_1, circuit
ENGINE X Transmission group 2.0_1, Circuit Yuchai YC6A240-30 group 1.0_1A2
005269
TRANSMISSION X Connection: CAN J1939 from D790-1/K13:1 and K13:2 to D793/22
and D793/23
Function: 11.6.3 CAN bus drive-train
Signal value:

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

0 No signal.

IGNITION, RELAY K315-1

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

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

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

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

0 No signal.

EMERGENCY STOP, RELAY K3009-1

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

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

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

0 No signal.
EMERGENCY STOP, RELAY K3009-2

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

K3007/86.
Signal value:

is missing.

790-1 CAB, POWER

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

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

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

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

790-1 CAB, 24V SENSOR SUPPLY

Description: 24 V voltage feed to components in cab.
DIAG CAN/POWER 8(X)
790-1 CAB Circuit diagram:
24V SENSOR SUPPLY XY 1. Circuit wiper group 9.5_1
24V SUPPLY,RPM>500 XY 2. Circuit drivetrain transmission group 2.0_1, Circuit extra
005275
equipment group 9.1_1, Circuit seat heating group 9.3_1, Circuit
working lights 20-40 group 9.6_1, Circuit working lights truck
9.6_2, Circuit working lights mast 9.6_3, Circuit lighting group
9.6_4 and Circuit wiper group 9.5_1
3. -
4. -
5. Circuit twistlock group 7.9_1, circuit 20-40, 30-35 stop group
7.5_1, circuit over height group 7.9_4, circuit horn servo panel
group 9.7_4, circuit power control breaker group 11.5_6, circuit
brake system group 4.0_1, circuit 20-40 opt. group 7.5_3, circuit
bypass group 8.2_1 and circuit extra equipment group 9.1_1
6. -
7. -
8. Circuit alarm, audible signals group 9.7_1
9. Circuit wiper group 9.5_1
10. Circuit wiper group 9.5_1
Contact:
1. signal from digital out D790-1/K4:14 to M650-1/53a
2. signal from digital out D790-1/K5:1 to S105-1/5, S105-2/5,
S105-3/5, S143/5, S100/5, S110/5, S199-1/5, S199-3/5, S199-4/5
and S220-1/1
3. signal from digital out D790-1/K6:13 not connected
5. signal from digital out D790-1/K8:16 to S1002/2, S1003/4,
S1003/3, S1004/5, S149-3/2, S250/1, S107/5, S1012/3,
S1012-2/5, S1031/3, S1005/5, and S199-2/5
8. signal from digital out D790-1/K11:12 to S230/2
Function:
1. 9.5.5 Wiper motor front
2. 2.0 Transmission, 9.3 Seat, 9.6 Lighting
3. -
4. -
5. 11.5.1.4 Emergency stop switch voltage; 4.5 Parking brake
system; 8.2.2 Bypassing; 9.10.4 Tiltable cab/Hydraulic sliding cab;
7.5 Spreading; 7.8 Levelling; 7.9.1 Twistlocks
6. -
7. -
8. 9.3.14 Sensor operator in seat
9. 9.5.7 Wiper motor rear
10. 9.5.6 Wiper motor roof

Signal value:

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

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

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

is missing.
795 DISPLAY, RED. POWER

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

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

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


797-1 FRAME, RED. POWER

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

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

Description: Battery voltage (30) to Control unit, transmission (D793).
793 TRANSMISSION Circuit diagram: Circuit power group 11.5_1, circuit drivetrain gearbox
POWER XX.XXV group 2.0_1, circuit Yuchai YC6A240-30 group 1.0_1A2
IGNITION POWER XX.XXV Connection: 30-voltage from F54/2 via F58-1/5 to D793/45
005279
SENSOR SUPPLY XX.XXV

Function: 11.5.1.1 Battery voltage (30)


793 TRANSMISSION, IGNITION POWER

Description: Ignition voltage (15) to Control unit, transmission (D793).
793 TRANSMISSION Circuit diagram: Circuit Yuchai YC6A240-30 group 1.0_1A2, Circuit
POWER XX.XXV drivetrain gearbox group 2.0_1, Circuit power group 11.5_1
IGNITION POWER XX.XXV Connection: 15 voltage from K315/87 via F54/4 and F58-2/6 to
005279
SENSOR SUPPLY XX.XXV D793/20, D793/60 and D793/21

793 TRANSMISSION, SENSOR SUPPLY

This menu row is not used.
793 TRANSMISSION
POWER XX.XXV
IGNITION POWER XX.XXV
005279
SENSOR SUPPLY XX.XXV
NOT USED
XXXXXXX X(X)
NOT USED
008793
NOT USED
XXXXXXX X(X)
NOT USED
008793
791-1 ATTACHMENT, EME POWER

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

791-1 ATTACHMENT, RED. POWER

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

Description: Emergency stop switch voltage (15E) to attachment
DIAG CAN/POWER 15(X) control unit (D791-1).
791-1 ATTACHMENT(OPT)
EME POWER XX.XXV Circuit diagram: Circuit 11.5_5
RED.POWER LE X RI X Connection: 15E voltage from K3009-1/87 via K3009-2/87, F58-3/1 to
005282
EME POWER 2 X D791-1/K2:11
Signal value:
1 Feed active.
0 No feed.
791-1 ATTACHMENT (OPT), 24V SENSOR SUPPLY

Description: Voltage feed to sensors connected to the attachment
DIAG CAN/POWER 16(X) control unit (D791-1).
791-1 ATTACHMENT (OPT)
24V SENSOR SUPPLY XY Circuit diagram: Circuit diagram: Attachment DCF90/100-45E group
5V REF X.XXV 7.5_3, 7.9_2, 11.5_2
005283
Connection: digital out from 791-1/K1:10 to B769L, B769R, B777L,

B777R, B7203L, B7203R, B7204L, B7204R, B7205LL and B7205LR
Function: 7.5.6 Spreading position sensor, 7.9.1.7 Alignment position

sensor, 7.9.1.8 Twistlocks sensor
Signal value:

is missing.

791-1 ATTACHMENT (OPT), 5V REF

791-1 ATTACHMENT (OPT)
24V SENSOR SUPPLY XY
5V REF X.XXV
005283
REDCAN STATUS CHECK

Description: Control function from the redundant CAN bus. Cab
DIAG CAN/POWER 17(X) control unit (D790-1) performs a segment check to verify that all
REDCAN STATUS CHECK control units are in contact and are connected in the correct order.
PRESS ENTER The control system indicates the fault by numbering the cables
between the control units (segments) from 1 onwards. Segment 1 is
005284
SEGMENT ERROR X always between cab control unit (D790 -1) and the next Control unit.
The last segment is always between Control unit KID (D795) and
Control unit, cab (D790-1). The segments in between vary depending
on machine configuration.
Circuit diagram: Circuit CANBUS ground group 11.6_1, Circuit
D790-1 D791 D797-1 diagram attachment DCF90/100-45E group 11.6_1
CAN L CAN R CAN L CAN R CAN L CAN R
1 2 Contact: -
4 3 Function: 11.6.2 Redundant CAN bus
CAN R CAN L
D795 Signal value:

015052
0 No errors.
Segment numbering with maximum number of control
units. >0 X > 0, the number indicates defective segment. Use the
circuit diagram to find the defective segment.

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

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

0 No signal.
PRESENT OUTPUT SIGNAL, SIDE LIGHTS

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

SIDE LIGHTS XY and H417-2
005287
REAR LIGHTS XY
Function: 9.6.2 Running lights
Signal value:

is missing.

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

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

SIDE LIGHTS XY
005287
REAR LIGHTS XY Function: 9.6.3 Tail lights
Signal value:

is missing.
HEAD LIGHTS, SWITCH

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

0 No signal.
HEADLIGHTS, HEAD LE/RI

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

is missing.

HEADLIGHTS, DIMMED LE/RI

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

is missing.
PRESENT INPUT SIGNAL, HAZARD SWITCH

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

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

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

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

0 No signal.

PRESENT OUTPUT SIGNAL HAZARD/FLASHER, LEFT

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

is missing.
PRESENT OUTPUT SIGNAL HAZARD/FLASHER,

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

is missing.

ROTATION BEACON, SWITCH

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

0 No signal.
ROTATION BEACON, OUTPUT

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

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

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

0 No signal.

PRESENT INPUT SIGNAL, REVERSE LGT SIGNAL

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

0 No signal.
PRESENT OUTPUT SIGNAL, BRAKE LGT

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

• RI: digital out from D797-1/K1:9 to H411R
Function: 9.6.4 Brake lights
Signal value:

is missing.

PRESENT OUTPUT SIGNAL, REV. LGT

Description: Voltage feed to back-up lights.
DIAG LIGHTS 8(X)
BRAKE LGT LE XY RI XY Contact:
005293
REVERSE ALARM XY • LE: digital out from D790-1/K2:6 to E405L
• RI: digital out from D790-1/K2:7 to E405R
Function: 9.6.5 Back-up lights
Signal value:

is missing.
PRESENT OUTPUT SIGNAL, REVERSE ALARM

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

is missing.
CAB LIGHT, MANUAL SWITCH

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

0 No signal.

CAB LIGHT, DOOR SWITCH

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

0 No signal.
CAB LIGHT, OUTPUT

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

corresponds to battery voltage).

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

0 No signal.
WORKING LIGHT MAST, OUTPUT

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

is missing.

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

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

is missing.
WORKING LIGHT EXTRA OUTPUT, D797-2 C1 P42

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

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

0 No signal.

WORKING LIGHT CAB, OUTPUT

Description: Control of relays for power supply to working lights cab
DIAG LIGHTS 12(X) roof.
WORKING LIGHT CAB
SWITCH X Circuit diagram: Circuit working lights 20-40 group 9.6_1
Contact:
005297
OUTPUT 20' XY 40' XY
• 20': digital out from D790-1/K7:8 to K3017-2. K3017-2 voltage
feeds E406L-2 and E406R-2
• 40': digital out from D790-1/K10:8 to K3017-1. K3017-1 voltage
feeds E406L-1 and E406R-1
Function: 9.6.10 Work light cab
Signal value:

is missing.
WORKING LIGHT ATTACH, SWITCH

Description: Signal from switch, working lights attachment
DIAG LIGHTS 13(X)
WORKING LIGHT ATTACH Circuit diagram: Circuit working lights truck group 9.6_2
OUTPUT LE XY RI XY
008895
Signal value:

0 No signal.

WORKING LIGHT ATTACH, OUTPUT

Description: Voltage feed to working light, attachment.
DIAG LIGHTS 13(X)
WORKING LIGHT ATTACH Circuit diagram: Attachment DCF 90/100/100-45E group 9.6_1
SWITCH X Contact:
OUTPUT LE XY RI XY
008895
• LE: digital out from D791-1/K1:1 to E404UL (and E404L )
• RI: digital out from D791-1/K1:15 to E404UR (and E404R )
Function: 9.6.12 Work light attachment
Signal value:

is missing.

SWITCH LIGHTS, OUTPUT

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

8 Control system – CAB 8:37
8.4.3 CAB
CAB, description
This group covers functions in the cab.
DIAGNOSIS
CLIMATE HYD ENGINE
005301
OLS EXTRA
8.4.3.1 CAB, menu 1
WASHER, SWITCH
Description: Signal from gear and multi-function lever switch washer.
DIAG CAB 1(X)
WASHER Circuit diagram: Circuit wiper group 9.5_1
SWITCH X Connection: signal from S162/53C to digital in D790-2/K3:4
OUTPUT FRONT XY
005541
OUTPUT REAR ROOF XY Function: 9.5 Wiper/washer system
Signal value:

0 No signal.
WASHER, OUTPUT FRONT

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


8:38 8 Control system – CAB
WASHER, OUTPUT REAR ROOF

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


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

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

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

FRONT WIPER, OUTPUT

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

FRONT WIPER, FEEDBACK

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

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

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

0 No signal.

REAR WIPER, OUTPUT

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

REAR WIPER, FEEDBACK

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

8.4.3.4 CAB, menu 4
ROOF WIPER, SWITCH

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

0 No signal.

ROOF WIPER, OUTPUT

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

is missing.
ROOF WIPER, FEEDBACK

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

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

0 No signal.

HORN, SWITCH 2
DIAG CAB 5(X)

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

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

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

8.4.3.6 CAB, menu 6
BUZZER
Description: Voltage feed to buzzer for alarm indication panel, feed.
DIAG CAB 6(X)
BUZZER XY Circuit diagram: Circuit alarm, audible signals group 9.7_1
SWITCH SEAT X Connection: digital out from D790-2/K8:4 to H853/1
ALARM X
005546
OP X Function: 9.3 Seats, 1 Engine, 8.2.1 Overload protection
Signal value:

is missing.

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

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

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

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

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

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

SEAT HEATER Description: Signal from switch, seat heating.
SWITCH X
OUTPUT XY Circuit diagram: Circuit seat heating group 9.3_1
005548
Connection: signal from S143/1 to digital in D790-1/K6:6
Function: 9.3 Seat
Signal value:

0 No signal.
SEAT HEATER, OUTPUT

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

is missing.

8 Control system – CLIMATE 8:45
8.4.4 CLIMATE
CLIMATE, description
This group covers the cab's air conditioning.
DIAGNOSIS
CLIMATE HYD ENGINE
005302
OLS EXTRA
8.4.4.1 CLIMATE, menu 1
PRESENT INPUT SIGNAL, REQUIRED TEMP

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

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

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

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

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

= Closed. 100 = Fully open.
TEMP COIL
Description: Temperature of the air out from the fan. The sensor is
DIAG CLIMATE 2(X) fitted in the air distributor.
TEMP COIL XXX
TEMP COOLANT XXX Circuit diagram: Circuit climate system group 9.4_1
TEMP AMBIENT XXX Connection: signal from B775-2 to input D790-1/K4:10
005550
TEMP DE-ICE XXX

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

8:46 8 Control system – CLIMATE
TEMP COOLANT
Description: Coolant temperature, temperature of the engine's
DIAG CLIMATE 2(X) coolant. Signal is retrieved from the engine via CAN bus drive-train.
TEMP COIL XXX
TEMP COOLANT XXX Circuit diagram: Circuit climate system group 9.4_1 and 9.4_2
TEMP AMBIENT XXX Connection: from engine via CAN bus, see PRESENT INPUT
005550
TEMP DE-ICE XXX SIGNAL, COOLANT TEMP, page 8:59.
Function: 1.7 Cooling system
Signal value: XXX = Engine temperature in tenths of degrees (200 =

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

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

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

Description: Signal from refrigerant pressure switch.
DIAG CLIMATE 3(X)
PRESSURE SWITCH X Connection: signal from S246/2 to digital in D797-1/K1:40
005551
Function: 9.4.10 Pressure switch
Signal value:
1 Input signal active. Press OK.

0 No signal, too high or too low pressure.


PRESENT INPUT SIGNAL, WATER VALVE
Description: Signal from water valve, the voltage is a measure of
DIAG CLIMATE 4(X) the position.
WATER VALVE XX.XXV Circuit diagram: Circuit climate system group 9.4_2
DRAUGHT VALVE XX.XXV Connection: signal from Y673/9 to analogue in D790-1/K10:4
005552
Function: 9.4.5 Water valve
Signal value: XX.XXV = 0.50 - 4.50 V
PRESENT INPUT SIGNAL, DRAUGHT VALVE

Description: Signal from the engine to the air distributor. The voltage
DIAG CLIMATE 4(X) is a measure of the damper's position.
WATER VALVE XX.XXV Circuit diagram: Circuit climate system group 9.4_2
DRAUGHT VALVE XX.XXV Connection: signal from Y672/9 to analogue in D790-1/K4:7
005552
Function: 9.4.14 Air distributor
Signal value: XX.XXV = 0.50 - 4.50 V

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

Description: Signal from switch, air distribution, voltage when switch
DIAG CLIMATE 5(X) is pressed in. The voltage level indicates change of air control against
PRESENT INPUT SIGNAL windscreen (up) or floor (down). The damper's position changes in
REQUIRED TEMP XX.XXV steps between windscreen - floor.
REQ. DRAUGHT XX.XXV
005553
REQ. FAN SPEED XX.XXV Circuit diagram: Circuit climate system group 9.4_1
Connection: signal from S139/3 to analogue in D790-1/K5:9
Signal value: XX.XXV ~ 2.4 / 0 / 5.0 V = Up / - / down.
PRESENT INPUT SIGNAL, REQ. FAN SPEED

Description: Signal from switch, fan speed, switch controls increase
DIAG CLIMATE 5(X) or decrease of fan speed. Speed is adjustable steplessly. The voltage
PRESENT INPUT SIGNAL level indicates if the speed should be increased or decreased.
REQ. DRAUGHT XX.XXV Circuit diagram: Circuit climate system group 9.4_1
005553
REQ. FAN SPEED XX.XXV Connection: signal from S118/3 to analogue in D790-1/K5:7
Signal value: XX.XXV ~ 2.4 / 0 / 5.0 V = Increase / - / decrease.

PRESENT OUTPUT SIGNAL, FAN SPEED

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

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

PRESENT OUTPUT SIGNAL, COMPRESSOR

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

is missing.

OUTPUT WATER VALVE, CLOCKWISE

Description: Voltage feed to water valve, for opening. The valve is
DIAG CLIMATE 7(X) connected to an H-bridge. The signal can only be diagnosed when
OUTPUT WATER VALVE the valve's position changes. The valve's opening and closing is
CLOCKWISE XY XY controlled by the air conditioning's software depending on desired
ANTI-CLOCKWISE XY XY temperature, outside temp. cab temperature and coolant temperature,
so it may be difficult to determine whether the valve is working as it
should.
24V Circuit diagram: Circuit climate system group 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
M Signal value: motor runs clockwise row 1: 11 11 row 2: 00 11

005555
0V
H-bridge 10 Output signal active, short circuit.
is missing.
OUTPUT WATER VALVE, ANTI-CLOCKWISE

Description: Voltage feed to water valve, for closing. The valve is
DIAG CLIMATE 7(X) connected to an H-bridge. The signal can only be diagnosed when
OUTPUT WATER VALVE the valve's position changes. The valve's opening and closing is
CLOCKWISE XY XY controlled by the air conditioning's software depending on desired
ANTI-CLOCKWISE XY XY temperature, outside temp. cab temperature and coolant temperature,
so it may be difficult to determine whether the valve is working as it
should.
24V Circuit diagram: Circuit climate system group 9.4_2

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

005555
0V
H-bridge 10 Output signal active, short circuit.
is missing.

OUTPUT DRAUGHT VALVE, CLOCKWISE

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

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

M
005556
0V Output signal active, circuit OK. It can also be an open

H-bridge
is missing.
OUTPUT DRAUGHT VALVE, ANTI-CLOCKWISE

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

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

M
005556
0V Output signal active, circuit OK. It can also be an open

H-bridge
is missing.

8 Control system – HYD 8:51
8.4.5 HYD
HYD, description
This group covers the hydraulic functions.
DIAGNOSIS
CLIMATE HYD ENGINE
005303
OLS EXTRA
8.4.5.1 HYD, menu 1

HYDRAULIC OIL, TEMP
Description: Signal from sensor hydraulic oil temperature.
DIAG HYDRAULIC 1(X)
HYDRAULIC OIL Circuit diagram: Circuit cooling hydraulic oil group 10.6_1
TEMP XXX Connection: signal from B776/1 to temperature in D797-1/K2:13
FAN XY
010070
SET OUTPUT + - X Function: 10.6.4 Sensor hydraulic oil temperature
Signal value: XXX = Temperature in tenths of degrees (200 = 20 ºC).
HYDRAULIC OIL, FAN

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

HYDRAULIC OIL, SET OUTPUT +/-

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

NOT USED
XXXXXXX X(X)
NOT USED
008793

8:52 8 Control system – HYD
8.4.5.3 HYD, menu 3
NOT USED
XXXXXXX X(X)
NOT USED
008793
8.4.5.4 HYD, menu 4
PRESSURE SWITCHES, BRAKE PRESSURE

Description: Signal from break contact (opening switch) brake
DIAG HYDRAULIC 4(X) pressure.
PRESSURE SWITCHES
BRAKE PRESSURE X Circuit diagram: Circuit brake system group 4.0_1
BRAKE LIGHT PRESS. X Connection: signal from S204/2 to analogue in D797-1/K1:13
007240
DECLUTCH PRESSURE X
Function: 4.3.7 Normally open (NO) switch, brake pressure
Signal value:

0 No signal.
PRESSURE SWITCHES, BRAKE LIGHT PRESSURE

Description: Signal from make-contact (closing switch) brake lights.
DIAG HYDRAULIC 4(X)
PRESSURE SWITCHES Circuit diagram: Circuit lighting group 9.6_5
BRAKE PRESSURE X Connection: signal from S216/2 to digital in D797-1/K1:20
007240
DECLUTCH PRESSURE X Function: 4.3.8 Make-contact (closing switch) brake lights
Signal value:

0 No signal.
PRESSURE SWITCHES, DECLUTCH PRESSURE

Description: Signal from break contact (opening switch) declutch.
DIAG HYDRAULIC 4(X)
PRESSURE SWITCHES Circuit diagram: Circuit drivetrain gearbox group 2.0_1
BRAKE PRESSURE X Connection: signal from S220-2/2 to analogue in D797-1/K1:27
007240
DECLUTCH PRESSURE X Function: 2.8.2 Normally closed (NC) switch, disengagement
Signal value:

0 No signal.

8 Control system – HYD 8:53
8.4.5.5 HYD, menu 5
P-BRAKE, SWITCH
Description: Signals from switch parking brake. Two signals, one
DIAG HYDRAULIC 5(X) for released parking brake and one for applied parking brake. Both
P-BRAKE signals must be valid to enable release of parking brake.
SWITCH X/Y
FEEDBACK SWITCH X Circuit diagram: Circuit brake system group 4.0_1
007241
VALVE XY Connection: signal from S107/1 to digital in D790-1/K8:13 and from
S107/7 to digital in D790-1/K8:5
Function: 4.5 Parking brake system
Signal value:
1/0 Open, parking brake released.

0/1 On, parking brake applied.
P-BRAKE, FEEDBACK SWITCH

Description: Signal from break contact (opening switch) parking
DIAG HYDRAULIC 5(X) brake.
P-BRAKE
SWITCH X/Y Circuit diagram: Circuit brake system group 4.0_1
FEEDBACK SWITCH X Connection: signal from S200/2 to analogue in D797-1/K1:41
007241
VALVE XY
Function: 4.5.5 Normally open (NO) switch, parking brake
Signal value:

0 No signal.
P-BRAKE, VALVE
Description: Voltage feed to Solenoid valve parking brake.
DIAG HYDRAULIC 5(X)
P-BRAKE Circuit diagram: Circuit brake system group 4.0_1
SWITCH X/Y Connection: digital out from D797-1/K1:34 to solenoid valve Y642/1
FEEDBACK SWITCH X
007241
VALVE XY Function: 4.5.3 Solenoid valve parking brake
Signal value:

is missing.

8:54 8 Control system – HYD
8.4.5.6 HYD, menu 6
NOT USED
XXXXXXX X(X)
NOT USED
008793
8.4.5.7 HYD, menu 7
NOT USED
XXXXXXX X(X)
NOT USED
008793
8.4.5.8 HYD, menu 8
PRESENT OUTPUT SIGNAL, PRESSURE TO

ATTACHM. VALVE
Description: Voltage feed to solenoid valve for main pump relief
DIAG HYDRAULIC 8(X) (pressurised attachment).
PRESSURE TO ATTACHM. Circuit diagram: circuit disengage. hydr pump group 10.4_1
VALVE XY Connection: digital out from circuit disengage hydraulic pump group
010074
SET OUTPUT + - X D797-1/K1:35 to solenoid valve Y6062-2
Function: 10.4.2 Axial piston pump with variable displacement
Signal value:
1 Output signal active.

0 No output signal.
PRESENT OUTPUT SIGNAL, PRESSURE TO

ATTACHM, SET OUTPUT +/-
Description: Begin sending or cut off hydraulic pressure to the
DIAG HYDRAULIC 8(X) attachment.
PRESSURE TO ATTACHM. Circuit diagram: circuit disengage. hydr pump group 10.4_1
VALVE XY Connection: digital out from D797-1/K1:35 to solenoid valve Y6062-2
010074
SET OUTPUT + - X is activated or deactivated with +/-
Function: 10.4.2 Axial piston pump with variable displacement
Signal value:

0 No output signal.

8 Control system – ENGINE 8:55
8.4.6 ENGINE
ENGINE, description
This group covers the engine functions.
DIAGNOSIS
CLIMATE HYD ENGINE
005306
OLS EXTRA
8.4.6.1 ENGINE, menu 1
PRESENT INPUT SIGNAL, ACCELERATOR

Description: Signal from accelerator pedal.
DIAG ENGINE 1(X)
PRESENT INPUT SIGNAL Circuit diagram: Circuit drivetrain engine group 1.0_1
ACCELERATOR X.XXV Connection: signal from B690-1/2 to analogue in D790-1/K6:11
REQUIRED SPD PROC XXX
006866
REQUIRED SPD RPM XXXX Function: 1 Engine
Signal value: X.XXV = 0.50-4.50 V
PRESENT INPUT SIGNAL, REQUIRED SPD PROC

Description: Required engine speed (in percent) which is sent from
DIAG ENGINE 1(X) Control unit, cab (D790-1) to Control unit, engine (D794) via CAN
PRESENT INPUT SIGNAL bus drive-train.
ACCELERATOR X.XXV
REQUIRED SPD PROC XXX Circuit diagram: -
006866
REQUIRED SPD RPM XXXX Contact: -
Function: 1.9 Control system, engine
Signal value: XXXX = 0-100%
PRESENT INPUT SIGNAL, REQUIRED SPD RPM

Description: Required engine speed (in percent) which is sent from
DIAG ENGINE 1(X) Control unit, cab (D790-1) to Control unit, engine (D794) via CAN
PRESENT INPUT SIGNAL bus drive-train.
ACCELERATOR X.XXV
REQUIRED SPD PROC XXX Circuit diagram: -
006866
REQUIRED SPD RPM XXXX Contact: -
Signal value: XXXX = 0-2010 rpm
PRESENT INPUT SIGNAL, ENGINE SPEED EDC

Description: Engine speed from Control unit, engine (D794) to Control
DIAG ENGINE 2(X) unit, cab (D790-1) via CAN bus drive-train. Actual value for engine
PRESENT INPUT SIGNAL speed.
ENGINE SPEED EDC XXXX
ENGINE SPEED TCU XXXX Circuit diagram: -
005308
Contact: -
Function: 1.9.2 Sensor engine rpm
Signal value: XXXX = Active speed in rpm.

8:56 8 Control system – ENGINE
PRESENT INPUT SIGNAL, ENGINE SPEED TCU
DIAG ENGINE 2(X)

PRESENT INPUT SIGNAL Description: Engine speed from Transmission control unit (D793)
ENGINE SPEED EDC XXXX to Cab control unit (D790-1) via CAN bus drivetrain. Actual value
ENGINE SPEED TCU XXXX for engine speed. Only used on machines with engine alternative
005308
Cummins QSB6.7.
Circuit diagram: -
Contact: -
Function: 2.2.5 Sensor engine speed and oil temperature transmission
Signal value: XXXX = active speed in rpm.
PRESENT INPUT SIGNAL, PRESENT TORQUE

Description: Actual torque from Control unit, engine (D794).
DIAG ENGINE 3(X) Percentage torque use of engine's capacity.
PRESENT TORQUE XXX Circuit diagram: -
REQUIRED TORQUE XXX Contact: -
005309
PRES TORQUE @ RPM XXX

Signal value: XXX = 0-100%
PRESENT INPUT SIGNAL, REQUIRED TORQUE
DIAG ENGINE 3(X)

PRESENT INPUT SIGNAL Description: Requested torque from cab control unit (D790-1) to
PRESENT TORQUE XXX engine control unit (D794). Only used on machines with engine
REQUIRED TORQUE XXX alternative Cummins QSB6.7.
005309
PRES TORQUE @ RPM XXX

Circuit diagram: -
Contact: -
PRESENT INPUT SIGNAL, PRES TORQUE @ PPM
DIAG ENGINE 3(X)

PRESENT INPUT SIGNAL Description: Available torque at current engine speed. Only used on
PRESENT TORQUE XXX machines with engine alternative Cummins QSB6.7.
REQUIRED TORQUE XXX
005309
PRES TORQUE @ RPM XXX Circuit diagram: -
Contact: -

PRESENT INPUT SIGNAL, PREHEAT SWITCH

DIAG ENGINE 4(X)
PREHEAT SWITCH X
CRANK ENGINE SWITCH X
009282
D+ X
PRESENT INPUT SIGNAL, CRANK ENGINE SWITCH

Description: Signal from ignition key lock, start position.
DIAG ENGINE 4(X)
PRESENT INPUT SIGNAL Circuit diagram: Circuit power group 11.5_3, Circuit drivetrain engine
PREHEAT SWITCH X group 1.0_1
CRANK ENGINE SWITCH X Connection: signal from S150/50 to digital in D790-2/K2:1
009282
D+ X
Function: 1 Engine, 1.11 Start and stop
Signal value:

0 No signal.
PRESENT INPUT SIGNAL, D+

Description: Signal from alternator, indicates if alternator supplies
DIAG ENGINE 4(X) current.
PREHEAT SWITCH X Circuit diagram: Circuit Yuchai YC6A240-30 group 1.0_1A1, circuit
CRANK ENGINE SWITCH X engine QSB6.7 group 1.0_2E1 and circuit drivetrain engine group
009282
D+ X 1.0_1
Connection: from G660/D+ to digital in D797-1/K2:16
Function: 11.4.1 Alternator
Signal value:

0 No signal.
PRESENT OUTPUT SIGNAL, PREHEAT

Description: Status for preheating of induction air. Only used on
machines with engine alternative Yuchai YC6M360-30.
DIAG ENGINE 5(X) Circuit diagram: -
PREHEAT X Connection: controlled by engine's control system
CRANK ENGINE X
015098
CRANK ENGINE WIRE XY Function: 1.10.1 Preheating
Signal value:

0 No output signal.

PRESENT OUTPUT SIGNAL, CRANK ENGINE

Description: Status for start signal to Engine control unit (D794) via
the CAN-bus.
DIAG ENGINE 5(X) Circuit diagram: -
PREHEAT X Connection: controlled by engine's control system
CRANK ENGINE X
015098
CRANK ENGINE WIRE XY Function: 1.11 Start and stop
Signal value:

0 No output signal.
PRESENT OUTPUT SIGNAL, CRANK ENGINE WIRE

Description: Status for voltage feed to the Starter relay (K360).
Circuit diagram: Circuit drivetrain engine group 1.0_1, Circuit Yuchai

DIAG ENGINE 5(X) YC6A240-30 group 1.0_1A1 and Circuit engine QSB6.7 group
PRESENT OUTPUT SIGNAL 1.0_2E1
PREHEAT X
CRANK ENGINE X Connection: digital out D797-1/K1:32 to K360/86
015098
CRANK ENGINE WIRE XY

Function: 1.11 Start and stop
Signal value:

PRESENT INPUT SIGNAL, OIL PRESSURE

Description: Engine oil pressure. CAN bus message from Control
DIAG ENGINE 6(10) unit, engine (D794) to Control unit, cab (D790-1).
OIL PRESSURE XXX Circuit diagram: see supplier documentation, engine
BOOST PRESSURE XXX Contact: -
000153
Function: 1.8 Lubrication system
Signal value: XXX = 10 corresponds to 100 kPa.
PRESENT INPUT SIGNAL, BOOST PRESSURE

Description: Boost pressure. CAN bus message from Control unit,
DIAG ENGINE 6(10) engine (D794) to Control unit, cab (D790-1).
OIL PRESSURE XXX Circuit diagram: see supplier documentation, engine
BOOST PRESSURE XXX Contact: -
000153
Function: 1.6 Air intake and exhaust outlet
Signal value: XXX = 10 corresponds to 100 kPa.

PRESENT INPUT SIGNAL, OIL TEMP

Description: Engine oil temperature. CAN bus message from Control
DIAG ENGINE 7(X) unit, engine (D794) to Control unit, cab (D790-1).
OIL TEMP XXX Circuit diagram: see supplier documentation, engine.
COOLANT TEMP XXX Contact:
009284
INTAKE MAIN.TEMP XXX
Cummins QSB6.7 : signal from "Oil pressure/temperature
sensor" sleeve 4 to Control unit, engine (D794) "Sensor
connector" sleeve 42
Yuchai YC6A240-30: -
Function: 1 Engine
Signal value: XXX = 200 corresponds to 20 ºC.
PRESENT INPUT SIGNAL, COOLANT TEMP

Description: Coolant temperature. CAN bus message from Control
OIL TEMP XXX Circuit diagram: see supplier documentation, engine
COOLANT TEMP XXX Contact: -
009284

PRESENT INPUT SIGNAL, INTAKE MAIN.TEMP

Description: Charge air temperature. CAN bus message from Control
OIL TEMP XXX Circuit diagram: see supplier documentation, engine
COOLANT TEMP XXX Contact: -
009284

PRESENT EDC ERROR, NO. OF ACT ERROR

Description: Number of active error codes from Control unit, engine
DIAG ENGINE 8(X) (D794).
PRESENT EDC ERROR
NR OF ACT ERROR XX Circuit diagram: -
SPN XXXX Contact: -
009279
FMI XX
Function: 1.9 Control system
Signal value: XX = number of active error codes.

PRESENT EDC ERROR, SPN

Description: SPN number for the first error code from Control unit,
DIAG ENGINE 8(X) engine (D794). SPN indicates the malfunction area, i.e. what
PRESENT EDC ERROR component or signal is defective. Error codes are shown with
NR OF ACT ERROR XX SPN/FMI in the error code menus.
SPN XXXX
009279
FMI XX Circuit diagram: -
Contact: -
Function: 8.3 Error codes
Signal value: XXXX = error code number. Use the error code list;
see section D Error codes.
PRESENT EDC ERROR, FMI

Description: FMI number for the first error code from the Control unit,
DIAG ENGINE 8(X) engine (D794). FMI indicates error type, e.g. short circuit or low
PRESENT EDC ERROR value. Error codes are shown with SPN/FMI in the error code menus.
NR OF ACT ERROR XX
SPN XXXX Circuit diagram: -
009279
FMI XX Contact: -
Function: 8.3 Error codes
Signal value: XX = fault type number. Use the error code list; see
section D Error codes.
FUEL CONSUMPTION, MOMENTARILY l/h

Description: Current fuel consumption in litres/hour.
DIAG ENGINE 9(X)
FUEL CONSUMTION Circuit diagram: -
MOMENTARILY l/h XXX Contact: -
009280
Function: 1.2 Fuel system
Signal value: XXX = fuel consumption in l/h.
PRESENT INPUT SIGNAL, PRE-HEAT FEEDBACK

Description: Signal from Control unit, engine (D794) which indicates
DIAG ENGINE 10(X) that preheating is active. Only used on machines with engine
PRESENT INPUT SIGNAL alternative Yuchai YC6A240-30.
PRE-HEAT FEEDBACK X Circuit diagram: Circuit Yuchai YC6A240-30 group 1.0_1A1, circuit
WATER IN FUEL SW. X mast sensor OLS group 8.2_3
013919
COOLANT LEVEL SW. X

Connection: signal from D794/1:38 to D797-1/K1:36
Signal value:
1 No signal
0 Input signal active. (Indication that preheating is activated by
Control unit, engine (D794) is active.)

PRESENT INPUT SIGNAL, WATER IN FUEL SW.

Description: Signal from Control unit, engine (D794) which indicates
DIAG ENGINE 10(X) that there is too much water in the fuel filter. Only used on machines
PRESENT INPUT SIGNAL with engine alternative Yuchai YC6A240-30.
PRE-HEAT FEEDBACK X Circuit diagram: Circuit Yuchai YC6A240-30 group 1.0_1A1, circuit
WATER IN FUEL SW. X mast sensor OLS group 8.2_3
013919
COOLANT LEVEL SW. X
Connection: signal from D794/1:39 to D797-1/K1:37
Function: 1.2 Fuel system
Signal value:
1 No signal
0 Input signal active. (Indication that there is too much water
in the fuel filter.)
PRESENT INPUT SIGNAL, COOLANT LEVEL SW.

Description: The signal from the make-contact (closing switch)
DIAG ENGINE 10(X) coolant level (B759), which indicates that the coolant level is low.
PRESENT INPUT SIGNAL Only used on machines with engine alternative Yuchai YC6A240-30.
PRE-HEAT FEEDBACK X Circuit diagram: Circuit Yuchai YC6A240-30 group 1.0_1A1
WATER IN FUEL SW. X
013919
COOLANT LEVEL SW. X Connection: signal from B759/2 to digital in D797-1/K1:12
Signal value:
1 No signal
0 Input signal active. Coolant level is low.

8:62 8 Control system – TRANSM
8.4.7 TRANSM
TRANSM, description
This group covers transmission functions.
DIAGNOSIS
CLIMATE HYD ENGINE
005324
OLS EXTRA
8.4.7.1 TRANSM, menu 1
PRESENT INPUT SIGNAL, BRAKE PEDAL

DIAG TRANSM. 1(X)
BRAKE PEDAL X.XXV
DECLUTCH SWITCH X
005325
DECLUTCH PRESS SW. X
PRESENT INPUT SIGNAL, DECLUTCH SWITCH

Description: Signal from declutch pedal.
DIAG TRANSM. 1(X)
PRESENT INPUT SIGNAL Circuit diagram: Circuit drivetrain gearbox group 2.0_1
BRAKE PEDAL X.XXV Connection: signal from S220-1/2 to digital in D790-1/K6:14
DECLUTCH SWITCH X
005325
DECLUTCH PRESS SW. X Function: 2 Transmission
Signal value:
1 Input signal active. Declutch pedal depressed.

0 No signal.
PRESENT INPUT SIGNAL, DECLUTCH PRESS SW.

Description: Signal from break contact (opening switch) declutch
DIAG TRANSM. 1(X) (pressure switch).
BRAKE PEDAL X.XXV Circuit diagram: Circuit drivetrain gearbox group 2.0_1
DECLUTCH SWITCH X Connection: signal from S220-2/2 to digital in D797-1/K1:27
005325
DECLUTCH PRESS SW. X

Function: 2.8.2 Normally closed (NC) switch, disengagement
Signal value:

0 No signal.

8 Control system – TRANSM 8:63

SWITCHES, FORWARD
Description: Signal from gear and multi-function lever (forward).
DIAG TRANSM. 2(X)
SWITCHES Circuit diagram: Circuit drivetrain gearbox group 2.0_1
FORWARD X Connection: signal from S162/F to digital in D790-2/K3:11
REVERSE X
005326
SHIFT MODE X Function: 2 Transmission
Signal value:
1 Input signal active. Travel direction forward selected.

0 No signal.
SWITCHES, REVERSE
Description: Signal from gear and multi-function lever (reverse).
DIAG TRANSM. 2(X)
SWITCHES Circuit diagram: Circuit drivetrain gearbox group 2.0_1
FORWARD X Connection: signal from S162/R to digital in D790-2/K3:12
REVERSE X
005326
SHIFT MODE X Function: 2 Transmission
Signal value:
1 Input signal active. Travel direction reverse selected.

0 No signal.
SWITCHES, SHIFT MODE

Description: Signal from switch, shifting program. Status on CAN
DIAG TRANSM. 2(X) bus from Control unit KIT (D790-2). The switches are integrated in
SWITCHES Control unit KIT (D790-2).
FORWARD X
REVERSE X Circuit diagram: -
005326
SHIFT MODE X Contact: -
Function: 2 Transmission
Signal value:
1 Shifting program 1 selected.

2 Shifting program 2 selected.
4 Automatic shifting selected.

PRESENT VALUE, FORWARD
Description: Status for forward direction of travel from Control unit,
DIAG TRANSM. 3(X) transmission (D793). Indicates if forward drive is activated in the
PRESENT VALUE transmission.
FORWARD X
005327
GEAR X Contact: -
Function: 2.8 Control system, transmission
Signal value:
1 Output signal for travel direction forward active.

0 No output signal.

PRESENT VALUE, REVERSE

Description: Status for rearward direction of travel from Control unit,
DIAG TRANSM. 3(X) transmission (D793). Indicates if rearward drive is activated in the
PRESENT VALUE transmission.
FORWARD X
005327
GEAR X Contact: -
Signal value:
1 Output signal for travel direction reverse active.

0 No output signal.
PRESENT VALUE, GEAR

Description: Current gear, status from Control unit, transmission
DIAG TRANSM. 3(X) (D793). Shows which gear is activated in the transmission.
PRESENT VALUE
FORWARD X Circuit diagram: -
REVERSE X Function: 2.8 Control system, transmission
005327
GEAR X
Contact: -
Signal value: X = current gear.
OPERATING STATE, AUT/MAN MODE

Description: Shows which shifting program is selected automatic or
DIAG TRANSM. 4(X) manual.
OPERATING STATE
AUT/MAN MODE X Circuit diagram: -
WARNING X Contact: -
005328
OPERATING MODE X
Signal value:
1 Automatic.
0 Manual.
OPERATING STATE, WARNING

Description: Warning for serious malfunction in transmission from
DIAG TRANSM. 4(X) Control unit, transmission (D793).
OPERATING STATE
005328
OPERATING MODE X
Signal value:
1 Active error.
0 No errors.

OPERATING STATE, OPERATING MODE

Description: Operating mode status for Control unit, transmission
DIAG TRANSM. 4(X) (D793), also shown in control unit display.
OPERATING STATE
005328
OPERATING MODE X
Signal value:
0 Not used.
1 Manual or automatic shifting, standard mode shown during
operation.
2 Not used.
3 Not used.
4 Limp home, reduced capacity due to malfunction in
transmission.
5 Shut down, serious transmission malfunction control unit
shuts down, likely that malfunction cannot be shown as
CAN-bus.
6 Calibration of transmission in progress.
OPERATING STATE, SHIFT IN PROGRESS

Description: Status for transmission function during operation, shifting
DIAG TRANSM. 5(X) in progress. Active during shifting.
OPERATING STATE
SHIFT IN PROGRESS X Circuit diagram: -
FAULT X Contact: -
005329
OLD FAULT X
Signal value:
1 Shifting in progress.
0 No activity.
OPERATING STATE, FAULT

Description: Status for transmission's function during operation,
DIAG TRANSM. 5(X) active error codes present.
OPERATING STATE
FAULT X Contact: -
005329
OLD FAULT X
Signal value:
1 Active error code.

0 No error codes.

OPERATING STATE, OLD FAULT

Description: Status for transmission's function during operation, there
DIAG TRANSM. 5(X) are inactive error codes that have not been acknowledged.
OPERATING STATE
FAULT X Contact: -
005329
OLD FAULT X
Signal value:
1 There are inactive error codes that have not been

acknowledged.
0 No unacknowledged error codes.
NOT USED
XXXXXXX X(X)
NOT USED
008793
NOT USED
XXXXXXX X(X)
NOT USED
008793
NOT USED
XXXXXXX X(X)
NOT USED
008793
NOT USED
XXXXXXX X(X)
NOT USED
008793

NOT USED
XXXXXXX X(X)
NOT USED
008793
NOT USED
XXXXXXX X(X)
NOT USED
008793
NOT USED
XXXXXXX X(X)
NOT USED
008793
ACT ERROR AREA

Description: Indicates malfunction area active error, first part of the
DIAG TRANSM. 13(X) error code. In the event of several error codes, the most serious error
ACT ERROR AREA XXX code is shown.
TYPE XXX
NUMBER OF OCCU. XXXXX Circuit diagram: -
005337
TIME AGO XXXXX Contact: -
Signal value: XXX = First part of error code; see section D Error codes
TYPE
Description: Indicates type of active error.
DIAG TRANSM. 13(X)
ACT ERROR AREA XXX Circuit diagram: -
TYPE XXX Contact: -
NUMBER OF OCCU. XXXXX
005337
TIME AGO XXXXX Function: 2.8 Control system, transmission
Signal value: XXX = Second part of error code.

NUMBER OF OCCU.
Description: Number of times active errors have occurred.
DIAG TRANSM. 13(X)
TYPE XXX Contact: -
005337
Signal value: XXXXX = Number of times active errors have occurred.
TIME AGO
Description: When latest active error occurred.
DIAG TRANSM. 13(X)
TYPE XXX Contact: -
005337
Signal value: XXXXX = Operating time in hours since latest error
MANUAL GEAR SHIFT, GEAR

Description: Manual control of the transmission with the plus
DIAG TRANSM. 14(X) and minus keys. The menu can be used to rule out mechanical
MANUAL GEAR SHIFT malfunctions in the transmission's gear control.
Circuit diagram: -
GEAR X
014102
(+/-) Contact: -
Signal value: X = Selected gear.

8 Control system – ELSERV 8:69
8.4.8 ELSERV
ELSERV, description
DIAGNOSIS
CAN/POWER LIGHTS CAB This group covers electric servo functions.
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH Confirm selections with function key for Enter.
005400
OLS EXTRA
PRESENT INPUT SIGNALS, P1

Description: Signal from control lever P1.
DIAG ELSERVO 1(X)
PRESENT INPUT SIGNALS Circuit diagram: Circuit electric servo levers group 7.0_1, circuit
P1 XX.XXV electric servo joystick group 7.0_2
P2 XX.XXV Connection: signal from R8071/3 (S815/8) to analogue in D790-1/K7:3
005401
P3 XX.XXV
Function: 7.1.1 Control levers
Signal value: XX.XXV = 0.50 - 4.50 V. 2.5 V in zero position.

DIAG ELSERVO 1(X)
P2 XX.XXV Connection: signal from R8072/3 (S815/4) to analogue in D790-1/K7:4
005401
P3 XX.XXV

DIAG ELSERVO 1(X)
P2 XX.XXV Connection: signal from R8073/3 (S815/11) to analogue in
005401
P3 XX.XXV D790-1/K7:5
NOT USED
XXXXXXX X(X)
NOT USED
008793

8:70 8 Control system – ELSERV
OUTPUT LIFT, REFERENCE

Description: Status for control current to control valve (solenoid valve,
DIAG ELSERVO 3(X) lift mast).
OUTPUT LIFT
REFERENCE XY Circuit diagram: Circuit lift/lower electric servo group 7.2_1
REQUIRED VALUE XXXmA Contact: digital output from D797-1/K1:4 to Y6005/1
005403
FEEDBACK XXXmA
Function: 7.2.5 Control valve, lift and tilt
Signal value:
00 No output signal, PWM off.

11 Output signal active, circuit OK.
NOTE
Depending on different types of PWM connections, the following is
also possible: XY = 01 No output signal, PWM off.
OUTPUT LIFT, REQUIRED VALUE

Description: Reference value for control current to control valve
DIAG ELSERVO 3(X) (solenoid valve, lift mast).
OUTPUT LIFT
REQUIRED VALUE XXXmA Connection: output signal reference value out from D797-1/K1:16
005403
FEEDBACK XXXmA to Y6005/2
Signal value: XXX = Current value in mA for controlling solenoid valve.
OUTPUT LIFT, FEEDBACK

Description: Current value for control current to control valve
DIAG ELSERVO 3(X) (solenoid valve, lift mast).
OUTPUT LIFT
REQUIRED VALUE XXXmA Connection: output signal, actual value out from D797-1/K1:16 to
005403
FEEDBACK XXXmA Y6005/2
Signal value: XXX = Measured current value in mA.

OUTPUT LOWER, REFERENCE

DIAG ELSERVO 4(X) lower mast).
OUTPUT LOWER
REQUIRED VALUE XXXmA Contact: digital output from D797-1/K1:4 to Y6004/1
005404
FEEDBACK XXXmA
Signal value:

NOTE
OUTPUT LOWER, REQUIRED VALUE

DIAG ELSERVO 4(X) (solenoid valve, lower mast).
OUTPUT LOWER
005404
OUTPUT LOWER, FEEDBACK

Description: Current value for control current to control valve (solenoid
DIAG ELSERVO 4(X) valve, lower mast).
OUTPUT LOWER
005404

OUTPUT TILT IN, REFERENCE

DIAG ELSERVO 5(X) tilt in).
OUTPUT TILT IN
REFERENCE XY Circuit diagram: Circuit tilt electric servo group 7.7_1
REQUIRED VALUE XXXmA Connection: digital out from D797-1/K1:5 to Y6011/1
005405
FEEDBACK XXXmA
Signal value:

NOTE
OUTPUT TILT IN, REQUIRED VALUE

DIAG ELSERVO 5(X) (solenoid valve, tilt in).
OUTPUT TILT IN
005405
OUTPUT TILT IN, FEEDBACK

DIAG ELSERVO 5(X) (solenoid valve, tilt in).
OUTPUT TILT IN
005405

OUTPUT TILT OUT, REFERENCE

DIAG ELSERVO 6(X) tilt out).
OUTPUT TILT OUT
REQUIRED VALUE XXXmA Connection: digital out from D797-1/K1:5 to Y6010/1
005406
FEEDBACK XXXmA
Signal value:

NOTE
OUTPUT TILT OUT, REQUIRED VALUE

DIAG ELSERVO 6(X) (solenoid valve, tilt out).
OUTPUT TILT OUT
REQUIRED VALUE XXXmA Connection: output signal, reference value out from D797-1/K1:19,
005406
FEEDBACK XXXmA to solenoid valve Y6010/1
OUTPUT TILT OUT, FEEDBACK

DIAG ELSERVO 6(X) (solenoid valve, tilt out).
OUTPUT TILT OUT
005406
FEEDBACK XXXmA solenoid valve Y6010/2
NOT USED
XXXXXXX X(X)
NOT USED
008793

NOT USED
XXXXXXX X(X)
NOT USED
008793
NOT USED
XXXXXXX X(X)
NOT USED
008793
NOT USED
XXXXXXX X(X)
NOT USED
008793
NOT USED
XXXXXXX X(X)
NOT USED
008793
NOT USED
XXXXXXX X(X)
NOT USED
008793


PRESENT INPUT SIGNALS, SPREADER
Description: Signal from switch for spreading the attachment.
DIAG ELSERVO 13(X)
PRESENT INPUT SIGNALS Circuit diagram: Circuit electric servo joystick group 7.0_2
SPREADER IN X OUT X Contact:
PISTOL X
007128
UNLOCK TW X IN: Signal from S815/14 to digital in D790-1/K7:14 (spreading in)
OUT: Signal from S815/16 to digital in D790-1/K7:13 (spreading
out)
Function: 7.1.1 Control lever
Signal value:

0 No signal.
PRESENT INPUT SIGNALS, PISTOL

DIAG ELSERVO 13(X)
PRESENT INPUT SIGNALS
SPREADER IN X OUT X
PISTOL X
007128
UNLOCK TW X
PRESENT INPUT SIGNALS, UNLOCK TW

Description: Signal from control lever to unlock twistlock.
DIAG ELSERVO 13(X)
PRESENT INPUT SIGNALS Circuit diagram: Circuit electric servo joystick group 7.0_2
SPREADER IN X OUT X Contact: Signal from S815/20 to digital in D790-1/K7:15
PISTOL X
007128
UNLOCK TW X Function: 7.1.1 Control lever
Signal value:

0 No signal.

NOT USED
XXXXXXX X(X)
NOT USED
008793

NOT USED
XXXXXXX X(X)
NOT USED
008793

8:76 8 Control system – ATTACH
8.4.9 ATTACH
ATTACH, description
This group covers attachment functions.
DIAGNOSIS
CLIMATE HYD ENGINE
005339
OLS EXTRA

DIAG ATTACHMENT 1(X)
P4 XX.XXV Connection: signal from R8073/3 (S815/11) to analogue in
005416
P7 XX.XXV D790-1/K7:5

P3 XX.XXV
P4 XX.XXV
005416
P7 XX.XXV

P3 XX.XXV
P4 XX.XXV
005416
P7 XX.XXV

P5 XX.XXV
005417

8 Control system – ATTACH 8:77

PRESENT INPUT SIGNALS, SPREADER
Description: Signals from switch for spreading the attachment.
PRESENT INPUT SIGNALS Circuit diagram: Circuit 20-40, 30-35 stop group 7.5-1, circuit electric
SPREADER IN X OUT X servo joystick group 7.0_2
AUTO 20/40 X Contact:
005418
30/35 STOP X
IN: Signal from S1012/1 (S815/14) to digital in D790-1/K7:14
(spreading in)
OUT: Signal from S1012/7 (S815/16) to digital in D790-1/K7:13
(spreading out)
Function: 7.1.3 Switch, spreading 20'-40', 7.1.1 Control lever
Signal value:

0 No signal.
PRESENT INPUT SIGNALS, AUTO 20/40

PRESENT INPUT SIGNALS Description: Signal from switch automatic spreading 20/40.
SPREADER IN X OUT X
AUTO 20/40 X Circuit diagram: Circuit 20-40 opt. group 7.5_3
005418
30/35 STOP X Connection: from S1012-2/1 to digital in D790-1/K8:11
Function: 7.5 Spreading
Signal value:

0 No signal.
PRESENT INPUT SIGNALS, 30/35 STOP

PRESENT INPUT SIGNALS Description: Signal from switch for stop at 30'/35'.
SPREADER IN X OUT X
AUTO 20/40 X Circuit diagram: Circuit 20-40, 30-35 stop group 7.5-1
005418
30/35 STOP X Connection: from S1004/1 to digital in D790-1/K8:10
Signal value:

0 No signal.

PRESENT INPUT SIGNALS, PISTOL
PISTOL X
007130

PRESENT INPUT SIGNALS, LOCK CONT

Description: Signal from switch, lock twistlocks.
PRESENT INPUT SIGNALS Circuit diagram: Circuit Twistlock group 7.9_1
LOCK CONT X Contact: Signal from S1003 to digital in D790-1/K8:12
UNLOCK CONT X
010079
Function: 7.9.1 Twistlocks
Signal value:

0 No signal.
PRESENT INPUT SIGNALS, UNLOCK CONT

Description: Signal from control lever to open twistlocks.
PRESENT INPUT SIGNALS Circuit diagram: Circuit Twistlock group 7.9_1
LOCK CONT X Contact: Signal from S1002 to digital in D790-1/K7:15
UNLOCK CONT X
010079
Signal value:

0 No signal.
PRESENT INPUT SIGNALS, LOW SPEED 20/40

Description: Signal from spreading position sensor for end position
DIAG ATTACHMENT 6(X) damping 20'/40' right or left.
LE RI Circuit diagram: Attachment DCF90/100-45E group 7.5_3
LOW SPEED 20/40 X X Connection: from inductive sensor B769L to digital in D791/K1:12 or
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.
PRESENT INPUT SIGNALS, 30/35 STOP

Description: Signal from position sensor for end position 30' right
DIAG ATTACHMENT 6(X) or left.
LE RI Circuit diagram: Attachment DCF90/100-45E group 7.5_3
LOW SPEED 20/40 X X Connection: from inductive sensor B777L to digital in D791/K1:20 or
010080
30/35 STOP X X from inductive sensor B777R to digital in D791/K1:37
Function: 7.5.6 Position sensor spreading
Signal value:

0 No signal.

PRESENT INPUT SIGNALS, ALIGNMENT LE RI

Description: Signals from right and left alignment sensors.
PRESENT INPUT SIGNALS Circuit diagram: Attachment DCF90/100-45E group 7.9_5A, 7.9_4
ALIGNMENT LE RI Contact:
X X
LE: signal from B7203L to digital in D791/K1:27
010093
RI: signal from B7203R to digital in D791/K1:26
Function: 7.9.1.7 Alignment sensor
Signal value:

0 No signal.
PRESENT INPUT SIGNAL LE RI, LOCKED CONT

Description: Signals from sensors locked twistlock right and left.
PRESENT INPUT SIGNALS Circuit diagram: Attachment DCF90/100-45E group 7.9_2
LE RI Contact:
LOCKED CONT X X
LE: Signal from B7205LL to analogue in (used as digital)
010082
UNLOCKED CONT X X
D791/K1:23
RI: Signal from B7205RL to analogue in (used as digital)
D791/K1:24
Function: 7.9.1.8 Twistlocks sensor
Signal value:

0 No signal.
PRESENT OUTPUT SIGNAL LE RI, UNLOCKED CONT

Description: Signals from sensors open twistlock right and left.
PRESENT INPUT SIGNALS Circuit diagram: Attachment DCF90/100-45E group 7.9_2
LE RI Contact:
LOCKED CONT X X
LE: Signal from B7204L to analogue in (used as digital)
010082
UNLOCKED CONT X X
D791-1/K1:22
RI: Signal from B7204R to analogue in (used as digital)
D791-1/K1:41
Function: 7.9.1.8 Twistlocks sensor
Signal value:

0 No signal.

PRESENT OUTPUT SIGNAL, LOCK CONT

Description: Voltage feed to control valve attachment, locked
DIAG ATTACHMENT 9(X) twistlock.
LOCK CONT XY Circuit diagram: Circuit Twistlock group 7.9_1
UNLOCK CONT XY Connection: digital out from D791/K1:7 to Y6040/1
010083
Function: 7.9.1.2 Attachment control valve
Signal value:

is missing.
PRESENT OUTPUT SIGNAL, UNLOCK CONT

Description: Voltage feed to control valve attachment, open twistlock.
PRESENT OUTPUT SIGNAL Circuit diagram: Circuit Twistlock group 7.9_1
LOCK CONT XY Connection: digital out from D791/K1:9 to Y6039/1
UNLOCK CONT XY
010083
Function: 7.9.1.2 Attachment control valve
Signal value:

is missing.

PRESENT OUTPUT SIGNAL, IND. LOCKED CONT

Description: Voltage feed, indicator light for locked twistlocks - located
DIAG ATTACHMENT 10(X) on carriage.
IND. LOCKED CONT XY Circuit diagram: Circuit attachment DCF90/100-45E group 11.5_2,
IND. UNLOCKED CONT XY 7.9_3A
010084
IND. ALIGNMENT XY Connection: digital out from D791/K1:29 to H563/1
Signal value:

is missing.
PRESENT OUTPUT SIGNAL, IND. UNLOCKED CONT

Description: Voltage feed, indicator light for unlocked twistlocks -
DIAG ATTACHMENT 10(X) located on carriage.
010084
Signal value:

is missing.

PRESENT OUTPUT SIGNAL, IND. ALIGNMENT

Description: Voltage feed, alignment indicator light - located on
DIAG ATTACHMENT 10(X) carriage.
010084
Signal value:

is missing.
OUTPUT SIDE SHIFT LE, REFERENCE

Description: Status for control current to attachment control valve
DIAG ATTACHMENT 11(X) for side shift left.
OUTPUT SIDESHIFT LE
REFERENCE XY Circuit diagram: Circuit attachment DCF90/100-45E group 7.4_1
REQUIRED VALUE XXX Connection: digital out from D791-1/K1:32 to Y6020/1
010088
FEEDBACK XXX
Function: 7.4.2 Control valve attachment
Signal value:

NOTE
OUTPUT SIDE SHIFT LE, REQUIRED VALUE

Description: Reference value for control current to attachment control
DIAG ATTACHMENT 11(X) valve for output signal, side shift left.
OUTPUT SIDESHIFT LE
REQUIRED VALUE XXX Connection: output signal reference value out from D791-1/K1:18
010088
FEEDBACK XXX to Y6020/2

OUTPUT SIDE SHIFT LE, FEEDBACK

Description: Current value for control current to attachment control
DIAG ATTACHMENT 11(X) valve for side shift left.
OUTPUT SIDESHIFT LE
REQUIRED VALUE XXX Connection: output signal actual value out from D791-1/K1:18 to
010088
FEEDBACK XXX Y6020/2
OUTPUT SIDE SHIFT RI, REFERENCE

DIAG ATTACHMENT 12(X) for side shift right.
OUTPUT SIDESHIFT RI
REQUIRED VALUE XXX Connection: digital out from D791/K1:33 to Y6021/1
010089
FEEDBACK XXX
Signal value:

NOTE
OUTPUT SIDE SHIFT RI, REQUIRED VALUE

DIAG ATTACHMENT 12(X) valve for output signal, side shift right.
OUTPUT SIDESHIFT RI
REQUIRED VALUE XXX Connection: output signal reference value out from D791-1/K1:18
010089
FEEDBACK XXX to Y6021/2
OUTPUT SIDE SHIFT RI, FEEDBACK

DIAG ATTACHMENT 12(X) valve for side shift right.
OUTPUT SIDESHIFT RI
REQUIRED VALUE XXX Connection: output signal, actual value out from D791-1/K1:18 to
010089
FEEDBACK XXX Y6021/2

NOT USED
XXXXXXX X(X)
NOT USED
008793
NOT USED
XXXXXXX X(X)
NOT USED
008793
NOT USED
XXXXXXX X(X)
NOT USED
008793
NOT USED
XXXXXXX X(X)
NOT USED
008793

OUTPUT SPREAD LE OUT, REFERENCE

DIAG ATTACHMENT 17(X) for spreading, left side out.
OUTPUT SPREAD LE OUT
REFERENCE XY Circuit diagram: Attachment DCF90/100-45E group 7.5_1
REQUIRED VALUE XXX Connection: digital out from D791/K1:3 to Y6018L/1
010087
FEEDBACK XXX
Signal value:

NOTE
OUTPUT SPREAD LE OUT, REQUIRED VALUE

DIAG ATTACHMENT 17(X) valve for output signal spreading left side out.
REQUIRED VALUE XXX Connection: output signal, reference value out from D791/K1:16 to
010087
FEEDBACK XXX Y6018L/2
OUTPUT SPREAD LE OUT, FEEDBACK

DIAG ATTACHMENT 17(X) valve for spreading, left side out.
REQUIRED VALUE XXX Connection: output signal, actual value out from D791/K1:16 to
010087

OUTPUT SPREADER LE IN, REFERENCE

DIAG ATTACHMENT 18(X) for spreading, left side in.
OUTPUT SPREADER LE IN
REQUIRED VALUE XXX Connection: digital out from D791/K1:2 to Y6019L/1
010090
FEEDBACK XXX
Signal value:

NOTE
OUTPUT SPREADER LE IN, REQUIRED VALUE

DIAG ATTACHMENT 18(X) valve for output signal spreading left side in.
010090
OUTPUT SPREADER LE IN, FEEDBACK

DIAG ATTACHMENT 18(X) valve for spreading, left side in.
010090

OUTPUT SPREAD RI OUT, REFERENCE

Description: Status for control current to attachment control valve for
DIAG ATTACHMENT 19(X) spreading, right side out.
OUTPUT SPREAD RI OUT
Circuit diagram: Attachment DCF90/100-45E group 7.5_1
REFERENCE XY
REQUIRED VALUE XXX Connection: digital out from D791/K1:5 to Y6018R/1
010091
FEEDBACK XXX
Signal value:

NOTE
OUTPUT SPREAD RI OUT, REQUIRED VALUE

DIAG ATTACHMENT 19(X) valve for output signal spreading right side out.
REFERENCE XY
010091
FEEDBACK XXX Y6018R/2
OUTPUT SPREAD RI OUT, FEEDBACK

DIAG ATTACHMENT 19(X) valve for spreading, right side out.
REFERENCE XY
010091

OUTPUT SPREADER RI IN, REFERENCE

DIAG ATTACHMENT 20(X) for spreading, right side in.
OUTPUT SPREADER RI IN
REQUIRED VALUE XXX Connection: digital out from D791/K1:4 to Y6019R/1
010092
FEEDBACK XXX
Signal value:

NOTE
OUTPUT SPREADER RI IN, REQUIRED VALUE

DIAG ATTACHMENT 20(X) valve for output signal spreading right side in.
010092
OUTPUT SPREADER RI IN, FEEDBACK

DIAG ATTACHMENT 20(X) valve for spreading, right side in.
010092

8 Control system – OLS 8:89
PRESENT OUTPUT SIGNAL, BUZZER AUTO 20-40

PRESENT OUTPUT SIGNAL Description: Voltage feed to buzzer, automatic spreading 20'-40'.
BUZZER AUTO 20-40 XY Circuit diagram: Attachment DCF90/100-45E group 7.5_2
009181
Connection: digital out from D791/K1:28 to H9003/1
Signal value:
01 No output signal. Error detection only possible when output

signal is active.
8.4.10 OLS
OLS, description
DIAGNOSIS
CLIMATE HYD ENGINE
005436
OLS EXTRA
8.4.11 EXTRA
EXTRA, description
DIAGNOSIS
CAN/POWER LIGHTS CAB This menu consists of optional functions:
CLIMATE HYD ENGINE
• Reversible driver's seat, VBFS
005440
OLS EXTRA • Joystick control or mini-wheel, EL-STEERING

• External attachment, EXT-ATTACH
• Freelift, FREELIFT
• Cab tipping, MOVE-CAB
• Auxiliary equipment, OPT
• Inputs and outputs, control units, I/O
• Remote machine interface, RMI
Confirm selections in the main menu with function key for Enter.
8.4.11.1 VBFS
VBFS, description
DIAGNOSIS EXTRA
VBFS EL-STEERING
EXT-ATTACH FREELIFT
MOVE-CAB OPT I/O RMI
008904

8:90 8 Control system – EXTRA
8.4.11.2 EL-STEERING
EL-STEERING, description
DIAGNOSIS EXTRA
VBFS EL-STEERING
EXT-ATTACH FREELIFT
008911
8.4.11.3 EXT-ATTACH
EXT-ATTACH, description
DIAGNOSIS EXTRA
VBFS EL-STEERING
EXT-ATTACH FREELIFT
007625
8.4.11.4 FREELIFT
FREELIFT, description
DIAGNOSIS EXTRA
VBFS EL-STEERING
EXT-ATTACH FREELIFT
008912
8.4.11.5 MOVE-CAB
MOVE-CAB, description
DIAGNOSIS EXTRA
VBFS EL-STEERING
EXT-ATTACH FREELIFT
008913
8.4.11.6 OPT
OPT, description
This group covers a number of options.
DIAGNOSIS EXTRA
VBFS EL-STEERING Confirm selections with function key for Enter.
EXT-ATTACH FREELIFT
008914

8 Control system – EXTRA 8:91
OPT, menu 1
OPTION SWITCH, S199-1
DIAG OPTION 1(X)
OPTION SWITCH Description: Signal from switch S199-1.
S199-1 X S199-4 X
Circuit diagram: Circuit extra equipment group 9.1_1
S199-2 X
005488
S199-3 X Connection: signal from S199-1/1 to digital in D790-1/K6:9
Function: -
Signal value:

0 No signal.
DIAG OPTION 1(X)
S199-1 X S199-4 X
S199-2 X
005488
Function: -
Signal value:

0 No signal.
DIAG OPTION 1(X)
S199-1 X S199-4 X
S199-2 X
005488
Function: -
Signal value:

0 No signal.
DIAG OPTION 1(X)
S199-1 X S199-4 X
S199-2 X
005488
Function: -
Signal value:

0 No signal.

OPT, menu 2
PRESENT OUTPUT SIGNAL CENTRAL LUBRICATION, FRAME
PRESENT OUTPUT SIGNAL CENTRAL LUBRICATION,
DIAG OPTION 2(X) FRAME
CENTRAL LUBRICATION Description: Voltage feed to central lubrication of frame.
FRAME XY
Circuit diagram: Circuit std. opt. group 9.0_1 and circuit central
005489
ATTACHMENT XY
lubrication group 9.14_1
Connection: digital out from D797-1/K1:42 to M693-1/1
Function: 9.14.1 Pump unit
Signal value:

is missing.
PRESENT OUTPUT SIGNAL CENTRAL LUBRICATION, ATTACHMENT
PRESENT OUTPUT SIGNAL CENTRAL LUBRICATION,
DIAG OPTION 2(X) ATTACHMENT
CENTRAL LUBRICATION Description: Voltage feed to central lubrication of attachment.
FRAME XY
005489
ATTACHMENT XY
Connection: digital out from D791-1/K1:14 to M693/1
Function: 9.14.1 Pump unit
Signal value:

signal is active.

8 Control system – EXTRA 8:93
OPT, menu 3
PRESENT OUTPUT SIGNAL, D797-1 C1 P42
DIAG OPTION 3(X)
PRESENT OUTPUT SIGNAL Description: Voltage feed from D797-1/K1:42.
D797-1 C1 P42 XY
Circuit diagram: -
005490
Connection: digital out D797-1/K1:42
Function: -
Signal value:

is missing.
OPT, menu 4
OPT, menu 5
DIAG OPTION 5(X)
D791-1 C1 P14 XY
Circuit diagram: -
D791-1 C1 P28 XY
005492
Connection: digital out from D791-1/K1:14
Function: -
Signal value:

signal is active.


DIAG OPTION 5(X)
D791-1 C1 P14 XY
Circuit diagram: -
D791-1 C1 P28 XY
005492
Connection: digital out from D791-1/K1:28
Function: -
Signal value:

is missing.
8.4.11.7 I/O
I/O, description
DIAGNOSIS EXTRA
VBFS EL-STEERING
EXT-ATTACH FREELIFT
I/O RMI
MOVE-CAB OPT I/O
015099
8.4.11.8 RMI
RMI, description
DIAGNOSIS EXTRA
VBFS EL-STEERING
EXT-ATTACH FREELIFT
007657

8 Control system – Setup 8:95
8.5 Setup
Setup, general
Settings are built-in functions to adapt the functions to the unique
machine individual. Settings are performed via menus in the display.
Settings are divided into 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 carried out in order to compensate for mechanical and
electrical tolerances (variations between different machines).
Calibration
Calibration is performed after the machine has started to be used for
work, after replacement of control units, and in certain cases, service
or replacement of components. Calibration is performed so that certain
functions shall function properly and show correct values.
8.5.1 Initiation
Initiation, description
1 2
DANGER
INIT ELSERVO 1(X)
START CURRENT The settings influence the functions. Adjustments
LIFT may impair the function.
4 STORED VALUE XXXmA 3 If uncertain, contact Cargotec Service.
008891
PRESENT VALUE XXXmA

Example of initiation menu, start current for lift function.
1. Menu group NOTE
2. Menu number. The number of menus depends
on the equipment fitted to the machine. For this Initiation does not need to be performed in one process but each
reason, number of menus is indicated with (X) step can be performed separately, independently of other steps.
in this manual.
3. Signal value In order that hydraulic functions shall work satisfactorily and safely,
4. Actual variable certain values must be set to operate the machine, this is known as
initiation.
Initiation consists of several menus grouped according to functions.

Each individual menu sets a specific variable. The menus are similar
in structure and use a common terminology explained here:
PRESENT
Displays the stored value when the menu is opened. Adjust the value
with the plus and minus keys. Store the set value with the Enter key.
Go to the next menu with the arrow keys. Go back with the R-key.
STORED
I [mA] STORED
States the stored value for the current variable.
1
2
3
006299
t [s]
1. Max. current (END CURRENT)
2. Damping (PROC DAMPING)
3. Start current (START CURRENT)

8:96 8 Control system – Initiation
START CURRENT
Specifies the start current to the solenoid valve for the selected function.
The start current is the lowest current that can be actuated. In practice,
it controls how slowly a function can be operated. On functions with
analogue control/activation (controllable), e.g. lift, this is the current
that is triggered when the lever leaves the zero position. On certain
functions with digital activation (off/on) which are soft-started, this is
the current which is triggered immediately the function is activated.
END CURRENT
Specifies the max. current to the solenoid valve for the selected
function. The max. current is the highest current that can be actuated.
In practice, it controls how quickly a function can be operated. On
functions with analogue control activation (controllable), e.g. lift, this is
the current which is triggered when the lever is in the end position. On
certain functions with digital activation (off/on) which are soft-started,
this is the current which is triggered after the ramp time when the
function is activated. The interval between START CURRENT and
END CURRENT is the active range for controlling the solenoid valve.
PROC DAMPING
Specifies how much the control current shall be reduced during
damping. The interval is specified as 0-100% of the active range
between START CURRENT and END CURRENT.
Function Menu
INIT DRIVE-TRAIN, menu 9, page
1 Engine, speed limitation 8:110
1 Engine, automatic engine shut-down on idle 8:110
1 Engine, automatic engine speed increase for lifting INIT DRIVE-TRAIN, menu 13, page
8:111
2 Transmission, starting gear INIT DRIVE-TRAIN, menu 1, page
8:108
2 Transmission, speed limitation (gear lock-out) 8:110
2 Transmission, automatic engine speed reduction for shift forward - reverse 8:111
7.2 Lifting/lowering, lift mast INIT ELSERVO, menu 1, page 8:98
INIT ELSERVO, menu 2, page 8:98
7.2 Lifting/lowering, lower mast INIT ELSERVO, menu 3, page 8:99
Comment: The current value is for unladen machines. When loaded, the current INIT ELSERVO, menu 4, page 8:99
value is controlled by the limited lowering speed.
7.4 Side shift INIT ATTACH, menu 5, page 8:105
INIT ATTACH, menu 6, page 8:105
7.5 Spreading out INIT ATTACH, menu 9, page 8:106
7.5 Spreading in INIT ATTACH, menu 12, page 8:107
7.7 Tilt INIT ELSERVO, menu 5, page 8:99
INIT ELSERVO, menu 6, page 8:100

8 Control system – Initiation 8:97
Initiate hydraulic function, work instruction

To select a hydraulic function to initiate, proceed as follows:
All hydraulic functions are initiated in the same way.

1 Navigate to the service menu.
2 Press Enter.
000056
3 Enter the code for initiation.
1 23
4 5 NOTE
000060

4 Select group by scrolling with the arrow keys (1 and 2) and confirm
INITIATION with Enter.
ELSERVO ATTACHMENT
Each initiation consists of a sequence of a number of menus. The
STEERING DRIVE-TRAIN first menu for the selected initiation opens in the display. Select
SLIDING-CAB the desired menu with the arrow keys (1 and 2).
007169
RETURN
5 Change the current value with the plus and minus keys.
INIT ELSERVO 1(X)
START CURRENT NOTE
LIFT
STORED VALUE XXXmA Current values can only be adjusted within specific limits.
005494
PRESENT VALUE XXXmA

6 Use the function key for Enter to store the desired current value
setting, "STORED".

8.5.1.1 ELECTRIC SERVO
INIT ELSERVO
The menu group for this function covers initiation of the electric servo
INITIATION functions for load handling.
ELSERVO ATTACHMENT
STEERING DRIVE-TRAIN The settings for lift, lower, tilt in, tilt out are made here. For other load
SLIDING-CAB handling functions, see INIT ATTACH, page 8:104.
007169
RETURN
DANGER
The settings influence the functions. Adjustments
may impair the function.
If uncertain, contact Cargotec Service.
NOTE
Initiation does not need to be performed in one process but each
step can be performed separately, independently of other steps.
INIT ELSERVO, menu 1

START CURRENT, LIFT
START CURRENT, LIFT
INIT ELSERVO 1(X)
START CURRENT Description: Start current for activation of solenoid valve, lift mast
LIFT (Y6005).
STORED VALUE XXXmA PRESENT VALUE: indicates the current value for the start current.
005494
PRESENT VALUE XXXmA Adjust the value with the plus and minus keys. Store the set value
with the Enter key. Go to the next menu with the arrow keys. Exit
initiation with the R-key.
STORED VALUE: indicates stored value for start current.
Component: Solenoid valve, lift mast (Y6005)
Signal value: XXXmA = 0 - 999 mA.

END CURRENT, LIFT
END CURRENT, LIFT
INIT ELSERVO 2(X)
END CURRENT Description: Control current on full lever actuation for the activation of
LIFT the solenoid valve for mast lift (Y6005).
STORED VALUE XXXmA PRESENT VALUE: indicates the current value for max. current.
005495
STORED VALUE: indicates stored value for max. current.


START CURRENT, LOWER
START CURRENT, LOWER
INIT ELSERVO 3(X)
START CURRENT Description: Start current for activation of solenoid valve, lower mast
LOWER (Y6004).
005496
Component: Solenoid valve, lower mast (Y6004)

END CURRENT, LOWER
END CURRENT, LOWER
INIT ELSERVO 4(X)
END CURRENT Description: Control current on full lever actuation for the activation
LOWER of the solenoid valve for mast lower (Y6004).
005497
Component: Solenoid valve, mast (Y6004)

START CURRENT, TILT IN
START CURRENT, TILT IN
INIT ELSERVO 5(X)
START CURRENT Description: Start current for the activation of the solenoid valve for
TILT IN tilt in (Y6011).
007139
Component: Solenoid valve, tilt in (Y6011)


END CURRENT, TILT IN
END CURRENT, TILT IN
INIT ELSERVO 6(X)
TILT IN the solenoid valve for tilt in (Y6011).
007140
Component: Solenoid valve, tilt in (Y6011)

START CURRENT, TILT OUT
START CURRENT, TILT OUT
INIT ELSERVO 7(X)
START CURRENT Description: Start current for the activation of the solenoid valve for
TILT OUT tilt out (Y6010).
007141
Component: Solenoid valve, tilt out (Y6010)

END CURRENT, TILT OUT
END CURRENT, TILT OUT
INIT ELSERVO 8(X)
TILT OUT the solenoid valve for tilt out (Y6010).
007142
Component: Solenoid valve, tilt out (Y6010)


START CURRENT, SIDE SHIFT LE/RI
START CURRENT, SIDE SHIFT LE/RI
INIT ELSERVO 9(X)
START CURRENT Description: Start current of activation of solenoid valve for side shift
SIDESHIFT LE/RI left (Y6020) and solenoid valve for side shift right (Y6021).
007143
Component: Solenoid valve for side shift left (Y6020) and solenoid
valve for side shift right (Y6021)

END CURRENT, SIDE SHIFT LE/RI
END CURRENT, SIDE SHIFT LE/RI
INIT ELSERVO 10(X)
END CURRENT Description: Control current at full lever actuation for activation of
SIDESHIFT LE/RI solenoid valve for side shift left (Y6020) and solenoid valve for side
STORED VALUE XXXmA shift right (Y6021).
007144
PRESENT VALUE XXXmA PRESENT VALUE: indicates the current value for max. current.
Adjust the value with the plus and minus keys. Store the set value
Component: Solenoid valve for side shift left (Y6020) and solenoid
valve for side shift right (Y6021)

START CURRENT, SPREADING IN/OUT
START CURRENT, SPREADING IN/OUT
INIT ELSERVO 11(X)
START CURRENT Description: Start current for activation of solenoid valve for spreading
SPREADING IN/OUT in (Y6019) and solenoid valve for spreading out (Y6018).
007145
Component: Solenoid valve for spreading in (Y6019) and solenoid

valve for spreading out (Y6018)


END CURRENT, SPREADING IN/OUT
END CURRENT, SPREADING IN/OUT
INIT ELSERVO 12(X)
END CURRENT Description: Control current at full lever actuation for activation
SPREADING IN/OUT of solenoid valve for spreading in (Y6019) and solenoid valve for
STORED VALUE XXXmA spreading out (Y6018).
007146
PRESENT VALUE XXXmA PRESENT VALUE: indicates the current value for max. current.
Component: Solenoid valve for spreading in (Y6019) and solenoid

valve for spreading out (Y6018)

START CURRENT, LIFT 2
START CURRENT, LIFT 2
INIT ELSERVO 13(X)
START CURRENT Description: Start current for activation of solenoid valve, lift trolley
LIFT 2 (Y6022).
007147
Component: Solenoid valve trolley (Y6022)

END CURRENT, LIFT 2
END CURRENT, LIFT 2
INIT ELSERVO 14(X)
END CURRENT Description: Control current on full lever actuation for the activation
LIFT 2 of the solenoid valve for lift trolley (Y6022).
007148
Component: Solenoid valve trolley (Y6022)


START CURRENT, LOWER 2
START CURRENT, LOWER 2
INIT ELSERVO 15(X)
START CURRENT Description: Start current for activation of solenoid valve, lower trolley
LOWER 2 (Y6023).
007149
Component: Solenoid valve, lower trolley (Y6023)

END CURRENT, LOWER 2
END CURRENT, LOWER 2
INIT ELSERVO 16(X)
LOWER 2 the solenoid valve for lower trolley (Y6023).
007150
Component: Solenoid valve, lower trolley (Y6023)

DAMP (PROC), LIFT
DAMP (PROC), LIFT
INIT ELSERVO 17(X)
DAMP (PROC) Description: Percentage damping of control current to solenoid valve
LIFT for mast lift (Y6005) when the mast reaches max height.
STORED VALUE XX
PRESENT VALUE: indicates the current value for damping. Adjust
PRESENT VALUE XX
the value with the plus and minus keys. Store the set value with the
I [mA] Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
1
STORED VALUE: indicates stored value in percent.
2
3
007151

t [s]
1. Max. current (END CURRENT) Signal value: XXX = 0 - 100%. 100% means no damping i.e. max.
current. 0% means full damping i.e. start current.

8.5.1.2 ATTACHMENT
INIT ATTACH
This function handles initialization of the attachment functions side
INITIATION shift and spreading.
ELSERVO ATTACHMENT
STEERING DRIVE-TRAIN
SLIDING-CAB DANGER
007170
RETURN

NOTE
INIT ATTACH, menu 1

NOT USED
NOT USED
XXXXXXX X(X)
NOT USED
008793
INIT ATTACH, menu 2

NOT USED
NOT USED
XXXXXXX X(X)
NOT USED
008793
INIT ATTACH, menu 3

NOT USED
NOT USED
XXXXXXX X(X)
NOT USED
008793
INIT ATTACH, menu 4

NOT USED
NOT USED
XXXXXXX X(X)
NOT USED
008793

INIT ATTACH, menu 5

START CURRENT, SIDE SHIFT
START CURRENT, SIDE SHIFT
INIT ATTACH 5(X)
START CURRENT Description: Start current of activation of solenoid valve for side shift
SIDESHIFT left (Y6020) and solenoid valve for side shift right (Y6021).
STORED VALUE XXXmA
005513
PRESENT VALUE XXXmA PRESENT VALUE: indicates the current value for the start current.
Component: Solenoid valve for side shift left (Y6020), Solenoid valve
for side shift right (Y6021)
Signal value: XXXmA = 0 - 999 mA
INIT ATTACH, menu 6

END CURRENT, SIDE SHIFT
END CURRENT, SIDE SHIFT
INIT ATTACH 6(X)
SIDESHIFT solenoid valve for side shift left (Y6020) and solenoid valve for side
STORED VALUE XXXmA shift right (Y6021).
005514
PRESENT VALUE XXXmA

PRESENT VALUE: indicates the current value for max. current.
Component: Solenoid valve for side shift left (Y6020), Solenoid valve
for side shift right (Y6021)
INIT ATTACH, menu 7

NOT USED
NOT USED
XXXXXXX X(X)
NOT USED
008793
INIT ATTACH, menu 8

NOT USED
NOT USED
XXXXXXX X(X)
NOT USED
008793

INIT ATTACH, menu 9

START CURRENT, SPREADER OUT, 20'-40'
START CURRENT, SPREADER OUT, 20'-40'
INIT ATTACH 9(X)
SPREADER OUT, 20'-40' out left (Y6018L) and solenoid valve for spreading out right (Y6018R).
STORED VALUE XXXmA
I [mA] with the Enter key. Go to the next menu with the arrow keys. Exit
1
2
3 005517
t [s] Component: Solenoid valve, spreading out 20'-40' (Y6018)
1. Max. current (END CURRENT) Signal value: XXXmA = 0 - 999 mA

INIT ATTACH, menu 10

END CURRENT, SPREADER OUT, 20'-40'
END CURRENT, SPREADER OUT, 20'-40'
INIT ATTACH 10(X)
SPREADER OUT, 20'-40' solenoid valve for spreading out left (Y6018L) and solenoid valve
STORED VALUE XXXmA for spreading out right (Y6018R).
PRESENT VALUE XXXmA
I [mA] Adjust the value with the plus and minus keys. Store the set value
1 initiation with the R-key.
2 STORED VALUE: indicates stored value for max. current.

3
005518

t [s]
Component: Solenoid valve for spreading out left (Y6018L) and
1. Max. current (END CURRENT) solenoid valve for spreading out right (Y6018R).
2. Damping (PROC DAMPING) Signal value: XXXmA = 0 - 999 mA

DAMP (PROC), SPREADER OUT, 20'-40'
DAMP (PROC), SPREADER OUT, 20'-40'
INIT ATTACH 11(X)
DAMP PROC Description: Percentage damping of control current to solenoid valve
SPREADER OUT, 20’-40’ for spreading out left (Y6018L) and solenoid valve for spreading out
STORED VALUE XX right (Y6018R) when spreading out approaches 40'.
PRESENT VALUE XX
I [mA] the value with the plus and minus keys. Store the set value with the
Enter key. Go to the next menu with the arrow keys. Exit initiation
1 with the R-key.
2 STORED VALUE: indicates stored value in percent.
3 Function: 7.5.2 Control valve attachment

014600
t [s]
Component: Solenoid valve for spreading out left (Y6018L) and
1. Max. current (END CURRENT) solenoid valve for spreading out right (Y6018R).
2. Damping (PROC DAMPING) Signal value: XXX = 0 - 100%. 100% means no damping, i.e. max.
3. Start current (START CURRENT) current. 0% means full damping, i.e. start current


START CURRENT, SPREADER IN, 40'-20'
START CURRENT, SPREADER IN, 40'-20'
INIT ATTACH 12(X)
SPREADER IN, 40'-20' in left (Y6019L) and solenoid valve for spreading in right (Y6019R).
STORED VALUE XXXmA
I [mA] with the Enter key. Go to the next menu with the arrow keys. Exit
1
2
3
005520
Component: Solenoid valve for spreading in left (Y6019L) and
t [s]
solenoid valve for spreading in right (Y6019R).
1. Max. current (END CURRENT)

END CURRENT, SPREADER IN, 40'-20'
END CURRENT, SPREADER IN, 40'-20'
INIT ATTACH 13(X)
SPREADER IN, 40'-20' solenoid valve for spreading in left (Y6019L) and solenoid valve for
STORED VALUE XXXmA spreading in right (Y6019R).
PRESENT VALUE XXXmA
I [mA] Adjust the value with the plus and minus keys. Store the set value
1 initiation with the R-key.
2 STORED VALUE: indicates stored value for max. current.

005521
t [s]
1. Max. current (END CURRENT) solenoid valve for spreading in right (Y6019R).
2. Damping (PROC DAMPING) Signal value: XXXmA = 0 - 999 mA

DAMP (PROC), SPREADER IN, 40'-20'
DAMP (PROC), SPREADER IN, 40'-20'
INIT ATTACH 14(X)
DAMP PROC Description: Percentage damping of control current to solenoid valve
SPREADER IN, 40’-20’ for spreading in left (Y6019L) and solenoid valve for spreading in right
STORED VALUE XX (Y6019R) when spreading in approaches 20'.
PRESENT VALUE XX
I [mA] the value with the plus and minus keys. Store the set value with the
Enter key. Go to the next menu with the arrow keys. Exit initiation
1 with the R-key.
2 STORED VALUE: indicates stored value in percent.

014704
t [s]
1. Max. current (END CURRENT) solenoid valve for spreading in right (Y6019R).
2. Damping (PROC DAMPING) Signal value: XXX = 0 - 100%. 100% means no damping, i.e. max.
3. Start current (START CURRENT) current. 0% means full damping, i.e. start current

8.5.1.3 STEERING
INIT STEERING
8.5.1.4 DRIVE-TRAIN
INIT DRIVE-TRAIN
This function covers engine and transmission initiation.
INITIATION
ELSERVO ATTACHMENT
STEERING DRIVE-TRAIN
SLIDING-CAB
DANGER
007172
RETURN
NOTE
NOTE
The machine must be stationary with parking brake applied in order
to enable access to the menus.
After changes have been made, the ignition must be switched off
and then on for the changes to be saved and start to apply.
INIT DRIVE-TRAIN, menu 1

START IN 1:ST
START IN 1:ST
INIT DRIVE-TRN 1(X)
Description: Setting to get transmission to always start in 1st gear.
START IN 1:ST
1=YES 0=NO PRESENT VALUE: indicates the present speed setting. Change the
STORED VALUE XXX value using the plus or minus keys. Save the set value with the Enter
013915
PRESENT VALUE XXX key. Go to the next menu with the arrow keys. Exit initiation with
the R-key.
STORED VALUE: indicates saved setting.
Component: -
Signal value: XXX = 1= yes, XXX = 0 = no

NOT USED
NOT USED
XXXXXXX X(X)
NOT USED
008793


NOT USED
NOT USED
XXXXXXX X(X)
NOT USED
008793
NOT USED
NOT USED
XXXXXXX X(X)
NOT USED 008793

NOT USED
NOT USED
XXXXXXX X(X)
NOT USED
008793

NOT USED
NOT USED
XXXXXXX X(X)
NOT USED
008793

NOT USED
NOT USED
XXXXXXX X(X)
NOT USED
008793

NOT USED
NOT USED
XXXXXXX X(X)
NOT USED
008793


OPTION SPEED LIMIT
OPTION SPEED LIMIT
INIT DRIVE-T 9(X)
OPTION SPEED LIMIT
(km/h)
Description: Setting of speed limitation.
STORED VALUE XXX
005587
PRESENT VALUE XXX PRESENT VALUE: indicates the current setting. Change the value
with the plus and minus keys. Save the set value with the Enter key.
Go to the next menu with the arrow keys. Exit initiation with the R-key.
Component: -
Signal value: XXX = speed (km/h)

OPTION HIGHEST GEAR AT SPEED LIMIT
OPTION HIGHEST GEAR AT SPEED LIMIT
INIT DRIVE-T 10(X)
OPTION HIGHEST GEAR
AT SPEED LIMIT
Description: Setting of highest permissible gear (speed limitation
STORED VALUE XXX
005588
through blocked gears).

PRESENT VALUE XXX
PRESENT VALUE: indicates the current setting. Change the value
Component: -
Signal value: XXX = gear

OPTION ENGINE SHUT DOWN
OPTION ENGINE SHUT DOWN
INIT DRIVE-T 11(X)
OPTION ENGINE SHUT
DOWN AT IDLE (sec)
Description: Setting of idle time prior to automatic engine shutdown.
STORED VALUE XXX
005589
PRESENT VALUE XXX PRESENT VALUE: indicates the current setting. Change the value
Function: 1 Engine
Component: -
Signal value: XXX = time in seconds before engine shutdown.


F-R WITHOUT ENGINE SPEED REDUCTION
F-R WITHOUT ENGINE SPEED REDUCTION
INIT DRIVE-T 12(X)
F-R WITHOUT ENGINE Description: Activation or deactivation of automatic engine speed
SPEED REDUCTION reduction when changing direction of travel forward - reverse. This
STORED VALUE X makes it possible to change direction of travel without releasing the
005590
PRESENT VALUE X accelerator pedal. Engine speed drops to that set in menu 3, see INIT
DRIVE-TRAIN, menu 3, page 8:109. If no value is set in menu 3,
engine speed is reduced to idle speed.

Component: -
Signal value:
X = 1, activated
X = 0, deactivated

AUTO ENGINE SPEED AT LIFT
AUTO ENGINE SPEED AT LIFT
INIT DRIVE-T 13(X)
AUTO ENGINE SPEED AT
LIFT
Description: Activation or deactivation of automatic engine speed
STORED VALUE X
005591
increase during lift.

PRESENT VALUE X
Function: 1 Engine
Component: -
Signal value:
X = 1, activated
X = 0, deactivated

8:112 8 Control system – Calibration
8.5.1.5 SLIDING-CAB
NOT USED
XXXXXXX X(X)
NOT USED
008793
8.5.2 Calibration
Calibration, description
Certain functions require calibration in order to operate correctly. The
control system has integrated calibrations for these functions.
SCALE
SCALE
CALIBRATION
SCALE STEERING
DRIVE-TRAIN RETURN
000062
STEERING
STEERING
CALIBRATION
SCALE STEERING
DRIVE-TRAIN RETURN
000074
DRIVE-TRAIN
DRIVE-TRAIN
CALIBRATION
This function handles calibration for engine and transmission. The
SCALE STEERING menu loop contains two different calibrations are not linked to each
DRIVE-TRAIN RETURN other, see:
000078
Accelerator pedal, calibration, page 8:114
NOTE

8 Control system – Calibration 8:113
Calibration menu, explanation
1 2 Calibration menu, explanation

The illustration shows an example of a menu, here for the calibration
5 CALIBR STEERING 1(X) of the centre position for lever joystick control. The table indicates
STEERING LEVER CENTER what a description contains (which follows in the next section):
POSITION
STORED VALUE X.XXV Designation: Example Description
4 3
008892
PRESENT VALUE X.XXV Variable (position 5): STEERING Name of the input
LEVER CENTRE POSITION signal/control signal affected.
1. Menu group Description: Setting the centre A short description of what is
2. Sequence number. The number of menus position for lever joystick control calibrated and the meaning
depends on the equipment fitted to the machine. (R825). of the variables.
For this reason, number of menus is indicated STORED VALUE: Gives the stored
with (X) in this manual. signal value for lever steering
3. Signal value control (R825), centre position.
4. STORED indicates stored value, PRESENT PRESENT VALUE: Gives the
indicates the current value of the signal to be present signal value for lever
calibrated steering control (R825), centre
position.
5. Heading of menu figure
Function: 5.2 Power-assisted Name of current function.
steering system
Component: Lever joystick control Indicates the component
(R825) whose signal is the basis for
calibration.
Calibration, work instructions

Calibration consists of a number of menus, the number of menus
depends on the function. All menus are similar in structure and
therefore the descriptions are similar.
To select a function to calibrate, proceed as follows:

1 Navigate to the service menu.
2 Press Enter.
000056
3 Enter the code for calibration.

1 23
4 5 NOTE
000060

4 Select group by scrolling with the arrow keys (1 and 2) and confirm
CALIBRATION with Enter.
Each calibration consists of a sequence of a number of menus.
SCALE STEERING The first menu for the selected calibration opens in the display.
DRIVE-TRAIN RETURN Select the next menu with key 1 and 2 (arrow function).
000062

8.5.2.3 Calibrate DRIVE-TRAIN
Accelerator pedal, calibration

1 Start key in operating position, engine switched off.
DRIVE-TRAIN, menu 1
CALIBR DRIVE-TRN 1(X)
2 Go into the calibration menus and select DRIVE-TRAIN, menu 1,
ACCELERATOR, see Calibration, work instructions, page 8:113.
RELEASE THE PEDAL
STORED VALUE X.XXV ACCELERATOR, RELEASE THE PEDAL
005532
PRESENT VALUE X.XXV Description: setting the accelerator's pedal zero position.
STORED VALUE: Indicates current calibrated control value from
accelerator pedal (R690-1).
PRESENT VALUE: indicates the current signal value from
Accelerator pedal (B690-1).
Function: 1 Engine
Component: Accelerator pedal (B690-1).
3 Release the accelerator pedal.
4 Store the position with function key for Enter.
DRIVE-TRAIN, menu 2
CALIBR DRIVE-TRN 2(X) 5 ACCELERATOR, PRESS THE PEDAL TO FLOOR
ACCELERATOR, PRESS Description: Setting of full-throttle position for Accelerator pedal
THE PEDAL TO FLOOR (B690-1).
STORED VALUE X.XXV
PRESENT VALUE X.XXV STORED VALUE: Indicates current calibrated control value from
accelerator pedal (R690-1).
00
PRESENT VALUE: indicates the current signal value from

Accelerator pedal (B690-1).
Function: 1 Engine
Component: Accelerator pedal (B690-1).
6 Press the accelerator pedal down fully and keep it down until the
position is stored.
7 Store the position with function key for Enter.

9:1
Contents 9 Frame, body, cab and accessories

9 Frame, body, cab and accessories ...................................................................9:3
9.1.1 Gear selector and multi-function lever.........................................................9:8
9.1.22 Switch, direction indicators..........................................................................9:9
9.2 Safety and emergency equipment .................................................................9:10
9.2.1 Control breaker .........................................................................................9:10
9.2.2 Seat belt ....................................................................................................9:10
9.2.3 Fire extinguisher........................................................................................9:10
9.2.4 Seat buzzer ...............................................................................................9:10
9.3 Seat................................................................................................................ 9:11
9.3.1 Seat cushion .............................................................................................9:14
9.3.2 Back rest cushion ......................................................................................9:15
9.3.3 Heating coil ...............................................................................................9:16
9.3.4 Bumper......................................................................................................9:16
9.3.5 Air suspension...........................................................................................9:17
9.3.6 Compressor air-suspension seat...............................................................9:17
9.3.7 Mechanical seat adjustment......................................................................9:18
9.3.8 Passenger seat .........................................................................................9:18
9.3.9 Arm rest.....................................................................................................9:18
9.3.14 Sensor, operator-in-seat............................................................................9:19
9.4 Heating, ventilation and air conditioning ........................................................9:21
9.4.1 Fresh air filter ............................................................................................9:28
9.4.2 Fresh air filter or recirculation damper.......................................................9:29
9.4.3 Cabin fan ...................................................................................................9:32
9.4.4 Heat exchanger heat .................................................................................9:35
9.4.5 Water valve ...............................................................................................9:38
9.4.6 Sensor, engine temperature ......................................................................9:38
9.4.7 Compressor...............................................................................................9:39
9.4.8 Condenser.................................................................................................9:43
9.4.9 Moisture filter.............................................................................................9:45
9.4.10 Pressure switch .........................................................................................9:45
9.4.11 Expansion valve ........................................................................................9:46
9.4.12 Sensor, temperature refrigerant ................................................................9:48
9.4.13 Heat exchanger, cooling............................................................................9:49
9.4.14 Air distributor .............................................................................................9:50
9.4.15 Defroster nozzles ......................................................................................9:51
9.4.16 Sensor, temperature outlet fan ..................................................................9:52
9.4.17 Sensor cab temperature............................................................................9:53
9.4.18 Sensor, ambient temperature ....................................................................9:54
9.5 Wiper/washer system.....................................................................................9:55
9.5.1 Wiper front.................................................................................................9:55
9.5.2 Wiper roof..................................................................................................9:55
9.5.3 Wiper rear .................................................................................................9:55
9.5.4 Washer motor and reservoir......................................................................9:55
9.5.5 Wiper motor front ......................................................................................9:56
9.5.6 Wiper motor roof .......................................................................................9:57
9.5.7 Wiper motor rear .......................................................................................9:58
9.6 Lighting system ..............................................................................................9:59
9.6.1 Headlights .................................................................................................9:63
9.6.2 Running lights ...........................................................................................9:63
9.6.3 Tail lights ...................................................................................................9:63
9.6.4 Brake lights ...............................................................................................9:63
9.6.5 Back-up lights............................................................................................9:64
9.6.6 Direction indicators....................................................................................9:64
9.6.7 Flashing hazard lights ...............................................................................9:64

9.6.8 Revolving beacon......................................................................................9:64

9.6.9 Working lights, mast ..................................................................................9:64
9.6.10 Working lights, cab ....................................................................................9:66
9.6.11 Interior lighting...........................................................................................9:66
9.6.12 Working lights, attachment ........................................................................9:67
9.6.14 Work lights, front wing ...............................................................................9:67
9.7 Signalling system ...........................................................................................9:68
9.7.1 Horn ..........................................................................................................9:70
9.7.2 Flashing hazard lights ...............................................................................9:70
9.7.3 Revolving beacon......................................................................................9:71
9.7.4 Warning parking brake ..............................................................................9:71
9.7.5 Back-up alarm ...........................................................................................9:71
9.8 Entertainment and communication ................................................................9:72
9.9 Glass/windows/mirrors...................................................................................9:73
9.9.1 Windscreen ...............................................................................................9:74
9.9.2 Side window ..............................................................................................9:76
9.9.3 Roof window..............................................................................................9:79
9.9.4 Rear window .............................................................................................9:79
9.9.5 Rear view mirror ........................................................................................9:79
9.10 Cab structure and suspension .......................................................................9:80
9.10.1 Cab frame .................................................................................................9:80
9.10.2 Doors.........................................................................................................9:80
9.10.3 Cab substructure .......................................................................................9:80
9.11 Cab interior ....................................................................................................9:81
9.11.1 Instrument and control panels ...................................................................9:81
9.11.2 Interior fittings, plastic ...............................................................................9:82
9.11.3 Interior fittings, textile ................................................................................9:82
9.11.4 Floor covering ...........................................................................................9:82
9.11.5 Insulation ...................................................................................................9:82
9.11.7 Terminal console .......................................................................................9:83
9.11.8 Writing desk...............................................................................................9:83
9.11.9 Reading-lamp ............................................................................................9:83
9.12 Chassis ..........................................................................................................9:84
9.13 Body structure................................................................................................9:85
9.13.1 Wings ........................................................................................................9:85
9.13.2 Hood engine compartment ........................................................................9:85
9.13.3 Footsteps and hand rail.............................................................................9:85
9.13.4 Counterweights .........................................................................................9:86
9.14 Central lubrication ..........................................................................................9:87
9.14.1 Pump unit ..................................................................................................9:89
9.14.2 Distribution block .......................................................................................9:90
9.14.3 Lines..........................................................................................................9:90
9.15 Paint/coatings ................................................................................................9:91

9 Frame, body, cab and accessories – Frame, body, cab and accessories 9:3
9 Frame, body, cab and

accessories
Controls and instruments, overview
Overview
Overview
1 2 3 4 5
15
12 13 12 11 10 9 8 7 6
14
015102
1. Left 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. Emergency stop switch for hydraulics (S250)
8. Switch for parking brake (S107)
9. Control lever (S815)
10. Driver's seat
11. Accelerator pedal (B690)
12. Brake pedals
13. Declutch pedal (S220-1)
14. Electronic box with fuses and relays
15. Hour meter (P708)

9:4 9 Frame, body, cab and accessories – Controls and instruments
Left-hand instrument panel

Left-hand instrument panel
16. Switch for fan (S118)
17. Switch for heating (S117)
29 30 31 18. Switch for air distribution (S139)
24..28
19. Switch for working lights cab roof (S105-1)
19..23 20. Switch, work lights on carriage and attachment (S105-2)
18 Auxiliary work lights, carriage and attachment
17
010907
21. Switch for work lights on mast (S105-3)
16
Auxiliary work lights, mast
Left instrument panel
22. Switch for revolving beacon (S110)
23. Switch for flashing hazard lights (S109)
24. Switch for headlights (S100)
25. Spare
26. Spare
27. Spare
28. Spare
29. Spare
30. Spare
31. Socket 12 VDC

9 Frame, body, cab and accessories – Controls and instruments 9:5
Steering wheel panel

Steering wheel panel
36
35
34 32. Warning lamp, low battery charging
33
32 33. Warning lamp for low brake pressure
34. Indicator for active error codes
35. Warning lamp, by-pass of hydraulic functions
36. Not used
37..41 37. Warning lamp, high coolant temperature
49
38. Warning light, low oil pressure engine
42..46 39. Indicator light for preheating
47 48 40. Warning lamp for low coolant level engine
41. Warning lamp for high transmission oil temperature
42. Warning lamp, low fuel level
43. Warning lamp, high temperature hydraulic oil
50 51 52 53 44. Indicator light, high beams
45. Indicator light, travel direction indication
46. Indicator light, parking brake
47. Indicator light, locked twistlock (secured load)
48. Indicator light, alignment (attachment / load)
49. Indicator light, unlocked twistlock (load released)
50. Panel, warning and indicator lights
51. Control system display
64
54 52. Control system indicator
63 53. Ignition
55
62 54. Switch for defroster
56
55. Switch, windscreen wiper roof, interval
008132
61 60 59 58 57
56. Switch, windscreen wiper roof, continuous
Steering wheel panel 57. Switch, interior lighting
58. Switch, windscreen wiper rear, interval
59. Switch, windscreen wiper rear, continuous
60. Control system function keys
61. Travel direction indicator, Forward Neutral Reverse
62. Shifting program A, automatic shifting
63. Shifting program 1, locked to 1st gear
64. Shifting program 2, locked to 2nd gear

9:6 9 Frame, body, cab and accessories – Controls and instruments
Panel for hydraulic functions

Panel for hydraulic functions
68 65. Lift/lower (R8071)
66. Tilt (R8072)
70
67. Side shift (R8073)
72
68. Opening the twistlocks (S1002)
69. Switch, horn (S149)
74
70. Switch for twistlock, automatic/manual locking (S1003)
71. Switch, spreading 20'-40' (attachment) (S1012)
74
72. Switch for stopping spreading at 30' (attachment) (S1004)
73
73. Switch, automatic spreading 20'-40' (S1012-2)
74. Switch for bypassing of hydraulic functions (S1005)
014179 Key for bypassing hydraulic functions
8 7 69
Panel for hydraulic functions and control lever
65
66
68 67
7
69
70
71
72
73
014178
8 74 74
Panel for hydraulic functions and linear control levers

9 Frame, body, cab and accessories – Controls and instruments 9:7
Operating menus, overview
1 2 3 4
9 8 7 6
10
014668
11 12 13 14
1. Engine and transmission operating menu 8. Service operating menu
2. Engine operating menu 9. Operating menu heating and air conditioning
3. Operating menu for oil temperature 10. Operating menu, code lock
4. Operating menu electrical system 11. Operating menu statistics, operating hours
5. Operating menu, container counter 12. Operating menu statistics, fuel consumption
6. Operating menu service interval 13. Operating menu statistics, driving distance
7. Operating menu statistics 14. Operating menu statistics, lift statistics
Event menus overview
Event menus overview
Side lift attachment with twistlocks
1 2 3 4
014669
1. Event menu, twistlock alignment

2. Event menu twistlocks
3. Event menu open door
4. Event menu automatic spreading

9:8 9 Frame, body, cab and accessories – Gear selector and multi-function lever
9.1.1 Gear selector and multi-function lever

Gear selector and multi-function lever, description
Movement
The following functions are handled by the gear and multi-function
2 lever (position 2).
3 1
0 Move-
ment Function
For- Travel direction (for selecting shifting program and
ward/Re- travel direction, see section 2 Transmission).
verse
000338
Inward, Washing of windscreen, roof window and rear window.
handle
The signal can be checked via the diagnostic menu.
see section 8 Control system, group 8.4.3.1 CAB,
menu 1
Rotation Windscreen wiper, front.
0 – No wiping of front window. If wiper rear or roof are
active then these run at slow interval wiping.
1 – Slow interval wiping front window, controls slow
interval wiping for roof window and rear window.
2 – Fast interval wiping front window, controls fast
interval wiping for roof window and rear window.
3 - Continuous wiping of front window. If wiper rear or
roof are active then these run at fast interval wiping.
See section 8 Control system, group 8.4.3.2 CAB,
menu 2.
Upward Light signal

Downward High beam (on/off)
With headlights on: The gear selector multi-function
lever are used for switching between high and low
beam.
With headlights off: The gear selector and
000339
A multi-function lever are used to flash with the

headlights.
See section 8 Control system, group 8.4.2.3 LIGHTS,
menu 3.
Inward, Horn (position A).
button
See section 8 Control system, group 8.4.3.5 CAB,
menu 5.

9 Frame, body, cab and accessories – Switch, direction indicators 9:9
Gear selector and multi-function lever, replacement

1 Separate the steering wheel panel.
6 attaching bolts and 2 bolts to the steering wheel shaft.
Remove the steering wheel, see Steering wheel panel,
2 Undo the attaching bolts (2 x hexagonal socket bolts).
3 Unplug the connector from Control unit KIT (D790-2).
4 Fit a new lever and refit the steering wheel panel.
9.1.22 Switch, direction indicators

Switch, direction indicators, replacement
2 Remove the steering wheel and separate the steering wheel panel.
3 Detach the cable harness from the direction indicator.

4 Press together the clips on the direction indicator and detach it
from the steering wheel panel.
5 Replace the direction indicator, fitting it in the reverse order.

9:10 9 Frame, body, cab and accessories – Safety and emergency equipment
9.2 Safety and emergency equipment

9.2.1 Control breaker
Emergency stop switch, description
See section 11 Common electrics, group 11.5.1.4 Emergency stop
switch voltage.
9.2.2 Seat belt

Seat belt, description
The seat belt is a two or a three-point belt, depending on the type of
seat fitted in the machine. The seat belt is mounted on the seat.
9.2.3 Fire extinguisher

Fire extinguisher, description
The fire extinguisher is located by the instep on the left-hand frame

member or inside the cab. Usage instructions are on the fire
extinguisher.
9.2.4 Seat buzzer

Seat buzzer, description
See 9.3.14 Sensor, operator-in-seat, page 9:19.

9 Frame, body, cab and accessories – Seat 9:11
9.3 Seat
Seat, general
There are three versions of the driver's seat:
• Seat, description (product alternative Hao Bang), page 9:11
• Seat, description (product alternative BE-GE 9200), page 9:12
• Seat, description (product alternative BE-GE 9200 air
suspension), page 9:13
As an option, the machine can be equipped with a fold-down passenger

seat to the left of the operator.
Seat, description (product alternative Hao Bang)

The seat's function is to provide the operator with a good sitting
position and contribute to a good work environment. The cab's seat
1 has several adjustment options and fulfils high comfort standards.
The seat has the following equipment:

• mechanical height adjustment
• seat cushion angling
• arm rest right
• two-point seat belt
• head rest
2 3
The seat is equipped with a sensor which detects if there is downward
pressure on the seat cushion. This is used to activate the buzzer if the
operator leaves the seat without applying the parking brake as well as
without putting the transmission in neutral position if leaving the seat.
7
5
014151
4
1. Head rest
2. Adjusting arm rest, right
3. Back rest rake adjustment
4. Display of weight setting
5. Seat height adjustment
6. Seat cushion angle adjustment
7. Front/rear adjustment

9:12 9 Frame, body, cab and accessories – Seat
Seat, description (product alternative BE-GE

9200)

1 2 position and contribute to a good work environment. The cab's seat
has several adjustment options and fulfils high comfort standards.
3 The seat has the following equipment:

• mechanical height adjustment
• arm rest right
4 • two-point seat belt
• seat heating
• head rest
• armrest left
5 The seat is equipped with a sensor that senses the spring deflection
of the seat. This is used to activate the buzzer if the operator leaves
the seat without applying the parking brake as well as without putting
8 6
006825
the transmission in neutral position if leaving the seat.

7
Controls
1. Adjusting lumbar support
3. Adjusting arm rest, left
5. Adjusting suspension position

9 Frame, body, cab and accessories – Seat 9:13
Seat, description (product alternative BE-GE 9200

air suspension)

1 2 position and contribute to a good work environment. The cab's seat
has several adjustment options and fulfils high comfort standards.
The air suspension automatically adjusts seat height and suspension
3 to the operator's weight. The air suspension is supplied by a special
compressor installed on the underside of the cab.
The seat has the following equipment:

4 • air suspension (with external compressor)
• arm rest right
• three-point seat belt
• seat heating
5 • armrest left
• head rest
8 6
006826
The seat is equipped with a sensor that senses the spring deflection
7 of the seat. This is used to activate the buzzer if the operator leaves
Controls BE-GE 9200 the seat without applying the parking brake as well as without putting
the transmission in neutral position if leaving the seat.
1. Adjusting lumbar support
3. Adjusting arm rest, left
5. Adjusting suspension position
Seat, replacement (product alternative BE-GE

9200)
2 Slide back the seat to its rear position, remove the front attaching
bolts.

9:14 9 Frame, body, cab and accessories – Seat cushion
3 Slide the seat to its front position, remove the rear attaching bolts.
4 Disconnect the seat's connectors from the machine's cabling.
5 Remove the seat.
9.3.1 Seat cushion

Seat cushion, description
The function of the seat cushion is to provide good comfort to the
operator. Under the seat cushion is the driver's seat frame and a circuit
breaker for the buzzer. There may be a heating coil fitted ( ).
For location, see Seat, general, page 9:11.
Seat cushion, replacement (product alternative

BE-GE)
2 Loosen the rubber bellows by removing the plastic clips.
3 Unhook the upholstery's rails from the seat frame and remove
the upholstery.
2 5 4 Remove the padding.
If the seat is equipped with seat heater.
4 Unplug the connector for the heating coil before the padding is
removed.
NOTE
The seat's heating coil is glued to the padding. Exercise caution
if the padding is to be replaced but the heating coil is to be
re-used, or if only the coil is to be replaced.
3
5 Assemble in reverse order.
1
006276
1. Plastic clip, rubber bellows

2. Upholstery
3. Seat frame
4. Padding
5. Heating coil

9 Frame, body, cab and accessories – Back rest cushion 9:15
9.3.2 Back rest cushion

Back rest cushion, description
The function of the back rest cushion is to provide good comfort to the
operator. Under the back rest cushion is the driver's seat frame. There
may be a heating coil fitted ( ).
For location, see Seat, general, page 9:11.
Back rest cushion, replacement (product alternative

BE-GE)
2 Detach the rubber bellows on the rear of the seat by removing
the plastic clips and folding down the rubber bellows. See Seat
cushion, replacement (product alternative BE-GE), page 9:14.
3 3 Remove the back rest by first removing the attaching bolts on the
right and left-hand side of the seat and then remove the attaching
bolts for the seat belt on the right and left-hand side of the seat.
4 4 If the seat is equipped with 3-point seat belt.
Remove the belt guide by removing the cover and the attaching
bolt.
5 If the seat is equipped with arm rests.
Remove the arm rest by removing the attaching bolts.
6 Position the back rest on the seat and fit the attaching bolts, do
5 not tighten them. Then fit the attaching bolts for the seat belt.
Tighten the attaching bolts for the seatbelt with a torque of 42 Nm,
then tighten the attaching bolts with a torque of 33 Nm.
7 If the seat is equipped with 3-point seat belt or arm rest.
6 Cut holes in the upholstery for seat belt and arm rest on the new
back rest before arm rest or seat belt is installed.
006278
1 2
1. Attaching bolt back rest
2. Attaching bolt, seat belt
3. Cover, belt guide
4. Attaching bolt, belt guide
5. Arm rest
6. Attaching bolt, arm rest

9:16 9 Frame, body, cab and accessories – Heating coil
9.3.3 Heating coil

Heating coil, description (product alternative BE-GE)
The function of the heating coil is to warm the back rest and seat
cushions in the driver's seat. The heating coil is fitted under the
upholstery on the seat.
The heating coil (E803) is supplied with voltage upon warm-up by the
Cab control unit, (D790-1) via the seat heating relay (K383). The
signal can be checked via the diagnostic menu. See section 8 Control
system, group 8.4.3.8 CAB, menu 8.
Heating coil, replacement (product alternative BE-GE)
See Seat cushion, replacement (product alternative BE-GE), page

9:14.
9.3.4 Bumper
Bumper, description
The bumpers are integrated in the suspension unit in the seat's
frame and are self-adjusting, that is, they adjust automatically to the
operator's weight.
Bumper, replacement (product alternative BE-GE)

2 Remove the driver's seat from the frame and lift it out of the
2 machine. See Seat, replacement (product alternative BE-GE
9200), page 9:13.
3 Remove the seat cushion, see Seat cushion, replacement (product
alternative BE-GE), page 9:14.
4 Remove the back rest cushion, see Back rest cushion,
1 replacement (product alternative BE-GE), page 9:15.
5 Remove the shock absorber's attaching bolts.
6 Replace the shock absorber.
7 Assemble in reverse order.
006277
1. Bumper
2. Attaching bolt
3. Attaching bolt

9 Frame, body, cab and accessories – Air suspension 9:17
9.3.5 Air suspension

Air suspension, description (product alternative
BE-GE 9200 air suspension)
The air-suspension driver's seat consists of a seat with rubber

bellows and compressor. The air suspension is self-adjusting, that
is, it adjusts automatically to the operator's weight. The compressor
provides air for the suspension unit.
001621
For location, see Seat, description (product alternative BE-GE 9200
air suspension), page 9:13.
Compressor air-suspension seat
9.3.6 Compressor air-suspension seat

Compressor air-suspension seat, description (product
alternative BE-GE 9200 air suspension)
The compressor is part of the air-suspension driver's seat and is fitted

inside the seat's suspension unit.
001621
Compressor air-suspension seat

9:18 9 Frame, body, cab and accessories – Mechanical seat adjustment
9.3.7 Mechanical seat adjustment

Mechanical seat adjustment, description
Seat adjustment is all mechanical and is adapted by the operator with
different controls in order to obtain a good sitting position.
See:
• Seat, description (product alternative BE-GE 9200), page 9:12
• Seat, description (product alternative BE-GE 9200 air suspension),
page 9:13
• Seat, description (product alternative Hao Bang), page 9:11
9.3.8 Passenger seat

Passenger seat, description
The passenger seat is collapsible (vertically), provided with a seat belt

and is located on the left-hand side of the driver's seat.
001627
Passenger seat with bracket
9.3.9 Arm rest

Armrests, description
The armrest is affixed to the back rest and is individually adjustable
vertically (around the attachment point).
An option there are also arm rests available on the left-hand side.

9 Frame, body, cab and accessories – Sensor, operator-in-seat 9:19
9.3.14 Sensor, operator-in-seat

Sensor, operator-in-seat, description (product
alternative Hao Bang)
Sensor, operator-in-seat (S230) is fitted under the seat cushion's
upholstery and it detects whether the driver's seat is depressed, which
indicates to the control system that the driver's seat is occupied.
This is used to allow the control system to indicate with Buzzer,
operator-in-seat (H853) if the operator leaves the driver's seat without
applying the parking brake.
The signal from Sensor, operator-in-seat (S230) is also used to set

the transmission in neutral position if the operator leaves the seat. In
an emergency situation the machine can be operated by bypassing
the safety system. Activate the by-pass switch, select travel direction
and drive the machine to the workshop. Speed is limited to 10 km/h.
014164
Sensor, operator-in-seat (S230) (product alternative Hao

DANGER
Bang)
Bypassing the safety systems results in a risk of

tipping. Use at your own risk.
damage!
situations.
Sensor, operator-in-seat (S230) is supplied with voltage by and

sends a voltage signal to Control unit, cab (D790-1). The signal can
be checked via the diagnostic menu. See section 8 Control system,

9:20 9 Frame, body, cab and accessories – Sensor, operator-in-seat
Sensor, operator-in-seat, description (product

alternative BE-GE)
1 Sensor, operator-in-seat (S230) is fitted under the seat cushion and

it detects whether the driver's seat suspension is depressed, which
indicates to the control system that the driver's seat is occupied.
This is used to allow the control system to indicate with Buzzer,
operator-in-seat (H853) if the operator leaves the driver's seat without
2 applying the parking brake.
The signal from Sensor, operator-in-seat (S230) is also used to set

the transmission in neutral position if the operator leaves the seat. In
an emergency situation the machine can be operated by bypassing
the safety system. Activate the by-pass switch, select travel direction
and drive the machine to the workshop. Speed is limited to 10 km/h.
008220
DANGER
Seat, view from below
1. Sensor, operator-in-seat, (S230) (product Bypassing the safety systems results in a risk of
alternative BE-GE) tipping. Use at your own risk.
2. Buzzer (H853)
damage!
situations.
Sensor, operator-in-seat (S230) is supplied with voltage by and

sends a voltage signal to Control unit, cab (D790-1). The signal can
be checked via the diagnostic menu. See section 8 Control system,

9 Frame, body, cab and accessories – Heating, ventilation and air conditioning 9:21
9.4 Heating, ventilation and air

conditioning
Heating, ventilation and air conditioning,
description
Heating system (EHC)
The heating system controls heating and ventilation of the cab. The
F cab can also be equipped with air conditioning ( ).
The temperature in the cab is thermostat-controlled by Control

unit, cab (D790-1). The cab temperature is regulated to the set
2 temperature. The temperature can be set between 16 and 28 °C. The
unit is operated with controls on the dashboard panel.
4
D Heating system (EHC)
C
The heating system (EHC) handles heating and ventilation. (The
heating system cannot provide cooling.)
E E
The heating system uses heat from the engine's cooling system via a
3
heating coil to heat the ambient air. The fan forces the ambient air
through the heating coil on through ducts in the cab interior. It is then
directed to the windscreen (defroster) or the feet.
Air conditioning (ECC)
6 A B
The climate control system (ECC) is responsible for heating,
ventilation, cooling and dehumidifying. The air is heated in the same
way as for the heating system (EHC).
During cooling, ambient air is forced through the evaporator, which

cools the air. The air can then be directed in the same way as for
1 the heating system.
5 G
The function of the air conditioning is to:
000762
• heat the air when it is cold

Outline view, air conditioning • dehumidify the air when it is damp
1. Fluid reservoir/filter dryer with integrated • clean the air of impurities
pressure switch
• cool the air when it is hot
2. Heating coil and evaporator
• defrost (defroster function)
3. Fan
4. Expansion valve
5. Condenser IMPORTANT
6. Compressor
A High-pressure gas On machines with ECC or AC, it is vital that the engine
B High-pressure fluid cooling system is refilled with coolant with the correct
concentration of antifreeze. Otherwise there is a risk
C Low-pressure fluid that the air conditioning system will freeze during
D Low-pressure gas usage.
E Outdoor air for cab ventilation
F Heated or cooled air to the cab
G Outdoor air for eliminating heat

9:22 9 Frame, body, cab and accessories – Heating, ventilation and air conditioning
Heating, ventilation and air conditioning, function

description
2 1 3 26
D D 25
D
4 °C D
D
°C
6
7 D790-1 D790-2 D795
D D D797-1
16
D D794
15 D
12
M D D
14 22 23
5 °C Pa °C
M D
D 19 21
13 20 C 24
M 18
17
D
D 9
M
°C
8 11
10
007690

1 Switch, temperature (S117) sends Raise: U = 2.0–2.5 V Controls and instruments, overview, page
a voltage signal to Control unit, cab 9:3
Unaffected: U = 0-0.5 V
(D790-1).
Lower: U = 4.5-5.0 V
system, group 8.4.4.5, CLIMATE menu 5
2 Switch, fan (S118) sends a voltage Raise: U = 2.0–2.5 V Controls and instruments, overview, page
signal to Control unit, cab (D790-1). 9:3
Unaffected: U = 0-0.5 V
Lower: U = 4.5-5.0 V
3 Switch, air distribution (S139) sends Scroll up: U = 2.0–2.5 V Controls and instruments, overview, page
a voltage signal to Control unit, cab 9:3
Unaffected: U = 0 V
(D790-1).
Scroll down: U = 4.5-5.0 V
4 Sensor, cab temperature (B775-1) R = 10 kΩ at 25 ºC Sensor, cab temperature, description, page
sends a voltage signal proportional to 9:53
the temperature to Control unit, cab
(D790-1).


5 The outlet fan temperature sensor R = 10 kΩ at 25 ºC Sensor, temperature outlet fan, description,
(B775-2) sends the cab control unit page 9:52
to temperature.
6 Sensor, ambient temperature (B774) R = 10 kΩ at 25 ºC Sensor, ambient temperature, description,
sends a voltage signal proportional to page 9:54
(D790-1).
7 Control unit, cab (D790-1) regulates Checked by control Section 11 Common electrics, group
temperature and air distribution with system, error shown with 11.5.3.1 Control unit, cab
signals from sensors and controls. error code.
8 The engine produces heat while running. - -
It is cooled with the cooling system. The
heat from the cooling system is used to
heat the cab air.
9 Control unit, cab (D790-1) controls U = 0.5-4.5 V Water valve, description, page 9:38
Water valve (Y673), which routes hot
water for heat exchanger heat.
system, group 8.4.4.7 CLIMATE, menu 7
The water valve's opening (%) is fed and 8.4.4.4 CLIMATE, menu 4
back to the Control unit, cab (D790-1).
This gives information for controlling the
water valve's position.
10 Sensor, engine temperature, sends a Checked by control Section 1 Engine
voltage signal proportional to the engine system, error shown with
temperature to Control unit, engine error code.
(D794).
11 Heat exchanger heat supplies heat to - Heat exchanger heat, description, page 9:35
the cab air. The heat is transferred from
the engine's cooling system to the cab
air.
12 Control unit, engine (D794) transmits Checked by control Section 11 Common electrics, group
engine temperature in the cooling system, error shown with 11.5.3.10 Control unit, engine
system on the CAN bus. error code.
13 Control unit, cab (D790-1) controls Checked by control Fresh air filter or recirculation damper,
Actuator motor, recirculation (M612) system, error shown with description, page 9:29
which sets the fresh air or recirculation error code.
damper in the required position.
14 Control unit, cab (D790-1) controls Fan Checked by control D14: Diagnostic menu, see section 8 Control
motor (M657), which increases the system, error shown with system, group 8.4.4.6, CLIMATE menu 6
airflow in the cab. error code.
15 Control unit, cab (D790-1) controls U = 0.5-4.5 V Air distributor, description, page 9:50
Damper motor (Y672), which sets the air
distributor to the required position.
Control system, group 8.4.4.8 CLIMATE,
The air distributor's position is fed back menu 8 and 8.4.4.4 CLIMATE, menu 4
to Control unit, cab (D790-1). This
gives information for controlling the air
distributor's position.
16 The frame control unit (D797-1) controls Checked by control Section 11 Common electrics, group
AC compressor connection. system, error shown with 11.5.3.3 Frame control unit
error code.


17 The frame control unit (D797-1) supplies U = 24 V Compressor, description (engine alternative
voltage to the compressor's solenoid Cummins QSB6.7 ), page 9:39
valve (645).
18 The compressor draws gaseous - Compressor, description (engine alternative
refrigerant from the evaporator, Cummins QSB6.7 ), page 9:39
compresses it, and forces it on to the
condenser.
19 The condenser cools the refrigerant. - Condenser, description, page 9:43
The gaseous refrigerant condenses to
liquid form and is pumped on in the
circuit.
20 The moisture filter absorbs any moisture - Moisture filter, description, page 9:45
from the cooling circuit. The fluid
reservoir stores the refrigerant.
21 The pressure switch (S246) sends a U = 24 V Pressure switch, description, page 9:45
signal to the frame control unit (D797-1)
if the pressure in the system becomes
abnormally high or low.
22 The expansion valve adjusts the - Expansion valve, description, page 9:46
amount of refrigerant that is let in to the
evaporator. If the temperature in the
evaporator's outlet pipe increases, the
expansion valve increases the flow of
refrigerant so that heat dissipation in the
evaporator increases.
23 Sensor, refrigerant circuit temperature, R = 10 kΩ at 25 ºC Sensor, temperature refrigerant, description,
sends a voltage signal proportional to page 9:48
(D790-1).
system, group 8.4.4.2, CLIMATE menu 2.
24 Heat exchanger, cooling, dissipates heat - Heat exchanger, cooling, description, page
from the cab air. The heat is transferred 9:49
from the air to the refrigerant and
transforms the refrigerant to a gaseous
state.
25 The defroster switch on Control unit KIT Checked by control Section 11 Common electrics, group
(D790-2) activates the defroster program system, error shown with 11.5.3.11 Control unit, KIT
for the air conditioning for six minutes. error code.
26 Control unit KID (D795) shows the Checked by control Section 11 Common electrics, group
heating and ventilation settings in the system, error shown with 11.5.3.12 Control unit, KID
display. error code.

Heating, ventilation and air conditioning,

checking
2 Navigate to the service menu and press Enter.
000056
3 Enter the code for diagnostics. Code is obtained from Cargotec
Support.
1 23
4 5 000060
NOTE
4 Select CLIMATE.
DIAGNOSIS
CLIMATE HYD ENGINE
004998
OLS EXTRA
Menu 1
DIAG CLIMATE 1(8)
5 Checking the desired temperature, inside temperature sensor and
PRESENT INPUT SIGNAL water valve.
REQUIRED TEMP XXX
PRESENT TEMP XXX REQUIRED TEMP: should be 160 (16.0 ºC) for max. cooling and
280 (28.0 ºC) for max. heating. The setting is changed with the
000132
WATER VALVE FEEDB. XXX temperature switch.

PRESENT TEMP: shows the temperature inside the cab. This is
measured by Sensor, cab temperature (located down to the left on
the instrument panel, behind the rubber lead-through). Blowing
through the hole should increase the value.
WATER VALVE FEEDB. should show 0 (closed) when the
requested temperature is 160, and 100 (open) when the requested
temperature is 280. The water valve is located under the cab.
Menu 2
DIAG CLIMATE 2(8)
6 Check of Sensor, temperature outlet fan (B775-2), engine
TEMP COIL XXX temperature, Sensor, outdoor temperature (B774), and check of
TEMP COOLANT XXX Sensor, temperature refrigerant (B775-1).
TEMP AMBIENT XXX
TEMP COIL: temperature that the air has in the air distributor is
000133
TEMP DE-ICE XXX measured by Sensor, temperature outlet fan (B775-2).

TEMP COOLANT: engine temperature that is sent on the CAN bus.
TEMP AMBIENT: outdoor temperature that is measured by
Sensor, outdoor temperature (B774).
TEMP DE-ICE: the cooling circuit's temperature is measured by
the refrigerant temperature sensor (B775-1). If the compressor
is activated, the value will be low. However, if heat has been
selected and the compressor is deactivated, the value will almost
be equal to TEMP COIL.

Menu 3
DIAG CLIMATE 3(X)
7
PRESENT INPUT SIGNAL (Only machines with ECC)
PRESSURE SWITCH X Checks that the refrigerant circuit is filled.
OPT DOOR SWITCH X
006865
PRESSURE SWITCH: 0 = not filled, 1 = filled.
The sensor is located on the receiver drier which is fitted right
rear in the frame.
Menu 4
DIAG CLIMATE 4(8)
8 Checks Water valve (Y673) and Air distributor (Y642).
WATER VALVE XX.XXV WATER VALVE: should work between 1.0-1.24 V and 2.95-3.2 V.
DRAUGHT VALVE XX.XXV This is checked by turning the temperature control and changing
000135 the temperature setting from min. to max.
DRAUGHT VALVE: should work in the range 1.0-4.0 V. The
difference between min. and max. should be approx. 1 V. This is
checked by changing the air distribution from floor to front window.
At the same time, feel with your hand so that air blows through
different vents.
NOTE
Air to the round panel vents is not controlled by the air
conditioning.
Menu 5
DIAG CLIMATE 5(8)
9 Checks the switches for temperature, air distribution and fan
PRESENT INPUT SIGNAL speed.
REQ. DRAUGHT XX.XXV REQUIRED TEMP: home position U = 0 V; raise U = 2-2.5 V;
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
DIAG CLIMATE 6(8)
10 Checks Cab fan (M657), Fresh air and recirculation damper
FAN SPEED XXX (M612) and Electromagnetic clutch, compressor (M645) .
RECIRKULATION XY FAN SPEED: increase and decrease fan speed, value should
000137
COMPRESSOR XY increase from 0 to 255 in steps.

RECIRCULATION: press in the Switch, bypass (S1005) (on the
panel for load handling functions). When checking, the display
should show "11". Check that the damper actually moves as it
should by removing the fresh air filter at the front of the climate
control system casing and feeling with your hand.
(Only machines with ECC)

COMPRESSOR: lower the temperature setting to max. cooling,
after approx. 45 seconds the compressor will be activated and
the display should show "11".
NOTE
Compressor activation can only be tested when the engine is
running and the system is filled.

Menu 7
DIAG CLIMATE 7(8) 11 Checks the direction selector for Water valve (Y673).
OUTPUT WATER VALVE
CLOCKWISE XY XY CLOCKWISE: when the temperature is increased and the water
ANTI-CLOCKWISE XY XY valve opens shows "CLOCKWISE 11 11" and "ANTI-CLOCKWISE
00 11".
ANTI-CLOCKWISE: when the temperature is decreased
and the water valve closes shows "CLOCKWISE 00 11" and
24V "ANTI-CLOCKWISE 11 11".
NOTE
The "ones" are only shown for a moment when the water valve
changes position, "zeros" are shown when the valve does not
change position. The water valve does not open if the engine
M temperature is low, or if the outdoor temperature is high.
000138
0V
Menu 8
DIAG CLIMATE 8(8)
OUTPUT DRAUGHT VALVE 12 Checks the direction selector for the air distributor.
CLOCKWISE XY XY CLOCKWISE: when the air is directed against the windscreen and
ANTI-CLOCKWISE XY XY the air distributor changes position shows "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 distributor
changes position, "zeros" are shown when the air distributor
does not change position.
M
000139
0V

9:28 9 Frame, body, cab and accessories – Fresh air filter
9.4.1 Fresh air filter

Fresh air filter, description
The fresh air filter is located under a cover in the external unit for fresh
air intake into the cab, in front of the cab fan.
1 004999
Fresh air intake, cab

1. Fresh air filter
2. Fresh air and recirculation damper

9 Frame, body, cab and accessories – Fresh air filter or recirculation damper 9:29
9.4.2 Fresh air filter or recirculation damper

Fresh air filter or recirculation damper, description
The damper is controlled electrically and controls the air between fully
open for fresh air to recirculation of air. The damper is located in the
external unit for fresh air intake into the cab.
The signal can be checked via the diagnostic menu, section 8 Control
system, group 8.4.4.6 CLIMATE, menu 6.
2
004999
1
1. Fresh air filter
2. Fresh air and recirculation damper

9:30 9 Frame, body, cab and accessories – Fresh air filter or recirculation damper
Motor, fresh air filter or recirculation damper,

replacement
2 Remove the wiper arms.
3 Remove the nuts which hold the wiper motor in the protective plate.
4 Remove the protective plate.
5 Remove the fresh air filter.

9 Frame, body, cab and accessories – Fresh air filter or recirculation damper 9:31
6 Remove the bolts which secure the arm and motor in the plate.
7 Detach the connector from the motor.
8 Replace the motor.
9 Fit in the reverse order. Tighten the wiper arm to torque 16-20 Nm.

9:32 9 Frame, body, cab and accessories – Cabin fan
9.4.3 Cabin fan

Cab fan, description
The cab fan is located in the external unit for fresh air intake into the
cab. The fan consists of two single fans that are driven by a motor.
1
003209

1. Cabin fan
Cab fan, replacement


9 Frame, body, cab and accessories – Cabin fan 9:33
3 Remove the bolts which hold the wiper motor in the protective
plate.
5 Detach the washer hose from the protective plate.

9:34 9 Frame, body, cab and accessories – Cabin fan
7 Remove the bolts which secure the plate and cab fan.
8 Detach the connector from the cab fan.

9 Remove the cab fan.
10 Replace the cab fan.

9 Frame, body, cab and accessories – Heat exchanger heat 9:35
9.4.4 Heat exchanger heat

Heat exchanger heat, description
The heat from the engine's coolant is transferred to the cab via the
heat exchanger. The heat exchanger is located behind the fan in the
external unit for fresh air intake into the cab.
1, 2
3
003210

1. Heat exchanger heat
2. Heat exchanger, cooling
3. Expansion valve and sensor for refrigerant
temperature
Heat exchanger, cooling/heating, replacement
WARNING
Personal injury, environmental damage.
Read the safety instructions for refrigerant, see section
B Safety.

9:36 9 Frame, body, cab and accessories – Heat exchanger heat
2 Drain the AC system of R134a refrigerant.
IMPORTANT
Working on the air conditioning requires special
authorisation.
3 Detach the AC system hoses and the coolant hoses.

5 Remove the nuts which hold the wiper motor in the protective plate.

9 Frame, body, cab and accessories – Heat exchanger heat 9:37
9 Remove the plate frame.
10 Remove the cab fan.
11 Remove the heat exchanger cover plate.
12 Detach all fluid inlets and outlets from the heat exchanger.
13 Lift out the heat exchanger carefully.
14 Replace the heat exchanger.
15 Fit in the reverse order. Tighten the wiper arm to 16-20 Nm.
16 Check for leaks and refill the AC-system with refrigerant R134a,
using the intended equipment.
For volume, see section F Technical data.
IMPORTANT
Connection points for cooling hoses. authorisation.

9:38 9 Frame, body, cab and accessories – Water valve
9.4.5 Water valve

Water valve, description
The water valve controls the climate control system's capacity for
heating from 0 (closed valve) to 100% (open valve). The water valve
is electrically controlled.
The signal can be checked from the diagnostic menu, section 8

Control system, group 8.4.4.1 CLIMATE, menu 1, 8.4.4.4 CLIMATE,
menu 4 and 8.4.4.7 CLIMATE, menu 7.
010021
Water valve position under cab floor (from below)
Water valve, replacement

2 Detach the connector from the water valve.

3 Stop the flow of fluid to and from the water valve using hose
pinch-off pliers.
4 Detach the coolant hoses from the water valve.
5 Remove the water valve from the cab floor.
6 Replace the water valve.
8 Check the coolant level.
9 Run the heating system at the highest setting (fully open valve) to
vent air from the system.
1. Water valve
2. Steering valve
9.4.6 Sensor, engine temperature

Sensor, engine temperature, description
Sensor, coolant temperature, is fitted on the engine and detects
engine's coolant temperature. See supplier documentation, engine.
For location, see section 1 Engine.

9 Frame, body, cab and accessories – Compressor 9:39
9.4.7 Compressor
Compressor, description (engine alternative Yuchai
YC6A240-30)
1
The compressor drives the air conditioning by working as a pump. It
draws in cold, low-pressure gas from the evaporator, compresses the
gas which then becomes warm, and then forces out high-pressure
gas to the condenser.
The compressor is driven by V-belts directly by the machine's engine.

Activation and deactivation of the compressor is handled by an
electromagnetic clutch, which is controlled by a thermostat.
3
2
015087
1. Compressor
2. Belt tensioner
3. Drive belt
Compressor, description (engine alternative Cummins

QSB6.7 )
1 2 3
The compressor drives the air conditioning by working as a pump. It
draws in cold, low-pressure gas from the evaporator, compresses the
gas which then becomes warm, and then forces out high-pressure
gas to the condenser.
The compressor is driven by V-belts directly by the machine's engine.

Activation and deactivation of the compressor is handled by an
electromagnetic clutch, which is controlled by a thermostat.
4
009116
1. Rigging screw (belt tensioner)

2. Compressor
3. Connections
4. Screw and nut
5. Drive belt

9:40 9 Frame, body, cab and accessories – Compressor
Compressor, changing (engine alternative Yuchai

YC6A240-30)
WARNING
B Safety.
NOTE
For tightening torque of refrigerant hoses and pressure switch, see
section F Technical data.
IMPORTANT
authorisation.
3 Detach the coolant hoses from the compressor.

1
4 Loosen the belt tensioner so that the drive belt is released.
5 Undo the hose couplings and detach the hoses from the
compressor intake and outlet. Plug the connections immediately
to prevent contamination.
6 Remove the bolts which secure the compressor.
7 Drain the oil from the old compressor (through the intake and
outlet connections) and the hoses. Measure the oil quantity.
3
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.
10 Fit the new compressor and other equipment in reverse order.
2 using the intended equipment.
015087
For volume, see the plate for the climate control system.
1. Compressor
2. Belt tensioner
IMPORTANT
3. Drive belt
authorisation.
NOTE
Fill new oil through the compressor's suction connection.

9 Frame, body, cab and accessories – Compressor 9:41
Compressor, replacement (engine alternative

Cummins QSB6.7 )
WARNING
B Safety.
NOTE
IMPORTANT
authorisation.
3 Detach the coolant hoses from the compressor.

1 2 3
4 Loosen the turnbuckle so that the compressor belt is released.
5 Undo the hose couplings and detach the hoses from the
compressor intake and outlet. Plug the connections immediately
to prevent contamination.
6 Remove the bolts which secure the compressor.
7 Drain the oil from the old compressor (through the intake and
outlet connections) and the hoses. Measure the oil quantity.
8 Drain the oil from the new compressor.
4
9 Fill the new compressor with the same quantity of oil as was
009116
5 drained from the old compressor - minimum 0.1 litre.

10 Fit the new compressor and other equipment in reverse order.
1. Rigging screw (belt tensioner)
2. Compressor 11 Check for leaks and refill the AC-system with refrigerant R134a,
3. Connections
For volume, see the plate for the climate control system.
4. Screw and nut
5. Drive belt
IMPORTANT
authorisation.
NOTE
Fill new oil through the compressor's suction connection.

9:42 9 Frame, body, cab and accessories – Compressor
Pulley and electromagnetic clutch, replacement

There is no need to drain refrigerant from the system before
replacement.
2 Slacken the belt tensioner and remove the drive belt.

3 Remove the screw from the centre of the pulley.
006263
4 Remove the locking washer and the outer lock ring.

1
2
006264
1. Lock ring
2. Locking washer
5 Remove the groove.

1
006265
1. Groove

9 Frame, body, cab and accessories – Condenser 9:43
6 Remove the three screws securing the electromagnetic clutch.
006266
7 Remove the clutch coil
1
006267 9 Check the function.
1. Electromagnetic clutch
9.4.8 Condenser
Condenser, description
The condenser is located on the radiator in the engine compartment.

The function of the condenser is to convert the hot, high-pressure
gas from the compressor to liquid form. Pipes and cooling fins in the
1 condenser battery absorb the heat, which is dissipated with a fan.
The temperature of the refrigerant in the condenser varies from

approx. 50 ºC to 70 ºC and the pressure varies between 12 and
2 14 bar, depending on ambient temperature and airflow through the
4 condenser. When the refrigerant has been condensed to liquid, it is
directed on to the fluid reservoir/filter dryer.
3
014686
1. Intercooler
3. Radiator
4. Condenser

9:44 9 Frame, body, cab and accessories – Condenser
Condenser, replacement
WARNING
B Safety.
NOTE

1
IMPORTANT
2 authorisation.
4
3 Detach the inlet and outlet hoses from the condenser.
3
4 Remove the bolts which secure the condenser at the top edge and
lift the condenser out in a suitable way.
5 Replace the condenser, fitting it in the reverse order.
014686

1. Intercooler
2.
3.
Transmission oil cooler
Radiator
IMPORTANT
4. Condenser
authorisation.

9 Frame, body, cab and accessories – Moisture filter 9:45
9.4.9 Moisture filter

Moisture filter, description
NOTE
For tightening torque of refrigerant hoses and pressure switch,
see section F Technical data.
The moisture filter collects the liquid refrigerant, binds moisture, and
filters out impurities. The reservoir functions as an expansion tank in
the cooling circuit.
When the refrigerant has passed through the dryer in the bottom of
the fluid reservoir, it rises through a standpipe. Through a sight glass,
it is possible to check that there is flow without bubbles and that the
system is adequately filled with refrigerant.
1. Moisture filter
2. Pressure switch
3. Sight glass
9.4.10 Pressure switch

Pressure switch, description
NOTE
For tightening torque of refrigerant hoses and pressure switch,
The pressure switch cuts off the current to the compressor's

electromagnetic clutch if the pressure in the cooling circuit becomes
abnormally high or low.
1. Moisture filter
2. Pressure switch
3. Sight glass

9:46 9 Frame, body, cab and accessories – Expansion valve
Pressure switch, replacement
WARNING
B Safety.

2 Drain the machine of refrigerant, R134a.
IMPORTANT
authorisation.
3 Detach the connector from the pressure switch.

4 Unscrew the pressure switch from its mounting.
5 Replace the pressure switch.
1. Moisture filter
2. Pressure switch using the intended equipment.
3. Sight glass For volume, see section F Technical data.
IMPORTANT
authorisation.
9.4.11 Expansion valve

Expansion valve, description
The expansion valve is the part in the circuit that separates the
high-pressure side from the low-pressure side. The refrigerant arrives
at the expansion valve under high pressure and leaves it under low
pressure. After the expansion valve, the refrigerant converts to a
gaseous state and is transported to the compressor once again.
The amount of refrigerant that passes through the evaporator varies

depending on the heat load. The valve works from fully open to fully
closed and searches between these for an optimal evaporation point.

9 Frame, body, cab and accessories – Expansion valve 9:47
Expansion valve, replacement
WARNING
B Safety.
2 Drain the AC system of refrigerant.
IMPORTANT
authorisation.
3 Detach the AC system hoses.
4 Detach the coolant hoses.
5 Remove the heat exchanger for cooling/heating to access

the expansion valve, see Heat exchanger, cooling/heating,
6 Replace the expansion valve.
IMPORTANT
authorisation.

9:48 9 Frame, body, cab and accessories – Sensor, temperature refrigerant
9.4.12 Sensor, temperature refrigerant

Sensor, temperature refrigerant, description
Sensor, temperature refrigerant, (position 2) detects the refrigerant

temperature in the heat exchanger, cooling. This is used to control
the air conditioning.
1 system, group 8.4.4.2 CLIMATE, menu 2.
005001
2
1. Sensor cab temperature

2. Sensor temperature refrigerant
3. Sensor, temperature outlet fan
Sensor, temperature refrigerant, replacement
WARNING
B Safety.
2 Drain the AC system of refrigerant.
IMPORTANT
authorisation.
3 Detach the AC system hoses from the heat exchanger.
4 Detach the coolant hoses from the heat exchanger.
5 Detach the heat exchanger to access the refrigerant temperature

sensor, see Heat exchanger, cooling/heating, replacement, page
9:35.
6 Replace the temperature sensor.

9 Frame, body, cab and accessories – Heat exchanger, cooling 9:49
IMPORTANT
authorisation.
9.4.13 Heat exchanger, cooling

Heat exchanger, cooling, description
Heat exchanger, cooling, consists of pipes and cooling fins. The cab
air is cooled as it passes through the heat exchanger, cooling. The
heat exchanger is located behind the fan in the external unit for fresh
air intake into the cab.
1, 2
3
003210

1. Heat exchanger heat
2. Heat exchanger, cooling
3. Expansion valve and sensor for refrigerant
temperature
Heat exchanger, cooling, replacement

See Heat exchanger, cooling/heating, replacement, page 9:35.

9:50 9 Frame, body, cab and accessories – Air distributor
9.4.14 Air distributor

Air distributor, description
The air distributor controls the air between defroster and floor and is
located behind the panel inside the cab. The damper is controlled
electrically by the control system.
The signal can be checked from the diagnostic menu, section

8 Control system, group 8.4.4.4 CLIMATE, menu 4 and 8.4.4.5
CLIMATE, menu 5 and 8.4.4.8 CLIMATE, menu 8.
002230
Air distributor, replacement

2 Remove the dashboard panel.

3 Remove the steering wheel shaft cover.
4 Detach the steering wheel shaft and angle it back against the
driver's seat.
5 Remove the lower cover in front of the pedal assembly.
6 Detach the air hoses from the air distributor and detach the
connector.
1. 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

9 Frame, body, cab and accessories – Defroster nozzles 9:51
9.4.15 Defroster nozzles

Defroster nozzles, description
There are a number of fixed defroster nozzles in the cab's interior: at
the front of the doors and the defroster for the windscreen. There are
also two adjustable air vents (flow and direction) in the instrument
panel's outside corners.
There is an air inlet towards the cab's lower part (floor).
001839
Defroster nozzles, replacement

2 Remove the air damper manually.
3 Remove the bolts which hold the other part of the defroster nozzle
in the dashboard.
4 Detach the air hose from the defroster nozzle.

5 Replace the defroster nozzle.

9:52 9 Frame, body, cab and accessories – Sensor, temperature outlet fan
9.4.16 Sensor, temperature outlet fan

Sensor, temperature outlet fan, description
Sensor, temperature outlet fan, detects the temperature of the air that
blows out in the defroster nozzles. The air conditioning is controlled
by signals from the following sensors:
1
3 system, group 8.4.4.2 CLIMATE, menu 2.
005001
2
Sensor, temperature outlet fan, replacement


3 Remove the lower protective cover in front of the steering wheel
shaft.
4 Detach the steering wheel shaft and angle it back against the
driver's seat.
1. Instrument panel
2. Steering column adjustment
3. Lower protective cover
5 Detach the temperature sensor from the air distributor.

Air distributor including temperature sensor.

9 Frame, body, cab and accessories – Sensor cab temperature 9:53
9.4.17 Sensor cab temperature

Sensor, cab temperature, description
Sensor, cab temperature, detects the temperature of the air in the cab.
1
3
005001
2

Sensor, cab temperature, replacement

3 Detach the hose from the temperature sensor.

4 Detach the connector from the temperature sensor.
5 Remove the temperature sensor.
007985

9:54 9 Frame, body, cab and accessories – Sensor, ambient temperature
9.4.18 Sensor, ambient temperature

Sensor, ambient temperature, description
Sensor, ambient temperature, detects the temperature of the air
outside the cab.
Sensor, ambient temperature
Sensor, ambient temperature, replacement

2 Detach the connector from the temperature sensor.

3 Remove the temperature sensor from its mounting in the cab.

9 Frame, body, cab and accessories – Wiper/washer system 9:55
9.5 Wiper/washer system

Wiper/washer system, description
The wipers automatically switch off 2 minutes after the operator has
left the driver's seat.
9.5.1 Wiper front

Wiper front, description
The front wiper is the parallel wiper type, i.e. the wiper blade is moved
in a constant vertical position over the front window.
9.5.2 Wiper roof

Wiper roof, description
The roof wiper is the sector wiper type. Wiping angle is approx. 180
degrees.
9.5.3 Wiper rear

Wiper rear, description
The rear wiper is the sector wiper type. Wiping angle is approx. 180
degrees.
9.5.4 Washer motor and reservoir

Washer motor and reservoir, description
Washer motors are located on the washer fluid reservoir. There
are non-return valves on the lines from the reservoir to the washer
nozzles, preventing the washer fluid from draining back in the line
between washings. This minimises the time between the activation of
the switch for washing and washer fluid spraying on the window.
The washer nozzles are mounted on the wiper arms.
Control system, group 8.4.3.1 CAB, menu 1.

9:56 9 Frame, body, cab and accessories – Wiper motor front
Washer motor and reservoir, replacement

2 Remove the protection over the washer fluid reservoir.

3 Drain the washer fluid from the fluid reservoir.
4 Remove the washer motors from the fluid reservoir.
5 Remove the bolts which secure the fluid reservoir in the cab wall.
6 Replace the washer fluid reservoir. Replace the washer motor, if
necessary.
003619
A B
Washer fluid reservoir without protective plate.
A Washer fluid reservoir
B Washer motors
9.5.5 Wiper motor front

Wiper motor front, description
The wiper motor drives the wiper for the front window. The wiper arm is
mounted on the motor. The motor produces the movement of the wiper.
Control system, group 8.4.3.2 CAB, menu 2
Wiper motor front, replacement


3 Remove the nuts which hold the motor in the protective plate.
6 Remove the nuts which hold the motor in the cab.

7 Detach the connector from the wiper motor.
8 Replace the motor.
9 Fit in the reverse order. Tighten the wiper arms to torque 16-20
Nm.

9 Frame, body, cab and accessories – Wiper motor roof 9:57
9.5.6 Wiper motor roof

Wiper motor roof, description
The wiper motor drives the wiper for the roof window. The wiper arm is
Wiper motor roof, replacement

2 Remove the plastic cover.
3 Detach the washer hose and the connector to the wiper motor.
4 Undo the lock nut securing the wiper arm and disconnect the
washer fluid hose.
5 Remove and replace the wiper motor.

9:58 9 Frame, body, cab and accessories – Wiper motor rear
9.5.7 Wiper motor rear

Wiper motor rear, description
The wiper motor drives the wiper for the rear window. The wiper arm is
Wiper motor rear, replacement

2 Remove the panels behind the driver's seat.
3 Remove the screws holding the motor's plastic cover.
4 Detach the connector to the motor.

5 Raise the plastic cover and remove the nut securing the wiper
arm. Detach the washer fluid hose.
6 Remove the screws securing the motor and the lock nut on the
motor.
7 Replace the wiper motor.
8 Fit in the reverse order. Tighten the wiper arms to torque 16-20
Nm.

9 Frame, body, cab and accessories – Lighting system 9:59
9.6 Lighting system

Lighting system, function description
The working lights are shut off automatically after 5 minute's idle in
order to prevent discharge of the batteries. Extra working lights are
shut off after 2 minutes. The lights are activated automatically again
when the operator sits in the seat, a gear is selected or the accelerator
pedal is pressed.
NOTE
It is important that the right type of bulb is used for each area. See
1 2 3 5 4
D1 D2 D3 D5 D4 8
9
13 D13 10
6 D8
D6
17 14 14
D17 D10
15
16 M D15
D9
D16 D790-1 D790-2
19 7, 12 11 28
D797-1 D791-1
D18
D20 D21 D22 D23 D24
Pa 18
D25
D29 D30
D26
015047
D27
20 21 22 23 24 25 26 27 29 30
1 The switch for cab roof work lights (S105-1) Switch in ON position: U D1: Diagnostic menu, see section
sends a voltage signal to the cab control unit = 24 V 8 Control system, group 8.4.2.12
(D790-1). LIGHTS, menu 12
2 Switch, working lights attachment (S105-2) Switch in ON position: U D2: Diagnostic menu, see section
sends a voltage signal to Control unit, cab = 24 V 8 Control system group 8.4.2.13
3 The switch for mast work lights (S105-3) Switch in ON position: U D3: Diagnostic menu, see section
sends a voltage signal to the cab control unit = 24 V 8 Control system group 8.4.2.10
4 Switch, headlights (S100) sends a voltage Switch in ON position: U D4: Diagnostic menu, see section 8
signal to Control unit, cab (D790-1). = 24 V Control system, group 8.4.2.1 LIGHTS,
menu 1
5 Switch, revolving beacon (S110) sends a Switch in ON position: U D5: Diagnostic menu, see section 8
voltage signal to Control unit, cab (D790-1). = 24 V Control system group 8.4.2.6 LIGHTS,
menu 6

9:60 9 Frame, body, cab and accessories – Lighting system
6 The door NC switch (S266-LE & S266-RI) Door open: U = 24 V Interior lighting cab, description, page
sends a voltage signal to the cab control unit 9:66
(D790-1).
Control system group 8.4.2.9 LIGHTS,
menu 9
7 Control unit, cab (D790-1) transmits "switch on Checked by control Section 11 Common electrics, group
lights" messages on the CAN bus. system, error shown with 11.5.3.1 Control unit, cab
error code.
8 Multi-function lever (S162) sends a voltage Lever in high beam Gear selector and multi-function lever,
signal to Control unit KIT (D790-2). position: US162/56a = 24 V description, page 9:8
menu 3
9 Lever, direction indicator (S161) sends a Left: US161/6 = 24 V D9: Diagnostic menu, see section 8
voltage signal to Control unit KIT (D790-2). Control system group 8.4.2.4 LIGHTS,
Right: US161/1 = 24 V
menu 4
10 Switch, interior lighting on Control unit KIT Checked by control D10: Diagnostic menu, see section 8
(D790-2) sends a voltage signal to Control unit system, error shown with Control system group 8.4.2.9 LIGHTS,
KIT (D790-2). error code. menu 9
11 Control unit KIT (D790-2) sends a "switch on Checked by control Section 11 Common electrics, group
lights" message on the CAN bus. system, error shown with 11.5.3.11 Control unit, KIT
error code.
12 Control unit, cab (D790-1) supplies voltage to Checked by control Section 11 Common electrics, group
the lights in and around the cab. system, error shown with 11.5.3.1 Control unit, cab
error code.
13 The relay for cab roof work lights (K3017-1 UK3017/30 = 24 V Working lights, cab, description, page
and K3017-2) is activated when the cab roof 9:66
UK3017/85 = 0 V
work lights are activated. It supplies voltage to
the cab roof work lights (E406L-1 E406R-1, Cab roof work lights on:
E406L-2 & E406R-2).
UK3017/86 = 24 V
UK3017/87 = 24 V
Cab roof work lights off:
UK3017/86 = 0 V
UK3017/87 = 0 V
14 The cab roof work lights (E406L-1 E406R-1, Light on: U = 24 V Working lights, cab, description, page
E406L-2 & E406R-2) come on when the cab 9:66
roof work lights are activated.
8 Control system group 8.4.2.12
LIGHTS, menu 12
15 Back-up lights, white (E405L & E405R) are Light on: U = 24 V Back-up lights, description, page 9:64
switched on when reverse gear is selected.
menu 8
16 Revolving beacon (H428) is switched on when Light on: U = 24 V Revolving beacon, description, page
the revolving working light is activated. 9:64
menu 6
17 Interior lighting (E434-1) comes on when a Light on: U = 24 V Interior lighting cab, description, page
door is opened or if activated when the switch 9:66
on the KIT control unit (D790-2).
Control system, group 8.4.2.9 LIGHTS,
menu 9

9 Frame, body, cab and accessories – Lighting system 9:61
18 The brake light NO switch (S216) sends Brake pressure over 0.2 Section 4 Brakes, group 4.3.8
a voltage signal to the frame control unit MPa: U = 24 V Make-contact (closing switch) brake
(D797-1). lights
menu 7
19 The frame control unit (D797-1) supplies Checked by control Section 11 Common electrics, group
voltage to the machine lights. system, error shown with 11.5.3.2 Frame control unit
error code.
20 The direction indicators (H422, H423, H426 Light on: U = 24 V Direction indicators, description, page
& H427) come on when they or the warning 9:64
lights are activated.
menu 5
21 The running lights (H416-1, H416-2, H417-1 & Light on: U = 24 V Running lights, description, page 9:63
H417-2) come on together with the headlights.
menu 2
22 Headlights, low beam (E400L & E400R) are Light on: U = 24 V Headlights, description, page 9:63
switched on when the headlight is activated.
menu 3
23 Headlights high beam (E402L-1 & E402R-1) Light on: U = 24 V Headlights, description, page 9:63
are lit when high beam is activated.
menu 3
24 Tail lights, red (H412L & H412R) are switched Light on: U = 24 V Tail lights, description, page 9:63
on when the headlight is activated.
menu 2
25 Brake lights (H411L & H411R) are switched on Light on: U = 24 V Brake lights, description, page 9:63
when the brake is activated.
menu 8
26 The mast work lights (E404L-1 & E404R-1) Light on: U = 24 V Mast working lights, description, page
come on when activated. 9:64
LIGHTS, menu 10
27 The auxiliary mast work lights (E404L-4 & Light on: U = 24 V Mast working lights, description, page
E404R-4) come on when the mast work lights 9:64
are activated.
LIGHTS, menu 11
28 Control unit, attachment (D791-1) supplies Checked by control Section 11 Common electrics, group
voltage to the attachment's lights. system, error shown with 11.5.3.5 Control unit, attachment
error code.
29 The twistlock attachment work lights (E404L-3 Light on: U = 24 V Working lights, attachment, description,
& E404R-3) come on when activated. page 9:67
LIGHTS, menu 13
30 The twistlock attachment auxiliary work lights Light on: U = 24 V Working lights, attachment, description,
(E404L-5 and E404R-5) come on when page 9:67
activated.
LIGHTS, menu 11

9:62 9 Frame, body, cab and accessories – Lighting system
Lighting system, component location

The purpose of the lighting is to increase safety during operation and
load handling.
NOTE
The machine has the following lights:
1 4 5 6 6 7 9
3,8,10
12
24
23
22
014664
19, 20, 21 18 17 16 15 11, 13, 14
1. Mast work lights (E404L-1 & E404R-1) 14. Direction indicators, rear (H426 & H427)
2. Auxiliary mast work lights (E404L-4 & E404R-4) 15. Door NC (normally closed) switch (S266-LE &
S266-RI)
3. Relay, cab roof work lights (K3017-1 & K3017-2)
4. Multi-function lever (S162) 16. Switch, see Controls and instruments, overview,
page 9:3
5. Control unit KIT (D790-2)
17. Frame control unit (D797-1)
6. Interior lighting (E434-1)
18. Make-contact (closing switch) brake light (S216)
7. Cab roof work lights (E406L-1 & E406R-1)
19. Direction indicators, front (H422 & H423)
8. Auxiliary cab roof work lights (E406L-2 & E406R-2)
20. Running lights, front (H416-1 & H417-1)
9. Revolving beacon (H428) 21. Headlights, low beam (E400L & E400R)
10. Control unit, cab (D790-1) Headlights, high beam (E402L-1 & E402R-1)
11. Running lights, rear (H416-2 & H417-2) 22. Control unit, attachment (D791-1)
12. Back-up lights, white (E405L & E405R) 23. Twistlock attachment work lights (E404L & E404R)
13. Tail lights, red (H412L & H412R) 24. Auxiliary carriage work lights (E404L-5 & E404R-5)
Brake lights (H411L & H411R)

9 Frame, body, cab and accessories – Headlights 9:63
9.6.1 Headlights
Headlights, description
Headlights are located in the front of the machine to give the
operator enhanced vision when operating in darkness, and to provide
surrounding traffic and the environment an indication of the machine's
position. Headlights have the options of high beam and low beam
(for meeting other traffic).
Switch between high and low beam with the gear and multi-function
lever. The signal travels to Control unit, cab (D790-1).
High and low beam signals can be checked from the diagnostic menu,
section 8 Control system, group 8.4.2.3 LIGHTS, menu 3.
9.6.2 Running lights

Running lights, description
The running lights are fitted on the right and left-hand sides of
the machine to provide surrounding traffic and the environment an
indication of the machine's position and direction of travel.
The running lights are controlled by selecting with the headlight switch.
The signal travels to Control unit, cab (D790-1).
The lights and their signal can be checked from the diagnostic menu,
9.6.3 Tail lights

Tail lights, description
Tail lights are located in the rear of the machine to provide surrounding
traffic and the environment an indication of the machine's position, and
a limited enhancement of the view for the operator in darkness.
The tail lights are controlled by selecting with the headlight switch. The
signal travels to Control unit, cab (D790-1).
9.6.4 Brake lights

Brake lights, description
The brake lights are fitted on the rear of the machine to provide
surrounding traffic and the environment an indication that the machine
is braking and consequently slowing down.
The brake lights are regulated by brake pedal position (via actuated
break contact (opening switch)). The signal travels to Control unit,
frame (D797-1), which supplies power to the brake lights.
see section 8 Control system, group 8.4.2.7 LIGHTS, menu 7 and
8.4.2.8 LIGHTS, menu 8.

9:64 9 Frame, body, cab and accessories – Back-up lights
9.6.5 Back-up lights

Back-up lights, description
The back-up lights are fitted on the rear of the machine to provide
surrounding traffic and the environment an indication that the machine
is travelling backwards. In addition, this provides the operator
enhanced view when operating in darkness.
The back-up lights are controlled by direction of travel. Signals are
sent via the CAN-bus).
8.4.2.8 LIGHTS, menu 8.
9.6.6 Direction indicators

Direction indicators, description
The direction indicators are located on both the front and rear of
the machine to provide surrounding traffic and the environment an
indication that the machine is changing direction, i.e. turning.
The direction indicators are controlled by the choice made with the
direction indicators switch (lever). The signal goes to frame control
unit (D797-1).
9.6.7 Flashing hazard lights

Flashing hazard lights, description
Flashing hazard lights (Hazard) are used to warn the surroundings,
flashing hazard lights activate all direction indicators simultaneously.
The flashing hazard lights are controlled by selecting with the switch for
flashing hazard lights. The signal travels to Control unit, cab (D790-1).
Control system, group 8.4.2.4 LIGHTS, menu 4 and 8.4.2.5 LIGHTS,
menu 5.
9.6.8 Revolving beacon

Revolving beacon, description
The revolving beacon is located high on the machine's cab. This is
used to provide surrounding traffic and the environment an indication
that a working vehicle is moving and at work. An indication to
bystanders to exercise caution.
The revolving beacon is controlled by selecting with the revolving
beacon switch. The signal travels to Control unit, cab (D790-1).
9.6.9 Working lights, mast

Mast working lights, description
Work lights on the mast provide enhanced view when load handling
in darkness.
The working lights are controlled by selecting with the switch for
working lights, mast. The signal travels to Control unit, cab (D790-1).

9 Frame, body, cab and accessories – Working lights, mast 9:65
The mast can be equipped with two auxiliary work lights ( ).

9:66 9 Frame, body, cab and accessories – Working lights, cab
Working lights, replacement (product alternative

Xenon lights)
DANGER
Xenon lights are activated with high voltage. Always
switch off the system voltage before working on Xenon
lights.
Handle the headlight with care since the light is under
gas pressure and may explode.
NOTE
The Xenon light is filled with different gases and metals. Replaced
Xenon headlights should be considered as hazardous waste and
should be deposited for recycling.
9.6.10 Working lights, cab

Working lights, cab, description
Working lights on the cab provide visibility when handling a load in

darkness.
working lights, cab roof. The signal travels to Control unit, cab
(D790-1), which in turn supplies power to the working lights.

Xenon lights)
See Working lights, replacement (product alternative Xenon lights),

page 9:66.
9.6.11 Interior lighting

Interior lighting cab, description
The interior lighting illuminates the cab when the doors are opened or
when activated with the interior lighting switch.
There is background lighting in all switches, function keys and rotary

controls. This is so that the operator will be able to read their functions
and settings in darkness. Brightness is controlled by the plus and
minus keys.

9 Frame, body, cab and accessories – Working lights, attachment 9:67
9.6.12 Working lights, attachment

Working lights, attachment, description
Working lights on the attachment provide increased visibility when
handling a load in darkness.
working lights, attachment. The signal travels to Control unit, cab
(D790-1).
The attachment can be equipped with two extra working lights ( ).

Xenon lights)

page 9:66.
9.6.14 Work lights, front wing

Front wing work lights, lighting
Work lights on the front wing provide enhanced view when load
handling in darkness.
The working lights are controlled by selecting with the switch for working
lights, cab roof . The signal travels to Control unit, cab (D790-1).

Xenon lights)

page 9:66.

9:68 9 Frame, body, cab and accessories – Signalling system
9.7 Signalling system

Signalling system, function description
NOTE
1 2 3 4
D2 D3 D17 17 6
7
D1 D4
15
16
D6
D6
D15 D13 D18
13 18
14 M
8 19
D790-1 D790-2 D795
D14 5
9
D797-1 D791-1
D10 20
D11
10 11 D21
21
010027
12
D12
Pos Description Signal description Reference

1 Switch, revolving beacon (S110) Switch in ON position: U = D1: Diagnostic menu, see section 8 Control
sends a voltage signal to Control unit, 24 V system group 8.4.2.6 LIGHTS, menu 6
cab (D790-1).
2 Switch, flashing hazard lights Switch in ON position: U = D2: Diagnostic menu, see section 8 Control
(Hazard) (S109) sends a voltage 24 V system group 8.4.2.4 LIGHTS, menu 4
signal to Control unit, cab (D790-1).
3 Switch, parking brake (S107) sends Switch in ON position: U = D3: Diagnostic menu, see section 8 Control
a voltage signal to Control unit, cab 24 V system group 8.4.5.4 HYD, menu 4
(D790-1).
4 The horn switch (S149-3) sends a Switch in ON position: U = D4: Diagnostic menu, see section 8 Control
voltage signal to the cab control unit 24 V system, group 8.4.3.5 CAB, menu 5
(D790-1).
5 Control unit, cab (D790-1) sends Checked by control Section 11 Common electrics, group 11.5.3.1
messages about activation on the system, error shown Control unit, cab
6 Multi-function lever (S162) sends a Signal button pressed in: Gear selector and multi-function lever,
voltage signal to Control unit KIT US162/H = 24 V description, page 9:8
(D790-2).
system group 8.4.3.5 CAB, menu 5
7 Lever, direction indicator (S161) Left: US161/6 = 24 V D7: Diagnostic menu, see section 8 Control
sends a voltage signal to Control unit system group 8.4.2.4 LIGHTS, menu 4
Right: US161/1 = 24 V
KIT (D790-2).
8 Control unit KIT (D790-2) sends Checked by control Section 11 Common electrics, group 11.5.3.11
messages about activation on the system, error shown Control unit, KIT
9 The frame control unit (D797-1) Checked by control Section 11 Common electrics, group 11.5.3.2
supplies voltage to the machine lights system, error shown Frame control unit
and buzzers. with error code.

9 Frame, body, cab and accessories – Signalling system 9:69
Pos Description Signal description Reference

10 The direction indicators (H422, H423, Light on: U = 24 V Direction indicators, description, page 9:64
H426 and H427) come on when the
warning lights are activated.
11 The reversing lights (E405L and Light on: U = 24 V Back-up lights, description, page 9:64
E405R) come on when reverse gear
is selected.
system group 8.4.2.8 LIGHTS, menu 8
12 Back-up alarm (H965) is activated Reverse gear selected: U Reverse alarm, description, page 9:71
when reverse gear is selected. = 24 V
system group 8.4.2.8 LIGHTS, menu 8
13 Horn (H850) sounds when the horn Horn active: U = 24 V Horn, description, page 9:70
is activated.
14 Revolving beacon (H428) is switched Light on: U = 24 V Revolving beacon, description, page 9:64
on when the flashing hazard light is
activated.
15 Relay loud horn (K3016) is activated UK3016/30 = 24 V Horn, description, page 9:70
when horn is activated.
UK3016/85 = 0 V D15: Diagnostic menu, see section 8 Control
Horn activated:
UK3016/86 = 24 V
UK3016/87 = 24 V
16 Loud horn (H850-1) sounds when the Horn active: U = 24 V Horn, description, page 9:70
horn is activated.
17 Make-contact (closing switch) Operator in seat: U = 24 V 9.3.14 Sensor, operator-in-seat, page 9:19
operator-in-seat (S230) sends a
voltage signal to Control unit, cab
(D790-1) when there is a load on the
driver's seat.
18 In the event of warnings, Buzzer, Checked by control D18: Diagnostic menu, see section 8 Control
cab (H853) is supplied voltage by system, error shown system group 8.4.3.6 CAB, menu 6
Control unit KIT (D790-2) to draw the with error code.
operator's attention to the warning
message.
19 In the event of warnings, control unit A clicking sound is audible Section 11 Common electrics, group 11.5.3.12
KID (D795) activates the warning when then termination Control unit, KID
lamp to draw the operator's attention resistor is activated.
to the warning message.
20 The attachment control unit (D791-1) Checked by control Section 11 Common electrics, group 11.5.3.5
supplies voltage to the automatic system, error shown Control unit, attachment
spreading buzzer during automatic with error code.
spreading.
21 The automatic spreading buzzer Buzzer active: U = 24 V Section 7 Load handling, group 7.5.10 Buzzer,
(H9003) is activated when automatic automatic spreading 20'-40'
spreading 20'-40' is activated.
NOTE
On machines with side lift attachment, an audible signal can also be given with the open twistlock button (S1002) on
the panel for hydraulic functions or the open twistlock button on the joystick, provided that the "open twistlocks upon
contact" function is not active.

9:70 9 Frame, body, cab and accessories – Horn
Signalling system, component location

The machine has the following signalling systems:
1 2 3 4 5 6
014665
19 18 17 16 15 14 13 12 10,1 1 9 8 7
1. Control unit, KID (D795) 11. Control unit, cab (D790-1)
2. Buzzer, cab (H853) 12. Make-contact (closing switch) operator-in-seat (S230)
3. Control unit KIT (D790-2) 13. Horn (H850)
4. Multi-function lever (S162) 14. Switch, see Controls and instruments, overview,
5. Direction indicator lever (S161) page 9:3
6. Revolving beacon (H428) 15. Loud horn (H850-1)
7. Reverse alarm (H965) 16. Frame control unit (D797-1)
8. Reversing lights (E405L & E405R) 17. Direction indicators, front (H422 & H423)
9. Direction indicators, rear (H426 & H427) 18. Control unit, attachment (D791-1)
10. Relay loud horn (K3016) 19. Buzzer automatic spreading (H9003)
9.7.1 Horn
Horn, description
The horn is electromagnetic. Compressed air horn can be selected
( ).
The horn is activated from the gear selector and multi-function lever
or from the horn switch ( ). The horn is located under the cab (the
air horn is located on the front of the cab).
001247
9.7.2 Flashing hazard lights

Flashing hazard lights, description
See Flashing hazard lights, description, page 9:64.

9 Frame, body, cab and accessories – Revolving beacon 9:71
9.7.3 Revolving beacon

Revolving beacon, description
See Revolving beacon, description, page 9:64.
9.7.4 Warning parking brake

Warning parking brake, description
If the operator leaves the machine without applying the parking brake,
a buzzer sounds to alert the operator, i.e. to ensure the operator
applies the parking brake.
A sensor in the driver's seat (see Sensor, operator-in-seat, description

(product alternative Hao Bang), page 9:19, Sensor, operator-in-seat,
description (product alternative BE-GE), page 9:20) indicates to the
control system if the operator leaves the seat.
The buzzer is located in the steering wheel panel.
9.7.5 Back-up alarm

Reverse alarm, description
When reverse is selected, a warning sound and the back-up lights

are activated. This is to give surrounding traffic an indication that the
machine is reversing. Indication to bystanders to take caution. An
indication to bystanders to exercise caution.
Control system, group 8.4.2.8 LIGHTS, menu 8.

9:72 9 Frame, body, cab and accessories – Entertainment and communication
9.8 Entertainment and

communication
Entertainment and communication, general
The machine is prepared with a connector for customer accessories,

see section 11 Common electrics, group 11.5.2.1 Electronic box, cab.
Entertainment and communication, repair
Repairs should be left to authorised personnel.

9 Frame, body, cab and accessories – Glass/windows/mirrors 9:73
9.9 Glass/windows/mirrors
Glass/windows/mirrors, component placement
The windows are designed to both enclose the cab and provide the
C operator with a good view. Toughened glass windows are standard on
all trucks. The roof window is a safety detail and is therefore always
D made of polycarbonate plastic.
The rear view mirrors are of the convex mirror type. There is an
interior rear view mirror on all machines.
The machine has tinted, toughened glass windows.
The following windows may have laminated glass:

• Side windows front, position E
001512
A E B • Windshield (front window), position B
A Side windows
B Windscreen (front window)
C Roof window
D Rear window
E Front side windows
Silicone adhesive, handling advice

The window panes are secured with decor strips adhesive and silicone
adhesive.
NOTE
The purpose of this instruction is to describe how silicone adhesive
923854.0100 should be handled in connection with replacement 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
temperatures between -50 ºC and +200 ºC. The hardening
properties of the adhesive are extremely dependent on the
ambient temperature. An increase of 10 ºC cuts hardening time
in half.
Silicone adhesive 923854.0100 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 in order to avoid undesired
hardening.
Fixing time:
10-20 minutes at 20 ºC
approx. 5 minutes at 60 ºC
Hardening time:
approx. 24 hours at 20 ºC
approx. 1 hour at 60 ºC
Full strength is obtained after 7 days.
• In warm climates, it is advantageous to cool the container to
increase hardening time. The silicone adhesive should not be
used at temperatures above +75 °C.
• In cold climates, the hardening time can be shortened by
covering the joints so that cooling is prevented. The window
pane can be warmed with defroster or cab heater.
• The recommended storage temperature is between -30 ºC
and +20 ºC. Storage in a refrigerator or a colder environment
is recommended.

9:74 9 Frame, body, cab and accessories – Windscreen
9.9.1 Windscreen
Windscreen, description
The windscreen consists of the front window and side windows. The
windscreen is attached to the cab with a decor strip and is glued to
the roof window with silicone adhesive. Front and side windows are
joined with silicone adhesive to give good all-round visibility from the
operator's station.
For location see, Glass/windows/mirrors, component placement, page

9:73.
Windscreen, replacement
NOTE
Read the handling advice for silicone adhesive before starting work.
See Silicone adhesive, handling advice, page 9:73.
2 Remove the decor strip.

3 Remove the broken window pane and check that no remains of
glass or other particles remain in the window pane's groove on the
strip. Cut apart silicone joints with a sharp tool.
NOTE
Make sure that no silicone adhesive remains between the
window pane and the strip by the window pane's lower front
edge.
If the roof window is to be replaced, then all bolts must be
removed before the silicone adhesive is cut away.
CAUTION
Removing the decor strip Acetone may not come into contact with a roof window
made of polycarbonate plastic. Acetone has a chemical
effect on the polycarbonate plastic which reduces the
roof window's strength.
4 Clean all surfaces thoroughly. Remove old remains of silicone with

a razor blade or similar.
5 Fit masking tape on the inside and outside of the window panes by
the surfaces that are to be glued.

9 Frame, body, cab and accessories – Windscreen 9:75
1 2 3 6 When the windscreen or a side window is to be replaced, then the

window panes must be adjusted so that the upper edge on the side
window has the same height as the upper edge of the cab roof and
so that the distance between windscreen and side window.
Use spacers against the roof member to ensure that the distances
are maintained.
1,0
006268
1
Adjusting side window - cab roof
1. Side window
2. Rubber strip
3. Cab frame/door opening
006269
1,0
Adjusting side window - windscreen
1. Masking tape
7 Fit the decor strip around the whole window pane.
8 Apply silicone adhesive 923854.0100 around the window panes.
Make the new joint wider than the old one in order to create a
good seam.
The silicone should be applied from the outside of the joints, to
give a full and smooth joint.
NOTE
There must be silicone between the window panes, to avoid
contact between the window panes.

9:76 9 Frame, body, cab and accessories – Side window
9 Remove excess silicone from the outer vertical corners, using a

tool made of cardboard. Smooth out the joints on the inside with a
finger soaked in water or soapy water.
10 Apply silicone adhesive 923854.0100 between the strip and
window pane at the bottom edge of the front corners, so-called
top sealing.
11 If the roof window is to be replaced, apply silicone adhesive
923854.0100 by the cab frame (where it was glued earlier).
12 Align the roof window into place and check that there is a uniform
distance of one or several millimetres along the window pane's
edges and by the protection over the frame's sides. Then tighten
the corner bolts for the window pane.
13 Apply silicone adhesive 923854.0100 by the edges and smooth
out the joints with a finger, wet with water or soapy water.
IMPORTANT
006272
Cardboard tool template for silicone joint scale 1:1 Mark the window panes with "New adhesive. Do not
touch".
14 Remove the masking tape immediately after applying adhesive to

avoid edge formation. Hardening time is dependent on ambient
temperature, plan the change so that downtime is minimised.
9.9.2 Side window

Side window, description
The side windows are secured in the cab and doors with decor strips.
For further details, see Glass/windows/mirrors, component placement,

page 9:73.
Side window, replacement
NOTE
The method describes a general procedure.
2 Use special tools to detach the decor strip.

9 Frame, body, cab and accessories – Side window 9:77
3 Remove the decor strip which runs around the whole window.
4 Carefully remove any remains of glass from the rubber strip.
5 Fit the new window, securing it at the bottom edge.
6 Spray soap solution on the window and rubber strip to facilitate

fitting.

9:78 9 Frame, body, cab and accessories – Side window
7 Thread the rubber strip around the whole window; use special
tools.
8 Secure the decor strip with a special tool.

9 Pull the decor strip around the whole window.
10 Cut off the decor strip approx. 2 cm too long.

11 Fit the other end of the decor strip edge to edge.
12 Adjust the decor strip so that the correct fit is obtained.

9 Frame, body, cab and accessories – Roof window 9:79
9.9.3 Roof window

Roof window, description
The roof window is made of polycarbonate plastic, which is a safety
feature for the operator, intended to protect the operator from falling
objects. The polycarbonate plastic plate is elastic.
Safety is maintained within a temperature interval of 120 ºC to -45 ºC

(becomes brittle at -110 ºC, glass conversion temperature 145 ºC). The
roof window has a patented surface layer that increases its resistance
to wear, UV light and chemicals.
The roof window is joined with the windscreen. Joints between the
window panes and between roof window and cab are sealed tightly
with silicone adhesive. Align a new seal of silicone adhesive when
replacing.
For location, see Glass/windows/mirrors, component placement, page

9:73.
WARNING
The strength of the roof window may be significantly
reduced in case of exposure to substances containing
aromatic hydrocarbons, ketones, esters, or chlorinated
hydrocarbons.
Low strength! Danger!
Check the surface layer of the roof window and
clean only with washer fluid or mild detergent. Rinse
thoroughly with lukewarm water afterwards. Replace a
damaged roof window that shows cracks or scratches
immediately!
Roof window, replacement

See Windscreen, replacement, page 9:74, for the general procedure.
The roof window is joined with the windscreen. The joint is sealed with
silicone. Align a new seal of silicone when replacing.
9.9.4 Rear window

Rear window, description
The rear window is attached to the cab with a decor strip.
For further details, see Glass/windows/mirrors, component placement,

page 9:73.
Rear window, replacement

See Side window, replacement, page 9:76 for the general procedure.
9.9.5 Rear view mirror

Rear view mirror, description
The cab has a rear-view mirror located inside the cab as well as
exterior mirrors on the outside of the machine. The function of the rear
view mirror is to give the operator visibility around the machine.

9:80 9 Frame, body, cab and accessories – Cab structure and suspension
9.10 Cab structure and suspension

Cab structure and suspension, description
The cab is mounted in a cab substructure via strong rubber insulators
fitted on the underside of the cab. This minimises vibrations from the
frame to the cab. There is an insulator at four points, one at each
1 corner. Each insulator mounting has one rubber bushing and one bolt.
003206
4
Cab Spirit Delta
1. Cab frame
2. Door
3. Cab suspension
4. Cab substructure
9.10.1 Cab frame

Cab frame, description
The cab 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!
9.10.2 Doors
Doors, description
The cab has two doors, the left is the operator's door and the right is
the emergency exit. The door has:
• hand rail
• handle
• key lock
• openable window (emergency exit )
Switches in the doors' locks sense if the door is open. The switch is
used to light the interior lighting and warn of an open door.
Control system, group 8.4.2.9 LIGHTS, menu 9.
9.10.3 Cab substructure

Cab substructure, description
The cab is mounted on a cab substructure via strong rubber insulators
fitted on the underside of the cab. This minimises vibrations from the
frame to the cab.
The cab substructure is fitted on the machine's chassis (frame) via a

mounting. The chassis mounting depends on whether the machine is
equipped with a hydraulic tiltable cab.

9 Frame, body, cab and accessories – Cab interior 9:81
9.11 Cab interior

9.11.1 Instrument and control panels
Steering wheel panel, description
The steering wheel panel is secured to the steering column and
contains warning and indicator lights, display (KID), function keys
(KIT) and switches.
Left-hand dashboard panel, description

The left-hand dashboard panel is located in the left-hand corner of the
cab. It contains rotary controls, switches, and ventilation.
Panel for load handling functions, description

The panel is mounted on the driver's seat. The panel includes switches
and controls for load handling functions and emergency stop switches
to interrupt ongoing load handling functions.
On machines equipped with a control lever, it is located next to the

panel .
Steering wheel panel, replacement

2 Remove the steering wheel centre cover.
3 Remove the nut and the steering wheel.
4 Remove the bolts on the underside of the steering wheel panel.

9:82 9 Frame, body, cab and accessories – Interior fittings, plastic
5 Remove the bolts on the top of the steering wheel panel.
6 Unplug the connector from the multi-function levers, ignition key

lock, Control unit KIT (D790-2) and Control unit KID (D795).
7 Transfer the components to the new steering wheel cover.
9.11.2 Interior fittings, plastic

Interior fittings, plastic, description
The interior of the cab consists of recyclable material.
9.11.3 Interior fittings, textile

Interior fittings, textile, description
The interior of the cab consists of recyclable material.
9.11.4 Floor covering

Floor covering, description
The floor covering is a wear-resistant and recyclable material.
9.11.5 Insulation
Insulation, description
The cab insulation consists of recyclable material.

9 Frame, body, cab and accessories – Terminal console 9:83
9.11.7 Terminal console

Terminal console, description
The function of terminal desk is to provide a work surface for a

computer/terminal. It is located to the right of the steering wheel,
easily accessible for the operator.
008227
9.11.8 Writing desk
Writing desk, description
The writing desk with a reading lamp is fitted on a jointed bracket to

the right in front of the door in the cab. Work orders, etc. can be
attached here.
008228
9.11.9 Reading-lamp
Reading lamp, description
The reading lamp is fitted on a jointed bracket to the right in front of

the door in the cab.

9:84 9 Frame, body, cab and accessories – Chassis
9.12 Chassis
Chassis, description
The frame is a modular construction and consists of front section, rear
section and a beam pair. This design provides advantages in terms of
rigidity and strength.
There are mounting points in the frame for engine, gearbox, drive axle,
steering axle, fuel and hydraulic tanks, cab, mast and body parts.
The space in the rear section of the frame is used for counterweights,
the number of which is adapted to the machine in question. The
counterweights are designed to allow as good visibility rearwards as
possible.
The front wings are bolted into the frame (which has advantages when
delivering the machine).
2 1
014666
3 4 5 6
1. Frame's rear section with counterweights 4. Bracket for front wings
2. Engine compartment with mountings for engine and 5. Cab mounting (4 points)
transmission
6. Steering axle mounting
3. Frame's front section with drive axle mounting

9 Frame, body, cab and accessories – Body structure 9:85
9.13 Body structure

Body structure, description
The body structure's components comprise:
2 1
014667
3
1. Counterweight
2. Hood engine compartment
3. Wings
9.13.1 Wings
Wings, description
There are wings over the wheels to protect from dirt thrown up by
the wheels during operation. The design of the counterweight (see
Counterweights, description, page 9:86) acts as a mudguard for the
rear wheels.
The fenders can be equipped with extra mudguards when the

machine's work environment requires such ( ).
9.13.2 Hood engine compartment

Hood engine compartment, description
The machine's engine compartment is protected by a hood.
The machine compartment for the transmission and drivetrain/axle is

protected by floor plates. The floor plates are secured with fastening
bolts. The floor plates are designed for walking on and are ribbed to
provide sure footing.
9.13.3 Footsteps and hand rail

Footsteps and hand rail, description
The cab has footsteps for easy access. There is a hand rail by the cab.

9:86 9 Frame, body, cab and accessories – Counterweights
9.13.4 Counterweights
Counterweights, description
The machine has counterweights to balance the machine's lift capacity
and these may therefore vary in quantity and weight.
The counterweights are located at the very back of the frame for
maximal leverage.
The machine has counterweights in the following locations:

• Under the steering axle
• Furthest back on the machine there are vertical counterweights
secured in the rear edge of the frame; the outer has a towing eye.
Between the outer counterweight and frame, there are smaller
counterweights whose dimensions and quantity are adapted to
balance the machine's lifting capacity.
• Upper horizontal counterweight.
Under the horizontal counterweight, there are smaller
counterweights whose dimensions and quantity are adapted to
balance the machine's lifting capacity.
DANGER
The counterweights are factory fitted and are adapted
according to the machine's properties.
The machine's operating characteristics are changed!
Never change the quantity of counterweights.

9 Frame, body, cab and accessories – Central lubrication 9:87
9.14 Central lubrication

Central lubrication, checking
1 Check that no grease has been forced out through the safety
valve (position 2).
If grease has been forced out through the safety valve, this means
that there is a blockage in the system. Locate the line that is
blocked by feeling the connections on the distribution blocks. A
blocked hose remains pressurized and the connection will be rigid.
NOTE
If several distribution blocks are connected in series, a clogged
line will be pressurised all the way to the first distribution block.
2 Turn the start key to position I.

3 Operate the pump manually and check that the indicator pin
moves in and out on the distribution block.
To operate the pump, loosen the cover and press in the switch for
manual operation (position 5).
If the indicator pins do not move even when the pump is running,
troubleshoot the pump unit.
NOTE
The system can be lubricated manually through the grease
nipple on the distribution block.
Overview central lubrication. Example illustration.
1. Grease nipple, filling point grease 4 Fill grease in the pump unit through the filler nipple, see section
F Technical data.
2. Safety valve
3. Grease nipple, manual lubrication of system
4. Indicator pin
5. Switch, manual operation

9:88 9 Frame, body, cab and accessories – Central lubrication
Central lubrication, adjusting lubrication times

Test or extra greasing
The central lubrication's pause and run-time must be set after
changing, the setting is unique to each machine, depending on the
machine's equipment. When changing the new pump unit must be
set in the same way as the old one.
If the machine does not lubricate properly the running and pause
times can be adjusted. The running time is adjusted first, so that all
the lubrication points on the machine have time to be lubricated each
time. If large amounts of grease are forced out to all lubrication points
the pause time can be increased.
NOTE
Only adjust one step each time. Small adjustments make a large
difference.
Test or extra greasing

Central lubrication can be run manually by pressing and holding
the button for manual operation for 2 seconds. This starts an extra
lubrication cycle.
Example illustration
1. Pause time setting (red)
2. Run-time setting (blue)
3. Manual pump operation
Pause time
The pause time is the length of the interval between lubrications. The
interval is adjusted in full hours between 1 and 15 hours. The pause
time is adjusted with the red dial.
Switch position 1 2 3 4 5 6 7 8 9 A B C D E F
Pause time [hours] 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Run-time
The run-time is the time that the pump is activated each time. The
run-time can be adjusted between 2 and 30 minutes. The pause time
is adjusted with the blue dial.
Switch position 1 2 3 4 5 6 7 8 9 A B C D E F
Run-time [minutes] 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30

9 Frame, body, cab and accessories – Pump unit 9:89
9.14.1 Pump unit

Pump unit, description
The pump unit consists of containers with stirrer, pump housing with
built-in motor, timer, pump element, filler nipple, and safety valve.
Central lubrication works with lubrication cycles (pause and run-time

and read time). There is a circuit board with a timer in the pump. This
can be used to set the run and pause time of the pump motor.
When the central lubrication works so that the lubrication points are
lubricated one by one in series. If there is a blockage in a lubrication
point, the pressure will rise and the safety valve will release grease, in
addition subsequent lubrication points will not be lubricated.
NOTE
The safety valve will force grease out if a lubrication point cannot
be lubricated. If a lubrication point is not lubricated, none of the
subsequent points will be lubricated. It is therefore very important
to check the safety valve.
Example illustration, components central lubrication

1. Pump unit
2. Safety valve

9:90 9 Frame, body, cab and accessories – Distribution block
9.14.2 Distribution block

Distribution block, description
The distribution blocks distribute grease from pump unit to the

lubrication points or to other distribution blocks. The number of
distribution blocks can vary depending on how many (and which)
lubrication points are selected.
The distribution blocks consist of pistons that proportion grease into

each lubrication point. The pistons are powered by the lubricant and
have no springs and seals. It is the grease that powers the pistons
inside the distributor. The design of the pistons and channels in the
distribution block make the pistons move in a predetermined manner.
Each piston must have complete its movement before the next piston
can move. The pistons are interdependent. It is technically impossible
for a connected lubrication point to be missed. If a lubrication point
cannot be lubricated, the complete system is blocked and the grease
is pressed out through the safety valve.
There is an indicator pin on the system's first distribution block (i.e.

the block closest to the pump unit). If the pin moves back and forth (at
the same rate as the piston movement) this indicates that the grease
is being pumped through the system. If one distributor block cannot
deliver grease to one of its lubrication points, the pin stops and thus
Example illustration, components central lubrication the whole system.
1. Pump unit
If there is a blockage in the system, this line will be pressurised from
2. Safety valve the pump to the stop through all distribution blocks on the circuit. This
3. Distribution block makes it easy to find a blockage in the system. The blockage can be
traced by feeling the distribution blocks' connectors and identifying
which connections are rigid. Note that several distribution blocks can
be connected in series.
9.14.3 Lines
Lines, description
Central lubrication works under very high pressure, only use lines that
meet the following specifications.
Main hose
Diameter 8.4 mm
Explosion pressure min. 60.0 MPa

9 Frame, body, cab and accessories – Paint/coatings 9:91
9.15 Paint/coatings
Paint/coatings, description
The machine is painted with an alkyd-based mono-component paint
that is applied with a brush or a spray. For paint codes (RAL), see
machine card.
Check the machine frequently for stone chips, dents and paint
scratches, repair them at once to prevent corrosion on the underlying
metal. Only use touch-up paint for small stone chips and scratches.
More extensive paint damage should be repaired by a paint workshop.
NOTE
Before touching up, the surfaces to be touched up must be
thoroughly cleaned.
Please contact Cargotec for information about other surface treatment

and material colours.

9:92

10:1
Contents 10 Common hydraulics

10 Common hydraulics .........................................................................................10:3
10.2 Safety valves..................................................................................................10:3
10.2.1 Accumulator drain valve ............................................................................10:3
10.2.3 Pressure limiting valve ..............................................................................10:4
10.2.4 Pipes and hoses........................................................................................10:4
10.3 Tanks and accumulators ................................................................................10:5
10.3.1 Hydraulic oil tank .......................................................................................10:5
10.3.2 Accumulator ..............................................................................................10:5
10.3.4 Pipes and hoses........................................................................................10:5
10.4 Pumps............................................................................................................10:6
10.4.1 Gear pump with fixed displacement ..........................................................10:6
10.4.3 Pipes and hoses......................................................................................10:12
10.5 Hoses, pipes and valves ..............................................................................10:13
10.5.1 Pipes and hoses......................................................................................10:13
10.5.4 Main valve ...............................................................................................10:14
10.6 Temperature control, cleaning and hydraulic oil...........................................10:18
10.6.2 Cooler hydraulic oil..................................................................................10:20
10.6.3 Cooling fan ..............................................................................................10:21
10.6.4 Sensor hydraulic oil temperature.............................................................10:21
10.6.5 Bypass valve, cooler ...............................................................................10:23
10.6.6 Breather filter hydraulic oil tank ...............................................................10:24
10.6.7 Hydraulic oil filter .....................................................................................10:24
10.6.8 Hydraulic oil.............................................................................................10:26
10.6.9 Pipes and hoses......................................................................................10:27
10.6.10 Fine filter hydraulic oil..............................................................................10:27
10.7 Other ............................................................................................................10:29
10.7.1 Hydraulic cylinders ..................................................................................10:29

10:2

10 Common hydraulics – Common hydraulics 10:3
10.2 Safety valves
10.2.1 Accumulator drain valve
Accumulator drain valve, description
The accumulator drain valve is located on the valve block brake
system and is used to drain the pressure in the brake system's
accumulators to the tank. See section 4 Brakes, group 4.3.12 Valve
block brake system.
014619
Accumulator drain valve, the illustration shows the

closing of the valve.

The relief valve is located on the pressure supply from the lift, tilt and
attachment control valve included in the main valve to the attachment
control valve. The valve drains the pressure build-up between the
lift, tilt and attachment control valve and the attachment control
1
valve to tank. See section 7 Load handling, group 7.4.7 Relief valve
attachment.
015019
Relief valve, attachment. The illustration depicts an open

valve.

10:4 10 Common hydraulics – Pressure limiting valve
10.2.3 Pressure limiting valve

Pressure limiting valve, description
The pressure limiting valve (position 3) is located on the valve block
1 2 3 brake system and protects the brake system against excessive
4 pressure. See section 4 Brakes, group 4.3.12 Valve block brake
system.
11
6
7
10
9 8
015018

priority valve [P]

Pipes and hoses, general
See Pipes and hoses, general, page 10:13.

10 Common hydraulics – Tanks and accumulators 10:5
10.3 Tanks and accumulators

10.3.1 Hydraulic oil tank
Tank, description
1 2 1 3 2 4 5 The hydraulic oil tank forms part of the side panel on the right-hand
side of the machine. The oil filters for the working hydraulics are
fitted inside the tank. These are accessible through hatches on top
of the tank.
Hydraulic oil is filled directly into the tank through the filler caps on
the filter manhole covers. For oil capacity and grade, see section
F Technical data. The whole filter unit can be removed to facilitate
access for cleaning. There is a drain plug located at the bottom of
the tank.
The tank is equipped with filtered breather that allows volume

changes in the tank, due to temperature variations and use.
The oil level is checked on the sight glass on the tank's side when all
hydraulic cylinders are in the bottom position.
008086
1. Hydraulic oil filter cover

2. Hydraulic oil filler plug
3. Sight glass hydraulic oil
4. Breather filter hydraulic oil tank
5. Hydraulic oil drain plugs
10.3.2 Accumulator
Accumulators, description
Brake system accumulators, see section 4 Brakes, group 4.3.4
1 2 Accumulator
Accumulator lift, see section 7 Load handling, group 7.2.14

Accumulator lift
014672
Accumulators
1. Brake system accumulators
2. Accumulator lift


10:6 10 Common hydraulics – Pumps
10.4 Pumps
10.4.1 Gear pump with fixed displacement
Gear pump with fixed displacement, description
The hydraulic system is fed by two gear pumps with fixed
6 1 displacement that are driven via the transmission's power take off. A
pump feeds the brakes, steering and cooling circuit, the second feeds
load handling.
The gear pumps pump oil by the two gears rotating against each
other. One gear wheel is driven by the pump's input shaft and the
other rotates freely. The gear wheel's movement creates suction
5 2 between the gear wheels and the housing. Each turn of the gear
wheels pumps a specific amount of oil (fixed displacement). The
pump's flow varies with the speed of the input shaft. The pump shafts
are plain bearing mounted and are lubricated by means of the through
flowing oil. There are pressure plates on each side of the pump
wheels that seal between the suction and pressure side.
3 The displacement, i.e. how many cubic centimetres of oil that the
000660
pump can deliver per pump revolution, differs on the various gear
4 pumps.
1. Pump housing
NOTE
2. Outlet
It is very important that the clearance between the gears and
3. Drive wheel between the gear and the housing is correct. Clearance that is too
4. Gear cover small creates wear damage. Clearance that is too large reduces
the pump's power output.
5. Intake
6. Trailing gear
Hydraulic oil pump brake and steering
1 2 Hydraulic oil pump brake and steering
Hydraulic oil pump brake and steering feds the servo brakes, parking
brake and steering, the residual flow is used for cleaning and
cooling. Distribution of the hydraulic power is handled by valve block
accumulator charging and priority valve on the main valve, see, Main
valve, description, page 10:14.
For a more detailed description of the various functions see:

• Section 4 Brakes, group 4.3 Servo brake system.
• Section 4 Brakes, group 4.5 Parking brake system.
• Section 5 Steering, group 5.2 Power assisted system.
• Temperature control, cleaning and hydraulic oil, function
014671
1. Hydraulic oil pump for load handling

2. Hydraulic oil pump for brake pressure, steering

10 Common hydraulics – Gear pump with fixed displacement 10:7
Hydraulic oil pump, load handling

The load handling hydraulic oil pump feeds the load handling functions
with hydraulic pressure. The lift, tilt and attachment control valve on
the main valve distributes the hydraulic pressure between the various
functions, see Main valve, description, page 10:14.
For a more detailed description of the various functions see:

• Section 7 Load handling, group 7.2 Lifting/lowering.
• Section 7 Load handling, group 7.4 Side shift.
• Section 7 Load handling, group 7.5 Spreading.
• Section 7 Load handling, group 7.7 Tilt.
• Section 7 Load handling, group 7.9.1 Twistlocks.
Hydraulic oil pump brake and steering, checking
NOTE
Safety.
˚C 3 Depressurise the hydraulic systems, see section B Safety.
˚C
000475

pump pressure brakes and steering on the main valve.
014649
Measuring outlet, pump pressure brake and steering

[PM]

10:8 10 Common hydraulics – Gear pump with fixed displacement
6 Close the accumulator drain valve and check the pump pressure
during charging.
NOTE
Check that the pressure rises to the specified feed pressure on

the pressure plate.
014619
measuring outlet.

015023
Pressure plate, pump pressure brakes and steering
NOTE
014619

Load handling hydraulic oil pump, checking

˚C
000475

pump pressure load handling on the main valve.
014650
Measuring outlet, pump pressure load handling [P2]
5 Close the accumulator drain valve and the attachment relief valve.
014619

10:10 10 Common hydraulics – Gear pump with fixed displacement
7 Check that the feed pressure corresponds with the pressure plate.
8 Turn off engine.
measuring outlet.
015024
Pressure plate, feed pressure load handling
NOTE
014619

Gear pump with fixed displacement, replacement
NOTE
Safety.
3 Clean the hydraulic oil pumps and the areas around them.
4 Mark up and detach the hydraulic hoses from the pump.
NOTE
from impurities.
5 Remove the pump.

Remove the attaching bolts, pull the pump forward and lift it away.
6 Transfer the connection adapters to the new pump.
NOTE
position.
Fastening screws hydraulic oil pump load handling
7 Check the seal between the pump and transmission, replace if
necessary.
8 Fit the pump and check that the pump's splines engage in the
shaft in the transmission.
Fit the pump fastening screws, use locking fluid to lock the screws
and seal the screw holes in the transmission.
9 Connect the hydraulic hoses in accordance with the markings.
NOTE
Prefill the pump with oil through the pressure connection before
it is put into service.
If necessary vent the pump before starting the engine by
Fastening screws hydraulic oil pump brake and steering removing the hoses on the pressure side.
NOTE
position.

10:12 10 Common hydraulics – Pipes and hoses
NOTE
11 Turn on the system voltage and start the engine.

12 Check that the hose connections are tight.
014619
13 Check the hydraulic oil level with all hydraulic cylinders fully
retracted. Top up if necessary.
NOTE
If the pump is replaced due to malfunction, change the oil and
filter in the hydraulic system as well.
CAUTION
Do not overfill!
fully retracted.


10 Common hydraulics – Hoses, pipes and valves 10:13
10.5 Hoses, pipes and valves

Hoses with ORFS couplings are used almost exclusively. For maximum
service life and function, the following should be observed when
replacing hoses.
1. To avoid stresses in the connection, there should be a length of
straight hose after the connection.
2. The hose must not be twisted. (A twist of 7% reduces service life
by 90%.)
3. Minimise the number of bends by using correct couplings.
4. Avoid sharp bends.
5. Keep the hoses clean internally. Leave the plugs in place as long
as possible when installing.
6. Check the position of the O-rings and tighten to the correct torque,
NOTE
Straight coupling requires a counterhold wrench to prevent
damage to the O-ring.
7. The O-rings must not be oiled when fitted.

Hose length
Hose length
C/L
Hose length is measured on a hose laid out between the sealing
surfaces. On angled connections, measure from the sealing surface's
centre line [C/L] as illustrated.
Cleanliness
The function and service life of hydraulic components depend to
a great extent on how clean the hydraulic oil is. It is therefore very
important to prevent dirt from entering the brake and hydraulic system.
Some simple advice to keep the hydraulic system clean.

• Always clean the area around a component before starting to
work.
001015
• Plug hose connections immediately after disconnecting. If

possible, use correct plugs for the connection type. If plugs are
C/L line for measuring hose length missing, use clean plastic bags and cable ties or tape to seal
the connection.
• Never re-use oil that has been drained from the machine.
• If possible, filter the oil before pouring it into the machine. Oil
barrels 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.

10:14 10 Common hydraulics – Main valve
10.5.4 Main valve

Main valve, description
1 2
3
4
5
6
28
7
27
26 8
10
11
25
24
12
23
22
13
21 14
20 15
015031
19 18 17 16
1. Solenoid valve, lower (Y6004) 15. Connection servo valves [PP]

2. Solenoid valve, lift (Y6005) 16. Measuring outlet servo pressure [PPM]
3. Adjuster screw max pressure lift 17. Adjusting screw accumulator charging pressure
4. Solenoid valve hydraulic pressure attachment 18. Connection valve block brakes, accumulator charging
(Y6012/Y6062) [ACC]
5. Solenoid valve, tilt in (Y6011) 19. Measuring outlet accumulator pressure [ACC M]
6. Solenoid valve, tilt out (Y6010) 20. Adjusting screw servo pressure
7. Adjuster screw max pressure tilt and attachment
21. Measuring outlet pump pressure brake and steering
8. Feed from the hydraulic oil pump brake and steering [PM]
[P]
22. Connection tilt cylinders, piston side
23. Connection tilt cylinders, rod side
24. Connection control valve, attachment
25. Connection lift cylinders, piston side
12. Connection brake cooling [SPOL], to the drive axle
block 26. Feed hydraulic oil pump load handling [P2]
13. Connection control valve, pilot pressure [LSO] 27. Return to filter [D]
14. Feed control valve [O] 28. Measuring outlet, pump pressure load handling [P2]

10 Common hydraulics – Main valve 10:15
The main valve comprises lift, tilt and attachment control valve which is
integrated with the valve block accumulator charging and priority valve.
Valve block accumulator charging and priority valve
Valve block accumulator charging and priority valve controls the
hydraulic pressure to the brakes, steering and cooling of the brakes
and hydraulic oil. In addition, it supplies the valve block lift, tilt and
attachment control valve with servo pressure.
Accumulator charging valve
The accumulator charging valve is a part of the valve block accumulator

charging and priority valve located on the main valve and distributes
oil from the hydraulic oil pump brakes and steering between pressure
storage and cooling of the wheel brakes.
See section 4 Brakes, group 4.3.3 Accumulator charging valve.
Priority valve
The priority valve is included in the valve block accumulator charging

and priority valve located on the main valve.
See section 5 Steering, group 5.2.2 Priority valve.
Pressure reducer
The pressure reducer is included in the valve block accumulator

charging and priority valve located on the main valve.
See section 7 Load handling, group 7.2.3 Pressure reducer.

Lift, tilt and attachment control valve
The control valve is the second part of the main valve and controls the
hydraulic pressure to the lift and tilt cylinders and to the attachment
control valve.
See section 7 Load handling, group 7.2.5 Lift, tilt and attachment
control valve, 7.4.9 Lift, tilt and attachment control valve and 7.7.5 Lift,
tilt and attachment control valve.

10:16 10 Common hydraulics – Main valve
Main valve, replacement
NOTE
Safety.
2 Depressurise the hydraulic systems, see section B Safety.
3 Place a container tray under the main valve and remove the cover
that sits over the main valve.
4 Mark up and detach the hydraulic hoses from the main valve.
NOTE
from impurities.
5 Mark up and detach the wiring from the main valve.

6 Remove the fastening screws and lift off the main valve. Place the
valve on a clean and protected surface.
7 Transfer the connection adapters to the new main valve.
NOTE
position.
NOTE
015103
Main valve Transfer one connection at a time so that the marking is not
mixed up.
8 Mark up the solenoid valves on the new main valve.

9 Lift the main valve into place and fit the fastening screws.
10 Connect the hydraulic hoses to the main valve in accordance
with the marking.
NOTE
position.
11 Connect the cable harness to the main valve in accordance with

the marking.

10 Common hydraulics – Main valve 10:17
NOTE

14 Check that the valve\qs hydraulic connections are sealed.
15 Bleed the brakes, see section 4 Brakes, group 4.3.9 Wheel brakes.
16 Check the steering
014619
Activate the steering gradually to bleed the steering's hydraulic
circuit.
CAUTION
Air in the hydraulic system may cavitate and result in
product damage.
Activate the steering carefully and operate at the lowest
possible speed a couple of times to avoid cavitation.
17 Check that the attachment is working.

Activate the lift function, tilt function and the attachment functions
gradually to bleed the hydraulic circuits.
18 Check the supply pressure to the brakes and steering, see
Hydraulic oil pump brake and steering, checking, page 10:7.
19 Check the supply pressure to the load-handling functions, see
Load handling hydraulic oil pump, checking, page 10:9.
20 Check the accumulator charging pressure, see 4 Brakes, group
4.3.3 Accumulator charging valve.
21 Check the brake pressure, see 4 Brakes, group 4.3.5 Brake valve.
22 Check the steering pressure, see 5 Steering, group 5.2.1 Hydraulic
oil pump.
23 Check the servo pressure, see 7 Load handling, group 7.2.3
Pressure reducer.
24 Remove the container tray and replace the cover over the main
valve.
25 Check the oil level in hydraulic oil tank with all hydraulic cylinders
in the retracted position. The oil level should be at the top of the
sight glass. Top up if necessary.
CAUTION
Do not overfill!
fully retracted.
26 Test drive the machine and check that all functions work correctly.

10:18 10 Common hydraulics – Temperature control, cleaning and hydraulic oil
10.6 Temperature control, cleaning

and hydraulic oil
Temperature control, cleaning and hydraulic oil,
function description
The hydraulic system's oil is cooled and purified by it circulating
through the wheel brakes, cooler and filters. The cooler has a
temperature-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.
Hydraulic oil pump brakes and steering pumps oil (from the tank)
through the brake system's cooling circuit to be cooled in the hydraulic
oil cooler. Some of the oil is filtered by the fine filter. An electric cooling
fan increases the air flow through the cooler when the temperature
needs to be lowered. A bypass valve opens when the oil is cold and
leads the oil directly to the tank in order that the resistance through
the cooler and filter should not be too high. The bypass valve closes
when the oil gets hot and then leads the oil through the cooler and
filter instead. The temperature sensor controls fan activation and
temperature display.
Excess oil from brakes and steering, and the return oil from load
handling is filtered by the hydraulic oil filter in the hydraulic oil tank.
10, 16 15
D795 D790-2
D797-1
9, 1 1, 14
D 2 4
18 C
SPOL
P2
D P
12 M
7 5
C 19 3 C
6
13
17 1
015037
8 °C 20

1 Hydraulic oil pump for the brakes and See pressure plate on left Gear pump with fixed displacement,
steering pumps oil from the hydraulic oil frame beam. description, page 10:6
tank.
2 Valve block accumulator charging and P < 0.3 MPa See section 4 Brakes, group 4.3.3
priority valve directs the oil to the steering, Accumulator charging valve
charging of the accumulators, hydraulic
oil filter or through the hydraulic system's
cooling circuit. Excess oil is led to the
hydraulic oil filter.

10 Common hydraulics – Temperature control, cleaning and hydraulic oil 10:19

3 The hydraulic oil filter cleans the oil. - Hydraulic oil filter, description, page
10:24
4 Hydraulic oil in the cooling circuit passes - See section 4 Brakes, group 4.3.6 Drive
through the drive axle block to the wheel axle block
brakes.
5 The hydraulic oil cools the wheel brakes. - See section 4 Brakes, group 4.3.9
Wheel brakes.
6 A small amount of oil is guided through the Fine filter hydraulic oil, description, page
fine filter and back to the hydraulic oil tank. 10:27
7 The hydraulic oil cooler cools the oil. - Hydraulic oil cooler, description, page
10:20
8 The hydraulic oil temperature sensor - Sensor, hydraulic oil temperature,
(B776) sends the frame control unit description, page 10:21
(D797-1) a voltage signal proportional to
the hydraulic oil temperature.
Control system, group 8.4.5.1 HYD,
menu 1
9 The frame control unit (D797-1) transmits Checked by the control Section 11 Common electrics, group
oil temperature on the CAN bus. system, error indicated 11.5.3.2 Frame control unit
with error code.
menu 1
10 The KID control unit (D795) shows - Section 9 Frame, body, cab and
oil temperature in the operating menu accessories, group 9.1 Controls and
hydraulic oil temperature. instruments.
11 If the hydraulic oil temperature is high, U = 24 V Cooling fan, description, page 10:21
the frame control unit (D797-1) supplies
voltage to the Cooling fan (M668).
menu 1
12 The cooling fan (M668) increases the - Cooling fan, description, page 10:21
airflow through the hydraulic oil cooler, thus
increasing cooling output
13 If the oil temperature is low or the pressure P = 0.2 MPa Bypass valve, cooler, description, page
through the cooler becomes too high, the 10:23
bypass valve opens and leads the oil past
the cooler.
14 If the hydraulic oil temperature is too high, Checked by the control Section 11 Common electrics, group
the frame control unit (D797-1) transmits a system; error shown with 11.5.3.2 Frame control unit
warning for high hydraulic oil temperature error code.
on the CAN bus.
menu 1
15 The KIT control unit (D790-2) activates the - Section 9 Frame, body, cab and
hydraulic oil temperature warning light. accessories, group 9.1 Controls and
instruments.
16 The KID control unit (D795) shows the error Checked by the control Section 11 Common electrics, group
code on the display. system; error shown with 11.5.3.12 Control unit, KID
error code.
17 The hydraulic oil pump load handling - Gear pump with fixed displacement,
pumps oil to lift, tilt and attachment control description, page 10:6
valve.
18 Lift, tilt and attachment control valve leads - Section 7 Load handling, group7.2.3 Lift,
the return oil from load handling to the tilt and attachment control valve
hydraulic oil filter.
19 The hydraulic oil filter cleans the oil. - Hydraulic oil filter, description, page
10:24
Hydraulic diagram, see section E Schematics group 10 Common


10:20 10 Common hydraulics – Cooler hydraulic oil
10.6.2 Cooler hydraulic oil

Hydraulic oil cooler, description
The hydraulics use a flow-through cooler with electric cooling fan.
The oil is cooled when it passes through the cooler. The cooler is
fitted inside the side panel on the right-hand side behind the hydraulic
oil tank.
009989
Hydraulic oil cooler, replacement
NOTE
Safety.
2 Drain the oil from the hydraulic oil tank, see Hydraulic oil,
changing, page 10:26.
3 Mark up and detach the hydraulic hoses from the cooler. Let the
oil in the cooler drain into the receptacle.
1
2
NOTE
3 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.
009990
8 Connect the cable harness to the cooling fan.

9 Connect the hydraulic hoses to the cooler.
1. Cooling fan
2. Hydraulic connections NOTE
3. Radiator Check that the O-rings are intact, clean and in the correct
position.

10 Common hydraulics – Cooling fan 10:21
10 Fill oil in the hydraulic oil tank, see Hydraulic oil, changing, page
10:26. The oil level should be visible in the sight glass.
CAUTION
Do not overfill!
The hydraulic oil level is checked with the boom
completely lowered and retracted.
10.6.3 Cooling fan

Cooling fan, description
The electric cooling fan is drawing. The cooling fan is located at the
rear of the cooler. The fan draws air from the machine's outside
through the cooler. Openings in the side cover allows air to pass
through the cooler.
The cooler is supplied with voltage by the frame control unit (D797-1)
at activation. The cooling fan is activated when oil temperature is
65 °C in the hydraulic oil tank and the fan is deactivated when oil
temperature is 55 °C.
009991
10.6.4 Sensor hydraulic oil temperature

Sensor, hydraulic oil temperature, description
Sensor, hydraulic oil temperature (B776) detects the temperature of
the hydraulic oil. The sensor is fitted on the hydraulic oil tank's rear
short side.
The sensor detects the oil temperature in the tank, and therefore
takes into account the accumulated heat in the hydraulic oil. Because
of this, the cooling fan may continue to run after the machine has
been parked and switched off provided that the system voltage is not
disconnected.
The hydraulic oil temperature sensor (B776) is supplied voltage by

the frame control unit (D797-1) and sends the control unit a voltage
signal proportional to oil temperature.
009992

10:22 10 Common hydraulics – Sensor hydraulic oil temperature
Sensor, hydraulic oil temperature, replacement
NOTE
Safety.
3 Disconnect the cable harness from Sensor, hydraulic oil

temperature (B776).
4 Replace Sensor, hydraulic oil temperature (B776).
NOTE
position.
5 Connect the cable harness to the sensor.

009992
Sensor, hydraulic oil temperature (B776)
CAUTION
Do not overfill!
7 Use the display, go to the diagnostic menu, see section 8 Control

DIAG HYD 1(6) system, group 8.4.5.1 HYD, menu 1.
HYDRAULIC OIL TEMP indicates hydraulic oil temperature in ºC. Check that correct
TEMP XXX temperature is shown.
FAN XY
000141
Diagnostic menu HYD, menu 1

10 Common hydraulics – Bypass valve, cooler 10:23
10.6.5 Bypass valve, cooler

Bypass valve, cooler, description
The bypass valve protects the cooler against excess pressure and
boosts the heating of the hydraulic oil by opening a passage past the
cooler directly to the tank if the resistance in the cooler is too great
or if the temperature is too low.
009993
Bypass valve
Bypass valve, cooler, replacement
NOTE
Safety.
IMPORTANT
Ensure cleanliness around the filter and filling point
when working on the hydraulic tank.
Dirt particles may cause machine damage.
1 Machine in service position, section B Safety.

4 Disconnect the bypass valve from the tank.
NOTE
Note how the bypass valve faces; the valve is marked with an
arrow.
5 Install the new bypass valve, turning the valve to face the same
way as the old one. Use Loctite when fitting the bypass valve.
009993
Bypass valve

10:24 10 Common hydraulics – Breather filter hydraulic oil tank
CAUTION
Do not overfill!
10.6.6 Breather filter hydraulic oil tank

Breather filter hydraulic oil tank, description
A breather filter of insert type is mounted on the hydraulic oil tank
to protect the tank from impurities. On the top of the filter housing
is an indicator that shows when the filter is clogged and needs to
be changed.
009970

Hydraulic oil filter, description
The oil in the hydraulic system is cleaned by two return filters fitted
inside the hydraulic oil tank. The return oil from the load handling
functions and excess oil from brakes and steering goes through the
filters back to the hydraulic oil tank.
009994

10 Common hydraulics – Hydraulic oil filter 10:25
Hydraulic oil filter, replacement
NOTE
Safety.
IMPORTANT
On machines with a raised cab: Remove the footstep over the

covers and clean the covers and the area around them.
3 Remove the cover plates (position 1) over the hydraulic oil filters.
1 2 1 3 2 4
4 Lift up the filter unit and place it in the receptacle. Let the hydraulic
oil drain.
5 Separate the filter unit and remove the filter insert. Handle the
filter insert as environmentally hazardous waste. Note the position
of the parts.
008084
1. Hydraulic oil filter cover

2. Filling point hydraulic oil
6 Clean the filter holder's parts. Be especially thorough with the

magnetic rod.
7 Fit the new filters and assemble the filter units.
8 Install the filter units and the covers. Tighten the screws crosswise.
9
On machines with a raised cab: Refit the footstep over the covers.
10 Check the oil level, see Hydraulic oil, level check, page 10:26.
Magnetic rod

10:26 10 Common hydraulics – Hydraulic oil
10.6.8 Hydraulic oil

Hydraulic oil, level check
NOTE
The oil level is checked with the mast down and the attachment in
the 20-foot position.
1 Machine in service position, section B Safety.
2 Check the oil level in the hydraulic oil tank. The oil level should
be in the centre of the sight glass. Top up the oil if necessary. For
the oil grade, see section F Technical data.
Hydraulic oil, changing
NOTE
Safety.
IMPORTANT
2 Remove the filler cap and pump out the hydraulic oil into a
1 2 1 3 2 4 receptacle.
3 When as much oil as possible has been pumped out. Place a
receptacle under the hydraulic oil tank's drain plug and drain the
last of the hydraulic oil.
4 Fit the drain plug when the oil has drained out.
NOTE
008084
Make sure that the seal washer for the drain plug is fitted as well.
1. Hydraulic oil filter cover 5 If the hydraulic oil filters are to be changed, change them before
filling the tank with oil, see Hydraulic oil filter, replacement, page
2. Filling point hydraulic oil 10:25.

10 Common hydraulics – Pipes and hoses 10:27
6 Fill new hydraulic oil through the filler holes on the filters' covers.
This results in the filtering of the oil that is filled and protects the
hydraulic system from impurities.
Fill oil until the oil level is in the middle of the sight glass. For
volume and quality, see section F Technical data.
CAUTION
Do not overfill!
fully retracted.

10.6.10 Fine filter hydraulic oil

Fine filter hydraulic oil, description
The fine filter is located behind the hydraulic oil tank on the machine's
right-hand side. The filter is connected in parallel with the hydraulic oil
cooler.
Some of the oil from the cooling circuit passes through the fine filter
and then back to the hydraulic oil tank.
The fine filter cleans a smaller amount of oil but with a higher degree
of filtration when the machine is running.
009968

10:28 10 Common hydraulics – Fine filter hydraulic oil
Fine filter hydraulic oil, replacement
NOTE
Safety.
IMPORTANT
2 Remove the cover.

3 Take out a collection vessel.
4 Lift up the filter insert and place it in the receptacle. Let the
hydraulic oil drain.
5 Fit the new filter insert and refit the cover over the fine filter.

10 Common hydraulics – Other 10:29
10.7 Other
10.7.1 Hydraulic cylinders
Fault tracing, leakage
Fault tracing, leakage
CAUTION
All fault tracing should be carried out with as low a
pressure in the system as possible so that the leakage
can be detected. High pressure causes the seals to
close tighter, which prevents detection of leaks.
1. Carefully check the source of the leakage before taking any

action. It may be possible to rectify the fault without disassembly.
2. Check for external leakage:
• At cylinder face end welds
• At sleeve coupling welds
• Between cylinder barrel and cylinder head
This could be due to a defective O-ring or damaged O-ring
sealing surfaces. Both faults can be rectified with the cylinder
in situ.
• Between cylinder head and piston rod
This could be due to a damaged piston rod or damaged or
worn piston rod seal.
3. Check for internal leakage. Pressurise the cylinder and check
whether the piston sinks back.
This could be due to a worn piston seal.
1. Piston rod
2. Scraper
3. Cylinder head
4. Piston rod seal
5. O-ring with support ring
6. Cylinder barrel
7. Sleeve coupling
8. Welded cylinder end face
9. Piston
10. Piston seal, double-acting
11. Example of weld

10:30 10 Common hydraulics – Hydraulic cylinders
Dismantling of cylinders
CAUTION
Before dismantling always check that the piston rod
is clean and free from all residual paint. Also check
that connections and couplings are free from burrs and
impact marks.
Make sure that the chamfer up to the chromium surface
of the piston rod is free from burrs and residual paint.
1 Remove the cylinder from its mounting and undo the connections.
2 Plug the cylinder connections and hoses without delay.
3 If the cylinder is opened - observe the strictest cleanliness!
Inspection of surfaces
Inspect the sealing surfaces. Always bearing mind the function of the
seals and the type of sealing surfaces they have. See the following
descriptions:
• O-ring groove, internal and external
• piston rod seal in the cylinder head
• sealing groove on the piston
• cylinder barrel surface
• piston rod surface. The piston rod is chromium plated with a layer
thickness of 20-50 my. Slight damage to the chromium plating may
not necessarily cause leakage directly.
• all slide surfaces (dynamic surfaces), e.g. cylinder barrel and
piston rod. These are always the hardest to seal.
CAUTION
When fitting the cylinder head:
Get it absolutely straight. This is best done by hand.
Under no circumstances hit it with a mallet of any type.
If the cylinder head is fitted crooked, the sealing lip
of the piston rod seal could be damaged, making an
improper seal. This applies to all types of piston rod
seals.

10 Common hydraulics – Hydraulic cylinders 10:31
Function and removal of the seals

Piston rod seal
2 Piston rod seal
The piston rod seal is the seal that sits in the groove in the cylinder
1 head and seals against the piston rod. This seal is very exposed to
wear since it is both a dynamic and a static seal, i.e. it seals against a
moving surface on the piston rod while the sealing surface with the
cylinder head is fixed. There are different types of piston rod seals:
• Single V-seal
3 • Pre-stressed V-seal with support ring
• Compressible seal
The single V-seal has a V-shaped section with two lips that seal
4 in opposite directions. The hydraulic pressure acts in the V-shape,
6
pressing the sealing lips out towards the sealing surfaces on the
piston rod and in the cylinder barrel. Even minor damage to the
sealing lips can generate large leaks. Examine the sealing lips by
carefully using a fingernail to feel around the seal. To remove, use a
screwdriver to prise the seal outward and bend it up (see illustration).
It is extremely important that the screwdriver is always inserted in
the V-shape so that it cannot touch and thereby damage a sealing
surface. A mark from a screwdriver on a sealing surface can have a
devastating effect and cause major leakage.
001497
5
1. Hydraulic pressure
2. Seal lip pressed out toward piston rod
3. Seal lip pressed inward toward cylinder head
4. Sealing surface, piston rod
5. Sealing surface, cylinder head
6. Screwdriver

2 The pretensioned V-seal also has an O-ring in the seal's V-shaped

space. The O-ring creates a strong seal at low hydraulic pressure
1 since the O-ring already presses the sealing lips out toward the
sealing surfaces when unloaded. It is just as sensitive to damage
as the V-seal. Examine in the same manner. To remove, use a
screwdriver to prise the seal outward and bend it up (see illustration).
It is extremely important that the screwdriver is always inserted in
the V-shape so that it cannot touch and thereby damage a sealing
3 surface. A mark from a screwdriver on a sealing surface can have a
7 devastating effect and cause major leakage.
6 4
001498
5
6. Screwdriver
7. O-ring
The compressible piston rod seal consists of a solid rubber profile
2
and provides a larger sealing surface than the V-seals. To remove,
use a screwdriver to prise the seal outward and bend it up (see
1 illustration). With this type of seal with sealing surfaces that cover so
much of the seal groove, it is particularly important that marks are
3
not made with the screwdriver.
6
4
5
001499
6. Screwdriver

Support ring and O-ring

Support ring and O-ring
The support ring and O-ring combination is used for sealing between
two fixed surfaces, such as between cylinder barrel and cylinder head.
The purpose of the support ring is to lend rigidity to the O-ring so that
3 it is not deformed. The O-ring is pressed against the support ring and
the sealing surface by the hydraulic pressure in the cylinder.
4 When the cylinder head is mounted in the barrel: Take extreme care
not to damage the O-ring.
2
001506
1
2. O-ring
3. Support ring
Scraper
Scraper
øD+10
1 The purpose of the scraper is to scrape the piston rod clean and
prevent impurities from entering the cylinder barrel.
The scraper must be fitted with a special fitting tool. This tool must
have a greater outer diameter than the scraper so that the press force
2 against the scraper ceases precisely when the scraper is pressed into
its position. If the scraper were to be pressed in further, the metal
capsule would be deformed (see lower illustration), which would
4 impair the function of the scraper.
3 To prevent the scraper from bottoming in its recess in the cylinder

head, the recess is slightly deeper than the width of the scraper.
øD
6
001496
1. Correct assembly tool

2. Scraper, correctly fitted
3. Cylinder head
4. Clearance between scraper and bottom of
cylinder head recess
5. Incorrect assembly tool
6. Deformed scraper

A screwdriver can be used for removal. This must always be applied

1 against the outer edge of the scraper (see illustration). Carefully tap
the screwdriver down between the scraper and the cylinder head and
2 then prise out the scraper. Polish away any damage to the cylinder
head.
CAUTION
No tool may be applied from the inside. This could
3 give rise to burrs on the cylinder head which could in
turn damage the piston rod. Burrs may also damage
the piston rod seal when fitting the piston.
001551
1. Screwdriver
2. Scraper
3. Cylinder head
On the single-acting V-seal it is always the long side that seals
2
against the fixed surface and the short side that seals against the
moving surface.
1 To remove, use a screwdriver to prise the seal outward and bend it

up (see illustration). It is extremely important that the screwdriver is
always inserted in the V-shape so that it cannot touch and thereby
damage a sealing surface. A mark from a screwdriver on a sealing
surface can have a devastating effect and cause major leakage.
3
6 4
002370
5
2. Seal pressed out toward cylinder barrel
3. Seal pressed in toward piston
4. Sealing surface, cylinder barrel
5. Sealing surface, piston
6. Screwdriver

The seal must always be fitted as a single assembly together with

the support ring.
Always assemble by hand. No tools should be used as they could

easily damage the surface of the piston.
To facilitate assembly the seal can be heated in hot water to make it

soft.
Lubricate with hydraulic oil.
002950
Double-acting piston seal
Double-acting piston seal
5 4 3 1 6
The double-acting seal functions with pressure from both sides, e.g.
in a steering cylinder.
All of the interior surface of the cylinder barrel is a sealing surface

and it is therefore extremely important that it is completely free from
damage.
Exercise caution when fitting the piston in the cylinder barrel, making
2
002951
sure that the seal is not damaged by the cylinder barrel threads.
1. Variable sealing surface to cylinder barrel

2. Fixed sealing surface with piston
3. Guide ring
4. Support ring
5. Piston head
6. Cylinder barrel
Dismantling:
1 Remove guide rings and support rings.
2 Move the seal body over to one side of the sealing groove.
3 Press up the material so that there is a gap between seal and

piston.
4 Without damaging the surface of the piston - cut off the seal with
a knife.
5 Carefully examine the seal to find any damage that could cause
leakage. This will be easier if you bend the seal sharply bit by bit
and feel over the sealing surface with a fingernail.
Assembly:
1 All double-acting piston seals are of similar design: a middle seal
body, then support rings and farthest out guide rings.
2 First fit the seal body, then the support rings and finally the guide
rings - all must be done by hand without tools to avoid damage.

Repairing the piston rod surface

A small impact mark on a piston rod may be sufficient to cause
leakage. The chromium plating on the piston rod has a thickness of
20-50 micrometres and can be treated to make good minor damage.
This may be a satisfactory alternative to costly disassembly.
1 2 3 1 Locate the damage using your fingertips and fingernails.
2 Use a small, highly-polished hammer and work the surrounding
material inwards towards the damage, starting from the outside.
3 Instead of a small sharp mark there will now be a small uniform
concavity in the chromium plating.
4 Polish with emery cloth, progressing from number 240 to 600.
4 Wrap the emery cloth round a file to give it good support. Note that
there must always be chromium plating present at the damage.
5 It is important to treat small impact marks before disassembly and
assembly to avoid damaging the cylinder head.
6 Repairing larger damage on a piston rod:
• fill the damage with weld metal, use chromium or stainless
steel electrodes
• remove all slag completely
• file the weld down to the same level as the chrome
• polish evenly using emery cloth.
002952
1. Piston rod
2. Chromium plating
3. Impact mark
4. Highly-polished hammer

Dismantling the steering cylinders

It can prove extremely difficult to extract the piston rod from the cylinder
barrel on steering cylinders. This is because the O-ring in the cylinder
head fastens in the lock ring groove in the cylinder barrel. It is therefore
best to remove the O-ring before trying to withdraw the piston rod from
the cylinder.
1 Unscrew the end washer at the cylinder head.
2 Unscrew the connecting nipple for the hydraulic hose.
3 Insert the piston rod with piston crown until the O-ring is visible
through the nipple hole.
4 Bend the end of a length of heavy-duty steel wire, piano wire or
similar into the shape of a hook. Use this to snag the O-ring.
5 Pull the O-ring up slightly and hold it with a pair of needle-nose
pliers.
6 Continue to pull the O-ring out through the hole.
7 Hold the O-ring steady and cut it with a knife.
8 Rotate the piston rod while pulling the O-ring out through the hole.
9 Remove the lock ring from the cylinder barrel.
10 Carefully extract the piston rod from the cylinder barrel.
002953

10:38

11:1
11 Common electrics
Contents 11 Common electrics

11 Common electrics ............................................................................................11:3
11.2 Electric protection .......................................................................................... 11:3
11.2.1 Battery disconnector ................................................................................. 11:3
11.2.2 Fuses ........................................................................................................ 11:3
11.2.3 Control breaker ......................................................................................... 11:3
11.3 Batteries......................................................................................................... 11:4
11.3.1 Start battery............................................................................................... 11:4
11.4 Alternator ....................................................................................................... 11:6
11.4.1 Alternator................................................................................................... 11:6
11.5 Distribution of electricity ................................................................................. 11:7
11.5.1 Voltage feed .............................................................................................. 11:7
11.5.2 Electronic box.......................................................................................... 11:14
11.5.3 Control units ............................................................................................ 11:16
11.5.5 Cable harness ......................................................................................... 11:25
11.6 Communication ............................................................................................ 11:34
11.6.1 CAN bus .................................................................................................. 11:34
11.6.2 Redundant CAN bus ............................................................................... 11:36
11.6.3 CAN bus drive-train ................................................................................. 11:38
11.6.4 Communication between PC and machine ............................................. 11:39

11:2

11 Common electrics – Common electrics 11:3
11 Common electrics
11.2 Electric protection
11.2.1 Battery disconnector
Battery disconnector, description
The positive terminals of the batteries connected in series are
connected to the machine's electrical system via the battery
disconnector. The battery disconnector cuts off all power from the
batteries to the machine's electrical system.
A
IMPORTANT
Never switch off the voltage with the battery
disconnector when the engine is running. This could
damage the alternator.
The battery disconnector must not be used as control
breaker!
010051
A Position of battery disconnector
11.2.2 Fuses
Fuses, changing
When checking and changing the main fuse:
1 Switch off the system voltage (battery disconnector).
2 Remove the plastic cover.
3 Check that the fuses are intact. Replace if necessary.

The fuses are 25 A or 50 A.
When checking and changing fuses:

1 Switch off the system voltage (battery disconnector).
2 Remove the cover from the electronic box.
3 Check and, if necessary, replace fuses.

The fuse plate gives information about each fuse.
11.2.3 Control breaker

Emergency stop switch, description
See Emergency stop switch voltage (15E), function description, page
11:11.

11:4 11 Common electrics – Batteries
11.3 Batteries
11.3.1 Start battery
Start battery, description
The machine's electrical system is supplied by two 12 V batteries
connected in series.
The negative terminal is connected to the frame. The positive terminal

is connected to the battery disconnector.
The batteries are charged by the alternator, see Alternator, description

(engine alternative Yuchai YC6A240-30), page 11:6 or Alternator,
description (engine alternative Cummins QSB6.7 ), page 11:6.
WARNING
Battery electrolyte contains corrosive sulphuric acid.
Risk of corrosive injuries! Health hazard!
Use protective glasses and protective gloves when
working with the batteries. Immediately remove any
electrolyte on bare skin. Wash with soap and plenty of
water. If the electrolyte has found its way into your
eyes, rinse immediately with lots of water and contact
a doctor immediately.
WARNING
Risk of explosion!
Personal injury!
During charging, hydrogen gas forms around the
batteries. Sparks could ignite the hydrogen gas,
causing an explosion. Disconnect the battery with the
battery disconnector.
WARNING
Short-circuiting of battery.
Risk of explosion! Fire hazard! Risk of personal injury!
The battery's terminals must not be connected to each
other or to common grounding point (chassis).

11 Common electrics – Start battery 11:5
Start battery, replacement

2 Disconnect the cables from the battery terminals. Start with the
negative (minus) cable.
3 Replace the batteries.
4 Connect the cables to the battery terminals. Connect the negative
cable last of all.
NOTE
Take great care when reconnecting the cables to prevent short
circuiting.

11:6 11 Common electrics – Alternator
11.4 Alternator
11.4.1 Alternator
Alternator, description (engine alternative Yuchai
YC6A240-30)
The alternator generates current during operation and supplies this
to the batteries. The alternator produces AC current and has an
integrated charge regulator.
The alternator is driven by the engine via a belt. Faults are indicated
by the warning lamp for low battery charging.
system, section 8.4.6.4 ENGINE, menu 4.
015061
Alternator, description (engine alternative Cummins

QSB6.7 )
The alternator generates current during operation and supplies this
to the batteries. The alternator produces AC current and has an
integrated charge regulator.
The alternator is driven by the engine via a belt. Faults are indicated
by the warning lamp for low battery charging.
system, section 8.4.6.4 ENGINE, menu 4.
010052
Alternator, replacement
See supplier documentation, engine.

11 Common electrics – Distribution of electricity 11:7
11.5 Distribution of electricity

11.5.1 Voltage feed
11.5.1.2 Redundant voltage feed of control units
Redundant voltage feed of control units, function

description
1 2 3 4
D1 D3 D4
D2
D793 D794
- +
D8
D790-1 D791
5, 6 8
9 7
D795 D790-2 D797-1
0015056
D9 D7

1 The NC switch, operator's door U = 24 V Section 9 Frame, body, cab and accessories, group
(S 266-LE) or the NC switch, 9.10.2 Doors
passenger door (S 266-RI) sends
a voltage signal to the cab control
system, group 8.4.2.9 LIGHTS, menu 9 or 8.4.11.5
unit (D790-1) when the door is
MOVE-CAB, menu 1
opened.
2 The interior lighting switch of the U = 24 V Section 9 Frame, body, cab and accessories, group
KIT control unit (D790-2) sends a 9.6.12 Interior lighting
voltage signal to the cab control
D2: Diagnostic menu, see section 8 Control system,
unit (D790-1).
group 8.4.2.13 LIGHTS, menu 13
3 Switch, flashing hazard lights U = 24 V Section 9 Frame, body, cab and accessories, group
(S109) sends a voltage signal to 9.6.7 Flashing hazard lights
Control unit, cab (D790-1).
4 When the ignition switch (S150) U = 24 V Section 9 Frame, body, cab and accessories, group
is turned to position I, it sends a 9.1 Controls and instruments
voltage signal to the cab control
unit (D790-1).
group 8.4.1.5 CAN/POWER, menu 5
5 Control unit, cab (D790-1) activates - Cab control unit, description, page 11:17
a hold circuit, which activates the
control unit's control logic.

11:8 11 Common electrics – Voltage feed

6 Control unit, cab (D790-1) activates UK11:7 = 24 V Cab control unit, description, page 11:17
a redundant voltage feed to other
U K11:8 = 24 V
control units.
UK11:9 = 24 V
Control unit, cab (D790-1) has 4
outputs for redundant voltage feed UK11:10 = 24 V
while other control units have two
inputs for redundant voltage feed.
In the event of a malfunction of
one voltage feed the control unit is
supplied by the other feed.
7 Control unit, cab (D790-1) supplies UK2:7 = 24 V Frame control unit, description, page 11:18
voltage to the control logic of
UK2:8 = 24 V D7: Diagnostic menu, see section 8 Control system,
the other control units via the
redundant voltage feed.
8 UK2:7 = 24 V Control unit, attachment, description, page 11:19
9 UK2:7 = 24 V D9: Control unit KID, description, page 11:24
UK2:8 = 24 V Diagnostic menu, see section 8 Control system,

11 Common electrics – Voltage feed 11:9
11.5.1.3 Ignition voltage (15)
Ignition voltage (15), function description

Battery disconnector In position 1 Battery disconnector, description, page 11:3
Redundant voltage feed Activated. Redundant voltage feed of control units, function description
, page 11:7
Redundant CAN bus Communication Redundant CAN bus, description, page 11:36
established.
- +
K315-2
1 2 K315-1
7 3, 6
D1 D2 D3 3
D794
D793
10 D10
4, 5
D8
D790-1 D791
2, 8
9
D795 D790-2 D797-1
015054
D9

1 Switch, flashing hazard U = 24 V Section 9 Frame, body, cab and accessories, group 9.6.7
lights (S109) sends a Flashing hazard lights
voltage signal to Control
unit, cab (D790-1).
2 When the ignition switch U = 24 V Section 9 Frame, body, cab and accessories, group 9.1
(S150) is turned to position I, Controls and instruments
it sends a voltage signal to
3 Cab control unit (D790-1) U = 24 V Cab control unit, description, page 11:17
voltage feeds the ignition
key lock power relay K315-1
and the ignition voltage
relay K315-2 in the frame
electronic box.
4 Relay, ignition voltage U = 24 V -
K315-1 supplies voltage
to fuse holder in the cab
electronic box and in the
5 The fuses feed voltage to U = 24 V -
control units, relays, solenoid
valves and other electronic
components.


6 Relay, ignition voltage U = 24 V Control unit, engine, description (engine alternative
K315-2 supplies voltage to Yuchaii YC6A240-30), page 11:21.
Control unit, engine (D794).
Control unit, engine, description (engine alternative
Cummins QSB6.7 ), page 11:22.
7 The drive-train's CAN-bus Checked by control CAN bus drive-train, description, page 11:38
establishes communication. system, error shown
with error code.
8 Ignition voltage to Control UK1:2 = 24 V Cab control unit, description, page 11:17
unit, cab (D790-1).
UK1:4 = 24 V
9 Ignition voltage to the frame UK2:1 = 24 V Frame control unit, description, page 11:18
control unit (D797-1).
UK2:10 = 24 V
10 Ignition voltage to Control UA1 = 24 V Control unit, transmission, description, page 11:20
unit, transmission (D793).

11.5.1.4 Emergency stop switch voltage (15E)
Emergency stop switch voltage (15E), function

description
Condition Reference Reference

value
Redundant voltage Activated. Redundant voltage feed of control units, function description , page 11:7
feed
Ignition voltage Activated. Ignition voltage (15), function description, page 11:9
Control breaker Not activated Section 9 Frame, body, cab and accessories, group 9.1 Controls and
instruments
D794
D793
D5
K3007
3, 4 6
K3009-1 K3009-2
- +
K3002
D4
D2
D7
D790-1 D797-1
1, 2, 5
7
D795 D790-2 D791
015055
1 Ignition voltage is activated by the cab Checked by control Ignition voltage (15), function description,
control unit (D790-1) system, error shown page 11:9
with error code.
2 Control unit, cab (D790-1) supplies voltage UK3009-1/86 = 24 V Cab control unit, description, page 11:17
to Relay, emergency stop switch voltage
(K3009-1) in the frame electronic box.
6
3 Relay, emergency stop switch voltage UK3009-2/87 = 24 V Electronic box frame, description, page
(K3009-1) supplies voltage to Relay, 11:15
emergency stop switch voltage (K3009-2) in
the frame electronic box.
(K3009-1) also sends a voltage signal to the 11:15
UK3009-2/87= 0 V
Control unit, cab (D790-1), which verifies
that Relay, emergency stop switch voltage
(K3009-1) is active but Relay, emergency
6
stop switch voltage (K3009-2) is inactive.
This verifies that the emergency stop switch
is working.
5 Control unit, cab (D790-1) activates Relay, UK3009-2/86 = 24 V Cab control unit, description, page 11:17
emergency stop switch voltage (K3009-2)
in the electronic box.
6


K3009-2 supplies voltage to the emergency 11:15
stop switch circuit.
7 The attachment control unit (D791) is Emergency stop Control unit, attachment, description, page
voltage fed with emergency stop switch switch in home 11:19
voltage as long as emergency stop switch position: UK2:1 = 24
is not depressed. V
system, group 8.4.1.15 CAN/POWER,
Attachment control unit D791 is only voltage Emergency stop menu 15
fed by the emergency stop switch, thus all switch in home
attachment functions stop if the emergency position: UK2:9 = 24
stop switch is activated. V
If the emergency stop switch is pressed, Emergency stop
ignition voltage to the cab control unit switch in home
(D790-1) is cut off, thereby cutting off control position: UK2:10 =
current to emergency stop switch voltage 24 V
relay K3009-1, emergency stop switch
Emergency stop
voltage relay K3009-2, the tilt relay (K3002)
switch in home
and the lift/lower relay (K3007). The power
position: UK2:11 =
supply to the control units is cut off and the
24 V
functions cease.
As an extra safety measure, the cab control
unit (D790-1) also transmits the status of the
emergency stop switch the CAN bus. Thus,
functions are also cut off at the signal level.
Emergency stop switch, checking

1 Start the machine and active any load handling function.
2 Activate lift.
3 Press in the emergency stop switch and check that the lift
movement stops.
4 Reset the emergency stop switch (turn in the direction of the
arrows) and check that the lift function is working again.
002084

11.5.1.5 Voltage converter
Voltage converter, description
The voltage converter is located under a protective casing to the left

behind the driver's seat.
The voltage converter converts 24 volts to 12 volts. 12 V power is

available for accessories through a connector in the cab electrical
distribution box and through a socket on the instrument panel.
Connector X067 in cab electronic box (contains 15-voltage,

30-voltage, ground and 12 V).
Voltage converter, replacement

2 Remove the covers behind the driver's seat.
3 Detach the electrical cables from the converter.
4 Remove the voltage converter.
The voltage converter is located diagonally behind the

driver's seat.

11:14 11 Common electrics – Electronic box
11.5.2 Electronic box

11.5.2.1 Electronic box, cab
Electronic box, cab, description

The electronic box is mounted on the rear wall of the cab, on the left.
7 Located there are:
• Control unit cab (D790-1).
6 • Cab battery voltage circuit fuses for (30), ignition voltage (15)
F58-4 and cab ignition voltage circuit fuses (15) F58-5.
• Buzzer for alarm if, for example, the operator leaves the machine
without the parking brake being applied.
• Connectors.
• Relays.
•
Voltage converter 24 V to 12 V
• Customer accessory connector. Output voltage 24 V, max. 10 A.
Connector 9-pin Universal mate-n-lock. For part number see
Spare parts catalogue.
1
2
NOTE
This connector is not fitted on the machine if the machine is
equipped with voltage converter.
3
4
CAUTION
5
Connector X067 must be used when connecting extra

008693
electrical equipment. The use of other connections

can lead to overloading of cable harness and product
1. Control unit, cab (D790-1) damage.
2. Diagnostic socket, machine
3. Diagnostic socket CAN Bus drivetrain
4. Fuse holders for cab battery voltage circuit fuses
(30) and the ignition voltage (15) F58 -4 (upper)
and cab ignition voltage circuit fuses (15) F58
-5 (lower).
5. Voltage converter
6. Termination resistor
7. Customer accessory connector (X067) 24V/10A
and 12V/20A
Customer accessory connector (X067)
Customer accessory connector (X067)
3 2 1
The connector is designed for customer accessories and contains
connections for 24 V. On machines with voltage converter 24 V to 12
4 V there is also a connection for 12 V .
Pin 1. 24 V, ignition voltage, 10 A
014169
Pin 2. 24 V, battery voltage, 10 A

Pin 3. Ground
Pin 4. 12 V, ignition voltage, 20 A

11 Common electrics – Electronic box 11:15
11.5.2.2 Electronic box frame
Electronic box frame, description

The electronic box is fitted on the side of the machine. Also located
5
4 there are:
3 • Circuit fuses.
2 • Outlet for programming Control unit, transmission (D793)
6 • Main fuses.
1
• Control unit, transmission (D793)
• Power relays for voltage feed to the machine's functions.
7
8
9
10
11
12
015057
13
1. Circuit fuses, battery voltage (30) F58-3
2. Circuit fuses, ignition voltage (15) F58-2
3. Circuit fuses, emergency stop switch voltage
(15E) F58-3
4. Diagnostic socket engine, (Engine alternative
Yuchai YC6A240-30) (the connector hangs
loose in the electronic box)
5. Main fuses
6. Terminal block
7. Circuit fuse transmission control unit (0.5 A)
(F51-3)
8. Tilt in/out relay K3002
9. Lifting/lowering relay K3007
10. Ignition switch relay K315-2
11. Ignition key lock power relay K315-1
12. Control breaker power relay K3009-1
13. Control breaker power relay K3009-2
-
1
-
2
- 1
3
-
4
5 -
-
6
007184
1. Termination resistor

11:16 11 Common electrics – Control units
11.5.3 Control units

Control units, location
1 2 3
014680
7 6 5
1. Frame control unit (D797-1) 5. Control unit, transmission (D793)
2. Control unit, KID (D795) 6. Engine control unit, Yuchai (D794)
3. Control unit KIT (D790-2) 7. Engine control unit, Cummins (D794)
4. Control unit, cab (D790-1) 8. Control unit, attachment (D791-1)

11 Common electrics – Control units 11:17
11.5.3.1 Control unit, cab
Cab control unit, description

2 1 Control unit, cab (D790-1) is the central control unit of the control
system. Control unit, cab (D790-1) sends activation signals to other
units, and controls and monitors their functions. It administrates work
in the control unit network. The control unit controls the redundant
voltage feed and handles communication via a redundant CAN bus
and gateway for CAN bus drive-train. Control unit, cab (D790-1) also
processes all input signals from cab controls and transmits these
signals on the CAN bus.
5 6
4
3 Control unit, cab has four indicator lights that indicate the control
000041
2 unit's function.
1. Connection terminals - fan, working lights, Lamp 1 Green light on when there is battery voltage to the unit.
windscreen wiper The light is physically controlled by voltage feed to the
2. Connection terminals, other control unit.
3. Light 1, battery voltage Lamp 2 Flashes green when redundant voltage feed to control
units and redundant CAN bus communication are
4. Light 2, redundant voltage feed, redundant CAN active. No power in the system.
bus and power supply
Green light when power electronics and 15-voltage
5. Light 3, communication are supplied voltage.
6. Light 4, error indication Lamp 3 Long single flash yellow during communication with
Control unit, display (D795). This is a basic condition
of fault tracing.
Short single flash yellow during communication
with Control unit, engine (D794) and Control unit,
transmission (D793).
Double flash yellow (short and long flash) during
communication with the display and engine or
transmission.
Lamp 4 Red light in the event of active error.
Control unit cab, replacement

2 Remove the cover from the electronic box.
3 Detach the connectors from Control unit, cab (D790-1).

4 Replace the control unit.
5 Check that the new control unit corresponds with the machine's
forklift number (Z-number).
6 Calibrate the new control unit. See section 8 Control system,
group 8.5.2.3 Calibrate DRIVE-TRAIN.

11.5.3.2 Frame control unit
Frame control unit, description

The frame control unit (D797-1) processes input data from sensors
1 and sends control signals to relays and solenoid valves.
2 The cab control unit has four indicator lights that indicate the control
unit's function.
3
Lamp 1 Green light on when there is battery voltage to the unit.
The light is physically controlled by voltage feed to the
4 control unit.
Lamp 2 Flashes green when one or more of the following
is missing: redundant voltage feed left, redundant
voltage feed right or 15-voltage.
Green light when redundant voltage feed left,
000043 redundant voltage feed right and 15-voltage are
supplied voltage.
6 5
Lamp 3 Single yellow flash during communication with the KID
1. Light 1, battery voltage control unit (D795) or cab control unit (D790-1).
2. Light 2, redundant voltage feed and power Double yellow flash during communication with the KID
supply control unit (D795) and the cab control unit (D790-1).
3. Light 3, communication Lamp 4 Red light in the event of active error.
4. Light 4, error indication
5. Control signals (inputs and outputs)
6. Power supply (redundant voltage feed for control
units, redundant CAN bus) and input data
Frame control unit, replacement

2 Detach the cables from the frame control unit (D797-1).

5 Check the initiation values for attachment functions; see section 8
Control system, group 8.5.1.1 ELSERVO.
6 The control unit is not calibrated.

11.5.3.5 Control unit, attachment
Control unit, attachment, description

The attachment control unit (D791) processes input data from sensors
1 and sends control signals to relays and solenoid valves of the side
lift attachment.
2
The cab control unit has four indicator lights that indicate the control
unit's function.
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.
Lamp 2 Flashes green when one or more of the following
is missing: redundant voltage feed left, redundant
voltage feed right or 15-voltage.
Green light when redundant voltage feed left,
000043
6 5 redundant voltage feed right and 15-voltage are
supplied voltage.
1. Light 1, battery voltage Lamp 3 Single yellow flash during communication with the KID
2. Light 2, redundant voltage feed and power control unit (D795) or cab control unit (D790-1).
supply Double yellow flash during communication with the KID
3. Light 3, communication control unit (D795) and the cab control unit (D790-1).
4. Light 4, error indication Lamp 4 Red light in the event of active error.
5. Control signals (inputs and outputs)
6. Power supply (redundant voltage feed for control
units, redundant CAN bus) and input data
Control unit, attachment, replacement

2 Disconnect the cable harness from the control unit.

5 Check the initiation values for attachment functions; see section 8
Control system, group 8.5.1.2 ATTACHMENT.
6 The control unit is not calibrated.

11.5.3.9 Transmission control unit
Control unit, transmission, description

Control unit, transmission TCU (D793) is part of the drive-train control
and handles the transmission's function, selection of gear at load and
engine speed, etc.
Control unit, transmission TCU (D793) is connected via separate CAN

bus communication to the engine, which is connected to Control unit,
cab (D790-1). In turn, Control unit, cab (D790-1) sends drive-train
information on to other units.
015058
Control unit, transmission, replacement

1 Machine in service position.
2 Disconnect the cable harness from Control unit, transmission

(D793).
5 Calibrate the new control unit; see section 8 Control system, group
8.5.2.3 Calibrate DRIVE-TRAIN and section 2 Transmission,
group 2.8 Control system, transmission.
015058

11.5.3.10 Engine control unit

Yuchaii YC6A240-30)
Control unit, engine (D794) is part of the drive-train control and
handles engine function, fuel injection, etc.
Control unit, engine (D794) is connected via separate CAN bus

communication to the transmission, which is connected to Control
unit, cab (D790-1). In turn, Control unit, cab (D790-1) sends
drive-train information on to other units.
The control unit is fitted on the engine has no function keys or display.
All functions are controlled via the CAN bus and an external control
system.
The control unit monitors the following values in order to optimise

engine performance.
• engine speed
• camshaft position
• boost pressure
• charge air temperature
013872
• coolant temperature
Engine control unit • oil pressure
• oil temperature
• oil level
• crankcase pressure
• water in fuel
• fuel pressure
• coolant level
The data gives exact information about the operating conditions and
makes it possible for the control unit to, for example, calculate the
correct fuel volume and to check the condition of the engine.


Cummins QSB6.7 )
The engine control unit (D794) is part of drivetrain control and handles
engine function, fuel injection, etc.
1 Engine control unit EDC (D794) is connected via separate CAN bus
communication to the transmission, which is connected to Cab control
unit (D790-1). In turn, Control unit, cab (D790-1) sends drive-train
2 information on to other units.
The control unit is fitted on the engine has no function keys or display.
All functions are controlled via the CAN bus and an external control
3 system.
The control unit monitors the following values in order to optimise

engine performance.
4 • engine speed
• camshaft position
• boost pressure
010053
• charge air temperature

1. Connector from Cummins cable harness • coolant temperature
2. Connector XD794-3 • oil pressure
3. Connector from Cummins cable harness • water in fuel
4. Connector XD794-3 • fuel pressure
• coolant level
The data gives exact information about the operating conditions and
makes it possible for the control unit to, for example, calculate the
correct fuel volume and to check the condition of the engine.
Control unit, engine, replacement

See supplier documentation, engine.
CAUTION
Each control unit is individually calibrated to each
engine. Control unit replacement between engines
must not be done under any circumstances.

11.5.3.11 Control unit KIT
Control unit KIT, description

The KIT control unit (D790-2) handles functions for the gear and
1 2
multi-function lever, the direction indicator switch and start key
positions II and III. It also handles the key panel for the control system
and its panel for warning and indicator lights.
Control unit KIT (D790-2) has several individual function keys and
indicator lights.
See the operator's manual for detailed information on warning and

indicator lights and function keys.
000049
1. Panel, warning and indicator lights

2. Panel for keys
Control unit KIT, replacement

3 Detach the KIT control unit (D790-2) from the steering wheel panel.
4 Detach the connector sockets.
5 Remove the warning panel for warning and indicator lights.
7 The KIT control unit (D790-2) is not calibrated.

11.5.3.12 Control unit KID
Control unit KID, description

Control unit KID (D795) displays to the operator information sent by
1 2 the control system, such as speed, in the form of messages, status,
error indications, etc.
There is an indicator light to the right of the display that is activated

with a red light when there is a serious malfunction in the control
system. The error code and information are shown on the display.
See the operator's manual for detailed information about the display.
000051
1. LCD display
2. Series of diodes that serve as an indicator light
for serious malfunction.
Control unit KID, replacement

3 Detach the connector from the KID control unit (D795).

4 Detach the KID control unit (D795) from the steering wheel panel.
6 The KID control unit (D795) is not calibrated.

11 Common electrics – Cable harness 11:25
11.5.5 Cable harness

Connectors, overview
The list includes all connectors on the machine with a brief description
of their locations and to which functions the signals in them are related.
Contact Location Function

X001 Control unit, cab (D790-1) Power supply and ground connection Control unit, cab (D790-1)
X002 Control unit, cab (D790-1) Front windscreen wiper
Heater fan
Actuator motor, recirculation
Rear window wiper
Motor, rotating beacon
Back-up lights
X004 Control unit, cab (D790-1) Water valve
Air distributor
Interior temperature sensor
Ambient temperature sensor
Temperature sensor, outlet fan
Sensor, temperature refrigerant
Air conditioning sensor
Front windscreen wiper motor
X005 Control unit, cab (D790-1) Switch, left panel
Switch, option
Window washer, roof rear
Switch flashing hazard lights (Hazard)
Setting fan speed
Setting temperature
Air distribution
Fan and recirculation controls
Accelerator
Alignment bypass
X006 Control unit, cab (D790-1) Instrument illumination
Switch, working lights
Switch, rotating beacon
Switch, headlights
Switch, option
Seat heater
Accelerator
Declutch pedal
X007 Control unit, cab (D790-1) Control lever
Twistlock
Spreading (positioning)

11:26 11 Common electrics – Cable harness

X008 Control unit, cab (D790-1) Switch, spreading
Switch, bypass
Emergency stop switch
Switch parking brake
Sensor twistlocks
Switch 30-35 stop
Switch, aut. 20-40
Switch, option
Instrument illumination
Switch, electric servo panel
X009 Control unit, cab (D790-1) Background illumination, switches
Switch, horn
X009-2 Control unit, cab (D790-1) Control lever
X010 Control unit, cab (D790-1) Sensor, alignment
Water valve
Horn
Relay, seat heating
Relay, working lights
Hour counter
Relay, compressor
Control current relay K315-1, K3009-1, K3009-2, K315-2, K3002 and
K3007
Front windscreen washing
Windscreen wiper, roof
X011 Control unit, cab (D790-1) Ignition
Break contacts (opening switches), cab doors
Interior lighting
Redundant feed, cab control unit (D790-1)
Horn
Break contact (opening switch), seat
Feedback relay K3009-1
X012 Control unit, cab (D790-1) Windscreen wiper, rear
Windscreen wiper, roof
X013 Control unit, cab (D790-1) CAN bus
RS232
X015 Control unit KIT (D790-2) CAN bus
Power supply and ground connection Control unit KIT (D790-2)
X016 Control unit KIT (D790-2) Ignition
X017 Control unit KIT (D790-2) Switch, horn
Control, windscreen wipers
Control, gear
Control, high and low beams


X018 Control unit KIT (D790-2) Sensor steering wheel movement
Buzzer
Switch, direction indicators
Switch, interior lighting
X020 Control unit, KID (D795) CAN bus

RS232
Power supply and ground connection Control unit KID (D795)
X033 Air conditioning Control, fan
Control, temperature
Control, air distribution
Fan and recirculation controls
Instrument illumination
X034 Air conditioning Heater fan
Water valve
X035 Air conditioning Valve, air distribution
Interior temperature sensor
Temperature sensor, outlet fan
X036 Air conditioning Actuator motor, recirculation
Sensor, temperature refrigerant
X038 Instrument panel, cab Accelerator
Declutch pedal
X039 Electronic box, cab Relay, compressor air-suspension seat
Break contact (opening switch), cab door
Actuator motor, recirculation
Fan motor, heating
Water valve, ECC
Air conditioning sensor
Ambient temperature sensor
X040 Electronic box, cab Alignment bypass
Window washer, roof/rear
Accelerator
X048 Electronic box, cab Termination resistor
X049 Electronic box, cab Termination resistor
X050 Electronic box, cab RS232 Control unit, cab (D790-1)
X051 Electronic box, cab Feedback relay K3009-1
Power supply, Control unit, cab (D790-1)
CAN bus
X052 Electronic box, cab CAN bus
Control relays K315-1, K3009-1, K3009-2 and K315-2
X054 Electronic box, cab Interior lighting
Back-up lights
Revolving beacon


X055 Electronic box, cab Windscreen wiper, roof
Power, CD player
Power, COM radio
X056 Electronic box, cab Revolving beacon
Working lights, cab
X057 Electronic box, cab Windscreen wiper, rear
X058 Electronic box, cab Motor, windscreen washing
Engine heater start inhibitor, bridged
Interior lighting
X060A Extension X060 CAN bus
Interior lighting
X061 Electronic box, cab Ground connection, Control unit, KID (D795)
Ground connection, Control unit KIT (D790-2)
X061A Extension X061 Ground connection, Control unit, KID (D795)
Ground connection, Control unit KIT (D790-2)
X062 Electronic box, cab Horn
Compressed air horn
Map lighting
Cigarette lighter 12V
Windscreen wiper, front
Heater fan motor
Motor, recirculation
X063 Electronic box, cab Sensor, operator-in-seat
Seat heater
Compressed-air damped seat
X065 Electronic box, cab Ambient temperature sensor
X066 Electronic box, cab Accelerator
Interior lighting
X067 Electronic box, cab Customisation
X069 Electronic box, cab Sensor, twistlock open/closed
Twistlock relay
Spreading relay
X070 Electronic box, cab Sensor twistlocks
Spreading relay
X072 To Right Behind Seat Current outlet
X080 Instrument panel, cab Switch, mast/attachment work lights
Switch, high beam
Switch, rotating beacon
Switch, seat heater
Switch, seat heater


X081 Instrument panel, cab Switch, seat heater
Extra sensors
Hour counter
X082 Instrument panel, cab NC switch, cab doors
X090 Electric servo panel, cab Electric servo
Electric servo, lift/lower
Electric servo, tilt
Electric servo, side shift
Electric servo, spreading
Electric servo, auxiliary
X091 Electric servo panel, cab Horn
Switch, spreading
Switch, twistlock
X092 Electric servo panel, cab Switch, twistlock
X168 Electronic box frame Power supply attachment control unit
X201 Electronic box frame Ground connection and power supply, Control unit, transmission
(D793)
X203 Electronic box frame Termination resistor
X204 Front edge of frame Mast work lights
X205 Electronic box frame CAN bus
Control unit, transmission (D793)
X207 Front edge of frame Sensor, alignment
Sensor twistlocks
X209 Front edge of frame Power supply, cab control unit (D790-1)
CAN bus, frame control unit (D797-1)
CAN bus, attachment control unit (D791)
X210 Between engine and transmission Power supply and ground connection Control unit, engine (D794)
CAN bus, Control unit, engine (D794)
Low coolant level sensor (engine alternative Cummins QSB6.7 )
D+ alternator (engine alternative Cummins QSB6.7 )

X211 Frame control unit (D797-1) 42-pin connector to frame control unit (D797-1)
X212 Frame control unit (D797-1) Power supply and ground connection, frame control unit (D797-1)
CAN bus, frame control unit (D797-1)
Temperature hydraulic oil
Emergency stop switch voltage
Sensor fuel level
D+ alternator
X214 Front edge of frame CAN bus, attachment control unit (D791)
X215 Electronic box frame Power supply attachment control unit
X230 Beneath driver's seat Sensor, operator-in-seat
X235 Front edge of frame Lift/lower valve
Tilt valve
Mast valves


X236 Engine Low coolant level sensor
X240 Front edge of frame Voltage feed
X241 Front edge of frame Option
X242 Front edge of frame Option
X243 Front edge of frame Low beam rear

High beam rear
Tail light front
X244 Front edge of frame Side shift valve
Spreading valve
Lift, tilt and attachment control valve
X247 Front edge of frame Brake light forward
X248 Front edge of frame Mast position sensor
X251 Control unit, transmission (D793), 60-pin connector for Control unit, transmission (D793)
electronic box frame
X261 Electronic box frame RS232 Control unit, transmission (D793)
X270 Lamp bracket left front High and low beams
Direction indicators
Side marker lights
X271 Lamp bracket right front High and low beams
Side marker lights
X272 Lamp bracket left rear Tail lights
Brake light
Side marker lights
X273 Lamp bracket right rear Tail lights
Brake light
Side marker lights
X275 Rear edge of frame Tail lights
Brake light
Side marker lights
Back-up alarm
X278 Between engine and transmission Electromagnetic clutch, compressor
Sensor pressure refrigerant
Relay, starter motor
X279 Control unit, engine (D794) Signals, Control unit, engine (D794)
CAN bus Drive-train
X280 Engine Coolant level
X281 Electronic box frame Diagnostic socket engine


X286 Engine Resistance, indication preheating active
Resistance, indication water in fuel
X287 Engine Power supply and ground connection Control unit, engine (D794)
X301 Mast Mast position sensor
X400 Attachment control unit (D791) Power supply and ground connection, attachment control unit (D791)
X401 Attachment control unit (D791) CAN bus, attachment control unit
X403 Carriage middle Sensor, alignment right side
Sensor, twistlocks right side
Work lighting, right side
X404 Carriage middle Sensor, alignment left side
Sensor, twistlocks left side
Work lighting, left side
X415 Attachment, right side Indicator light locked twistlocks
Indicator light, unlocked twistlocks
Indicator light alignment
X421 Attachment control unit (D791) 42-pin connector for Control unit attachment (D791)
X422 Attachment control unit (D791) Power supply and earth connection, Control unit attachment (D791)
CAN bus Control unit attachment option (D791)
Emergency stop switch voltage
X425 Carriage middle Sensor, stop at 30' left
Sensor, end position 20'-40' left
X426 Carriage middle Sensor, stop at 30' right
Sensor, end position 20'-40' right
X428 Cab Revolving beacon
X612 Air conditioning Actuator motor, recirculation
X645 Engine Compressor air conditioning
X651 Cab Motor, windscreen washing
X657 Cab Heater fan
X660 Engine Alternator
X690 Cab Accelerator
X759 Engine Coolant level
X774 Cab Ambient temperature
X775 Cab Temperature sensor, cab, fan, refrigerant
X815 Cab Power assisted system
X900 Cab CD player
X901 Voltage converter, cab Voltage converter 24 V/12 V
Socket 24 V

Signal types, general

The machine's control units use a number of different types of signals
to receive signals from sensors and switches and control solenoid
valves, lights, etc. The table below describes the different signal types.
Signal type Explanation Application area

Analogue input signals
Rheostat Resistance input 0–200 Ω. Linear work range with accuracy of 3%. E.g. fuel level sensor.
Temperature Rheostat input with non-linear work area. The resistance value is E.g. hydraulic oil
equivalent to temperature and the work range of approx. -40 till 150 °C. temperature sensor
and air conditioning
There are two different resistance curves, one for Control unit, cab
temperature sensor.
(D790-1) and one for the frame and attachment control units.
Accuracy is ±0.5 in the interval 0-100 °C (sensor's measurement
inaccuracy not included). Outside of the interval 0-100 °C, accuracy is
±2 °C.
Voltage An analogue signal 0-5 V. The work range is 0.5 to 4.5 V. E.g. accelerator pedal
and analogue cab controls
(operating lever and
heater controls).
Analogue outputs
Current feedback A modulated signal between 0 V and system voltage, i.e. 24 V. The work Hydraulics, e.g.
voltage out, PWM range is 0 to 2 A. lifting/lowering of the
boom.
A modulated signal is a digital signal translated to an analogue
(continuous) signal adapted for a purpose, such as solenoid valve control. Used when the
output signal actuates
When the slide in a solenoid valve gets hot, resistance drops. This
proportional solenoid
generates a lower current through the valve spool, which can cause
valves.
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, A modulated signal between 0 V and system voltage, i.e. 24 V. Requires E.g. cab fan.
reversed polarity, 24 V as reference.
NPN PWM
Digital input signals
Digital input signal Signal in, U < 5 V generates logical zero (0) E.g. input signal from a
with pull down and circuit breaker with search
Signal in, U > 16 V generates logical one (1)
search lighting lighting.
If there is no signal in, the input is grounded.
Digital input signal Signal in, U < 5 V generates logical zero (0) E.g. position sensors
with pull down (inductive sensors) and
Signal in, U > 12 V generates logical one (1)
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 solenoid valves.
Max. load 1.5 A
Open load 0.15 A
Max. instantaneous current load, 8 A
High side driver, 5 Logical one (1) generates voltage out, U >= 22.5 V E.g. working lights and
A wiper motors.
Max. load 5 A
Open load 0.9 A

Signal type Explanation Application area

High side driver, Logical one (1) generates voltage out, U >= 22.5 V E.g. cooling fan.
10 A
Max. load 10 A This output is only
found on the frame and
Open load 1.9 A
attachment control units.
H-bridge Logical one (1) generates voltage out, U >= 22.5 V or grounded output, E.g. air conditioning
U=0V water valve (works in both
directions).
Max. load 0.5 A
Open load 0.15 A
The H-bridge works with two outputs in a pair. At logical one (1), one
output gives voltage while the other output is grounded. At logical zero
(0), the outputs switch voltage levels.

11:34 11 Common electrics – Communication
11.6 Communication
11.6.1 CAN bus
CAN bus, description
1 2 Communication between the control units takes place using so-called
"CAN buses" (Controller Area Network) based on the ISO 11898
standard and CAN specification 2.0B.
The CAN bus is a fast control bus with logical hardware circuits. A
120 ohm 120 ohm
simple technology that is highly reliable (low error frequency), which
is a requirement for control signals to be able to regulate systems
based on varying conditions and requirements.
CAN specifies:
5 5 • that the signal traffic is carried by "twisted pair" cables.
3 • that termination resistors (position 1) are necessary (adapted to
4 cables' impedance) so that the pulse train (position 4) should
obtain a sharp signal.
2
U [V]
• that the signal valve is given as the potential difference between

the cables, CAN + and CAN - (position 2 and 3).
3 • form of signal messages.
000026
t [S]
Messages are sequential and signal is high (voltage

high) or low (voltage low).
1. Termination resistor (120 ohm)
2. CAN + (voltage high)
3. CAN - (voltage low)
4. Pulse
5. Control unit
Message
Message
A
There are two types of messages:
• CAN Standard, has identity field of 11 bits
B C D E F G • CAN Extended, has identity field of 29 bits
000027
t [S] CAN works in messages sent in frames of 8 bytes (64 bits). A

complete message is approx. 100 bits long. The illustration depicts
Messages are sequential and signal is high (voltage how a message is structured.
high) or low (voltage low).
Start bit (B)
A Length message
B Start bit Indicates that the transmission of a frame, i.e. a message, is now
beginning.
C Identity field/Priority
D Control field (length of data segment) Identity field (C)
E Data segment Indicates what kind of information the message contains, e.g.
F Checksum for error detection measurement information on engine speed.
G Acknowledge bit Does not indicate address to control unit. CAN does not work with
addressing. All control units receive messages and send them on.
Control field (D)
Indicates how the length of the data segment that follows.
Data segment (E)

Contains the information to be conveyed to control units in the network.

11 Common electrics – CAN bus 11:35
Checksum for error detection (F)

Calculates a checksum for the message. This makes it possible for the
receiving control unit to detect errors in the sent message.
Acknowledge (G)
The transmitting control unit sets a bit to logical one (1) when the
message is sent. The first control unit to receive the message sends it
on and sets the bit to logical zero (0).
Communication
Communication
The CAN network consists of control units and segments. The

segment (bus) is a twisted pair cable that leads CAN + and CAN -
signal levels from control unit to control unit.
3,5 V
Each control unit measures the potential difference of its two inputs.
The potential difference generates logical zero and logical one. The
illustration depicts an approved interval according to the standard for
U [V]
potential levels. CAN + has a recommended value of 3.5 V and CAN

0,5 V - has 1.5 V. As a worst case scenario, the potential difference can be
only 0.5 V and still be approved. In practice, a potential difference of
2 V is recommended for reliable communication.
1,5 V A pulse train can only be observed using an oscilloscope, NOT with
a digital multimeter.
When a message is sent, all control units in the network listen.

Messages are saved in the control unit and relevant information is
000028
processed. The control unit that receives the message first confirms
t [S] receipt (sets an acknowledge bit). The transmitting control unit then
knows that the message has been received by at least one control
Potential levels CAN + and CAN - unit.
One control unit at a time sends the message. Other control units
listen and wait until the bus is available. If two messages are to be
sent simultaneously then the sending of the message with the lowest
priority (highest value in identity field) is concluded. This means that
messages do not need to be re-sent in the event of a communication
conflict but only in the event of a bus error (erroneous message).
The CAN bus exchanges around 100 messages per second in the
network.
Different bus systems can be used e.g. random sending or primary

(master) / secondary (slave).
HLP High Layer Protocol

CAN only specifies messages and how communication shall take
place, i.e. one protocol. In order to manage the network the CAN
protocol needs to be supplemented by a HLP which specifies:
• flow control
• transport of data above a length of 8 bits in 8 bit messages
(division)
• how control units are addressed in the network
• how bits in the message's data field should be interpreted

11:36 11 Common electrics – Redundant CAN bus
11.6.2 Redundant CAN bus

Redundant CAN bus, description
The redundant CAN bus handles communication between all of the
D791 D790-1 D790-2 D795 machine's control units except Control unit, transmission (D793) and
CAN R CAN L CAN R CAN L CAN R CAN L
Control unit, engine (D794). These have a separate CAN bus; see
CAN bus drive-train, description, page 11:38.
CAN L CAN R
014682
D797-1
Outline view, redundant CAN bus
Redundant CAN bus means that the control units are connected into a
D790-1 D791 D797-1 network that communicates via a CAN bus (see CAN bus, description,
page 11:34) and that there are double communication routes on the
1 2 network. The network is divided into control units and segments
4 (segments are the cables between the control units). The number of
3 active segments depends on the number of control units the machine
CAN R CAN L
has, which depends on the machine's equipment level (options).
009752
D795
Segment numbering starts from the CAN-R (right)

connection
The network is built on the CAN kingdom principle, which means
D790-1 D791 D797-1 that one control unit is central and is the master unit. In this case, it
is the cab control unit (D790-1). Other control units in the network
1 2 are secondary (slaves) and handle special areas, e.g. machine
4 3 components.
CAN R CAN L
The control units have two CAN bus connections - CAN L (left) and
D795
015052
CAN R (right). The control units are connected to one another in

series in a loop.
Segment numbering
The redundant CAN bus can handle the loss of a segment. The link is
analysed upon start-up. If a segment has a malfunction, messages
are sent via another route.
If several segments are lost, one or more control units lose

communication and work independently, often with significantly
limited functionality.
CAN bus faults are indicated with an error code and a warning in the
display. If several CAN bus segments are faulty, the system only
shows an error code for the first faulty out segment.

11 Common electrics – Redundant CAN bus 11:37
Connection of redundant CAN bus
Condition Refer- Reference

ence
value
Battery disconnector In position Battery disconnector, description, page 11:3
1
Redundant voltage feed Activated. Redundant voltage feed of control units, function description , page 11:7
5
D790-2
1, 6 4
S1 D790-1 S4 D795
D791 S2 D797-1 S3
2 3
015060
1 Control unit, cab (D790-1) establishes Checked by control Cab control unit, description, page 11:17
redundant CAN bus communication by system, error shown with
Diagnostic menu, see section 8 Control
sending a request on the CAN bus via error code.
CAN R.
1 and 8.4.1.2 CAN/POWER, menu 2
2 The attachment control unit (D791) A clicking sound is Control unit, attachment, description, page
sends a response back on the CAN bus audible when then 11:19
via CAN L and sends the request on via termination resistor is
CAN R. activated.
Termination resistors in the control 1 and 8.4.1.2 CAN/POWER, menu 2
nodes ensure communication segment
by segment.
3 The frame control unit (D797-1) sends a A clicking sound is Frame control unit, description, page 11:18
response back on the CAN bus via CAN audible when then
L and sends the request on via CAN R. termination resistor is
activated.
by segment.
4 Control unit KID (D795) sends a A clicking sound is Control unit KID, description, page 11:24
response back on the CAN bus via CAN audible when then
L and sends the request on via CAN R. termination resistor is
activated.
by segment.

11:38 11 Common electrics – CAN bus drive-train

5 The KIT control unit (D790-2) is not A clicking sound is Control unit KIT, description, page 11:23
connected to the redundant CAN bus. audible when then
The KIT control unit (D790-2) does not termination resistor is
communicate until ignition voltage (15) activated.
is activated.
6 If all control units have responded, the Checked by control Diagnostic menu, see section 8 Control
cab control unit (D790-1) deactivates system, error shown with system, group 8.4.1.1 CAN/POWER, menu
the segment to the attachment control error code. 1 and 8.4.1.2 CAN/POWER, menu 2
unit (D791).
If a control unit has not responded,
then Control unit, cab (D790-1) uses
both CAN L and CAN R to keep
communication open and analyses
which segment is faulty.
11.6.3 CAN bus drive-train

CAN bus drive-train, description
4 6 The drive-train CAN bus is based on the SAE J1939 standard where
selected messages are used to control engine.
SAE J1939 is a standard from SAE (Society of Automotive Engineers)

for data communication in vehicles. The standard regulates hardware
interface, bit times and message composition.
D790-1 3 5
Control units for engine and transmission come from the respective
transmission and engine supplier.
The machine only uses one model, while there are several engine
alternatives. All engine alternatives use the standard and therefore
the messages for each engine are structured in the same way.
Communication with Control unit, engine (D794) and Control unit,

transmission (D793) are separate from the redundant CAN bus.
The signals can be checked via the diagnostic menu. See section 8
Control system, group 8.4.1.4 CAN/POWER, menu 4.
000033
1 2
1. Redundant CAN bus
2. CAN bus drive-train
3. Control unit, engine (D794)
4. Engine
5. Control unit, transmission (D793)
6. Transmission

11 Common electrics – Communication between PC and machine 11:39
11.6.4 Communication between PC and machine

Communication between PC and machine, description
The machine has three sockets for communication between control
units and PC. Two are fitted in electronic box cab and one is in
1 electronic box frame. The diagnostic socket for the engine is loose in
electronic box frame.
2 Sockets for programming control units in electronic box cab (position

1) are used for programming the control units in the cab, on the frame
and on the attachment.
Sockets for CAN bus drive-train in electronic box cab (position 2) are
used for communicating with the engine and transmission via CAN
bus.
For further details on communication between computer and machine,

contact Cargotec.
015059
3
1. Diagnostic socket, machine
2. Diagnostic socket CAN bus drive-train
3. Diagnostic socket engine (loose in electronic
box)

11:40

D:1
D Error codes
Contents D Error codes

D Error codes ........................................................................................................ D:3
1 Engine................................................................................................................. D:9
2 Transmission ................................................................................................... D:59
8 Control system ................................................................................................ D:95

D:2

D Error codes – Error codes D:3
D Error codes
Error codes, explanation
The error codes are explained in table form for Engine, Transmission
as well as Control system. They are sorted according to error code
number.
The error code table has the following information:

• Code, error code\qs number, shown in field C on display.
C • Description, explanation of the error code and when it\qs
generated.
D E
• Limitation, in case of certain error codes certain functions are
impaired or limited to protect the machine and operator.
B
000389
• Action, information of what should be checked to find the cause

of the error code.
B. Error code level (symbol) • Diagnostic menu, reference to suitable diagnostic menu to rectify
the problem, read signal value or check the function.
C. Error code number
In addition to the explanation of the display figure, the description
D. Error cause (symbol) of the diagnostic menus contains reference to circuit diagrams
that are found in section E Schematics and reference to function
E. Function (symbol) group for further information about functions and components.
• Function group is a reference to which function group the
error code is associated. This field is used to search for more
information as necessary. The function group can be used to find
different types of information.
Sections 0-12 contain a description of the function and its
components, component location and work instructions for
different tasks.

D:4 D Error codes – Error codes
Error code menu, description

The control and monitoring system's display is divided into four fields
C where the information is shown (see figure to the left).
• Field B: Error code level is shown with a symbol.
D E
• Field C: Shows error code.
B • Field D: Shows type of error.
000389
• Field E: Indicates which function is affected by error code.
• Book symbol means that information is available in the operator's
manual.
Field B: Error code level
The control and monitoring system gives error code information in

three levels which are indicated with a symbol in the lower left corner
(B) on the display unit.
• Stop
C Indicates a serious malfunction that may jeopardise the operator's
safety or cause machine failure. The error code must be attended
D E to immediately. Stop working with the machine and contact
service immediately.
000350
• Warning
C Indicates malfunction in machine that should be taken care of as
soon as possible. After the finished work shift with the machine,
D E contact service as soon as possible.
000351
• Information
C Information to the operator that something should be taken care
of as soon as possible, e.g., defective light bulb. Take action to
D E fix the cause of the error code as soon as possible. See section 6
Inspection and maintenance in the operator's manual.
The error code is stored in the error code list under operating
000352
menu for service.

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

• Transmission:
XXX/YY Shown with error code number XX/YY on display.
001344
1 2 3
1. Temperature too high/too low.
2. Incorrect signal to solenoid valve.
3. Incorrect hydraulic pressure.
4. Incorrect sensor signal.
4 5 6
5. Incorrect signal from control.
6. Incorrect signal to bulb.
7. Incorrect signal, for example, open circuit.
7
000396


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

Reading out error code
NOTE
In the event of an error code, perform the actions recommended in
the error code table to identify the fault.
Error codes are stored as active and inactive. Active errors are
shown in the error code menu.
Always use error code menus for reading error codes, otherwise
there is a risk of missing error codes.
1 Turn the start key to position I.
WARNING
Risk of machine damage.
In the event of error codes of level "WARNING" and
"STOP", serious machine damage may result if the
engine is started.
Do not start the engine until the cause of the error code
has been identified or repaired.
2 Navigate to the service menu and press Enter.

000056
3 The safety menu is shown. Hold Enter depressed for at least

two seconds.
1 23
4 5
000060
4 The error code list is shown on the display. An active error code is
shown on display where field C shows error code number together
with X(Y). X shows sequence number for displayed error code and
(Y) shows total number of active error codes.
Scroll between error codes with key 1 and 2 (arrow function).
Error codes disappear from the list when the cause has been
001998
remedied.

5 Note error code number (field C) to avoid forgetting.

C • Error code level is shown with a symbol in field B
D E • Error code is shown in field C
• Error cause is shown with a symbol in field D
B
000389
• The function affected by the error is shown with a symbol in
field E
The book symbol is an instruction for the operator to read
the operator's manual.
6 Use the error code tables to find more information about the error
code.
7 After the remedial action, check that no active error codes remain
for the function in question.

1 Engine – Engine D:9
1 Engine
Error codes engine, general
When contacting engine suppliers, use the supplier code.
• Display indicates error code as shown in the machine, in
accordance with SAE J1939 in SPN/FMI
• The supplier code indicates the error code in accordance with the
engine manufacturer's specification.
Table Specifications FMI
FMI Description SAE-text

0 Too high value. Data valid, but higher than normal operating range.
1 Too low value. Data valid, but lower than normal operating range.
2 Incorrect data. Intermittent or incorrect data.
3 Electrical problem. Abnormally high voltage or short-circuit to higher voltage.
4 Electrical problem. Abnormally low voltage or short-circuit to lower voltage.
5 Electrical problem. Abnormally low current or open circuit.
6 Electrical problem. Abnormally high current or short-circuit to ground.
7 Mechanical problem. Incorrect response from mechanical system.
8 Mechanical problem or electrical Abnormal frequency.
problem.
9 Communication error. Abnormal update rate.
10 Mechanical problem or electrical Abnormally wide variations.
problem.
11 Unknown malfunction. Non-identifiable malfunction.
12 Component error. Incorrect unit or component.
13 Incorrect calibration. Values outside calibration values.
14 Unknown malfunction. Special instructions.
15 Too high value. Data valid, but higher than normal operating range. The least serious
level
16 Too high value. Data valid, but higher than normal operating range. Moderately severe
level
17 Too low value. Data valid, but below normal operating range: The least serious level
18 Too low value. Data valid, but below normal operating range: Moderately severe level
19 Communication error. Received network data incorrect
20-30 Reserved for SAE-assignment
31 FMI is not available or the condition Not available or condition exists
that is identified by the SPN exists.

D:10 1 Engine – Engine
Error codes engine (engine alternative

Yuchai YC6A240-30)
Table Error codes Yuchai YC6A240-30
Connec-
tions and Diagnos-
Display Sup- compo- tic menu
plier nents
code
29/2 P2135 Signal from Reduced engine Check the cable D794/1:79 -
accelerator pedal, power. harness at the control
D794/1:80
signal 2 and 1 do not unit.
correspond.
29/3 P0223 Accelerator pedal, Reduced engine Check the cable D794/1:80 -
short circuit to voltage. power. harness at the control
unit.
short circuit to ground. power. harness at the control
unit.
84/0 P0501 Machine speed too Engine speed is Ease off throttle or - -
high. limited. select higher gear.
84/2 P0501 Speed signal Engine speed is Check the engine D794/1:71 ENGINE,
unreasonable. limited. speed sensor. menu 1
Machine speed
Check the speed
does not correspond
sensor on the
with values from fuel
transmission.
injection and engine
speed.
84/11 P0510 Speed signal wrong. Engine speed is Check the engine - -
Internal error engine limited. speed sensor.
control unit.
Check the speed
sensor on the
transmission.
84/12 P0500 Speed signal wrong. Engine speed is Check the engine - ENGINE,
limited. speed sensor. menu 1
Check the speed
sensor on the
transmission.
91/2 P2135 Signal from Reduced engine Check the cable D794/1:79 -
accelerator pedal, power. harness at the control
D794/1:80
signal 1 and 2 do not unit.
correspond.
unit.
short circuit to ground. power. harness at the control
unit.
91/7 P2299 Signal from No limitation. Check the cable D794/1:79 -
accelerator pedal harness at the control
D794/1:80
and brake pedal not unit.
consistent.
95/2 P1017 Sensor pressure fuel No limitation. Check the cable D794/1:81 -
filter, unreasonable harness between
signal. control unit and sensor.
Check the sensor.

Connec-
tions and Diagnos-
plier nents
code
filter, signal high. harness between
control unit and sensor.
Check the sensor.
filter, signal low. harness between
Check the sensor.
95/7 P1018 Fuel filter clogged. No limitation. Change the fuel filter. - -
97/3 P2267 Water-in-fuel sensor No limitation. Check the cable D794/1:43 – ENGINE,
(B760), short circuit to harness between B760/1 menu 10
voltage. control unit and sensor.
Check the sensor.
97/4 P2266 Water-in-fuel sensor No limitation. Check the cable D794/1:43 – ENGINE,
(B760), short circuit to harness between B760/1 menu 10
ground. control unit and sensor.
Check the sensor.
97/11 P2269 Water in fuel. No limitation. Change the fuel D794/1:43 – ENGINE,
prefilter. B760/1 menu 10
98/2 P250B Sensor engine oil No limitation. Check the cable - -
level, unreasonable harness at the control
signal. unit.
98/3 P250D Sensor engine oil No limitation. Check the cable - -
level, short circuit to harness at the control
voltage. unit.
98/4 P250C Sensor engine oil No limitation. Check the cable - -
level, short circuit to harness at the control
ground. unit.
98/12 P250A Sensor engine oil No limitation. Use diagnostic D794/1:34 CAN/POW-
level, incorrect signal menu to check ER, menu 3
D794/1:35
via CAN bus. communication.
Check the cable
harness between
Control unit, cab
(D790-1) and Control
unit, engine (D794).
100/2 P0521 Sensor engine No limitation. Check the cable - ENGINE,
oil pressure, harness between menu 6
unreasonable signal. control unit and sensor.
Check the sensor.
Check the oil level in
the engine.
100/3 P0523 Sensor engine oil No limitation. Check the cable - ENGINE,
pressure, short circuit harness between menu 6
to voltage. control unit and sensor.
Check the sensor.
pressure, short circuit harness between menu 6
to ground. control unit and sensor.
Check the sensor.

Connec-
tions and Diagnos-
plier nents
code
100/12 P0520 Sensor engine oil No limitation. Use diagnostic D794/1:34 CAN/POW-
pressure, incorrect menu to check ER, menu 3
D794/1:35
signal via CAN bus. communication.
Check the cable
harness between
Control unit, cab
100/17 P0524 Low engine oil Reduced engine Check the oil level in - ENGINE,
pressure. power. the engine. menu 6
Change oil filter.
Check the system
pressure valves and
the safety valve in the
lubrication system.
Check the sensor.
102/2 P0236 Sensor boost Reduced engine Check the cable D794/2:32 – ENGINE,
pressure and power. harness between 36 menu 6
sensor air pressure, control unit and sensor.
unreasonable signal
Check the sensors.
combination.
102/3 P0238 Sensor boost Reduced engine Check the cable D794/2:34 ENGINE,
pressure, short circuit power. harness between menu 6
to voltage. control unit and sensor.
Check the sensor.
102/4 P0237 Sensor boost Reduced engine Check the cable D794/2:34 ENGINE,
pressure, short circuit power. harness between menu 6
to ground. control unit and sensor.
Check the sensor.
102/12 P0235 Sensor boost Reduced engine Use diagnostic D794/1:34 CAN/POW-
pressure, incorrect power. menu to check ER, menu 3
D794/1:35
Check the cable
harness between
Control unit, cab
105/3 P0098 Sensor intake No limitation. Check the cable D794/2:36 ENGINE,
temperature, incorrect harness between menu 7
signal. Short circuit to control unit and sensor.
voltage.
Check the sensor.
temperature, short harness between menu 7
circuit to ground. control unit and sensor.
Check the sensor.
105/12 P0099 Sensor intake No limitation. Use diagnostic D794/1:34 CAN/POW-
temperature, incorrect menu to check ER, menu 3
D794/1:35
Check the cable
harness between
Control unit, cab

Connec-
tions and Diagnos-
plier nents
code
108/2 P2227 Sensor air pressure Reduced engine Check the cable D794/2:32 – ENGINE,
and sensor power. harness between 2:36 menu 6
boost pressure, control unit and sensor.
unreasonable signal
Check the sensors.
combination.
108/3 P2229 Sensor air pressure, Reduced engine Check the cable - -
short circuit to voltage. power. harness between
Check the sensor.
108/4 P2228 Sensor air pressure, Reduced engine Check the cable - -
short circuit to ground. power. harness between
Check the sensor.
108/12 P0000 Sensor air pressure, Reduced engine Use diagnostic D794/1:34 CAN/POW-
incorrect signal via power. menu to check ER, menu 3
D794/1:35
CAN bus. communication.
Check the cable
harness between
Control unit, cab
110/2 P0116 Coolant temperature Reduced engine Check the cable D794/2:15 ENGINE,
sensor, the power. harness between menu 7
temperature is control unit and sensor.
unreasonable in
Check the sensor.
relation to the oil
temperature.
110/3 P0118 Sensor coolant Reduced engine Check the cable D794/2:15 ENGINE,
temperature, short power. harness between menu 7
circuit to voltage. control unit and sensor.
Check the sensor.
110/4 P0117 Sensor coolant Reduced engine Check the cable D794/2:15 ENGINE,
temperature, short power. harness between menu 7
Check the sensor.
110/12 P0115 Sensor coolant Reduced engine Use diagnostic D794/1:34 CAN/POW-
temperature, incorrect power. menu to check ER, menu 3
D794/1:35
Check the cable
harness between
Control unit, cab

Connec-
tions and Diagnos-
plier nents
code
110/15 P0217 Coolant temperature No limitation. Check the coolant D794/2:15 -
too high. level.
Check that radiator is
clean.
Check the thermostat.
Check the cap on the
expansion tank.
Check if there is air in
coolant system.
Check the cable
harness between
Check the sensor.
111/2 P2557 Sensor coolant level, No limitation. Check the cable - ENGINE,
unreasonable signal harness at the control menu 10
combination. unit.
short circuit to voltage. harness at the control menu 10
unit.
short circuit to voltage. harness at the control menu 10
unit.
open circuit. harness at the control menu 10
unit.
132/3 P0101 Mass air flow sensor, No limitation. Check the cable - -
signal deviation too harness at the control
high. unit.
air flow too high. harness at the control
unit.
signal deviation too harness at the control
low. unit.
air flow too low. harness at the control
unit.
157/3 P0193 Sensor fuel pressure, Reduced engine Check the cable D794/2:14 -
short circuit to voltage. power. harness between
Check the sensor.
short circuit to ground. power. harness between
Check the sensor.
signal deviation too power. harness between
high. control unit and sensor.
Check the sensor.

Connec-
tions and Diagnos-
plier nents
code
signal deviation too power. harness between
low. control unit and sensor.
Check the sensor.
158/12 P2533 Ignition key lock, open No limitation. Check the cable D794/1:40 -
circuit. harness at the control
unit.
168/3 P0563 High battery voltage. No limitation. Check the voltage D794/1:2 -
feed.
If equipment for
assisted start is
connected, disconnect
it.
168/4 P0562 Low battery voltage. The engine may be Check and charge the D794/1:2 -
difficult to start. batteries.
Check the cable
harness to the control
unit.
Check alternator,
battery and cable
harness between
battery and alternator.
171/3 P0073 Sensor outdoor No limitation. Check the cable - -
temperature, short harness at the control
circuit to voltage. unit.
circuit to ground. unit.
171/12 P0071 Sensor outdoor No limitation. Use diagnostic D794/1:34 CAN/POW-
D794/1:35
Check the cable
harness between
Control unit, cab
temperature, high harness between menu 7
Check the sensor.
temperature, low harness between menu 7
Check the sensor.
174/3 P0183 Sensor fuel No limitation. Check the cable - -
temperature, short harness between
Check the sensor.
174/4 P0182 Sensor fuel No limitation. Check the cable - -
temperature, short harness between
Check the sensor.

Connec-
tions and Diagnos-
plier nents
code
Check the sensor.
Check the sensor.
175/12 P0195 Sensor engine oil No limitation. Use diagnostic D794/1:34 CAN/POW-
D794/1:35
Check the cable
harness between
Control unit, cab
175/17 P0196 High oil temperature. No limitation. Check the oil level. - ENGINE,
menu 7
Check coolant
temperature and level.
190/7 P0016 Sensor camshaft and No limitation. Check the cable D794/2:09 -
sensor crankshaft, harness between
D794/2:23
unreasonable signal control unit and
combination. sensors.
Check the sensors.
190/11 P0336 Sensor rotation speed The engine is Check the cable D794/2:23 ENGINE,
crankshaft, irregular extremely difficult harness between menu 2
signal. to start and runs control unit and sensor.
unevenly or stops.
Check the sensor.
Reduced engine
power.
190/12 P0008 Sensor camshaft No limitation. Check the cable D794/2:09 -
rotation speed, signal harness between
error. control unit and sensor.
Check the sensor.
190/12 P0335 Sensor rotation speed The engine is Check the cable D794/2:23 -
crankshaft, no signal. extremely difficult harness between
to start and runs control unit and sensor.
unevenly or stops.
Check the sensor.
Reduced engine
power.
520/11 UD13A CAN bus, No limitation. Use diagnostic D794/1:34 CAN/POW-
communication error. menu to check ER, menu 3
520/12 UD13B D794/1:35
communication.
Check the cable
harness between
Control unit, cab

Connec-
tions and Diagnos-
plier nents
code
533/15 P0219 Engine speed too No limitation. Check the fuel D794/2:09 Engine,
high. pressure. menu 2
D794/2:23
Check the cable
harness between
control unit and
sensors.
Check sensor
camshaft rotation
speed and sensor
crankshaft.
596/2 P0564 Cruise control input, No limitation. Check the cable D794/1:31 -
unreasonable signal. harness at the control
D794/1:64
unit.
D794/1:74
D794/1:46
597/2 P0504 The signal from the No limitation. Check the cable - -
brake pedal does not harness at the control
correspond with the unit.
accelerator pedal.
597/12 P0571 Brake pedal, incorrect No limitation. Use diagnostic D794/1:34 CAN/POW-
signal via CAN bus. menu to check ER, menu 3
D794/1:35
communication.
Check the cable
harness between
Control unit, cab
598/2 P0704 Sensor clutch, No limitation. Check the cable - -
unit.
598/12 P0704 Sensor clutch, No limitation. Use diagnostic D794/1:34 CAN/POW-
incorrect signal via menu to check ER, menu 3
D794/1:35
CAN bus. communication.
Check the cable
harness between
Control unit, cab
624/2 P1626 Drive circuit lamp 1, No limitation. Check the cable - -
overheating. harness at the control
unit.
624/2 P162A Drive circuit lamp 2, No limitation. Check the cable - -
overheating. harness at the control
unit.
624/2 P162E Drive circuit lamp 3, No limitation. Check the cable - -
overheated. harness at the control
unit.
624/2 P161C Drive circuit system No limitation. Check the cable - -
lamp, overheated. harness at the control
unit.
624/2 P1632 Drive circuit warning No limitation. Check the cable - -
lamp, overheated. harness at the control
unit.

Connec-
tions and Diagnos-
plier nents
code
short circuit to voltage. harness at the control
unit.
unit.
624/3 P162B Drive circuit lamp 3, No limitation. Check the cable - -
unit.
624/3 P1619 Drive circuit system No limitation. Check the cable - -
lamp, short circuit to harness at the control
voltage. unit.
624/3 P162F Drive circuit warning No limitation. Check the cable - -
voltage. unit.
short circuit to ground. harness at the control
unit.
unit.
624/4 P162C Drive circuit lamp 3, No limitation. Check the cable - -
unit.
624/4 P161A Drive circuit system No limitation. Check the cable - -
ground. unit.
ground. unit.
open circuit. harness at the control
unit.
unit.
624/12 P162D Drive circuit lamp 3, No limitation. Check the cable - -
unit.
624/12 P161B Drive circuit system No limitation. Check the cable - -
lamp, open circuit. harness at the control
unit.
lamp, open circuit. harness at the control
unit.
630/2 P062F Internal error engine No limitation. Contact Yuchai - -
control unit. service.
630/4 P062F
630/12 P062F

Connec-
tions and Diagnos-
plier nents
code
636/11 P0341 Sensor rotation speed The engine takes Check the cable D794/2:09 -
camshaft, irregular longer to start than harness between
signal. normal. The engine control unit and sensor.
is running normally
Check the sensor.
once it has started.
636/12 P0340 Sensor rotation speed The engine takes Check the cable D794/2:09 -
camshaft, no signal. longer to start than harness between
normal. The engine control unit and sensor.
is running normally
Check the sensor.
639/12 UC029 CAN bus (A), electrical No limitation. Use diagnostic D794/1:34 CAN/POW-
problem. menu to check ER, menu 3
D794/1:35
communication.
Check the cable
harness between
Control unit, cab
645/3 P1511 Sensor machine Engine speed is Check the cable D794/1:71 ENGINE,
speed, incorrect signal limited. harness between menu 2
form. control unit and sensor.
Check the sensor.
Check the sensor.
Check the sensor.
651/3 P0262 Injector cylinder 1, Engine only runs on Check the cable D794/3:04 -
short circuit to ground. 3 cylinders and has harness between
D794/3:13
reduced power. control unit and
injector.
Check the injector.
short circuit between 3 cylinders and has harness between
D794/3:13
cables. reduced power. control unit and
injector.
Check the injector.
installation-dependent 3 cylinders and has harness between
D794/3:13
error. reduced power. control unit and
injector.
Check the injector.
indefinable error. 3 cylinders and has harness between
D794/3:13
injector.
Check the injector.

Connec-
tions and Diagnos-
plier nents
code
651/11 P1213 Injector cylinder 1, No limitation. Check the cable D794/3:04 -
installation-dependent harness between
D794/3:13
error. control unit and
injector.
Check the injector.
D794/3:13
injector.
Check the injector.
D794/3:13
injector.
Check the injector.
open circuit. harness between
D794/3:13
control unit and
injector.
Check the injector.
D794/3:11
injector.
Check the injector.
D794/3:11
injector.
Check the injector.
D794/3:11
injector.
Check the injector.
D794/3:11
injector.
Check the injector.
D794/3:11
injector.
Check the injector.
D794/3:11
injector.
Check the injector.

Connec-
tions and Diagnos-
plier nents
code
D794/3:11
injector.
Check the injector.
D794/3:11
control unit and
injector.
Check the injector.
D794/3:12
injector.
Check the injector.
D794/3:12
injector.
Check the injector.
D794/3:12
injector.
Check the injector.
D794/3:12
injector.
Check the injector.
D794/3:12
injector.
Check the injector.
653/11 P121A Injector cylinder 3, No limitation. Check the cable D794/3:05 -
D794/3:12
injector.
Check the injector.
653/11 P121B Injector cylinder 3, No limitation. Check the cable D794/3:05 -
D794/3:12
injector.
Check the injector.
D794/3:12
control unit and
injector.
Check the injector.

Connec-
tions and Diagnos-
plier nents
code
D794/3:14
injector.
Check the injector.
D794/3:14
injector.
Check the injector.
D794/3:14
injector.
Check the injector.
D794/3:14
injector.
Check the injector.
654/11 P121C Injector cylinder 4, No limitation. Check the cable D794/3:03 -
D794/3:14
injector.
Check the injector.
654/11 P121D Injector cylinder 4, No limitation. Check the cable D794/3:03 -
D794/3:14
injector.
Check the injector.
654/11 P121E Injector cylinder 4, No limitation. Check the cable D794/3:03 -
D794/3:14
injector.
Check the injector.
D794/3:14
control unit and
injector.
Check the injector.
D794/3:16
injector.
Check the injector.
D794/3:16
injector.
Check the injector.

Connec-
tions and Diagnos-
plier nents
code
D794/3:16
injector.
Check the injector.
D794/3:16
injector.
Check the injector.
655/11 P121F Injector cylinder 5, No limitation. Check the cable D794/3:01 -
D794/3:16
injector.
Check the injector.
D794/3:16
injector.
Check the injector.
D794/3:16
injector.
Check the injector.
D794/3:16
control unit and
injector.
Check the injector.
D794/3:15
injector.
Check the injector.
D794/3:15
injector.
Check the injector.
D794/3:15
injector.
Check the injector.
D794/3:15
injector.
Check the injector.

Connec-
tions and Diagnos-
plier nents
code
D794/3:15
injector.
Check the injector.
D794/3:15
injector.
Check the injector.
D794/3:15
injector.
Check the injector.
D794/3:15
control unit and
injector.
Check the injector.
676/7 P0540 Relay, preheating Preheating not Check the cable D794/1:55 – ENGINE,
(K312), signal error. working. harness between K312/86 menu 5
control unit and
D794/1:59 –
component.
K312/85
Check the component.
677/3 P0617 Relay starter motor, No limitation. Check the cable D794/1:37 -
short circuit to voltage harness at the control
P1638 D794/1:51
or activated too long. unit.
677/4 P0616 Relay starter motor, No limitation. Check the cable D794/1:37 -
P1639 D794/1:51
unit.
677/5 P163A Relay starter motor, No limitation. Check the cable D794/1:37 -
D794/1:51
unit.
729/3 P0541 Relay preheating No limitation. Check the cable D794/1:55 – ENGINE,
(K312), short circuit to harness between K312/86 menu 5
ground. control unit and
D794/1:59 –
component.
K312/85
(K312), short circuit to harness between K312/86 menu 5
voltage. control unit and
D794/1:59 –
component.
K312/85
(K312), high signal. harness between K312/86 menu 5
control unit and
D794/1:59 –
component.
K312/85

Connec-
tions and Diagnos-
plier nents
code
(K312), active too harness between K312/86 menu 5
short time. control unit and
D794/1:59 –
component.
K312/85
(K312), high signal. harness between K312/86 menu 5
control unit and
D794/1:59 –
component.
K312/85
(K312), low signal. harness between K312/86 menu 5
control unit and
D794/1:59 –
component.
K312/85
898/11 UD10E CAN bus, No limitation. Use diagnostic D794/1:34 CAN/POW-
communication error. menu to check ER, menu 3
898/12 UD10F D794/1:35
communication.
Check the cable
harness between
Control unit, cab
970/3 P1617 Voltage error at Reduced engine Check the cable D794/1:02 -
shut-off, high battery power. harness at the control
voltage. unit.
shut-off, low battery power. harness at the control
voltage. unit.
shut-off, monitoring power. harness at the control
switched off. unit.
985/2 P2519 AC compressor, No limitation. Use diagnostic D794/1:34 CAN/POW-
incorrect CAN menu to check ER, menu 3
985/12 P2519 D794/1:35
message. communication.
Check the cable
harness between
Control unit, cab
1041/7 P2530 Ignition key lock, No limitation. Check the cable D794/1:61 -
incorrect signal. harness at the control
unit.
1041/8 P2530 Switch remote start No limitation. Check the cable D794/1:61 -
engine, fixed in harness at the control
activated position. unit.
1071/2 P0483 Drive circuit cooling No limitation. Check the cable D794/1:13 -
fan, overheated. harness at the control
D794/1:58
unit.

Connec-
tions and Diagnos-
plier nents
code
fan, short circuit to harness at the control
D794/1:58
voltage. unit.
1071/3 P0694 Drive circuit cooling No limitation. Check the cable - -
fan 2, short circuit to harness at the control
voltage. unit.
fan, short circuit to harness at the control
D794/1:58
ground. unit.
1071/4 P0693 Drive circuit cooling No limitation. Check the cable - -
fan 2, short circuit to harness at the control
ground. unit.
fan, open circuit. harness at the control
D794/1:58
unit.
1072/3 P0080 Drive circuit brake No limitation. Check the cable - -
valve, short circuit to harness at the control
voltage. unit.
ground. unit.
valve, open circuit. harness at the control
unit.
1072/255 P1634 Drive circuit brake No limitation. Check the cable D794/3:08 -
voltage. unit.
1074/2 P0476 Drive circuit exhaust No limitation. Check the cable D794/3:08 -
brake, overheated. harness at the control
unit.
brake, short circuit to harness at the control
voltage. unit.
brake, short circuit to harness at the control
ground. unit.
brake, open circuit. harness at the control
unit.
1079/3 P0643 Voltage feed 1 sensor Reduced engine Check the cable - -
engine, high signal. power. harness at the control
unit.
1079/4 P0642 Voltage feed 1 sensor No limitation. Check the cable - -
engine, low signal. harness at the control
unit.
1080/3 P0653 Voltage feed 2 sensor Reduced engine Check the cable - -
engine, high signal. power. harness at the control
unit.
1080/4 P0652 Voltage feed 2 sensor No limitation. Check the cable - -
engine, low signal. harness at the control
unit.

Connec-
tions and Diagnos-
plier nents
code
1081/2 P1638 Drive circuit indicator No limitation. Check the cable D794/1:38 ENGINE,
light preheating, harness between – D797- menu 10
overheated. control unit and F/K1:26
component.
light preheating, short harness between – D797- menu 10
circuit to voltage. control unit and F/K1:26
component.
light preheating, short harness between – D797- menu 10
circuit to ground. control unit and F/K1:26
component.
light preheating, open harness between – D797- menu 10
circuit. control unit and F/K1:26
component.
1108/16 P1613 Engine speed too No limitation. Check the cable D794/2:09 ENGINE,
high. harness between menu 2
D794/2:23
control unit and the
components.
Check sensor
camshaft rotation
speed and sensor
crankshaft.
Check the fuel
pressure.
1192/2 P0046 Valve boost pressure No limitation. Check the cable D794/2:01 -
control, overheating. harness at the control
unit.
control, short circuit to harness at the control
voltage. unit.
control, signal too harness at the control
high. unit.
control, short circuit to harness at the control
ground. unit.
control, signal too low. harness at the control
unit.
control, open circuit. harness at the control
unit.
control, incorrect harness at the control
signal. unit.

Connec-
tions and Diagnos-
plier nents
code
lamp engine fault, harness between
overheated. control unit and
component.
lamp engine fault, harness at the control
short circuit to voltage. unit.
short circuit to ground. unit.
open circuit. unit.
1231/12 UC038 CAN bus (C), electrical No limitation. Use diagnostic D794/1:34 CAN/POW-
problem. menu to check ER, menu 3
1235/12 UC047 D794/1:35
communication.
Check the cable
harness between
Control unit, cab
1322/3 P0300 Misfiring on multiple Reduced engine Contact Yuchai - -
cylinders. power. service.
1323/3 P0301 Misfiring cylinder 1. Reduced engine Contact Yuchai - -
power. service.
power. service.
power. service.
power. service.
power. service.
power. service.
1351/2 P0645 Drive circuit No limitation. Check the cable D794/2:11 -
AC compressor, harness at the control
overheated. unit.
1351/3 P0647 Drive circuit AC No limitation. Check the cable D794/2:11 -
compressor, short harness at the control
compressor, short harness at the control
compressor, open harness at the control
circuit. unit.
1485/3 P0687 Main relay 2, electrical No limitation. Check the cable - -
problem. harness at the control
unit.

Connec-
tions and Diagnos-
plier nents
code
1485/4 P0686 Main relay 2, electrical No limitation. Check the cable - -
problem. harness at the control
unit.
1624/3 P2158 Sensor machine Engine speed is Check the cable D794/1:71 -
speed, speed too limited. harness at the control
high. unit.
speed, speed too limited. harness at the control
low. unit.
1624/12 P2157 Sensor machine Engine speed is Use diagnostic D794/1:34 CAN/POW-
speed, speed limited. menu to check ER, menu 3
D794/1:35
message via CAN communication.
bus incorrect.
Check the cable
harness between
Control unit, cab
speed, unreasonable limited. harness at the control
speed. unit.
1639/3 P0526 Sensor fan speed, No limitation. Check the cable D794/1:68 -
D794/1:69
unit.
1639/4 P0527 Sensor fan speed, No limitation. Check the cable D794/1:68 -
D794/1:69
unit.
2634/3 P160E Main relay, short No limitation. Check the cable - -
circuit to voltage. harness at the control
unit.
2634/4 P160F Main relay, short No limitation. Check the cable - -
circuit to ground. harness at the control
unit.
2791/2 P0403 Drive circuit EGR No limitation. Check the cable - -
valve, overheating. harness at the control
unit.
voltage. unit.
ground. unit.
valve, open circuit. harness at the control
unit.
520192/2 P063B Voltage feed speed The engine is only Check the cable - -
sensor, incorrect running at idle. harness between
signal (ADC). control unit and sensor.
Check the sensor.
sensor, signal too high running at idle. harness between
(ADC). control unit and sensor.
Check the sensor.

Connec-
tions and Diagnos-
plier nents
code
sensor, signal too low running at idle. harness between
(ADC). control unit and sensor.
Check the sensor.
520192 P062B Voltage feed speed The engine is only Check the cable - -
/11 sensor, incorrect test running at idle. harness between
impulse(ADC). control unit and sensor.
Check the sensor.
air flow too high. harness at the control
unit.
air flow too low, harness at the control
unit.
520194/2 P0649 Warning lamp speed No limitation. Check the cable - -
limitation, overheated. harness at the control
unit.
limitation, short circuit harness at the control
to voltage. unit.
limitation, short circuit harness at the control
to ground. unit.
limitation, open circuit. harness at the control
unit.
520195 P0402 EGR control, signal No limitation. Check the cable - -
/15 too high. harness at the control
unit.
520196 P0401 EGR control, signal No limitation. Check the cable - -
/17 too low. harness at the control
unit.
520197/3 P022C Bypass valve cold No limitation. Check the cable - -
start, short circuit to harness at the control
voltage. unit.
520197/4 P022B Bypass valve cold No limitation. Check the cable - -
start, short circuit to harness at the control
ground. unit.
520197 P022A Bypass valve cold No limitation. Check the cable - -
/12 start, open circuit. harness at the control
unit.
520198/2 P0116 Sensor coolant No limitation. Check the cable D794/2:15 ENGINE,
temperature, harness between menu 7
Check the sensor.
520198/2 P0116 Sensor coolant No limitation. Check the cable D794/2:15 ENGINE,
temperature, harness between menu 7
Check the sensor.

Connec-
tions and Diagnos-
plier nents
code
520199/2 P0856 DCS, unreasonable No limitation. Check the cable - -
signal. harness at the control
unit.
520200 P161F Incorrect compression No limitation. contact Yuchai service. - -
/20 test.
temperature (BET), harness at the control
signal too high. unit.
temperature (BET), harness at the control
signal too low. unit.
temperature (ClgZn), harness at the control
signal too high. unit.
temperature (ClgZn), harness at the control
signal too low. unit.
520203/3 P1509 Sensor intake No limitation. Check the cable D794/2:36 -
temperature, signal harness between
too high. control unit and sensor.
Check the sensor.
520203/4 P150A Sensor intake No limitation. Check the cable D794/2:36 -
temperature, signal harness between
too low. control unit and sensor.
Check the sensor.
520204/2 P1635 Switch exhaust brake, No limitation. Check the cable D794/2:29 -
unit.
520205/3 P245D EGR valve, short No limitation. Check the cable - -
circuit to voltage or harness at the control
overheated. unit.
520205/4 P245C EGR valve, short No limitation. Check the cable - -
circuit to ground. harness at the control
unit.
520205 P245A EGR valve, open No limitation. Check the cable - -
/12 circuit. harness at the control
unit.
520206/2 P0470 Exhaust back No limitation. Check the cable - -
pressure sensor, harness at the control
unreasonable signal. unit.
520206/3 P0473 Sensor exhaust back No limitation. Check the cable - -
pressure, signal too harness at the control
high. unit.
520206/4 P0472 Sensor exhaust back No limitation. Check the cable - -
pressure, signal too harness at the control
low. unit.
520207/3 P1008 Relay heating coil fuel No limitation. Check the cable D794/2:04 -
filter, short circuit to harness at the control
D794/2:05
voltage. unit.
520207/4 P1009 Relay heating coil fuel No limitation. Check the cable D794/2:04 -
filter, short circuit to harness at the control
D794/2:05
ground. unit.

Connec-
tions and Diagnos-
plier nents
code
520208/2 P0409 Sensor airflow EGR No limitation. Check the cable - -
valve, unreasonable harness at the control
signal. unit.
voltage. unit.
ground. unit.
520208 P0409 Sensor airflow EGR No limitation. Check the cable - -
/12 valve, open circuit. harness at the control
unit.
520209/2 P040B Sensor exhaust No limitation. Check the cable - -
temperature, harness at the control
unreasonable signal. unit.
520209/3 P040D Sensor exhaust No limitation. Check the cable - -
520209/4 P040C Sensor exhaust No limitation. Check the cable - -
520209 P040A Sensor exhaust No limitation. Check the cable - -
/12 temperature, open harness at the control
circuit. unit.
520210/3 UC158 Communication error, No limitation. Check the cable - -
or/255 display. harness at the control
unit.
520211 P0000 Communication error, No limitation. Use diagnostic D794/1:34 CAN/POW-
/12 CAN bus. menu to check ER, menu 3
D794/1:35
communication.
520212/3 UD100
Check the cable
520213 UC103 harness between
/12 Control unit, cab
520214 UC113
/12
520215/3 UD101
520216/3 UC156
520217/3 UD103
520218/3 UD10C
520218/4 UD10D
520218 UD104
/12
520219/3 UD110
520219 UD111
/12
520220/3 UD112
520220 UD113
/12

Connec-
tions and Diagnos-
plier nents
code
520222 P0607 Internal error engine Engine switched Contact Yuchai - -
/14 control unit. off: engine cannot service.
be started. Engine
520222 P0607 running: engine
/14 misfires.
520222 P0607
/14
520223 P160C Fuel injection, test No limitation. Contact Yuchai - -
/20 mode. service.
520224/3 P150B Sensor air humidity, No limitation. Check the cable - -
signal too high. harness at the control
unit.
520224/4 P150C Sensor air humidity, No limitation. Check the cable - -
signal too low. harness at the control
unit.
520225 P1302 Injection error, No limitation. Check the cable - -
/11 software error. harness at the control
unit.
520225 P1301 Injection error, uneven No limitation. Check the cable - -
/15 amount of fuel harness at the control
between the cylinders. unit.
520225 P1300 Injection error, uneven No limitation. Check the cable - -
/16 output between the harness at the control
cylinders. unit.
520226 P1225 Pressure fault on The engine is Check the injectors. - -
/12 multiple injectors. switched off.
520227/2 P154C Multi-function lever, No limitation. Check the cable D794/1:62 -
unreasonable harness at the control
position. unit.
520227/3 P154A Multi-function lever, No limitation. Check the cable D794/1:62 -
unit.
520227/4 23/04 Multi-function lever, No limitation. Check the cable D794/1:62 -
unit.
520228 P1614 Sensor engine speed, No limitation. Check the cable D794/2:23 ENGINE,
/15 unreasonable signal harness between menu 2
Check the sensor.
520229 P2263 Intake pressure No limitation. Check the cable - -
/15 difference too high. harness between
Check the sensor.
520230 P2263 Intake pressure No limitation. Check the cable - -
/17 difference too low. harness between
Check the sensor.
520231/2 P062A Feed pump, No limitation. Check the cable D794/23:09 -
overheated. harness between
D794/23:10
control unit and
component.

Connec-
tions and Diagnos-
plier nents
code
520231/3 P0629 Feed pump, short No limitation. Check the cable D794/23:09 -
circuit to voltage. harness between
D794/23:10
control unit and
component.
520231/4 P0628 Feed pump, short No limitation. Check the cable D794/23:09 -
circuit to ground. harness between
D794/23:10
control unit and
component.
520231 P0627 Feed pump, open No limitation. Check the cable D794/23:09 -
/12 circuit. harness between
D794/23:10
control unit and
component.
520232/ P1615 Test mode. No limitation. Contact Yuchai - -
255 service.
520233 P1621
/20
520234/2 P0488 Throttle, overheated. No limitation. Check the cable D794/1:79 -
harness at the control
D794/1:80
unit.
520234/3 P2142 Throttle, short circuit No limitation. Check the cable D794/1:79 -
to voltage. harness at the control
D794/1:80
unit.
520234/4 P2141 Throttle, short circuit The engine is Check the cable D794/1:79 -
to ground. running at idle. harness at the control
D794/1:80
unit.
520234 P0487 Throttle, open circuit. No limitation. Check the cable D794/1:79 -
/12 harness at the control
D794/1:80
unit.
520235/3 P1636 Reference voltage 12 No limitation. Check the cable - -
V, signal too high. harness at the control
unit.
520235/4 P1637 Reference voltage 12 No limitation. Check the cable - -
V, signal too high. harness at the control
unit.
520236/2 P1007 Software error engine No limitation. Contact Yuchai - -
control unit (FMTC). service.
520237/3 UD114 Communication error, No limitation. Use diagnostic D794/1:34 CAN/POW-
CAN bus. menu to check ER, menu 3
520238 UD115 D794/1:35
communication.
/12
Check the cable
harness between
Control unit, cab
520239/2 P161E Internal error engine No limitation. Contact Yuchai - -
520239 P161D
/11

Connec-
tions and Diagnos-
plier nents
code
523218 UC104 Communication error, No limitation. Use diagnostic D794/1:34 CAN/POW-
D794/1:35
communication.
523222 UC157
/12 Check the cable
harness between
Control unit, cab
523350/3 P1203 Injector bank 1, short The engine is only Check the cable D794/3:04 -
circuit between cables. running on three harness between
D794/3:13
cylinders. control unit and the
components. D794/3:06
Check the injectors. D794/3:11
D794/3:05
D794/3:12
523350/4 P1204 Injector bank 1, short The engine is only Check the cable D794/3:04 -
circuit to ground. running on three harness between
D794/3:13
D794/3:05
D794/3:12
523350 P1205 Injector bank 1, The engine is only Check the cable D794/3:04 -
/11 installation-dependent running on three harness between
D794/3:13
error. cylinders. control unit and the
D794/3:05
D794/3:12
/11 electrical problem. running on three harness between
D794/3:13
D794/3:05
D794/3:12
D794/3:13
D794/3:05
D794/3:12
D794/3:13
D794/3:05
D794/3:12

Connec-
tions and Diagnos-
plier nents
code
523351 P120A Injector bank 1, The engine is only Check the cable D794/3:04 -
D794/3:13
D794/3:05
D794/3:12
523351 P1209 Injector bank 1, open The engine is only Check the cable D794/3:04 -
/12 circuit. running on three harness between
D794/3:13
D794/3:05
D794/3:12
523352/3 P120B Injector bank 2, short The engine is only Check the cable D794/3:03 -
circuit between cables. running on three harness between
D794/3:14
D794/3:02
D794/3:15
523352/4 P120C Injector bank 2, short The engine is only Check the cable D794/3:03 -
circuit to ground. running on three harness between
D794/3:14
D794/3:02
D794/3:15
523352 P120D Injector bank 2, The engine is only Check the cable D794/3:03 -
D794/3:14
D794/3:02
D794/3:15
523352 P120E Injector bank 2, The engine is only Check the cable D794/3:03
/11 electrical problem. running on three harness between
D794/3:14
D794/3:02
D794/3:15
523353 P120F Injector bank 2, The engine is only Check the cable D794/3:03 -
D794/3:14
D794/3:02
D794/3:15

Connec-
tions and Diagnos-
plier nents
code
D794/3:14
D794/3:02
D794/3:15
D794/3:14
D794/3:02
D794/3:15
523352 P1211 Injector bank 2, open The engine is only Check the cable D794/3:03 -
/12 circuit. running on three harness between
D794/3:14
D794/3:02
D794/3:15
523354/2 P062B Internal error engine The engine is Contact Yuchai - -
control unit. switched off. service.
523354/3 P062B
523354/4 P062B
523354 P062B
/12
523355/2 P062B
523355/3 P062B
523355/4 P062B
523355 P062B
/12
523420/2 P060C
523470/0 P100E Valve fuel pressure Reduced engine Check the component. D794/2:14 -
control, leakage. power.
523470/7 P1010 Valve fuel pressure Reduced engine Check the component. D794/2:14 -
control, does not power.
open.
523470 P100F Valve fuel pressure Reduced engine Check the component. D794/2:14 -
/11 control, fuel pressure power.
too high.
523500 UC001 Communication error, No limitation. Use diagnostic D794/1:34 CAN/POW-
D794/1:35
communication.
523550/2 P0607
Check the cable
harness between
Control unit, cab

Connec-
tions and Diagnos-
plier nents
code
523600 P0607 Internal error engine No limitation. Contact Yuchai - -
/12 control unit. service.
523601/3 P0699 Voltage feed 3 sensor, Reduced engine Check the cable -
unit.
523601/4 P0698 Voltage feed 3 sensor, The engine takes Check the cable -
short circuit to ground. longer to start than harness at the control
normal. The engine unit.
is running normally
523604 UD1102 Communication error, No limitation. Use diagnostic D794/1:34 CAN/POW-
D794/1:35
communication.
523605 UD1104
/11 Check the cable
harness between
523605 UD1105 Control unit, cab
/12 (D790-1) and Control
523606 UD1106
/11
523606 UD1107
/12
523607 UD1108
/11
523608 UD110A
/11
523608 UD110B
/12
523612/3 P1607 Internal error engine No limitation. Contact Yuchai - -
523612/4 P1608 Internal error engine
control unit.
523613/2 P1014 Unreasonable fuel Reduced engine Check the cable D794/2:14 -
pressure. power. harness between
Check the sensor.
523613/3 P0088 Fuel pressure too Reduced engine Check the fuel D794/2:14 -
high. power. pressure.
Check the fuel pump.
Check the sensor.
523613/4 P0087 Fuel pressure too low. Reduced engine Check the fuel D794/2:14 -
power. pressure.
Check the fuel filters.
Check the sensor.
523613/5 P1019 Fuel pressure too Reduced engine Check the fuel D794/2:14 -
high. power. pressure.
Check the sensor.

Connec-
tions and Diagnos-
plier nents
code
523613/7 P1018 Fuel pressure too low. Reduced engine Check the fuel D794/2:14 -
power. pressure.
Check the fuel filters
Check the sensor.
523613 P1012 Fuel pressure too Reduced engine Check the fuel D794/2:14 -
/15 high. power. pressure.
Check the sensor.
523613 P1011 Fuel pressure too Reduced engine Check the component. D794/2:14 -
/16 high. power.
523613 P1013 Fuel pressure too low. Reduced engine Check the fuel D794/2:14 -
/17 power. pressure.
Check the sensor.
523613 P101A Fuel pressure too Reduced engine Check the fuel D794/2:14 -
/18 high. power. pressure.
Check the sensor.
523615/2 P0252 Fuel metering valve, No limitation. Check the cable - -
overheated power harness at the control
stage. unit.
523615/3 P0254 Valve fuel metering, No limitation. Check the cable - -
unit.
unit.
unit.
523615 P025C Fuel metering valve, No limitation. Check the cable - -
/16 status signal too low. harness at the control
unit.
523615 P025D Fuel metering valve, No limitation. Check the cable - -
/18 status signal too high. harness at the control
unit.
523617 P060A Communication error, No limitation. Use diagnostic D794/1:34 CAN/POW-
D794/1:35
communication.
Check the cable
harness between
Control unit, cab

Error codes engine (engine alternative

Cummins QSB6.7)
Table Error codes engine (engine alternative Cummins QSB6.7)
Description Limitation Action Connec- Diagnos-

tions and tic menu
compo-
nents
Code J1587
84 / 2 P084 / 2 Machine speed sensor Engine speed Check the D794 ENGINE,
circuit: Data erratic, limited to Maximum cable harness menu 2
intermittent or incorrect. Engine Speed between control
The ECU 794 lost the without VSS unit and
machine speed signal. parameter value. component.
Cruise control,
Check the
Gear-Down
sensor.
Protection, and
Road Speed
Governor will not
work.
84 / 10 P084 / Manipulation of machine Engine speed Check the D794 ENGINE,
10 speed sensor circuit has limited to Maximum cable harness menu 2
been detected: Abnormal Engine Speed between control
change rate. Invalid or without VSS unit and
incorrect machine speed parameter value. component.
signal. The signal indicates Cruise control,
Check the
an erratic connection or VSS Gear-Down
sensor.
manipulation. Protection, and
Road Speed
Governor will not
work.
91 / 0 P91 / 0 Accelerator pedal or lever Heavy derating - - ENGINE,
position sensor 1: Data valid in power output menu 1
but higher than the normal of the engine.
working range, the most Only emergency
severe level. A frequency operation power.
above 1500 Hz has been
detected on the accelerator
pedal's frequency input to
ECU 794.
91 / 1 P91 / 1 Frequency in the accelerator Heavy derating - - ENGINE,
pedal or lever position sensor in power output menu 1
circuit 1: Data valid but lower of the engine.
than the normal working Only emergency
range, the most severe operation power.
level. A frequency under
100 Hz has been detected
on the accelerator pedal's
frequency input to ECU 794.
91 / 19 P91 System error for SAE J1939 Engine may only Use diagnostic - -
multiplexing accelerator idle or engine will menu to
pedal or lever sensors: not accelerate to full find incorrect
Network data error received. speed. segment.
The machine's OEM control
unit (VECU) detected an
error on its accelerator
pedal.
91 / 2 P31 / 2 Accelerator pedal position - - ENGINE,
sensor. menu 1


tions and tic menu
compo-
nents
Code J1587
91 / 3 P091 / 3 Accelerator pedal or Heavy derating Check the - ENGINE,
lever position sensor in power output cable harness menu 1
circuit: Short.circuit high. of the engine. between control
High voltage detected in Only emergency unit and
accelerator pedal or lever operation possible. component.
position circuit.
Check the
component.
91 / 4 P091 / 4 Accelerator pedal or lever Heavy derating Check the - ENGINE,
position sensor circuit: in power output cable harness menu 1
Voltage lower than normal of the engine. between control
or shorted to low source. Only emergency unit and
Low voltage detected in operation possible. component.
accelerator pedal or lever
Check the
position signal circuit.
component.
94 / 1 P94 / 1 Fuel pump's delivery Possibly difficult to - D794 -
pressure: Data valid but start, low power,
below normal operational possibly smoke from
range - moderately severe the engine. The
level. The ECU 794 has engine may not be
detected the fuel pressure in possible to start.
the fuel rail is lower than the
commanded performance.
94 / 2 P094 / 2 Injector Metering Rail 1 The ECU 794 - D794 -
Pressure - Data Erratic, will estimate fuel
Intermittent, or Incorrect. pressure, and power
The ECU 794 has detected is reduced.
that the fuel pressure signal
is not changing.
94 / 18 P94 / 0 Fuel pump's delivery None or possible - D794 -
pressure: Data valid engine noise
but higher than normal associated
operational range - with higher
moderately severe level. injection pressures
The ECU 794 has detected (especially at idle or
fuel pressure in the fuel light load). Engine
rail that is higher than the power derate.
commanded pressure.
97 / 3 P097 / 3 Sensor circuit for water in None on Check the D794 -
fuel indicator: Voltage higher performance. No cable harness
than normal or short-circuited water in fuel warning between control
to a high source. High available. unit and
voltage detected on the component.
water in the fuel circuit.
Check the
sensor.
97 / 4 P097 / 4 Sensor circuit for water in None on Check the D794 -
fuel indicator: Voltage lower performance. No cable harness
than normal or short-circuited water in fuel warning between control
to a low source. Low voltage available. unit and
detected on the water in the component.
fuel circuit.
Check the
sensor.
97 / 15 P097 / 0 Water-in-fuel indicator - Possible white Drain water - -
Data valid but above normal smoke, loss of from the fuel.
operational range - least power, or hard
severe level. Water has starting
been detected in the fuel
filter.


tions and tic menu
compo-
nents
Code J1587
100 / 1 P100 / 1 Engine oil duct pressure: Progressive power Check the oil - ENGINE,
Data valid but lower than derate increasing in level in the menu 6
normal operational range, severity from time of engine; fill if
the most severe level. The alert. If the function necessary.
oil pressure signal indicates Engine protection
that the oil pressure is lower cut- off is activated,
than the critical limit for the the engine switches
engine's protection. off 30 seconds after
the red STOP light
starts flashing.
100 / 2 P100 / 2 Oil pressure switch sensor None on Check the D794 ENGINE,
circuit Data erratic, performance. No cable harness menu 6
intermittent or incorrect. engine protection for between control
An error in the engine oil the oil pressure. unit and
pressure switch signal has component.
been detected by ECU 794.
Check the
sensor.
100 / 3 P100 / 3 Oil pressure sensor circuit: None on Check the D794 ENGINE,
Voltage higher than normal performance. No cable harness menu 6
or shorted to high source. engine protection for between control
High signal voltage detected the oil pressure. unit and
in engine oil pressure circuit. component.
Check the
sensor.
100 / 4 P100 / 4 Oil pressure sensor circuit: None on Check the D794 ENGINE,
Voltage lower than normal or performance. No cable harness menu 6
shorted to low source. Low engine protection for between control
signal voltage detected in the oil pressure. unit and
engine oil pressure circuit. component.
Check the
sensor.
100 / 18 P100 / 1 Engine oil duct pressure: None on Check the oil - ENGINE,
Data valid but lower than performance. level in the menu 6
normal operational range, engine; fill if
moderately severe level. necessary.
Engine oil pressure signal
indicates that the engine oil
pressure is lower than the
limit for engine protection
warning.
102 / 2 P102 /2 Intake manifold pressure Engine power Check the D794 ENGINE,
sensor circuit: Manifold derate. cable harness menu 6
Pressure Sensor Circuit - between control
Data Erratic, Intermittent or unit and
Incorrect. The ECU 794 has component.
detected an intake manifold
Check the
pressure signal that is too
sensor.
high or low for current engine
operating conditions.
102 / 2 P102 /2 Intake manifold pressure Derate in power Check the D794 ENGINE,
sensor circuit: Incorrect output of the engine. cable harness menu 6
data. An error in the intake between control
manifold pressure sensor unit and
signal has been detected by component.
ECU 794.
Check the
sensor.


tions and tic menu
compo-
nents
Code J1587
102 / 3 P102 / 3 Intake manifold pressure Derate in power Check the D794 ENGINE,
sensor circuit: Voltage output of the engine. cable harness menu 6
higher than normal or between control
shorted to high source. High unit and
signal voltage detected in component.
the intake manifold pressure
Check the
circuit.
sensor.
102 / 4 P102 / 4 Intake manifold pressure Derate in power Check the D794 ENGINE,
sensor circuit: Voltage lower output of the engine. cable harness menu 6
than normal or short-circuited between control
to low source. Low signal unit and
voltage detected in the intake component.
manifold pressure circuit.
Check the
sensor.
103 / 10 P103 / Turbocharger speed: Possible-low-power Check the D794 -
10 Incorrect change rate estimated cable harness
detected. Turbocharger turbocharger speed between control
speed sensor detected an will be used. unit and
incorrect speed value. component.
Check the
sensor.
103 / 16 P103 / 0 Turbocharger number 1 Engine power Check the D794 -
speed high: Warning level. derate. The component.
High turbocharger speed has ECU 794 uses
been detected. an estimated
turbocharger speed.
103 / 18 P103 / 1 Turbocharger number 1 Engine power Check the D794 -
speed low: Warning level. derate. The component.
Low turbocharger speed has ECU 794 uses
been detected by ECU 794. an estimated
turbocharger speed.
105 / 0 P105 / 0 Temperate intake manifold Progressive power Check the - ENGINE,
1: Data valid but higher derate increasing in coolant level menu 7
than normal operational severity from time of in the engine;
range, the most severe alert. If the function fill if necessary.
level. The intake manifold air Engine protection
Check that
temperature signal indicates cut- off is activated,
the charge
that the air temperature in the engine switches
air cooler is
the intake manifold is higher off 30 seconds after
clean, clean if
than the critical limit for the red STOP light
necessary.
engine protection. starts flashing.
Check that the
fan belts are
intact. Check
the sensor.
105 / 3 P105 / 3 Intake manifold air Possible white Check cable D794 ENGINE,
temperature sensor circuit: smoke. Fan will harness menu 7
Voltage higher than normal stay ON if controlled between control
or shorted to high source. by the ECU 794. No unit and
High signal voltage detected engine protection for component.
in the intake manifold air intake manifold air
Check the
temperature circuit. temperature.
sensor.


tions and tic menu
compo-
nents
Code J1587
105 / 4 P105 / 4 Intake manifold air Possible white Check cable D794 ENGINE,
temperature sensor circuit: smoke. Fan will harness menu 7
Voltage lower than normal or stay ON if controlled between control
short-circuited to low source. by the ECU 794. No unit and
Low signal voltage detected engine protection for component.
in the intake manifold air intake manifold air
Check the
temperature circuit. temperature.
sensor.
105 / 15 P105 / 0 Intake manifold temperature Progressive power Check the D794 ENGINE,
high: Data valid but higher derate increasing in coolant level menu 7
than normal operational severity from time of in the engine;
range, the least severe alert. fill if necessary.
level. The intake manifold air
Check that
temperature signal indicates
the charge
that the air temperature in
air cooler is
the intake manifold is higher
clean, clean if
than the warning limit for
necessary.
engine protection.
Check that the
fan belts are
intact. Check
the sensor.
108 / 2 P108 / 2 Barometric pressure: Data Engine power Check cable - -
erratic, intermittent or derate. harness
incorrect. The pressure between control
sensor for the ambient air unit and
pressure reads an erratic component.
value on power-up.
Check the
sensor.
108 / 3 P108 / 3 Barometric pressure sensor Engine power Check cable D794 -
circuit: Voltage higher than derate. harness
normal or shorted to high between control
source. High signal voltage unit and
detected in barometric component.
pressure sensor circuit.
Check the
sensor.
108 / 4 P108 / 4 Barometric pressure sensor Engine power Check cable D794 -
circuit: Voltage lower than derate. harness
normal or shorted to low between control
source. Low signal voltage unit and
detected in barometric component.
pressure sensor circuit.
Check the
sensor.
110 / 0 P110 / 0 Engine coolant temperature: Progressive power Check the - ENGINE,
Data valid but higher than derate increasing in coolant level. menu 7
normal operational range, severity from time of
Check that
the most severe level. The alert. If the function
radiator is
engine coolant temperature Engine protection
clean.
signal indicates that the cut- off is activated,
coolant temperature is the engine switches Check if there
higher than the critical limit off 30 seconds after is air in coolant
for engine protection. the red STOP light system.
starts flashing.
Check the
cap on the
expansion tank.
Check the
sensor.
Check the
thermostat.


tions and tic menu
compo-
nents
Code J1587
110 / 2 P110 / 2 Engine coolant temperature: The ECU 794 will Check cable D794 ENGINE,
Data erratic, intermittent estimate engine harness menu 7
or incorrect. The engine coolant temperature. between control
coolant temperature reading unit and
does not change when component.
operating conditions change.
Check the
sensor.
110 / 3 P110 / 3 Engine coolant temperature Possible white Check cable D794 ENGINE,
sensor circuit 1: Voltage smoke. Fan will harness menu 7
higher than normal or stay ON if controlled between control
shorted to high source. by the ECU 794. No unit and
High signal voltage or open engine protection for component.
circuit detected in the engine the engine coolant
Check the
coolant temperature circuit. temperature.
sensor.
110 / 4 P110 / 4 Engine coolant temperature Possible white Check cable D794 ENGINE,
sensor circuit 1: Voltage smoke. Fan will harness menu 7
lower than normal or shorted stay ON if controlled between control
to low source. Low signal by the ECU 794. No unit and
voltage detected in the engine protection for component.
engine coolant temperature the engine coolant
Check the
circuit. temperature.
sensor.
110 / 15 P110 / 0 Engine coolant temperature Progressive power Check the D794 ENGINE,
high: Data valid but higher derate increasing in coolant level. menu 7
than normal operational severity from time of
Check that
range, the least severe alert.
radiator is
level. The engine coolant
clean.
temperature signal indicates
that the coolant temperature Check if there
is higher than the warning is air in coolant
limit for engine protection. system.
Check the
cap on the
expansion tank.
Check the
sensor.
Check the
thermostat.
110 / 16 P110 / 0 Engine coolant temperature: Progressive power Check the D794 ENGINE,
Data valid but higher than derate increasing in coolant level. menu 7
normal operational range, severity from time of
Check that
moderately severe level. The alert.
radiator is
engine coolant temperature
clean.
signal indicates that the
coolant temperature is Check if there
higher than the warning limit is air in coolant
for engine protection. system.
Check the
cap on the
expansion tank.
Check the
sensor.
Check the
thermostat.


tions and tic menu
compo-
nents
Code J1587
111 / 1 P111 / 1 Coolant level: Data valid Progressive power Check the - -
but lower than normal derate increasing coolant level;
operational range, the most in severity from fill if necessary.
severe level. Low coolant time of alert. If the
Check the
level detected. function Motor cut-
sensor.
off is activated, the
engine switches off
in 30 seconds after
the red STOP light
starts flashing.
111 / 3 P111 / 3 Radiator coolant level sensor None on Check cable D794 -
circuit: Voltage higher than performance. harness
normal or shorted to high between control
source. High signal voltage unit and
detected in the engine component.
coolant level circuit.
Check the
sensor.
111 / 4 P111 / 4 Radiator coolant level sensor None on Check cable D794 -
circuit: Voltage lower than performance. harness
normal or shorted to low between control
source. Low signal voltage unit and
detected in the engine component.
coolant level circuit.
Check the
sensor.
157 / 0 P94 / 0 Injector Metering Rail None or possible - D794 -
Number 1 Pressure - Data engine noise
Valid But Above Normal associated
Operating Range - Most with higher
Severe Level. The ECU injection pressures
794 has detected that fuel (especially at idle or
pressure in the rail fuel is light load). Engine
higher than the commanded power derate.
pressure.
157 / 2 P157 / 2 Injector Metering Rail 1 The ECU 794 - D794 -
Pressure - Data Erratic, will estimate fuel
Intermittent, or Incorrect. the pressure, and power
ECU 794 has detected that is reduced.
the fuel pressure signal is
not changing.
157 / 3 P157 / 3 Injector measurement Power and or speed - D794 -
channel number 1, pressure derate.
sensor circuit: Voltage higher
than normal or shorted to
high source. High signal
voltage detected in the fuel
rail fuel pressure sensor
circuit.
157 / 4 P157 / 4 Injector measurement Power and or speed - D794 -
channel number 1, pressure derate.
sensor circuit: Voltage lower
than normal or short-circuited
to low source. Low signal
voltage detected in the fuel
rail fuel pressure sensor
circuit.


tions and tic menu
compo-
nents
Code J1587
157 / 16 P157 / 0 Injector measurement None or possible - D794 -
channel 1, pressure Data engine noise
valid but higher than associated
normal operational range with higher
- moderately severe level. injection pressures
The ECU 794 has detected (especially at idle or
that the fuel pressure is light load). Engine
higher than the commanded power derate.
pressure.
157 / 18 P157 / 1 Fuel pump's delivery Possibly difficult to - D794 -
pressure low: Data valid start, low power
but lower than normal or smoke from the
operational range - engine. The engine
moderately severe level. may not be possible
The ECU 794 has detected to start.
that the fuel pressure is
lower than the commanded
pressure.
167 / 1 P167 / 1 Charging system voltage Warning lamp Check batteries D794 -
low: Data valid but lower illuminated until and alternator.
than normal operational very low battery
range, the most severe level. voltage condition is
Very low battery voltage corrected.
detected by battery voltage
monitoring.
167 / 16 P167 / 0 Charging system voltage Amber warning Check fuses. D794 -
high: Data valid but higher lamp illuminated Check batteries
than normal operational until high battery and alternator.
range, moderately severe voltage condition is
level. High battery voltage corrected.
monitoring.
167 / 18 P167 / 1 Charging system voltage Amber lamp will Check batteries D794 -
low: Data valid but lower light until low battery and alternator.
than normal operational voltage condition is
range, moderately severe corrected.
level. Low battery voltage
monitoring.
168 / 16 P168 / 0 Battery 1 Voltage - Data Possible electrical Check fuses. D794 -
Valid but Above Normal damage to Check batteries
Operational Range - all electrical and alternator.
Moderately Severe Level. components.
ECU 794 supply voltage is
above the maximum system
voltage level.
168 / 18 S168 / 1 Battery 1 Voltage - Data Engine may stop Check fuses. D794 -
Valid but Below Normal running or be difficult Check batteries
Operational Range - to start. and alternator.
Moderately Severe Level.
ECU 794 supply voltage is
below the minimum system
voltage level.
171 / 3 P171 / 3 Outdoor temperature sensor, - D794 -
circuit error: Abnormally high
voltage or short-circuit to
higher voltage.


tions and tic menu
compo-
nents
Code J1587
171 / 4 P171 / 4 Outdoor temperature sensor, - D794 -
circuit error: Abnormally low
voltage or short-circuit to
lower voltage.
190 / 0 P190 / 0 Engine crankshaft Fuel injection Ease off the - -
speed/position: Data valid disabled until engine throttle or select
but higher than the normal speed fails below higher gear.
working range: The most the overspeed limit.
severe level. The engine
speed signal indicates the
engine speed over the
engine protection limit.
190 / 2 P190 / 2 Engine crankshaft The engine may Check cable D794 -
speed/position: Data erratic, misfire when harness
intermittent or incorrect. steering switches between control
Engine speed sensor on from the primary to unit and
the crankshaft uneven the backup speed component.
synchronised. sensor. The engine
Check the
power derates while
sensor.
the engine is driven
with the backup
speed sensor.
190 / 2 P190 / 2 Engine crankshaft The engine runs Check cable D794 -
speed/position: Data erratic, unevenly. Can be harness
intermittent or incorrect. The difficult to start. The between control
signal from the crankshaft engine is driven unit and
sensor missing. by backup speed component.
sensor. Engine
Check the
power derated.
sensor.
251 / 2 P251 / 2 Real-time clock power supply None on - - -
open circuit: Data erratic, performance. Data
intermittent or incorrect. The in the ECU 794 will
real time clock has no power. not have accurate
time and date
information.
441 / 3 P441 / 3 Auxiliary temperature sensor None on Check cable D794 -
input signal 1: Voltage performance. harness
higher than normal or between control
shorted to high source. unit and
High signal voltage or open component.
circuit detected in the OEM
Check the
auxiliary temperature circuit.
sensor.
441 / 4 P441 / 4 Auxiliary temperature None on Check cable D794 -
sensor circuit input signal 1: performance. harness
Voltage lower than normal or between control
short-circuited to low source. unit and
Low voltage detected in the component.
OEM auxiliary temperature
Check the
circuit.
sensor.
558 / 2 S230 / 2 Accelerator pedal or lever Engine only running Check cable D794 -
idle validation circuit: Data at idle. harness
erratic, intermittent or between control
incorrect. Voltage detected unit and
simultaneously on the component.
validating switches for both
Check
idling and not idling.
component.


tions and tic menu
compo-
nents
Code J1587
558 / 4 S230 / 4 Accelerator pedal or lever Engine only running Check cable D794 -
idle validation circuit: at idle. harness
Voltage lower than normal between control
or short-circuited to low unit and
source. No voltage detected component.
simultaneously on the
Check
validating switches for both
component.
idling and not idling.
558 / 13 S230 / Accelerator pedal or lever Engine only running Check cable D794 -
13 idle validation circuit: Not at idle. harness
calibrated. Voltage in between control
the validation circuits for unit and
idling and not idling does component.
not correspond with the
Check
accelerator pedal position.
component.
611 / 2 P089 / 2 Validation of auxiliary Intermediate speed - D794 -
transfer speed switch (PTO): control switch
Data erratic, intermittent or may not operate
incorrect. The position of correctly.
the transfer speed protection
switch 1 does not correspond
with the position of the
validation switch for the
transfer speed protection.
611 / 3 S232 / 3 Circuit for sensor supply Engine only running - D794 -
voltage 4: Voltage higher at idle.
than normal or shorted
to high source. High
voltage detected at +5 volt
sensor supply circuit to the
accelerator pedal position
sensor.
611 / 4 S232 / 4 Circuit for sensor supply 3: Possible hard - D794 -
Voltage lower than normal or starting and rough
short-circuited to low source. running.
Low voltage detected at +5
volt sensor supply circuit
to the accelerator pedal
position sensor.
611 / 4 S232 / 4 Circuit for sensor supply Engine will only die. - D794 -
voltage 4: Voltage lower than
normal or short-circuited
to low source. Low
voltage detected at +5
volt sensor supply circuit
to the accelerator pedal
position sensor.
611 / 15 S151 / 0 Turbocharger compressor Fuel is limited in an - D794 -
outlet temperature: Data attempt to decrease
higher than normal. High the calculated
outlet temperature for the turbocharger
turbocharger compressor compressor outlet
calculated by ECU 794. temperature.


tions and tic menu
compo-
nents
Code J1587
612 / 2 P190 / 2 The engine's magnetic Fuelling to the - D794 -
crankshaft speed/position injectors is disabled,
sensor has lost both signals: and the engine can
Data erratic, intermittent or not be started.
incorrect. ECU 794 has
detected that the signals
from the primary and backup
engine speed sensor are
reversed.
627 / 2 S251 / 2 No power without the Possibly no Check fuses. D794 -
ignition switch turned off: noticeable Check batteries
Data erratic, intermittent or performance impact, and alternator.
incorrect. The supply voltage or the engine
to ECU 794 temporarily falls stops or is hard
below 6.2 volt, or ECU 794 to start. Incorrect
not allowed to shutdown information, release
correctly (battery voltage information and
maintained for 30 seconds maintenance
after the ignition has been monitoring data
turned off). may be incorrect.
627 / 2 S251 / 2 Power supply missing with Possibly no Check fuses. D794 -
the ignition on: Data erratic, noticeable Check batteries
intermittent or incorrect. The performance impact, and alternator.
supply voltage to ECU 794 or the engine
temporarily falls below 6.2 stops or is hard
volt, or ECU 794 not allowed to start. Incorrect
to shutdown correctly information, release
(battery voltage maintained information and
for 30 seconds after the maintenance
ignition has been turned off). monitoring data
may be incorrect.
627 / 2 S254 / Injectors power supply: Possible smoke, Check fuses. D794 -
12 Bad Intelligent Device or low power, engine Check batteries
Component. The ECU 794 misfire, and/or and alternator.
measured injector boost engine will not start.
voltage is low.
629 / 12 S254 / Engine control unit: Critical Engine may not Check the D794 -
12 internal error. Error internally start. control unit.
in ECU 794 related to
memory hardware failures
or internal ECU 794 voltage
supply circuits.
629 / 12 S254 / Engine control unit, warning No performance Check the D794 -
12 internal hardware error. effects or possible control unit.
Incorrect intelligent unit or severe power
component. derate.
630 / 2 S253 / 2 Engine control unit data lost: Possibly no Reprogram D794 -
Data erratic, intermittent or noticeable the software
incorrect. Serious data loss performance impact, in Control unit,
from ECU 794. or the engine engine (D794).
stops or is hard
to start. Incorrect
information, release
information and
maintenance
monitoring data
may be incorrect.


tions and tic menu
compo-
nents
Code J1587
630 / 31 S240 / 11 Error occurs in the engine Possibly no - D794 -
control unit calibration noticeable
programme memory (RAM). performance impact,
Serious data loss from ECU or the engine
794. stops or is hard
to start. Incorrect
information, release
information and
maintenance
monitoring data
may be incorrect.
633 / 31 S018 / 11 Fuelling Actuator Number Possible low power. - D794 -
1 Circuit Error Conditions
Exists. Fuel pump actuator
circuit resistance too high or
too low.
639 / 9 S231 / 9 Timeout error for SAE J1939 One or more Use diagnostic - CAN/POW-
multiplexer-PNG: Abnormal multiplexed units not menu to ER, menu 2
update rate. Cummins working correctly. find incorrect
ECU 794 did not receive a One or more segment.
multiplexed message from symptoms may
an OEM-VECU by the time occur.
limit or not at all.
639 / 13 S231 / SAE J1939 Multiplexing At least one Use diagnostic - CAN/POW-
13 Configuration Error - Out of multiplexed devices menu to ER, menu 2
Calibration. The ECU 794 will not operate find incorrect
expected information from a properly. segment.
multiplexed device but only
received a portion of the
necessary information.
641 / 3 S027 / 3 VGT actuator driver circuit Possible low power. - D794 -
- voltage above normal or Power switched off
shorted to high source. to the turbocharger's
actuator motor.
641 / 4 S027 / 4 VGT actuator driver circuit Possible low power. - D794 -
- voltage below normal, or Power switched off
shorted to low source. to the turbocharger's
actuator motor.
644 / 2 S030 / 2 Input signal from Primary or Check cable - -
external speed request secondary engines harness
(synchronisation of multiple may be shut down. between control
units): Data erratic, unit and
intermittent or incorrect. The component.
accelerator pedal input signal
Check
to the primary or secondary
component.
motor for synchronisation of
multiple devices is less than
3 percent or greater than 97
percent.
647 / 3 S033 / 3 Fan control circuit: Voltage The fan may stay on Check cable D794 -
higher than normal or shorted continuously or not harness
to high source. Open circuit run at all. between control
or high voltage detected in unit and
the fan control circuit. component.
Check
component.


tions and tic menu
compo-
nents
Code J1587
647 / 4 S033 / 4 Fan control circuit: Voltage The fan may stay on Check cable D794 -
lower than normal or shorted continuously or not harness
to low source. Low signal run at all. between control
voltage detected in the fan unit and
control circuit when this is component.
requested.
Check
component.
651 / 5 S001 / 5 Circuit injector magnetic coil Engine can misfire Check cable D794 -
drive cylinder 1: Current or possibly run harness
lower than normal or open rough. between control
circuit. High resistance unit and
or no current detected on component.
injector no. 1, pin DRIVE or
Check the
RETURN.
injector.
651 / 7 S001 / 7 Injector magnetic coil drive The engine is Check cable D794 -
cylinder 1: Mechanical switched off. harness
system not responding between control
correctly or incorrectly unit and
adjusted. Accidental fuel component.
supply detected in cylinder
Check the
no. 1.
injector.
Check the
RETURN.
injector.
Check the
no. 2.
injector.
Check the
RETURN.
injector.
Check the
no. 3.
injector.
Check the
RETURN.
injector.


tions and tic menu
compo-
nents
Code J1587
Check the
no. 4.
injector.
Check the
RETURN.
injector.
Check the
no. 5.
injector.
Check the
RETURN.
injector.
Check the
no. 6.
injector.
677 / 3 S39 / 3 Starter relay circuit: Voltage Either the engine Check cable D794 ENGINE,
higher than normal or shorted will not start or harness menu 5
to high source. Open circuit the engine will not between control
or high voltage detected in have starter lockout unit and
the start locking circuit. protection. component.
Check the relay.
677 / 4 S39 / 4 Starter relay circuit: Voltage The engine will not Check cable D794 ENGINE,
lower than normal or shorted have starter lockout harness menu 5
to low source. Low voltage protection. between control
detected in the start locking unit and
circuit. component.
Check the relay.
697 / 3 S057 / 3 Auxiliary PWM drive no. 1: Can not control - D794 -
Voltage higher than normal transmission.
or shorted to high source.
High signal voltage detected
in the analogue torque
circuit.


tions and tic menu
compo-
nents
Code J1587
697 / 4 S057 / 4 Auxiliary PWM drive no. 1: Can not control - D794 -
Voltage lower than normal or transmission.
shorted to low source. Low
signal voltage detected in
the analogue torque circuit.
703 / 11 S051 /11 Auxiliary Equipment Sensor Possible engine Check cable D794 -
Input #3 (OEM Switch) - power derate. harness
Root Cause Not Known. between control
unit and
component.
Check the
component.
723 / 2 S064 / 2 Engine backup crankshaft Possible low power. Check cable D794 -
speed/position sensor no. harness
2: Data erratic, intermittent between control
or incorrect Engine speed unit and
sensor on the crankshaft component.
uneven synchronised.
Check the
sensor.
723 / 2 S064 / 2 Engine Speed Sensor Can be difficult to Check cable D794 -
(Camshaft) Error - Data start. Engine power harness
Erratic, Intermittent, or derate. between control
Incorrect. The ECU 794 unit and
has detected an error in the component.
camshaft position sensor
Check the
signal.
sensor.
723 / 7 S064 / 7 Engine speed/position The engine runs Check cable D794 -
sensor camshaft and at lower power. harness
crankshaft, misaligned: Abnormal smoke, between control
Mechanical system not difficult to start and unit and
responding correctly erratic idling can component.
or incorrectly adjusted. occur.
Check the
Mechanical misalignment
sensor.
between the crankshaft and
camshaft speed sensors.
729 / 3 S070 / 3 Circuit for intake air heater The intake air Check cable D794 -
no. 1: Voltage higher heaters may be harness
than normal or shorted to ON or OFF all the between control
high source. High voltage time. unit and
detected at the intake air component.
heater signal circuit.
Check
component.
729 / 4 S070 / 4 Circuit for intake air heater The intake air Check cable D794 -
no. 1: Voltage lower heaters may be harness
than normal or shorted to ON or OFF all the between control
low source. Low voltage time. unit and
detected at the intake air component.
heater signal circuit.
Check
component.
974 / 3 P974 / 3 Circuit for remote accelerator Remote accelerator Check cable D794 -
pedal or lever position pedal not working. harness
sensor 1: Voltage higher Remote accelerator between control
than normal or shorted to pedal position set to unit and
high source. High voltage zero percent. component.
detected at the remote
Check
component.
circuit.


tions and tic menu
compo-
nents
Code J1587
974 / 4 P974 / 4 Circuit for remote accelerator Remote accelerator Check cable D794 -
pedal or lever position pedal not working. harness
sensor 1: Voltage lower than Remote accelerator between control
normal or short-circuited pedal position set to unit and
to low source. Low zero percent. component.
voltage detected in remote
Check
component.
signal.
974 / 19 P29 Data error for SAE J1939 The engine does not Use diagnostic - CAN/POW-
multiplexing remote react to the remote menu to ER, menu 2
accelerator pedal or lever: accelerator pedal. find incorrect
Network data error received. Perhaps the engine segment.
The machine's OEM control is only running at
unit (VECU) detected idle. The primary
an error on the remote accelerator or the
accelerator pedal. one in the cab can
possibly be used.
1043 / 3 S221 / 3 Supply voltage circuit for Engine only running Check cable D794 -
accelerator pedal or lever at idle. harness
position sensor: Voltage between control
higher than normal or unit and
shorted to high source. component.
High voltage detected in the
Check
voltage supply circuit for the
component.
position sensor.
1043 / 4 S221 / 4 Supply voltage circuit for Engine will only die. Check cable D794 -
accelerator pedal or lever harness
position sensor: Voltage between control
lower than normal or unit and
shorted to low source. component.
Low voltage detected in the
Check
voltage supply circuit to the
component.
position sensor.
1043 / 4 S221 / 4 Supply voltage circuit for Possible hard Check cable D794 -
engine speed/position starting and rough harness
sensor (crankshaft): Voltage running. between control
lower than normal or shorted unit and
to low source. Low voltage component.
detected on ECU 794 voltage
Check
supply cable to the engine
component.
speed sensor.
1072 / 3 S028 / 3 Engine brake actuator circuit Engine brake on Check cable D794 -
no. 1: Voltage higher than cylinders 1, 2, and 3 harness
normal or shorted to high can not be activated between control
source. Open circuit or high or exhaust brake will unit and
voltage detected on the not operate. component.
signal circuit for the motor
Check
brake solenoid coil no. 1.
component.
1072 / 4 S028 / 4 Engine brake actuator Engine brake on Check cable D794 -
circuit no. 1: Voltage lower cylinders 1, 2, and 3 harness
than normal or shorted to can not be activated between control
low source. Low voltage or exhaust brake will unit and
detected in signal circuit for not operate. component.
the motor brake solenoid coil
Check
no. 1.
component.


tions and tic menu
compo-
nents
Code J1587
1073 / 3 S029 / 3 Engine brake actuator circuit Engine brake on Check cable D794 -
no. 2: Voltage higher than cylinders 4, 5, and 6 harness
normal or shorted to high can not be activated. between control
source. Open circuit or high unit and
voltage detected on the component.
signal circuit for the motor
Check
brake solenoid coil no. 2.
component.
1073 / 4 S029 / 4 Engine brake actuator Engine brake on Check cable D794 -
circuit no. 2: Voltage lower cylinders 4, 5, and 6 harness
than normal or shorted to can not be activated. between control
low source. Low voltage unit and
detected in signal circuit for component.
the motor brake solenoid coil
Check
no. 2.
component.
1075 / 3 S126 / 3 Electrical lift pump for the Engine can be - D794 -
engine fuel delivery circuit: difficult to start.
Voltage higher than normal
High signal voltage or open
circuit detected in the fuel lift
pump's signal circuit.
1075 / 4 S126 / 4 Electrical lift pump for the Engine can be - D794 -
engine fuel delivery circuit: difficult to start.
Voltage lower than normal or
short-circuited to low source.
Low signal voltage detected
in fuel lift pump circuit.
1079 / 3 S212 / 3 Circuit for sensor supply Engine power Check cable D794 -
voltage no. 1: Voltage higher derate. harness
than normal or shorted to between control
high source. High voltage unit and
detected in the sensor supply component.
circuit no. 1.
Check the
sensor.
voltage no. 1: Voltage derate. harness
lower than normal or shorted between control
to low source. Low voltage unit and
circuit no. 1.
Check the
sensor.
no. 2: Voltage higher derate. harness
than normal or shorted to between control
high source. High voltage unit and
circuit no. 2.
Check the
sensor.
voltage no. 2: Voltage derate. harness
lower than normal or shorted between control
to low source. Low voltage unit and
circuit no. 2.
Check the
sensor.


tions and tic menu
compo-
nents
Code J1587
1137 / 2 S114 / 2 Synchronisation switch for Multiple Unit - D794 -
multiple units: Data erratic, Synchronisation
intermittent or incorrect. feature is disabled.
Synchronised ON/OFF
switch for multiple units and
supplementary synchronised
ON/OFF switch for multiple
units have different values in
ECU 794.
1172 / 3 /3 Intake temperature sensor Engine power - D794 -
circuit for compressor derate.
turbocharger no. 1: Voltage
higher than normal or
shorted to high source. High
signal voltage detected in the
intake temperature sensor
circuit for the compressor
turbocharger.
1172 / 4 /4 Intake temperature sensor Engine power - D794 -
circuit for compressor derate.
turbocharger no. 1: Voltage
lower than normal or shorted
to low source. Low signal
voltage detected in the
intake temperature sensor
circuit for the compressor
turbocharger.
1347 / 3 S126 / 3 Circuit for the fuel high Engine runs - D794 -
pressure solenoid valve: badly and with
Voltage higher than normal derated power.
or shorted to high source. Fuel rail pressure
Electronic fuel control becomes higher
actuator short-circuited high. than requested.
1347 / 4 S126 / 4 Circuit for the fuel high The engine runs - D794 -
pressure solenoid valve: poorly when idling
Voltage lower than normal and has low power.
or shorted to low source. Fuel pressure
Electronic fuel control becomes higher
actuator short-circuited low. than requested.
1347 / 7 S126 / 7 Fuel pump pressure Engine will not run or - D794 -
attachment 1: Mechanical possible low power.
system not responding
correctly or incorrectly
adjusted. Pumping
imbalance between the
front and rear pump pistons
have been detected.
1347 / 7 S126 / 7 Fuel Pumping Element Engine will not run or - D794 -
Number 1 (Front) - possible low power.
Mechanical System Not
Responding Properly or Out
of Adjustment.
1378 / 31 S153 / 11 It is time to change the None on - D794 -
lubricating oil and filter. performance;
Change the engine oil and maintenance
filter. reminder only.


tions and tic menu
compo-
nents
Code J1587
1388 / 3 P223 / 3 Circuit for auxiliary pressure None on - D794 -
sensor, input signal 1: performance.
Voltage higher than normal
High signal voltage detected
in the OEM pressure circuit.
1388 / 4 P223 / 4 Circuit for auxiliary pressure None on - D794 -
sensor, input signal 1: performance.
Voltage lower than normal or
shorted to low source. Low
signal voltage detected in
the OEM pressure circuit.
2047 / xx Undetectable error code - Contact the D794 -
from the engine. Error codes engine supplier
above 2047 cannot be shown for further
in the display. Possible error information.
code: 2789.
2789 / 15 /0 Exhaust temperature: Data Derate in power - D794 -
higher than normal. High output of the
exhaust temperature has engine in attempt
been calculated by the to decrease the
electronic control system. calculated exhaust
gas temperature
value.

2 Transmission – Transmission D:59
2 Transmission
Error codes transmission
When contacting engine suppliers, use the supplier code.
• Display indicates error code as shown in the machine, in
accordance with SAE J1939 in SPN/FMI
• The supplier code indicates the error code in accordance with the
engine manufacturer's specification.
Control unit transmission can generate two states with reduced
functionality to protect the transmission in the event of serious
malfunctions:
Limp home
In this condition only gear 1-2 in each direction can be used. If
the error occurs in a higher gear then downshifting to gear 1 or 2
must take place manually.
Shut down
In this mode the transmission is permanently in neutral as there
is no oil pressure to enable gear selection.
Table Error codes Dana HR32000
Connec-
tions Diag-
Description Limitation Action and nostic
Sup- compo- menu
plier nents
Display code
520192 00/31 Digital input 0, active No limitation or Shut Check for more error D793/59 -
/31 error. down while error is codes and rectify them
active. first.
For inactive error Check the cable
code, Limp home until harness to the control
ignition is switched off. unit.
active. first.
active. first.
active. first.
520196 04/31 Digital input 4, No limitation or Shut Check for more error D793/55 -
/31 active error. The down while error is codes and rectify them
transmission control active. first.
unit activates Shut
down or Limp home
depending on speed.

D:60 2 Transmission – Transmission
Connec-
tions Diag-
Sup- compo- menu
plier nents
Display code
active. first.
active. first.
active. first.
520208/3 16/03 Analogue input 0, No limitation. Check for more error D793/24 -
short circuit to voltage. codes and rectify them
D793/25
first.
Check the cable
unit.
520208/4 16/04 Analogue input 0, No limitation. Check for more error D793/24 -
short circuit to ground. codes and rectify them
D793/25
first.
Check the cable
unit.
520208 16/16 Analogue input 0, the No limitation. Check for more error D793/24 -
/16 value is above highest codes and rectify them
D793/25
normal value. first.
Check the cable
unit.
520208 16/18 Analogue input 0, the No limitation. Check for more error D793/24 -
/18 value is below lowest codes and rectify them
D793/25
normal value. first.
Check the cable
unit.
520208 16/31 Analogue input 0, No limitation or Shut Check for more error D793/24 -
/31 active error. down while error is codes and rectify them
D793/25
active. first.
520209/3 17/03 Sensor oil temperature No limitation or Shut Check the cable D793/26 – TRANSM,
transmission (B766), down while error is harness between B766/1 menu 10
short circuit to voltage. active. control unit and
D793/27 –
sensor.
For inactive error B766/2
code, Limp home until Check the sensor.
ignition is switched off.

Connec-
tions Diag-
Sup- compo- menu
plier nents
Display code
520209/4 17/04 Sensor oil temperature No limitation. Check the cable D793/26 – TRANSM,
transmission (B766), harness between B766/1 menu 10
short circuit to ground. control unit and
D793/27 –
sensor.
B766/2
Check the sensor.
520209 17/18 Sensor oil pressure No limitation. Check the cable D793/26 – TRANSM,
/18 transmission (B766), harness between B766/1 menu 10
value is below lowest control unit and
D793/27 –
calibrated value. sensor.
B766/2
Check the sensor.
value is above highest control unit and
D793/27 –
calibrated value. sensor.
B766/2
Check the sensor.
520209 17/13 Sensor oil temperature No limitation. Check the cable D793/26 – TRANSM,
calibration incorrect. control unit and
D793/27 –
sensor.
B766/2
Check the sensor.
520209 17/31 Sensor oil temperature No limitation or Shut Check the cable D793/26 – TRANSM,
/31 transmission (B766), down while error is harness between B766/1 menu 10
active error. active. control unit and
D793/27 –
sensor.
520210/3 18/03 Sensor oil pressure No limitation. Check the cable D793/28 – TRANSM,
(D765), short circuit to harness between B765/A menu 10
voltage. control unit and
D793/29 –
sensor.
B765/B
Check the sensor.
520210/4 18/04 Sensor oil pressure No limitation. Check the cable D793/28 – TRANSM,
(D765), short circuit to harness between B765/A menu 10
ground. control unit and
D793/29 –
sensor.
B765/B
Check the sensor.
/16 (B765), value is above harness between B765/A menu 10
highest normal value. control unit and
D793/29 –
sensor.
B765/B
Check the sensor.
/18 (B765), value is below harness between B765/A menu 10
lowest normal value. control unit and
D793/29 –
sensor.
B765/B
Check the sensor.
/13 (B765), incorrectly harness between B765/A menu 10
calibrated. control unit and
D793/29 –
sensor.
B765/B
Check the sensor.

Connec-
tions Diag-
Sup- compo- menu
plier nents
Display code
520210 18/31 Sensor oil pressure No limitation or Shut Check the cable D793/28 – TRANSM,
/31 (B765), active error. down while error is harness between B765/A menu 10
active. control unit and
D793/29 –
sensor.
For inactive error B765/B
520211/3 19/03 Analogue input 3, No limitation. Check the cable D793/13 -
short circuit to voltage. harness to the control
D793/14
unit.
520211/4 19/04 Analogue input 3, No limitation. Check the cable D793/13 -
short circuit to ground. harness to the control
D793/14
unit.
520211 19/16 Analogue input 3, the No limitation. Check the cable D793/13 -
/16 value is above highest harness to the control
D793/14
normal value. unit.
520211 19/18 Analogue input 3, the No limitation. Check the cable D793/13 - -
/18 value is below lowest harness to the control
D793/14
normal value. unit.
520211 19/13 Analogue input 3, No limitation. Check the cable D793/13 -
/13 incorrectly calibrated harness to the control
D793/14
unit.
520211 19/31 Analogue input 3, No limitation or Shut Check the cable D793/13 -
/31 active error. down while error is harness to the control
D793/14
active. unit.
For inactive error
code, Limp home until
520218/5 26/05 Speed input 0, short No limitation or Shut Check the cable D793/09 -
circuit to voltage. down while error is harness to the control
D793/10
active. unit.
For inactive error
520218/6 26/06 Speed input 0, short No limitation or Shut Check the cable D793/09 -
circuit to ground. down while error is harness to the control
D793/10
active. unit.
For inactive error
520218 26/10 Speed input 0, value No limitation or Shut Check the cable D793/09 -
/10 outside limit values. down while error is harness to the control
D793/10
active. unit.
For inactive error
520218 26/31 Speed input 0, No limitation or Shut Check the cable D793/09 -
/31 active error. The down while error is harness to the control
D793/10
transmission control active. unit.
unit activates Shut
For inactive error
down or Limp home
depending on speed.

Connec-
tions Diag-
Sup- compo- menu
plier nents
Display code
520219/5 27/05 Sensor turbine speed No limitation or Shut Check the cable D793/11 – -
(B751), short circuit to down while error is harness between B751/2
voltage. active. control unit and
D793/12 –
sensor.
520219/6 27/06 Sensor turbine speed No limitation or Shut Check the cable D793/11 – -
(B751), short circuit to down while error is harness between B751/2
ground. active. control unit and
D793/12 –
sensor.
520219 27/10 Sensor turbine speed No limitation or Shut Check the cable D793/11 – -
/10 (B751), value outside down while error is harness between B751/2
limit values. active. control unit and
D793/12 –
sensor.
520219 27/31 Sensor turbine speed No limitation or Shut Check the cable D793/11 – -
/31 (B751), active error. down while error is harness between B751/2
active. control unit and
D793/12 –
sensor.
552022 32/03 Solenoid valve clutch No limitation or Shut Check the cable D793/33 – -
4/3 forward (Y630), short down while error is harness between Y630/1
circuit to voltage. active. control unit and
D793/34 –
solenoid valve.
For inactive error Y630/2
code, Limp home until Check the solenoid
ignition is switched off. valve.
520224/4 32/04 Solenoid valve clutch No limitation or Shut Check the cable D793/33 – -
forward (Y630), short down while error is harness between Y630/1
circuit to ground. active. control unit and
D793/34 –
solenoid valve.
forward (Y630), open down while error is harness between Y630/1
circuit or short circuit active. control unit and
D793/34 –
to battery. solenoid valve.
/31 forward (Y630), active down while error is harness between Y630/1
error. active. control unit and
D793/34 –
solenoid valve.
reverse (Y631), short down while error is harness between Y631/1
D793/32 –
solenoid valve.

Connec-
tions Diag-
Sup- compo- menu
plier nents
Display code
reverse (Y631), short down while error is harness between Y631/1
circuit to ground. active. control unit and
D793/32 –
solenoid valve.
reverse (Y631), open down while error is harness between Y631/1
D793/32 –
to battery. solenoid valve.
/31 reverse (Y631), active down while error is harness between Y631/1
D793/32 –
solenoid valve.
520226/3 34/03 Solenoid valve clutch No limitation or Shut Check the cable D793/48 -
gear 1 (Y6067-1), down while error is harness between – Y6067-
short circuit to voltage. active. control unit and 1/1
solenoid valve.
For inactive error D793/49
code, Limp home until Check the solenoid – Y6067-
ignition is switched off. valve. 2/2
short circuit to ground. active. control unit and 1/1
solenoid valve.
open circuit or short active. control unit and 1/1
circuit to battery. solenoid valve.
520226 34/31 Solenoid valve clutch No limitation or Shut Check the cable D793/48 -
/31 gear 1 (Y6067-1), down while error is harness between – Y6067-
active error. active. control unit and 1/1
solenoid valve.
gear 2 (Y6069), short down while error is harness between Y6069/1
D793/19 –
solenoid valve.
gear 2 (Y6069), open down while error is harness between Y6069/1
D793/19 –
to battery voltage. solenoid valve.

Connec-
tions Diag-
Sup- compo- menu
plier nents
Display code
/31 gear 2 (Y6069), active down while error is harness between Y6069/1
D793/19 –
solenoid valve.
520229/3 37/03 Digital output 05, short No limitation or Shut Check the cable D793/17 -
D793/18
active. unit.
For inactive error
D793/18
active. unit.
For inactive error
520229/5 37/05 Digital output 05, open No limitation or Shut Check the cable D793/17 -
circuit or short circuit down while error is harness to the control
D793/18
to battery. active. unit.
For inactive error
520229 37/31 Digital output 05, No limitation or Shut Check for more error D793/17 -
D793/18
active. first.
D793/50
active. unit.
For inactive error
D793/50
active. unit.
For inactive error
D793/50
For inactive error
D793/50
active. first.

Connec-
tions Diag-
Sup- compo- menu
plier nents
Display code
D793/02
active. unit.
For inactive error
D793/02
active. unit.
For inactive error
D793/02
For inactive error
D793/02
active. unit.
For inactive error
D793/02
active. first.
D793/04
active. unit.
For inactive error
D793/04
active. unit.
For inactive error
D793/04
For inactive error
D793/04
active. unit.
For inactive error

Connec-
tions Diag-
Sup- compo- menu
plier nents
Display code
D793/04
active. first.
520240/9 48/09 Incorrect declutch Declutch of Use diagnostic D793/22 CAN/P-
signal via the CAN transmission with menu to check – D790- OWER,
bus. declutch pedal does communication. 1/K13:1 menu 3
not work.
Check the cable D790-
harness between 1/K13:1 –
Control unit, cab D793/23
unit, transmission
(D793).
520240 48/19 Incorrect declutch Declutch of Use diagnostic D793/22 CAN/P-
/19 signal via the CAN transmission with menu to check – D790- OWER,
bus. declutch pedal does communication. 1/K13:1 menu 3
not work.
unit, transmission
(D793).
520240 48/31 Incorrect declutch Declutch of Check for more error - -
/31 signal via the CAN transmission with codes and rectify them
bus. declutch pedal does first.
not work.
Check the cable
unit.
520241/9 49/09 Incorrect gear Transmission control Use diagnostic D793/22 CAN/P-
programme selection unit does not allow menu to check – D790- OWER,
via the CAN bus. change of gear range, communication. 1/K13:1 menu 3
however, operation of
machine is possible.
unit, transmission
(D793).
520241 49/19 Incorrect gear Transmission control Use diagnostic D793/22 CAN/P-
/19 programme selection unit does not allow menu to check – D790- OWER,
via the CAN bus. change of gear range, communication. 1/K13:1 menu 3
unit, transmission
(D793).
520241 49/31 Incorrect gear Transmission control Check for more error - -
/31 programme selection unit does not allow codes and rectify them
via the CAN bus. change of gear range, first.
Check the cable
unit.

Connec-
tions Diag-
Sup- compo- menu
plier nents
Display code
520242/9 50/09 Incorrect kickdown Kickdown does not Use diagnostic D793/22 CAN/P-
signal via the CAN work. menu to check – D790- OWER,
bus. communication. 1/K13:1 menu 3
unit, transmission
(D793).
520242 50/19 Incorrect kickdown Kickdown does not Use diagnostic D793/22 CAN/P-
/19 signal via the CAN work. menu to check – D790- OWER,
unit, transmission
(D793).
520242 50/31 Incorrect kickdown Kickdown does not Check for more error - -
/31 signal via the CAN work. codes and rectify them
bus. first.
Check the cable
unit.
520243/9 51/09 Incorrect neutral The transmission Use diagnostic D793/22 CAN/P-
position signal via is locked in neutral menu to check – D790- OWER,
the CAN bus. position. communication. 1/K13:1 menu 3
unit, transmission
(D793).
520243 51/19 Incorrect neutral The transmission Use diagnostic D793/22 CAN/P-
/19 position signal via is locked in neutral menu to check – D790- OWER,
the CAN bus. position. communication. 1/K13:1 menu 3
unit, transmission
(D793).
520243 51/31 Incorrect neutral The transmission Check for more error - -
/31 position signal via is locked in neutral codes and rectify them
the CAN bus. position. first.
Check the cable
unit.

Connec-
tions Diag-
Sup- compo- menu
plier nents
Display code
520244/2 52/02 Incorrect idle signal No limitation. Use diagnostic D793/22 CAN/P-
from accelerator pedal menu to check – D790- OWER,
via CAN bus. communication. 1/K13:1 menu 3
unit, transmission
(D793).
520244/9 52/09 Incorrect idle signal No limitation. Use diagnostic D793/22 CAN/P-
from accelerator pedal menu to check – D790- OWER,
unit, transmission
(D793).
520244 52/19 Incorrect idle signal No limitation. Use diagnostic D793/22 CAN/P-
/19 from accelerator pedal menu to check – D790- OWER,
unit, transmission
(D793).
520244 52/31 Incorrect idle signal No limitation. Check for more error - -
/31 from accelerator pedal codes and rectify them
via CAN bus. first.
Check the cable
unit.
520245/2 53/02 Incorrect full throttle No limitation. Use diagnostic D793/22 CAN/P-
signal from accelerator menu to check – D790- OWER,
pedal via CAN bus. communication. 1/K13:1 menu 3
unit, transmission
(D793).
520245/9 53/09 Incorrect full throttle No limitation. Use diagnostic D793/22 CAN/P-
signal from accelerator menu to check – D790- OWER,
unit, transmission
(D793).

Connec-
tions Diag-
Sup- compo- menu
plier nents
Display code
520245 53/19 Incorrect full throttle No limitation. Use diagnostic D793/22 CAN/P-
/19 signal from accelerator menu to check – D790- OWER,
unit, transmission
(D793).
520245 53/31 Incorrect full throttle No limitation. Check for more error - -
/31 signal from accelerator codes and rectify them
pedal via CAN bus. first.
Check the cable
unit.
520249/9 57/09 Incorrect parking The transmission Use diagnostic D793/22 CAN/P-
brake signal via the is locked in neutral menu to check – D790- OWER,
CAN bus. position. communication. 1/K13:1 menu 3
unit, transmission
(D793).
520249 57/19 Incorrect parking The transmission Use diagnostic D793/22 CAN/P-
/19 brake signal via the is locked in neutral menu to check – D790- OWER,
CAN bus. position. communication. 1/K13:1 menu 3
unit, transmission
(D793).
520249 57/31 Incorrect parking The transmission Check for more error - -
/31 brake signal via the is locked in neutral codes and rectify them
CAN bus. position. first.
Check the cable
unit.
520250/9 58/09 Incorrect load signal No limitation. Use diagnostic D793/22 CAN/P-
via the CAN bus. menu to check – D790- OWER,
communication. 1/K13:1 menu 3
unit, transmission
(D793).

Connec-
tions Diag-
Sup- compo- menu
plier nents
Display code
520250 58/19 Incorrect load signal No limitation. Use diagnostic D793/22 CAN/P-
/19 via the CAN bus. menu to check – D790- OWER,
unit, transmission
(D793).
520250 58/31 Incorrect load signal No limitation. Check for more error - -
/31 via the CAN bus. codes and rectify them
first.
Check the cable
unit.
520251/9 59/09 Incorrect signal for No limitation. Use diagnostic D793/22 CAN/P-
disengagement menu to check – D790- OWER,
4WD/2WD via the communication. 1/K13:1 menu 3
CAN bus.
unit, transmission
(D793).
520251 59/19 Incorrect signal for No limitation. Use diagnostic D793/22 CAN/P-
/19 disengagement menu to check – D790- OWER,
4WD/2WD via the communication. 1/K13:1 menu 3
CAN bus.
unit, transmission
(D793).
520251 59/31 Incorrect signal for No limitation. Check for more error - -
/31 disengagement codes and rectify them
4WD/2WD via the first.
CAN bus.
Check the cable
unit.
520252/9 60/09 Incorrect high/low No limitation. Use diagnostic D793/22 CAN/P-
gear signal via the menu to check – D790- OWER,
CAN bus. communication. 1/K13:1 menu 3
unit, transmission
(D793).

Connec-
tions Diag-
Sup- compo- menu
plier nents
Display code
520252 60/19 Incorrect high/low No limitation. Use diagnostic D793/22 CAN/P-
/19 gear signal via the menu to check – D790- OWER,
unit, transmission
(D793).
250252 60/31 Incorrect high/low No limitation. Check for more error - -
/31 gear signal via the codes and rectify them
CAN bus. first.
Check the cable
unit.
520253/9 61/09 Incorrect extra neutral No limitation. Use diagnostic D793/22 CAN/P-
position signal via the menu to check – D790- OWER,
unit, transmission
(D793).
520253 61/19 Incorrect extra neutral No limitation. Use diagnostic D793/22 CAN/P-
/19 position signal via the menu to check – D790- OWER,
unit, transmission
(D793).
520253 61/31 Incorrect extra neutral No limitation. Check for more error - -
/31 position signal via the codes and rectify them
CAN bus. first.
Check the cable
unit.
520254/1 62/01 Low oil pressure Risk of slipping Check the - -
transmission. clutches. transmission oil level.
Check the sensor.
520254/9 62/09 Incorrect oil pressure No limitation. Use diagnostic D793/22 CAN/P-
signal via the CAN menu to check – D790- OWER,
unit, transmission
(D793).

Connec-
tions Diag-
Sup- compo- menu
plier nents
Display code
520254 62/19 Incorrect oil pressure No limitation. Use diagnostic D793/22 CAN/P-
/19 signal via the CAN menu to check – D790- OWER,
unit, transmission
(D793).
520254 62/31 Oil pressure signal, No limitation. Check for more error - -
/31 active error. codes and rectify them
first.
Check the cable
unit.
520255/9 63/09 Incorrect brake signal No limitation. Use diagnostic D793/22 CAN/P-
unit, transmission
(D793).
520255 63/19 Incorrect brake signal No limitation. Use diagnostic D793/22 CAN/P-
unit, transmission
(D793).
520255 63/31 Brake signal, active No limitation. Check for more error - -
/31 error. codes and rectify them
first.
Check the cable
unit.
operator-in-seat via menu to check – D790- OWER,
the CAN bus. communication. 1/K13:1 menu 3
unit, transmission
(D793).

Connec-
tions Diag-
Sup- compo- menu
plier nents
Display code
/19 operator-in-seat via menu to check – D790- OWER,
unit, transmission
(D793).
520256 64/31 Signal operator-in- No limitation. Check for more error - -
/31 seat, active error. codes and rectify them
first.
Check the cable
unit.
seat direction via the menu to check – D790- OWER,
unit, transmission
(D793).
/19 seat direction via the menu to check – D790- OWER,
unit, transmission
(D793).
520257 65/31 Signal for seat No limitation. Check for more error - -
/31 direction, active error. codes and rectify them
first.
Check the cable
unit.
prevent shifting via the menu to check – D790- OWER,
unit, transmission
(D793).

Connec-
tions Diag-
Sup- compo- menu
plier nents
Display code
/19 prevent shifting via the menu to check – D790- OWER,
unit, transmission
(D793).
520258 66/31 Signal prevent shifting, No limitation. Check for more error - -
first.
Check the cable
unit.
520260/0 68/00 High transmission oil Control unit indicates Check the - -
temperature. the error to make transmission oil cooler,
operator aware of the clean if necessary.
warning's level.
Check the thermostat
in the transmission oil
cooler.
520260/9 68/09 Incorrect transmission No limitation. Use diagnostic D793/22 CAN/P-
oil temperature via the menu to check – D790- OWER,
unit, transmission
(D793).
520260 68/19 Incorrect transmission No limitation. Use diagnostic D793/22 CAN/P-
/19 oil temperature via the menu to check – D790- OWER,
unit, transmission
(D793).
520260 68/31 Transmission oil No limitation. Check for more error - -
/31 temperature, active codes and rectify them
error. first.
Check the cable
unit.
lock-up function via menu to check – D790- OWER,
unit, transmission
(D793).

Connec-
tions Diag-
Sup- compo- menu
plier nents
Display code
/19 lock-up function via menu to check – D790- OWER,
unit, transmission
(D793).
520261 68/31 Signal lock-up function No limitation. Check for more error - -
first.
Check the cable
unit.
exhaust brake via the menu to check – D790- OWER,
unit, transmission
(D793).
/19 exhaust brake via the menu to check – D790- OWER,
unit, transmission
(D793).
520262 70/31 Exhaust brake signal, No limitation. Check for more error - -
first.
Check the cable
unit.
retarder via the CAN menu to check – D790- OWER,
unit, transmission
(D793).

Connec-
tions Diag-
Sup- compo- menu
plier nents
Display code
/19 retarder via the CAN menu to check – D790- OWER,
unit, transmission
(D793).
520263 71/31 Signal retarder, active No limitation. Check for more error - -
/31 error. codes and rectify them
first.
Check the cable
unit.
raised idle via the menu to check – D790- OWER,
unit, transmission
(D793).
/19 raised idle via the menu to check – D790- OWER,
unit, transmission
(D793).
520264 72/31 Signal raised idle, No limitation. Check for more error - -
first.
Check the cable
unit.
520276/2 84/02 Incorrect gear position No limitation. Check the cable - -
limitation. harness to the control
unit.
520276/9 84/09 Incorrect gear position No limitation. Use diagnostic D793/22 CAN/P-
limitation via the CAN menu to check – D790- OWER,
unit, transmission
(D793).

Connec-
tions Diag-
Sup- compo- menu
plier nents
Display code
520276 84/19 Incorrect gear position No limitation. Use diagnostic D793/22 CAN/P-
/19 limitation via the CAN menu to check – D790- OWER,
unit, transmission
(D793).
520276 84/31 Signal gear position No limitation. Check for more error - -
/31 limitation, active error. codes and rectify them
first.
Check the cable
unit.
customer function 1 menu to check – D790- OWER,
via the CAN bus. communication. 1/K13:1 menu 3
unit, transmission
(D793).
/19 customer function 1 menu to check – D790- OWER,
unit, transmission
(D793).
520277 85/31 Signal customer No limitation. Check for more error - -
/31 function 1, active codes and rectify them
error. first.
Check the cable
unit.
unit, transmission
(D793).

Connec-
tions Diag-
Sup- compo- menu
plier nents
Display code
unit, transmission
(D793).
error. first.
Check the cable
unit.
unit, transmission
(D793).
unit, transmission
(D793).
error. first.
Check the cable
unit.
unit, transmission
(D793).

Connec-
tions Diag-
Sup- compo- menu
plier nents
Display code
unit, transmission
(D793).
error. first.
Check the cable
unit.
unit, transmission
(D793).
unit, transmission
(D793).
error. first.
Check the cable
unit.
unit, transmission
(D793).

Connec-
tions Diag-
Sup- compo- menu
plier nents
Display code
unit, transmission
(D793).
error. first.
Check the cable
unit.
unit, transmission
(D793).
unit, transmission
(D793).
error. first.
Check the cable
unit.
unit, transmission
(D793).

Connec-
tions Diag-
Sup- compo- menu
plier nents
Display code
unit, transmission
(D793).
error. first.
Check the cable
unit.
unit, transmission
(D793).
unit, transmission
(D793).
error. first.
Check the cable
unit.
unit, transmission
(D793).

Connec-
tions Diag-
Sup- compo- menu
plier nents
Display code
unit, transmission
(D793).
error. first.
Check the cable
unit.
520287/2 95/02 Incorrect signal from No limitation or Shut Check the cable - -
gear selector. down while error is harness to the control
active. unit.
For inactive error
520287/9 95/09 Incorrect signal for No limitation or Shut Use diagnostic D793/22 CAN/P-
gear selection via the down while error is menu to check – D790- OWER,
CAN bus. active. communication. 1/K13:1 menu 3
For inactive error Check the cable D790-
code, Limp home until harness between 1/K13:1 –
ignition is switched off. Control unit, cab D793/23
unit, transmission
(D793).
520287 95/19 Incorrect signal for No limitation or Shut Use diagnostic D793/22 CAN/P-
/19 gear selection via the down while error is menu to check – D790- OWER,
unit, transmission
(D793).
520287 95/31 Signal gear selection, No limitation or Shut Check for more error - -
active. first.
520288 96/02 Incorrect signal from No limitation. Check for more error - -
/02 accelerator pedal. codes and rectify them
first.
Check the cable
unit.

Connec-
tions Diag-
Sup- compo- menu
plier nents
Display code
520288 96/09 Incorrect accelerator No limitation. Use diagnostic D793/22 CAN/P-
/09 pedal signal via the menu to check – D790- OWER,
unit, transmission
(D793).
520288 96/19 Incorrect accelerator No limitation. Use diagnostic D793/22 CAN/P-
/19 pedal signal via the menu to check – D790- OWER,
unit, transmission
(D793).
520288 96/31 Signal accelerator No limitation. Check for more error - -
/31 pedal, active error. codes and rectify them
first.
Check the cable
unit.
520289/2 97/02 Incorrect signal from No limitation. Check for more error - -
brake pedal. codes and rectify them
first.
Check the cable
unit.
520289/9 97/09 Incorrect brake signal No limitation. Use diagnostic D793/22 CAN/P-
unit, transmission
(D793).
520289 97/19 Incorrect brake signal No limitation. Use diagnostic D793/22 CAN/P-
unit, transmission
(D793).
520289 97/31 Signal brake pedal, No limitation. Check for more error - -
first.
Check the cable
unit.

Connec-
tions Diag-
Sup- compo- menu
plier nents
Display code
520290/0 98/00 Transmission oil Transmission locked Check the - -
temperature too high in neutral position transmission oil cooler,
sump. (Shut down). clean if necessary.
cooler.
520290/2 98/02 Incorrect signal Transmission locked Check for more error - -
from sensor for in neutral position codes and rectify them
transmission oil (Shut down). first.
temperature sump.
Check the cable
unit.
520290 98/16 High transmission oil No limitation. Check the - -
/16 temperature sump. transmission oil cooler,
clean if necessary.
cooler.
520290 98/31 Signal transmission No limitation. Check for more error - -
/31 oil temperature sump, codes and rectify them
active error. first.
Check the cable
unit.
520291/0 99/00 Transmission oil Transmission locked Check the - -
temperature too high, in neutral position transmission oil cooler,
radiator. (Shut down). clean if necessary.
cooler.
520291/2 99/02 Incorrect signal Transmission locked Check for more error - -
from sensor for in neutral position codes and rectify them
transmission oil (Shut down). first.
temperature radiator.
Check the cable
unit.
520291 99/16 High transmission oil No limitation. Check the - -
/16 temperature radiator. transmission oil cooler,
clean if necessary.
cooler.
520291 99/31 Signal transmission No limitation. Check for more error - -
/31 oil temperature cooler, codes and rectify them
Check the cable
unit.
520293/1 101/01 Oil pressure too low, Risk of slipping Check the - -
transmission. clutches transmission oil level
Check the sensor.

Connec-
tions Diag-
Sup- compo- menu
plier nents
Display code
520293/2 101/02 Incorrect signal Transmission in locked Check for more error - -
oil pressure neutral position (Shut codes and rectify them
transmission. down). first.
Check the cable
unit.
520293 101/31 Signal oil pressure No limitation. Check for more error - -
/31 transmission, active codes and rectify them
error. first.
Check the cable
unit.
520294/0 102/00 Clutch pressure, No limitation. Check the - -
clutch forward, too transmission oil level
high.
Check the sensor.
Check the hydraulics
in the transmission.
520294/2 102/02 Incorrect signal clutch No limitation. Check for more error - -
pressure, clutch codes and rectify them
forward. first.
Check the cable
unit.
520294 102/16 High clutch pressure, No limitation. Check the - -
/16 clutch forward. transmission oil level
Check the sensor.
520294 102/31 Signal clutch pressure, No limitation. Check for more error - -
/31 clutch forward, active codes and rectify them
error. first.
Check the cable
unit.
clutch reverse, too transmission oil level
high.
Check the sensor.
reverse. first.
Check the cable
unit.
/16 clutch reverse. transmission oil level
Check the sensor.

Connec-
tions Diag-
Sup- compo- menu
plier nents
Display code
/31 clutch reverse, active codes and rectify them
error. first.
Check the cable
unit.
clutch forward high transmission oil level
gear, too high.
Check the sensor.
forward, high gear. first.
Check the cable
unit.
/16 clutch forward high transmission oil level
gear.
Check the sensor.
/31 clutch forward high codes and rectify them
gear, active error. first.
Check the cable
unit.
clutch gear 1, too transmission oil level
high.
Check the sensor.
pressure, clutch gear codes and rectify them
1. first.
Check the cable
unit.
/16 clutch gear 1. transmission oil level
Check the sensor.
/31 clutch gear 1, active codes and rectify them
error. first.
Check the cable
unit.

Connec-
tions Diag-
Sup- compo- menu
plier nents
Display code
high.
Check the sensor.
2. first.
Check the cable
unit.
Check the sensor.
error. first.
Check the cable
unit.
high.
Check the sensor.
3. first.
Check the cable
unit.
Check the sensor.
error. first.
Check the cable
unit.
high.
Check the sensor.

Connec-
tions Diag-
Sup- compo- menu
plier nents
Display code
4. first.
Check the cable
unit.
Check the sensor.
error. first.
Check the cable
unit.
520314/0 122/02 Incorrect signal engine No limitation or Shut Check for more error - -
speed. down while error is codes and rectify them
active. first.
520314/9 122/09 Incorrect signal for No limitation or Shut Use diagnostic D793/22 CAN/P-
engine speed via the down while error is menu to check – D790- OWER,
unit, transmission
(D793).
520314 122/19 Incorrect signal for No limitation or Shut Use diagnostic D793/22 CAN/P-
/19 engine speed via the down while error is menu to check – D790- OWER,
unit, transmission
(D793).
520314 122/31 Signal engine speed, No limitation or Shut Check for more error - -
active. first.
520315/2 123/02 Incorrect signal from No limitation or Shut Check the cable D793/11 – -
Sensor, turbine speed. down while error is harness between B751/2
active. the sensor and control
D793/12 –
unit.

Connec-
tions Diag-
Sup- compo- menu
plier nents
Display code
520315 123/31 Signal turbine speed, No limitation. Check for more error D793/11 – -
/31 active error. codes and rectify them B751/2
first.
D793/12 –
Check the cable B751/1
unit.
520316/2 124/02 Incorrect signal No limitation or Shut Check for more error - -
rotation speed drum. down while error is codes and rectify them
active. first.
520316 124/31 Signal rotation speed No limitation. Check for more error - -
/31 drum, active error. codes and rectify them
first.
Check the cable
unit.
520317/2 125/02 Incorrect signal No limitation or Shut Check for more error - -
rotation speed output down while error is codes and rectify them
shaft. active. first.
520317 125/31 Signal rotation speed No limitation. Check for more error - -
/31 output shaft, active codes and rectify them
error. first.
Check the cable
unit.
520336/0 144/00 Control unit, Transmission locked Check the voltage D793/45 CAN/P-
transmission (D793), in neutral position feed. OWER,
battery voltage too (Shut down). menu 15
If equipment for
high.
assisted start is
it.
520336/1 144/01 Control unit, Transmission locked Check the cable D793/45 CAN/P-
transmission (D793), in neutral position harness to the control OWER,
battery voltage too (Shut down). unit. menu 15
low.
Check alternator,
battery and cable
harness between
520336 144/16 Control unit, No limitation. Check the voltage D793/45 CAN/P-
/16 transmission (D793), feed. OWER,
battery voltage high. menu 15
If equipment for
assisted start is
it.

Connec-
tions Diag-
Sup- compo- menu
plier nents
Display code
520336 144/18 Control unit, No limitation. Check the cable D793/45 CAN/P-
/18 transmission (D793), harness to the control OWER,
battery voltage low. unit. menu 15
Check alternator,
battery and cable
harness between
520337/0 145/00 Control unit, Transmission locked Check the voltage D793/20 CAN/P-
transmission (D793), in neutral position feed. OWER,
D793/60
ignition voltage too (Shut down). menu 15
If equipment for
high.
assisted start is
it.
520337/1 145/01 Control unit, Transmission locked Check the cable D793/20 CAN/P-
transmission (D793), in neutral position harness to the control OWER,
D793/60
ignition voltage too (Shut down). unit. menu 15
low.
Check alternator,
battery and cable
harness between
520337 145/16 Control unit, No limitation. Check the voltage D793/20 CAN/P-
/16 transmission (D793), feed. OWER,
D793/60
ignition voltage high. menu 15
If equipment for
assisted start is
it.
520337 145/18 Control unit, No limitation. Check the cable D793/20 CAN/P-
/18 transmission (D793), harness to the control OWER,
D793/60
ignition voltage low. unit. menu 15
Check alternator,
battery and cable
harness between
520346 154/12 Control unit, Transmission locked Switch off the ignition - -
/12 transmission (D793), in neutral position and the battery
memory error. (Shut down). voltage, and check
if the error remains.
520353 161/31 Incorrect No limitation. Reprogram the control - -
/31 configuration. unit.

Connec-
tions Diag-
Sup- compo- menu
plier nents
Display code
520368 176/31 Output parking brake, No limitation. Check for more error - -
first.
Check the cable
unit.
520371 179/31 Output disengage- No limitation. Check for more error - -
/31 ment 4WD/2WD, codes and rectify them
Check the cable
unit.
520372 180/31 Output high/low gear, No limitation. Check for more error - -
first.
Check the cable
unit.
520373 181/31 Output speed No limitation. Check for more error - -
/31 limitation, active error. codes and rectify them
first.
Check the cable
unit.
520374 182/31 Output signal start No limitation. Check for more error - -
/31 interlock neutral codes and rectify them
position, active error. first.
Check the cable
unit.
520375 183/31 Output signal warning No limitation. Check for more error - -
/31 lamp transmission codes and rectify them
error, active error. first.
Check the cable
unit.
520376 184/31 Output signal lock-up, No limitation. Check for more error - -
first.
Check the cable
unit.
520377 185/31 Output gear position, No limitation. Check for more error - -
first.
Check the cable
unit.

Connec-
tions Diag-
Sup- compo- menu
plier nents
Display code
520385/9 193/09 Control unit, No limitation. Use diagnostic D793/22 CAN/P-
cab (D790-1), menu to check – D790- OWER,
communication error. communication. 1/K13:1 menu 3
unit, transmission
(D793).
unit, transmission
(D793).
unit, transmission
(D793).
unit, transmission
(D793).
unit, transmission
(D793).
520432 240/XX Incorrect No limitation. Reprogram Control - -
/XX configuration. unit, transmission
(D793).
(D793).
(D793).

Connec-
tions Diag-
Sup- compo- menu
plier nents
Display code
(D793).
(D793).
(D793).
(D793).
(D793).
(D793).
(D793).
(D793).
(D793).
(D793).

8 Control system – Control system D:95
8 Control system
Error codes machine
Error codes marked with * do not apply to the machine, but can be
shown with an error in the cable harness to the control unit.
Connections
Cod- and Diagnos-
e Description Limitation Action components tic menu Group
1 Communication - Use diagnostic menu to D797-1 CAN/POW- 11.6.2
error with frame find incorrect segment. ER, menu Redundant
control unit 1-3 CAN bus
(D797-1)
2* Communication - Use diagnostic menu to D797-2 CAN/POW- 11.6.2
error with frame find incorrect segment. ER, menu Redundant
control unit 1-3 CAN bus
(D797-2).
3 Communication - Use diagnostic menu to D791-1 CAN/POW- 11.6.2
error with Control find incorrect segment. ER, menu Redundant
unit, attachment 1-3 CAN bus
(D791-1).
8 Communication - Use diagnostic menu to D795 CAN/POW- 11.6.2
error with Control find incorrect segment. ER, menu Redundant
unit KID (D795). 1-3 CAN bus
11 Error in cable, CAN - Use diagnostic menu to Varies CAN/POW- 11.6.2
network, segment find incorrect segment. depending ER, menu Redundant
1. on machine 1-3 CAN bus
configuration.
configuration.
configuration.
network, segment find incorrect segment. depending ER, menu 2 Redundant
4. on machine and 3 CAN bus
configuration.
configuration.
19 * Accelerator pedal Accelerator Calibrate the accelerator D790-1/K6:12 – CALIBRA- 1. Engine
2 VBFS not pedal for pedal. See section R690-2 TION:
calibrated. reversing does 8 Control system, DRIVE-
not work. group 8.5.2.3 Calibrate TRAIN,
Engine speed DRIVE-TRAIN. menu 5 and
limited to idle. 6
20 Accelerator pedal Accelerator Calibrate the accelerator D790-1/K6:11 – CALIBRA- 1. Engine
not calibrated. pedal does not pedal. See section R690-1 TION:
work. Engine 8 Control system, DRIVE-
speed limited group 8.5.2.3 Calibrate TRAIN,
to idle. DRIVE-TRAIN. menu 1 and
2

D:96 8 Control system – Control system
Connections
Cod- and Diagnos-
21 Communication Gear selection Use diagnostic menu to D790-1/K13:1 – CAN/POW- 11.6.3 CAN
error with Control not working. check communication. D793/M2 ER, menu 4 bus drive-train
unit, transmission
Check the cable harness D790-1/K13:2 –
(D793).
between Control unit, D793/L2
cab (D790-1) and
Control unit, transmission
(D793).
22 Communication Engine does Use diagnostic menu to Volvo: D790- CAN/POW- 11.6.3 CAN
error with Control not respond check communication. 1/K13:1, K13:2 ER, menu 4 bus drive-train
unit, engine (D794). to commands – D794/2, 1
Check the cable harness
from the cab.
between Control unit, Cummins:
cab (D790-1) and Control D790-1/K13:1,
unit, engine (D794). K13:2 –
D794/46, 37
23 The set-up file No controls in Contact Cargotec. D790-1 - 11.5.3.1
cannot be read in the cab are Control unit,
Control unit, cab working. cab
(D790-1).
24 Power supply to Cab fan not Check fuse F58-5/3 D790-1/K2:8 – - 9.4.3 Cabin
cab fan below 18 V. working. 58-5/3:2 fan
25 Interference during Error code Switch the ignition off D794 ENGINE, 11.5.3.10
software download. stored in and on. menu 8 Engine control
26 Buffer for error Control unit, unit
Repeat software
27 codes from Control engine (D794).
download.
unit, engine (D794),
28 active error code
when downloading.
29
30
31 Incorrect power Controls in cab Check fuse F58-5/1. D790-1/K1:2, CAN/POW- 11.5.1.3
supply to Control not working. K1:3, K1:4 – ER, menu 7 Ignition
Check cabling between
unit, cab (D790-1). F58-5/1:1, 1:2 voltage (15)
the control unit and
Voltage below 18 V
the component with
or above 32 V.
diagnostic menu.
Check the control unit.
32 Incorrect 5 V Analogue Check the wiring D790-1/K4:5, CAN/POW- 11.5.3.1
reference voltage controls in between the control K 5:11, K5:13, ER, menu 7 Control unit,
to analogue cab cab not unit and component with K7:2, K 9:7 cab
controls. Voltage working (mini- the diagnostic menu.
below 4.9 V or wheel/steering
Check component.
above 5.1 V. lever and
controls for air
conditioning).
33 No feedback signal Control Check fuse F58-3/8. D790-1/K11:13 CAN/POW- 11.5.1.4
for emergency stop breaker – K3009-1/87 ER, menu 5 Emergency
switch voltage from cannot be stop switch
Relay, emergency disengaged. voltage (15E)
the component with
stop switch voltage All hydraulic
diagnostic menu.
(K3009-1). functions are
blocked.
34 Incorrect signal Parking brake Check cabling between D791-1/K8:5 – HYD, menu 4.5 Parking
from Switch, cannot be the control unit and S107/7 5 brake
parking brake released. the component with
D791-1/K8:13 –
(S107), indicates diagnostic menu.
S107/1
released and
Check the switch.
applied at same
time or nothing at
all.

Connections
Cod- and Diagnos-
35 Interference during Error code Switch the ignition off D793 TRANSM, 11.5.3.9
software download. stored in and on. menu 13 Transmission
36 Buffer for error Control unit, control unit
Repeat software
37 codes from Control transmission
download.
unit, transmission (D793).
38 (D793), active
error code when
39 downloading.
40
41 Transistor has been Wiper rear not Check cabling between D790-1/K2:4 – CAB, menu 9.5.7 Wiper
triggered due to working. the control unit and M650-2/53 3 motor rear
short circuit or open the component with
circuit in circuit for diagnostic menu.
rear wiper motor
Check the motor.
(M650-2).
42 Transistor has been Revolving Check cabling between D790-1/K2:5 – LIGHTS, 9.6.8
triggered due to beacon not the control unit and H428 menu 6 Revolving
short circuit or open working. the component with beacon
rotating beacon
(H428).
43 Transistor has been Left cab Check bulb. D790-1/K2:6 – LIGHTS, 9.6.5 Back-up
triggered due to reversing light E405L menu 8 lights
short circuit or open not working.
circuit in circuit for
the component with
left reversing light
diagnostic menu.
(E405L).
44 Transistor has been Right cab Check bulb. D790-1/K2:7 – LIGHTS, 9.6.5 Back-up
triggered due to reversing light E405R menu 8 lights
short circuit or open not working.
the component with
right reversing light
diagnostic menu.
(E405R).
45 Transistor has been Wiper front not Check cabling between D790-1/K2:1 – CAB, menu 9.5.5 Wiper
triggered due to working. the control unit and M650-1/53 2 motor front
front wiper motor
(M650-1).
46 Transistor has been Cab fan not Check cabling between D790-1/K2:2 – CLIMATE, 9.4.3 Cabin
triggered due to working. the control unit and M657/2 menu 6 fan
fan motor (M657).
Check the motor.
47 Transistor has been Recirculation Check cabling between D790-1/K2:3 – CLIMATE, 9.4.2 Fresh
triggered due to damper to the control unit and M612/3 menu 6 air filter and
short circuit or open ventilation not the component with recirculation
circuit in circuit working. diagnostic menu. damper
for recirculation
Check the motor.
actuating motor
(M612).
48 Transistor has been Heat in cab Check cabling between D790-1/K4:1 – CLIMATE, 9.4.5 Water
triggered due to cannot be the control unit and Y673/5 menu 7 valve
short circuit or open adjusted. the component with
water valve (Y673).
Check the motor.

Connections
Cod- and Diagnos-
49 Transistor has been Heat in cab Check cabling between D790-1/K4:2 – CLIMATE, 9.4.5 Water
triggered due to cannot be the control unit and Y673/6 menu 7 valve
short circuit or open adjusted. the component with
water valve (Y673).
Check the motor.
50 Transistor has been Air distribution Check cabling between D790-1/K4:3 – CLIMATE, 9.4.14 Air
triggered due to in cab cannot the control unit and Y672/5 menu 8 distributor
short circuit or open be adjusted. the component with
actuating motor
Check the motor.
(Y672).
51 Transistor has been Air distribution Check cabling between D790-1/K4:4 – CLIMATE, 9.4.14 Air
triggered due to in cab cannot the control unit and Y672/6 menu 8 distributor
short circuit or open be adjusted. the component with
actuating motor
Check the motor.
(Y672).
52 * Transistor has been Bypass of Check component. D790-1/K5:3 – - -
triggered due to external top
Check the wiring.
short circuit or open lift attachment
circuit in circuit for not working.
bypass of external
top lift attachment.
53 Transistor has been Windscreen Check cabling between D790-1/K5:4 – CAB, menu 9.5.4 Washer
triggered due to washer rear the control unit and M651-2 1 motor and
short circuit or and roof not the component with reservoir
open circuit in working. diagnostic menu.
circuit for roof and
Check the motor.
rear washer motor
(M651-2).
54 Transistor has been Flashing Check cabling between D790-1/K5:5 – LIGHTS, 9.6.7 Flashing
triggered due to hazard lights the control unit and S109/ menu 7 hazard lights
short circuit or open not working. the component with
flashing hazard light
Check the switch.
switch (S109).
55 Transistor has been Reduced or no Check bulbs for D7901/K6:1, K LIGHTS, 9.1 Controls
triggered due to background background lighting, 8:15, K 9:2, all menu 14 and
short circuit or open lighting in replace if necessary. inputs of type A instruments
circuit in circuit for instruments Digital in
Check the cable harness
background lighting and controls.
for background lighting.
in switches and
instruments.
56 Transistor has been Work lights 20' Check cabling between D790-1/ K7:8 – LIGHTS, 9.6.10
triggered due to not working. the control unit and R3017-2/86 menu 12 Working
short circuit or open the component with lights, cab
relay for 20' working
lights.
57 Transistor has been Indicator light Check cabling between D790-1/ K7:9 – - 7.1.1 Control
triggered due to for levelling the control unit and S815/7 levers/Joy-
short circuit or open lock in joystick the component with stick
circuit in circuit for not working. diagnostic menu.
indicator light for
levelling lock in
joystick (S815).

Connections
Cod- and Diagnos-
58 * Transistor has been Twistlock on Check cabling between D790-1/ K7:10 EXT- 7.9.2
triggered due to external top the control unit and – K3005/86 ATTACH, Twistlocks
short circuit or open lift attachment the component with menu 6
circuit in circuit for does not work. diagnostic menu.
relay for twistlock
on external top
lift attachment
(K3005).
59 * Transistor has been Spreading on Check cabling between D790-1/ K7:11 – EXT- 7.10.5.1
triggered due to external top the control unit and K3006/86 ATTACH, Spreading
short circuit or open lift attachment the component with menu 6
circuit in circuit for does not work. diagnostic menu.
relay for spreading
on external top
lift attachment
(K3006).
60 Transistor has been Seat heating Check cabling between D790-1/ K10:7 CAB, menu 9.3.3 Heating
triggered due to does not work. the control unit and – K383/86 8 coil
relay for heating
element in driver's
seat (K383).
61 Transistor has been Work lights 40' Check cabling between D790-1/ K10:8 LIGHTS, 9.6.10
triggered due to not working. the control unit and – K3017-1/86 menu 12 Working
short circuit or open the component with lights, cab
relay for 40' working
lights (K3017-1).
63 Transistor has been No ignition Check cabling between D790-1/K10:10 CAN/POW- 11.5.1.3
triggered due to voltage to the control unit and – K315-1/86 ER, menu 5 Ignition
short circuit or open the machine's the component with voltage (15)
circuit in circuit for Control units. diagnostic menu.
relay for ignition
voltage (K315-1).
64 The transistor has No emergency Check cabling between D790-1/K10:11 CAN/POW- 11.5.1.4
been triggered due stop switch the control unit and – K3009-1/86 ER, menu 6 Emergency
to short circuit or voltage to the component with stop switch
open circuit in the machine's diagnostic menu. voltage
circuit for Relay, Control units.
emergency stop
switch voltage
(K3009-1).
65 The transistor has No emergency Check cabling between D790-1/K10:12 CAN/POW- 11.5.1.4
been triggered due stop switch the control unit and – K3009-2/86 ER, menu 6 Emergency
to short circuit or voltage to the component with stop switch
open circuit in the machine's diagnostic menu. voltage
circuit for Relay, Control units.
emergency stop
switch voltage
(K3009-2).
66 Transistor has been Windshield Check cabling between D790-1/K10:13 CAB, menu 9.5.4 Washer
triggered due to washer not the control unit and – M651-1, 1 motor and
short circuit or open working. the component with M651-2 reservoir
windscreen washer
motor (M651-1,
M651-2).

Connections
Cod- and Diagnos-
67 Transistor has been Wiper roof not Check cabling between D790-1/K10:14 CAB, menu 9.5.6 Wiper
triggered due to working. the control unit and – M650-3 4 motor roof
roof wiper motor
Check the motor.
(M650-3).
68 * Transistor has been Pause heater Check cabling between D790-1/K10:15 - 9.4 Heating,
triggered due to not working. the control unit and – M667 ventilation
short circuit or the component with and air
open circuit in diagnostic menu. conditioning
circuit for circulation
Check the motor.
pump, pause heater
(M667).
69 Transistor has been No voltage Check cabling between D790-1/K10:16 - 11.5.1.3
triggered due to feed to the control unit and – K315-2/86 Ignition
short circuit or open engine and the component with voltage (15)
circuit in circuit for transmission. diagnostic menu.
relay for drivetrain
ignition voltage
(K315-2).
71 Transistor has been Interior lighting Check bulb. D790-1/K11:6 – LIGHTS, 9.6.11 Interior
triggered due to in cab not E434-1 menu 9 lighting cab
short circuit or open working.
the component with
cab interior lighting
diagnostic menu.
(E434-1).
75 Relay ignition The cab Check cabling between - CAN/POW- 11.5.1.3
voltage (K315-1) control unit the control unit and ER, menu 5 Ignition
has jammed in (D790-1) still the component with voltage
position on. has a power diagnostic menu.
supply and is
thereby active.
80 No signal from Air Check the drive belt for D797-1/K1:40 – CLIMATE, 9.4.10
Pressure switch, conditioning the compressor for air S246 menu 3 Pressure
air conditioning not working. conditioning. switch
(S246), despite the
Check that compressor
AC compressor
for air conditioning is
being activated.
activated.
the component with
diagnostic menu.
81 Incorrect signal Air distribution Check cabling between D790-1/K4:7 – CLIMATE, 9.4.6 Fresh
from Damper motor cannot be the control unit and Y672/9 menu 4 air and
(Y672). Signal adjusted. the component with recirculation
voltage below 0.2 V diagnostic menu. damper
or above 4.8 V.
Check the motor.
85 Incorrect signal Accelerator Check cabling between D790-1/K6:11 – ENGINE, 1 Engine
from accelerator pedal for the control unit and B690-1/2 menu 1
pedal (B690-1). driving forward the component with
Signal voltage does not work. diagnostic menu.
below 0.2 V or Engine speed
above 4.8 V. limited to idle.
86 * Incorrect signal Accelerator Check the wiring D790-1/K6:12 – VBFS, 1 Engine
from extra pedal for between the control B690-2/2 menu 4
accelerator pedal reversing does unit and component with
(B690-2). Signal not work. the diagnostic menu.
voltage below 0.2 V Engine speed
Check component.
or above 4.8 V. limited to idle.

Connections
Cod- and Diagnos-
87 Error signal from Lift and lower Check cabling between D790-1/K7:3 – ELSERV, 7.1.1 Control
Control lever not working. the control unit and R8071/3 menu 1 lever
lifting/lowering the component with (P1)
(R8071). Signal diagnostic menu.
voltage below 0.2 V
Check the lever.
or above 4.8 V.
88 Error signal from Tilt not Check cabling between D790-1/K7:4 – ELSERV, 7.1.1 Control
Control lever tilt working. the control unit and R8072/3 menu 1 lever
(R8072). Signal the component with (P2)
voltage below 0.2 V diagnostic menu.
or above 4.8 V.
Check the lever.
89 Error signal from Side shift not Check cabling between D790-1/K7:5 – ELSERV, 7.1.1 Control
Control lever side working. the control unit and R8073/3 menu 1 lever
shift (R8073). the component with (P3)
Signal voltage diagnostic menu.
below 0.2 V or
Check the lever.
above 4.8 V.
90 * Error signal from Spreading not Check cabling between D790-1/K7:6 – ELSERV, 7.1.1 Control
Control lever working. the control unit and R8074/3 menu 2 lever
spreading (R8074). the component with (P4)
below 0.2 V or
Check the lever.
above 4.8 V.
91 * Error signal from Extra load Check the wiring D790-1/K7:7 ELSERV, 7.1.1 Control
Control lever extra handling between the control –R8075-1/3 menu 2 lever
function (R8075-1). function not unit and component with (P5)
Signal voltage working. the diagnostic menu.
below 0.2 V or
Check component.
above 4.8 V.
92 * Incorrect signal Joystick Check cabling between D790-1/K9:8 – EL-STE- 5.1.2 Mini-
from Steering control or the control unit and R825-1/H1 ERING, wheel
lever (R825-1) mini-wheel not the component with menu 1
5.1.3 Joystick
or Mini-wheel working. diagnostic menu.
(R825-1). Signal
Check the switch.
voltage below 0.2 V
or above 4.8 V.
93 * Incorrect signal Joystick Check cabling between D790-1/K9:9 – EL-STE- 5.1.2 Mini
from Mini-wheel control or the control unit and R825-2/H2 ERING, steering wheel
(R825-2). Signal mini-wheel not the component with menu 1
voltage below 0.2 V working. diagnostic menu.
or above 4.8 V.
Check the switch.
94 Incorrect signal Cab heat Check cabling between D790-1/K10:4 – CLIMATE, 9.4.5 Water
from Water valve, cannot be the control unit and Y673/9 menu 4 valve
cab heating (Y673). adjusted. the component with
below 0.2 V or
Check the motor.
above 4.8 V.
95 * Error signal from Extra load Check cabling between D790-1/K9:9 – ELSERV, 7.1.1 Control
Control lever extra handling the control unit and R8075-2/3 menu 2 lever
function (R8075-2). function not the component with (P7)
Signal voltage working. diagnostic menu.
below 0.2 V or
Check the lever.
above 4.8 V.

Connections
Cod- and Diagnos-
96 Incorrect signal Air Check cabling between D790-1/K4:8 – CLIMATE, 9.4.17
from Sensor, conditioning the control unit and B775-1/2 menu 1 Sensor cab
cab temperature not working. the component with temperature
(B775-1). diagnostic menu.
Sensor indicates
Check the sensor.
temperature below
-43 °C or above 105
°C.
97 Incorrect signal Air Check cabling between D790-1/K4:9 – CLIMATE, 9.4.18 Sensor,
from Sensor, conditioning the control unit and B774/2 menu 2 ambient
outer temperature not working. the component with temperature
(B774). diagnostic menu.
Temperature signal
Check the sensor.
above 105 °C.
98 Incorrect signal Air Check cabling between D790-1/K4:10 – CLIMATE, 9.4.16 Sensor,
from Sensor, outlet conditioning the control unit and B775-2/2 menu 2 temperature
fan temperature not working. the component with outlet fan
(B775-2). diagnostic menu.
Sensor indicates
Check the sensor.
temperature below
°C.
99 Incorrect signal Air Check cabling between D790-1/K4:11 – CLIMATE, 9.4.12 Sensor
from Sensor, conditioning the control unit and B775-3/2 menu 2 temperature
refrigerant not working. the component with refrigerant
temperature diagnostic menu.
(B775-3).
Check the sensor.
Sensor indicates
temperature below
°C.
101 Redundant voltage - Check cabling between D797-1/K2:7 CAN/POW- 11.5.1.2
feed left to the control unit and ER, menu Redundant
frame control unit the component with 10 voltage feed
(D797-1) does not diagnostic menu. of control units
reach destination.
feed right to the control unit and ER, menu Redundant
frame control unit the component with 10 voltage feed
(D797-1) does not diagnostic menu. of control units
reach destination.
103 Incorrect power No electric Check fuse F58-2/1, D797-1/K2:1, CAN/POW- 11.5.1.3
supply to Control power feed to replace if necessary. K2:9, K2:10 – ER, menu Ignition
unit, frame components. F58-2/1:1, 1:2 10 voltage (15)
(D797-1). Voltage
below 18 V or above
the component with
32 V.
diagnostic menu.
104 Incorrect Functions Check fuse F58-2:1 and D797-1/K2:11 – CAN/POW- 11.5.1.4
emergency stop normally replace if necessary. F58-2/1:1 ER, menu Emergency
switch voltage to supplied 10 stop switch
Check the wiring
frame control unit emergency voltage
between the control
(D797-1). stop switch
unit and component with
voltage have
the diagnostic menu.
no feed. All
hydraulic Check component.
functions are
blocked.

Connections
Cod- and Diagnos-
105 Incorrect 5 V Incorrect Check cabling between D797-1/K1:8 CAN/POW- 8.2.1
reference voltage function, lift the control unit and – B768-1/1, ER, menu Overload
to pressure sensor. and tilt sensor. the component with B768-2/1 11 protection
Voltage below 4.9 V diagnostic menu.
or above 5.1 V.
Check the sensor.
106 Transistor has been Cooling fan Check cabling between D797-1/K1:14 – HYD, menu 10.6.3 Cooling
triggered due to hydraulic oil the control unit and M668/1 1 fan
hydraulic oil cooling
Check the motor.
fan (M668).
107 Transistor has been Mast work Check bulb. D797-1/K1:1 LIGHTS, 9.6.9 Working
triggered due to lights not – E404L-1, menu 10 lights mast
Check the bulb holder.
short circuit or open working. E404R-1
circuit in circuit Check cabling between
for mast work the control unit and
lights (E404R-1, the component with
E404L-1). diagnostic menu.
108 Transistor has been High beam not Check bulb. D797-1/K1:15 LIGHTS, 9.6.1
triggered due to working. – E402L-1, menu 3 Headlights
short circuit or E402R-1
open circuit in Check cabling between
circuit for high the control unit and
beam (E402R-1, the component with
E402L-1). diagnostic menu.
109 Transistor has been Low beams not Check bulb. D797-1/K1:28 – LIGHTS, 9.6.1
triggered due to working. E400L, E400R menu 3 Headlights
short circuit or open
circuit in circuit for Check cabling between
low beam (E400L, the control unit and
E400R). the component with
diagnostic menu.
111 Transistor has been Running lights Check bulb. D797-1/K1:2 LIGHTS, 9.6.2 Running
triggered due to not working. – H416-1, menu 2 lights
short circuit or open H416-2,
circuit in circuit Check cabling between H417-1, H417-2
for running lights the control unit and
(H416-1, H416-2, the component with
H417-1, H417-2). diagnostic menu.
112 Transistor has been Cooling fan Check cabling between D797-1/K1:3 – HYD, menu 4.8.9 Cooling
triggered due to brake oil not the control unit and M674/1 2 fan
short circuit or open working. the component with
brake oil cooling fan
Check the motor.
(M674).
113 Transistor has been Lift and lower Check cabling between D797-1/K1:4 ELSERV, 7.2.5 Control
triggered due to not working. the control unit and – Y6004/1, menu 3 and valve, lift and
short circuit or open the component with Y6005/1 4 tilt
circuit in circuit diagnostic menu.
for solenoid valve,
Check the solenoid
lift mast (Y6005)
valves.
and solenoid valve,
lower mast (Y6004).
114 Transistor has been Tilt not Check cabling between D797-1/K1:5 ELSERV, 7.7.5 Control
triggered due to working. the control unit and – Y6010/1, menu 5 and valve, lift and
short circuit or open the component with Y6011/1 6 tilt
for solenoid valve,
Check the solenoid
tilt in (Y6011) and
valve.
solenoid valve, tilt
out (Y6010)

Connections
Cod- and Diagnos-
115 Transistor has been Left direction Check bulb. D797-1/K1:30 – LIGHTS, 9.6.6 Direction
triggered due to indicator not H422/1, H426/1 menu 4 indicators
for left direction the control unit and
indicator (H422, the component with
H426). diagnostic menu.
116 Transistor has been Right direction Check bulb. D797-1/K1:31 – LIGHTS, 9.6.6 Direction
triggered due to indicator not H423/1, H427/1 menu 4 indicators
for right direction the control unit and
indicator (H423, the component with
H427). diagnostic menu.
117 Transistor has been Starter motor Check cabling between D797-1/K1:32 – ENGINE, 1.11 Start and
triggered due to not working. the control unit and K315/85 menu 5 stop
start relay (K315)
for starter motor.
118 Transistor has been Tail lights not Check bulb. D797-1/K1:33 LIGHTS, 9.6.3 Tail
triggered due to working. – H412L/1, menu 2 lights
short circuit or open H412R/1
tail light (H412L, the control unit and
H412R). the component with
diagnostic menu.
119 Transistor has been Brake light left Check bulb. D797-1/K1:7 – LIGHTS, 9.6.4 Brake
triggered due to not working. H411L/1 menu 8 light
short circuit or open
for left brake light the control unit and
(H411L). the component with
diagnostic menu.
120 Transistor has been Brake light Check bulb. D797-1/K1:9 – LIGHTS, 9.6.4 Brake
triggered due to right not H411R/1 menu 8 light
right brake light the control unit and
(H411R). the component with
diagnostic menu.
121 The transistor has Back-up alarm Check cabling between D797-1/K1:10 – LIGHTS, 9.7.5 Back-up
been triggered due not working. the control unit and H965/1 menu 8 alarm
to short circuit or the component with
open circuit in circuit diagnostic menu.
for Back-up warning
device (H965).
122 Transistor has been Air Check cabling between D797-1/K1:25 – CLIMATE, 9.4.7
triggered due to conditioning the control unit and M645/1 menu 6 Compressor
123 circuit in circuit for diagnostic menu. D797-1/K1:29 –
electromagnetic M645/1
clutch of AC
compressor
(M645).
NOTE! Error code
122 and 123 apply
to the same user.

Connections
Cod- and Diagnos-
124 Transistor has been Pressurising Check cabling between D797-1/K1:39 – HYD, menu 7.4.9 Lift,
triggered due to of attachment the control unit and Y6062/1 6 tilt and
short circuit or open control valve the component with attachment
circuit in circuit does not work. diagnostic menu. control valve
for solenoid valve, No attachment
Check the solenoid
hydraulic pump functions
valve.
disengagement working.
(Y6062).
125 * Transistor has been Regeneration Check cabling between D797-1/K1:11 – ELSERV, 7.2.6 Valve
triggered due to not working. the control unit and Y6051/1 menu 15 block lift
short circuit or open the component with cylinder
for solenoid valve
Check component.
regeneration, lift,
right (Y6051).
126 * Transistor has been Regeneration Check cabling between D797-1/K1:12 – ELSERV, 7.2.6 Valve
triggered due to not working. the control unit and Y6052/1 menu 15 block lift
short circuit or open the component with cylinder
for solenoid valve
Check component.
regeneration, lift,
left (Y6052).
132 Vehicle Data file Some - - - -
missing. functions in
machine not
working.
133 * Faulty signal from Scales, Check the sensor. D797-1/K1:21 – HYD, menu 7.2.8 Sensor
hydraulic pressure regeneration B768-1/3 3 hydraulic
sensor for lift and slack pressure lift
the control unit and OLS, menu
cylinder (B768-1). chain logic, cylinder
the component with 1
not working.
diagnostic menu.
Overload
system not
working. Error
code 150
activated.
134 * Faulty signal from Overload Check the sensor. D797-1/K1:22 – HYD, menu 7.7.8
hydraulic pressure system not B768-2/3 3 Hydraulic
sensor for tilt working. Error pressure
the control unit and OLS, menu
cylinder (B768-2). code 150 sensor, tilt
the component with 1
activated. cylinder
diagnostic menu.
135 * No feedback signal - Check that cooling fan is D797-1/K2:6 – HYD, menu 4.8.9 Cooling
from brake oil working. M674/2 2 fan
cooling fan (M674).
the component with
diagnostic menu.
137 Error signal from Lift mast not Check cabling between D797-1/K1:16 – ELSERV, 7.2.5 Control
Solenoid valve working. the control unit and Y6005/2 menu 3 valve, lift and
lift mast (Y6005). the component with tilt
Return current does diagnostic menu.
not correspond with
Check the solenoid
control current.
valve.

Connections
Cod- and Diagnos-
138 Error signal from Lower mast not Check cabling between D797-1/K1:17 – ELSERV, 7.2.5 Control
Solenoid valve working. the control unit and Y6004/2 menu 4 valve, lift and
lower mast (Y6004). the component with tilt
not correspond with
Check the solenoid
control current.
valve.
139 Incorrect signal Tilt in not Check cabling between D797-1/K1:18 – ELSERV, 7.7.5 Control
from Solenoid working. the control unit and Y6011/2 menu 5 valve, lift and
valve, tilt in (Y6011). the component with tilt
not correspond with
Check the solenoid
control current.
valve.
140 Incorrect signal Tilt out not Check cabling between D797-1/K1:19 – ELSERV, 7.7.5 Control
from Solenoid working. the control unit and Y6010/2 menu 6 valve, lift and
valve, tilt out the component with tilt
(Y6010). Return diagnostic menu.
current does not
Check the solenoid
correspond with
valve.
control current.
141 Transistor has been Parking brake Check cabling between D797-1/K1:34 – HYD, menu 4.5.3 Solenoid
triggered due to cannot be the control unit and Y642/1 5 valve parking
short circuit or open released. the component with brake
for parking brake
Check the solenoid
solenoid valve
valve.
(Y642).
142 Transistor has been Pressurising Check cabling between D797-1/K1:35 – HYD, menu 7.4.9 Lift,
triggered due to of attachment the control unit and Y6012/6062/1 6 tilt and
short circuit or open control valve the component with attachment
circuit in circuit does not work. diagnostic menu. control valve
for solenoid valve, No attachment
Check the solenoid
hydraulic pump functions
valve.
disengagement working.
(Y6012/6062).
143 * Transistor has been Spreading Check cabling between D797-1/K1:36 – EXT- 7.10.5
triggered due to and twistlocks the control unit and Y6039/6018/1 ATTACH, Separate top
short circuit or on top lift the component with menu 5 lift attachment
open circuit in cir- attachment not diagnostic menu.
cuit for solenoid working.
Check the solenoid
valve, lock twist-
valve.
locks/spreading out
(Y6039/6018).
144 * Transistor has been Spreading Check cabling between D797-1/K1:37 – EXT- 7.10.5
triggered due to and twistlocks the control unit and Y6040/6019/1 ATTACH, Separate top
short circuit or on top lift the component with menu 5 lift attachment
open circuit in cir- attachment not diagnostic menu.
cuit for solenoid working.
Check the solenoid
valve, open twist-
valve.
locks/spreading in
(Y6040/6019).
145 * High brake oil Reduced Check that cooling fan is D797-1/K2:6 – HYD, menu 4.8.10 Sensor
temperature. braking working. B772/1 2 brake oil
capacity. If the temperature
Check that the radiator is
temperature
not clogged.
continues to
rise, speed is Check the brake oil level.
limited to 5
Check the sensor.
km/h.

Connections
Cod- and Diagnos-
146 * Incorrect signal Speed limited Check the sensor. D797-1/K2:6 – HYD, menu 4.8.10 Sensor
from Sensor, brake to 5 km/h. B772/1 2 brake oil
oil temperature temperature
(Y772). Signal
the component with
voltage below 0.2 V
diagnostic menu.
or above 4.8 V.
147 High temperature Reduced Check that cooling fan is D797-1/K2:13 – HYD, menu 10.6.4 Sensor
hydraulic oil. braking working. B776/1 1 hydraulic oil
capacity. If the temperature
Check that the radiator is
temperature
not clogged.
continues to
rise, speed is Check the sensor.
limited to 5
km/h.
148 Incorrect signal Incorrect Check the sensor. D797-1/K2:13 – HYD, menu 10.6.4 Sensor
from Sensor, temperature B776/1 1 hydraulic oil
hydraulic oil display. temperature
temperature
the component with
(B776).
diagnostic menu.
149 Incorrect signal Incorrect Check the sensor. D797-1/K2:15 CAB, menu 1.2.2 Sensor
from fuel level display of fuel –B757/1 7 fuel level
sensor (B757). volume (empty
Resistance above or full).
the component with
180Ω.
diagnostic menu.
150 * Defective overload Overload Check if there are error - OLS, menu 8.2.1
protection. system not codes for sensors in the 1–7 Overload
working. All overload system. protection
This error code
lift functions
cannot be removed
run at reduced
with Reset.
speed.
193 Transistor has been Right front Check bulb. D797-1/K1:36 – VBFS, 9.6.4 Brake
triggered due to brake light not H410R/1 menu 8 light
right front brake the control unit and
light (H410R). the component with
diagnostic menu.
194 Transistor has been Left front Check bulb. D797-1/K1:37 – VBFS, 9.6.4 Brake
triggered due to brake light not H410L/1 menu 8 light
left front brake light the control unit and
(H410L). the component with
diagnostic menu.
feed left to the control unit and ER, menu Redundant
attachment control the component with 15 voltage feed of
unit (D791-1) diagnostic menu. Control units
does not reach
destination.
feed right to the control unit and ER, menu Redundant
frame control unit the component with 15 voltage feed of
(D791-1) does not diagnostic menu. Control units
reach destination.

Connections
Cod- and Diagnos-
253 Incorrect power Functions Check fuse F58-3/1, D791-1/K2:1, CAN/POW- 11.5.1.4
supply to Control normally replace if necessary. K2:9, K2:10 – ER, menu Emergency
unit, attachment supplied F58-3/1:1 15 stop switch
(D791-1). Voltage emergency voltage
below 18 V or above stop switch
the component with
32 V. voltage have
diagnostic menu.
no feed. No
attachment
functions
working.
254 Incorrect Functions Check fuse F58-3/1, D791-1/K2:11 – CAN/POW- 11.5.1.4
emergency stop normally replace if necessary. F58-3/1:1 ER, menu Emergency
switch voltage supplied 15 stop switch
to Control unit, emergency voltage
attachment stop switch
the component with
(D791-1). voltage have
diagnostic menu.
no feed. No
attachment
functions
working.
255 Incorrect 5 V - Check cabling between D791-1/K1:8 CAN/POW- 11.5.1 Power
reference voltage the control unit and ER, menu supply
to pressure sensor. the component with 16
Voltage below 4.9 V diagnostic menu.
or above 5.1 V.
Check the sensor.
256 Transistor has been Central Check cabling between D791-1/K1:14 – OPT, menu 9.14.1 Pump
triggered due to lubrication the control unit and M693-2/1 2 unit
short circuit or open attachment not the component with
circuit in circuit working. diagnostic menu.
for central unit for
central lubrication
(M693-2).
257 Transistor has been Work light Check bulb. D791-1/K1:1 LIGHTS, 9.6.12
triggered due to attachment left – E404L, menu 13 Work light
short circuit or open not working. E404UL, attachment
circuit in circuit Check cabling between E404LL-3/1
for attachment the control unit and
work lights, left the component with
(E404L-3). diagnostic menu.
258 Transistor has been Work light Check bulb. D791-1/K1:15 LIGHTS, 9.6.12
triggered due to attachment – E404R, menu 13 Work light
short circuit or open right not E404UR, attachment
circuit in circuit working. Check cabling between E404LR-3/1
for attachment the control unit and
work lights, right the component with
(E404R-3). diagnostic menu.
259 Transistor has been Warning signal Check the buzzer. D791-1/K1:28 – ATTACH, 7.5.7 Buzzer,
triggered due to for automatic H9003/1 menu 21 automatic
short circuit or spreading not spread
open circuit in working. 20"-40"
the component with
circuit for warning
diagnostic menu.
signal, automatic
spreading (H9003).
260 * Transistor has been Levelling of Check cabling between D791-1/K1:42 ATTACH, -
triggered due to attachment not the control unit and – Y637-1/1, menu 15
short circuit or open working. the component with Y637-2/1
control valve for
Check the solenoid
levelling clockwise
valve.
(Y637-1, Y637-2).

Connections
Cod- and Diagnos-
261 Transistor has been Spreading Check cabling between D791-1/K1:16 – ATTACH, 7.5.2 Control
triggered due to left in of the control unit and Y6019L/2 menu 18 valve
short circuit or open attachment not the component with attachment
for solenoid valve,
Check the solenoid
spreading left in
valve.
(Y6019L).
triggered due to left out of the control unit and Y6018L/2 menu 17 valve
circuit in circuit functioning. diagnostic menu.
for solenoid valve,
Check the solenoid
spreading left out
valve.
(Y6018L).
triggered due to right in of the control unit and Y6019R/2 menu 20 valve
for solenoid valve,
Check the solenoid
spreading right in
valve.
(Y6019R).
triggered due to right out of the control unit and Y6018R/2 menu 19 valve
circuit in circuit functioning. diagnostic menu.
for solenoid valve,
Check the solenoid
spreading right out
valve.
(Y6018R).
265 * Transistor has been Levelling left of Check cabling between D791-1/K1:19 – ATTACH, -
triggered due to attachment not the control unit and Y6036/2 menu 13
short circuit or open working. the component with
for levelling, left
Check the solenoid
(Y6036).
valve.
266 * Transistor has been Levelling right Check cabling between D791-1/K1:19 – ATTACH, -
triggered due to of attachment the control unit and Y6036/2 menu 14
short circuit or not working. the component with
open circuit in diagnostic menu.
circuit for solenoid
Check the solenoid
valve, levelling right
valve.
(Y6035).
267 Transistor has been Side shift left of Check cabling between D791-1/K1:18 – ATTACH, 7.4.2 Control
triggered due to attachment not the control unit and Y6020/2 menu 11 valve
short circuit or open working. the component with attachment
solenoid valve, side
Check the solenoid
shift left (Y6020).
valve.
268 Transistor has been Side shift right Check cabling between D791-1/K1:18 – ATTACH, 7.4.2 Control
triggered due to of attachment the control unit and Y6021/2 menu 12 valve
short circuit or open not working. the component with attachment
solenoid valve, side
Check the solenoid
shift right (Y6021).
valve.
269 Transistor has been Twistlock not Check cabling between D791-1/K1:7 – ATTACH, 7.9.1.2
triggered due to working. the control unit and Y6040/1 menu 9 Control valve
short circuit or open the component with attachment
solenoid valve for
Check the solenoid
locked twistlocks
valve.
(Y6040).

Connections
Cod- and Diagnos-
270 Transistor has been Twistlock not Check cabling between D791-1/K1:9 – ATTACH, 7.9.1.2
triggered due to working. the control unit and Y6039/1 menu 9 Control valve
short circuit or the component with attachment
Check the solenoid
valve for open
valve.
twistlocks(Y6039).
271 The transistor has Twistlocks and Check cabling between D791-1/K1:10 CAN/POW- 7.9.1.2
been triggered due spreading not the control unit and – B769L/A, ER, menu Control valve
to short circuit or working. the component with B769R/A, 16 attachment
open circuit in circuit diagnostic menu. B777L/A,
for Voltage feed, B777R/A,
Check the sensor.
position sensor B7203L/A,
attachment. B7203R/A,
B7204L/A,
B7204R/A,
B7205LL/A,
B7205RL/A
272 The transistor has Indicator Check bulb. D791-1/K1:25 – ATTACH, 7.9.1
been triggered due light, open H562/1 menu 10 Twistlocks
to short circuit twistlock/lock
or open circuit tongue not Check cabling between
in the circuit for working. the control unit and
Indicator light, open the component with
twistlocks (H562). diagnostic menu.
273 The transistor has Indicator Check bulb. D791-1/K1:29 – ATTACH, 7.9.1
been triggered due light, locked H563/1 menu 10 Twistlocks
to short circuit twistlock/lock
or open circuit tongues not Check cabling between
in the circuit for working. the control unit and
Indicator light, the component with
locked twistlocks diagnostic menu.
(H563).
274 The transistor has Indicator light, Check bulb. D791-1/K1:39 – ATTACH, 7.9.1
been triggered due attachment H564/1 menu 10 Twistlocks
to short circuit or alignment not
open circuit in circuit working. Check cabling between
for Indicator light, the control unit and
alignment (H564). the component with
diagnostic menu.
287 Error signal from Spreading left Check cabling between D791-1/K1:16 ATTACH, 7.5.2 Control
the Solenoid not working. the control unit and – Y6019L/2, menu 17 valve
valve spreading the component with Y6019R/2 and 18 attachment
left in (Y6019L) diagnostic menu.
and Solenoid
Check the solenoid
valve spreading
valve.
left out(Y6018L).
Return current does
not correspond with
control current.
288 Error signal from Spreading right Check cabling between D791-1/K1:17 ATTACH, 7.5.2 Control
the Solenoid valve not working. the control unit and – Y6019R/2, menu 19 valve
spreading right the component with Y6018R/2 and 20 attachment
in (Y6019R) and diagnostic menu.
Solenoid valve
Check the solenoid
spreading right out
valve.
(Y6018R). Return
current does not
correspond with
control current.

Connections
Cod- and Diagnos-
289 Error signal from Side shift of Check cabling between D791-1/K1:18 ATTACH, 7.4.2 Control
Solenoid valve attachment not the control unit and – Y6020/2, menu 11 valve
for side shift working. the component with Y6021/2 and 12 attachment
left (Y6020) and diagnostic menu.
Solenoid valve
Check the solenoid
for side shift right
valve.
(Y6021). Return
current does not
correspond with
control current.
290 * Error signal from Levelling of Check cabling between D791-1/K1:19 ATTACH, -
Solenoid valve attachment not the control unit and – Y6035/2, menu 13
levelling right working. the component with Y6036/2 and 14
(Y6036) and diagnostic menu.
Solenoid valve
Check the solenoid
levelling left
valve.
(Y6035). Return
current does not
correspond with
control current.
291 * Transistor has been Indicator light Check bulb. D791-1/K1:34 – ATTACH, -
triggered due to for upper H564UL/1 menu 23
short circuit or open alignment not
circuit in circuit working. Check cabling between
for indicator light, the control unit and
upper alignment the component with
(H564UL). diagnostic menu.
292 Transistor has been Spreading in of Check cabling between D791-1/K1:35 – ATTACH, 7.5.2 Control
triggered due to attachment not the control unit and Y6019/1 menu 14 valve
short circuit or working. the component with attachment
Check the solenoid
valve, spreading in
valve.
(Y6019).
298 Sensor twistlock - Check that Sensors, D791-1/K2:13 ATTACH, 7.9.1.7
left side indicates twistlock, are clean and menu 8 Sensor
both locked and correctly adjusted. twistlocks
open twistlock at
the same time.
the component with
diagnostic menu.
299 Sensor twistlock - Check that Sensors, D791-1/K2:15 ATTACH, 7.9.1.7
right side indicates twistlock, are clean and menu 8 Sensor
both locked and correctly adjusted. twistlocks
open twistlock at
the same time.
the component with
diagnostic menu.
300 Sensor, alignment, Twistlock not Check that Sensors, - ATTACH, 7.9.1.6
indicates working. alignment, are clean and menu 7 Sensor
unreasonable correctly adjusted. alignment
distance.
Check that the contact
pin runs smoothly.
the component with
diagnostic menu.

Connections
Cod- and Diagnos-
451 Redundant voltage - Check cabling between D795/K1:7 CAN/POW- 11.5.1.2
feed left to Control the control unit and ER, menu 9 Redundant
unit KID (D795) the component with voltage feed
does not reach diagnostic menu. of control units
destination.
452 Redundant voltage - Check cabling between D795/K1:8 CAN/POW- 11.5.1.2
feed right to Control the control unit and ER, menu 9 Redundant
unit KID (D795) the component with voltage feed
does not reach diagnostic menu. of control units
destination.
460 No messages Incorrect Use diagnostic menu to D795/K1:10, CAN/POW- 11.6.2
received on CAN values in check the CAN bus. K1:11, K1:12, ER, menu Redundant
buffer 1. operating K1:13 1, 2, 17 CAN bus
menus.
461 No messages Error codes Use diagnostic menu to D795/K1:5, CAN/POW- 11.6.2
received on CAN from other check the CAN bus. K1:6 ER, menu Redundant
buffer 2. Control units 1, 2, 17 CAN bus
cannot be
shown.
500 Time for service. - Check that servicing - - C Preventive
has been performed. maintenance
If servicing has been
performed following
the Cargotec service
schedule, reset the
service indicator; see
section 8 Control system,
group 8.2.4 Service
indicator.

E:1
E Schematics
Contents E Schematics
Schematics......................................................................................................... E:3
Common hydraulics ........................................................................................ E:3
Hydraulic diagrams, compilation ................................................................ E:3
Hydraulic diagrams..................................................................................... E:4
Common electrics ........................................................................................... E:6
Circuit diagram, description ....................................................................... E:6
Component designations ........................................................................... E:8
Circuit diagrams, compilation ..................................................................... E:8

E:2

E Schematics – Schematics E:3
E Schematics
Common hydraulics
Hydraulic diagrams, compilation
Designation Drawing number
Hydraulic diagrams, page E:4 A54948.0100

E:4
13 13 17
12 16
VDCT01.02GB
14
1 2 1
7
15
3 3 6
11
a b c d e f g h
5
4
18
d a b
9 20
19
a
8
b
10
Workshop Manual DCT 80-90

e c
E Schematics – Common hydraulics
32
Hydraulic diagrams
21
24 24
22 22
34 29 28
25 25 23 23
36 35
33
27
31 30 26
015048 [A58447-0200 ver . 03]

E Schematics – Common hydraulics E:5
1. Wheel brakes 17. Spreading cylinder right spreader beam

2. Drive axle block 18. Main valve
3. Brake cylinder a Solenoid valve hydraulic pressure attachment
(Y6012/6062)
4. Parking brake caliper
b Relief valve, attachment
5. Make-contact (closing switch) declutch (S220)
c Servo valve, lift (Y6005)
6. Make-contact (closing switch) brake light (S216)
d Servo valve, lower (Y6004)
7. Brake valve
e Servo valve, tilt in (Y6011)
8. Valve block brake system
f Servo valve, tilt out (Y6010)
a Accumulator drain valve
19. Lift, tilt and attachment control valve
b Solenoid valve parking brake (Y642)
20. Valve block accumulator charging and priority valve
9. Switch (NC) low brake pressure (S204)
21. Accumulator lift cylinder
22. Load control valve
11. Accumulator brake system
23. Lift cylinder
12. Side shift cylinder
24. Overcentre valve
13. Lock cylinder, twistlock
25. Tilt cylinder
14. Overcentre valve
26. Hydraulic oil tank
15. Control valve, attachment
27. Breather filter
a Servo valve, side shift left (Y6020)
28. Hydraulic oil pump, load handling
b Servo valve, side shift right (Y6021)
29. Hydraulic oil pump, brake and steering
c Servo valve, open twistlock (Y6039)
30. Hydraulic oil filter, load handling
d Servo valve, lock twistlock (Y6040)
31. Hydraulic oil filter, cooling circuit
e Servo valve spreading out left (Y6018L)
32. Steering valve
f Servo valve spreading in left (Y6019L)
g Servo valve spreading out right (Y6018R)
34. Oil cooler
h Servo valve spreading in right (Y6019R)
35. Thermal bypass valve
16. Spreading cylinder left spreader beam
36. Fine filter

E:6 E Schematics – Common electrics
Common electrics
Circuit diagram, description
A circuit diagram is divided into circuit names (drawing numbers) and
consists of a set of numbered pages.
The circuits and their contents are governed by the following set of
rules:
• 20015.0001 circuit drawings-post designations K-standard.
• K-standard 1: norms, rules
• K-standard 2: cables, general physical
• K-standard 5: Designation and marking system, item designations
circuit drawings
The following is an explanation of symbols and texts in a circuit

diagram:
Connectors
Connectors
-X M 6 7 4 m -X M 6 7 4 f
2 2
Connectors in the wiring start with an X followed by a number
and end with f = female or m = male. If a connector is connected
to a component then the component number is inherited into the
connector's number, e.g. XB72002Rm which is the connector for
Sensor, alignment front right (B7202R).
013017
-X 3 7 -2 0 1 Under the connector's number the pin is specified with numbers or

letters depending on the connector.
• X000-X199: In the cab.
• X200-X299: On the frame.
• X300-X399: On the boom.
• X400-: On the attachment.
• X37-: All grounding points start with X37, e.g. X37-201, which is
a grounding point on the frame.
X37-A, X37-B, X37-C and X37-D are grounding points in
electronic box, cab.
Zero references are in the control units.
Components
+ C H A S S IS Components
-S 2 2 0 -2
Components are described with component number (S220-2) and
P
a short descriptive text. Components (sensors, switches, etc.) are
1 1 2 1 shown in standby mode i.e. de-energised mode or not mechanical
standby mode.
013018
D E C L U C H IN G
3 ,0 M P a • S indicates the type of component, see Component designations,
page E:8.
• 220 is component number and indicates the function the
component has.
• -2 indicates that it is the second component of this type for the
specific diagram.

E Schematics – Common electrics E:7
Cable marking
A 01012 0525 W 212D

Cable marking
All cables are either white (ground signal) or grey (other wiring) and
A 01011 0524 W 212C labelled with numbers.
Cable numbering is interpreted as follows:

A 01010 0523 W 212B • 0525: the number on a cable can usually be traced to a pin in a
connector, in this example, connector X052 pin 5.
• W212: cables that start with W and serial number cannot be
A 01016 0527 W 212E traced directly to a connector.
• A01012: cables that start with A are in the electronic box in the
cab.
013019
W 212A
• W212D: cables that end with a capital letter are jointed in the
wiring from a main cable with the same number. Each joint will
have its own letter.
References
0 References
00816
1 An arrow symbol means that the circuit continues on another page in
/4 .0 _ 1 .B 1 5 1 the circuit diagram at the specified coordinates. Sometimes there are
013020
/9 .1 0 _ 1 .A 2
00816 also references for components that can then be part of a component
whose other parts are on a different diagram. In some cases there
is also a help text where the cable connects.
Example: /11.5_1.D3 means page 11.5_1 coordinate D3.

Connection to control unit
Connection to control unit
-X 4 1 1 Connections to control units are described as a table with two fields;
21 K 1 :2 1 A n a lo g In 0 -5 V +BO O M
-D 7 9 1 -1 the upper one shows the type of connection, the lower one has a
/0 .0 _ 4 .D 5
reference to the compilation of the control unit's connections. Together
013021
M E A S U R E P O IN T S C A L E with this there are descriptive texts that specify control unit and signal.
For more information about the different connection types on the

control units, see section 11 Common electrics, group 11.5.5 Wiring.
Fuses
Fuse boxes always start with F5. Example: F58-3 means fuse box
3 with 8 fuses.
For most fuse boxes there is also a table and an explanation of the
circuits that the various fuses protect.

Component designations
The components in circuit diagrams have a prefix and number, the
prefix describes the type of component, the number which component.
Component list with component number, prefix and designation is
provided as an appendix after the circuit diagrams.
Prefix Description
B Converter from non-electric to electric signals or vice versa. Example: inductive sensor.
D Binary element, delay unit, memory. Example: control unit.
E White light. Example: work lighting.
F Protective device. Example: fuse.
G Alternator, power supply device. Example: battery.
H Signal device. Example: horn, brake lights.
K Relay, contactor. Example: power relay ignition key lock.
M Motor. Example: electric motor.
P Measuring instrument, testing equipment. Example: hour meter.
R Resistor. Example: potentiometer.
S Electric switch for control circuit, selector. Example: switch.
X Outlet/socket, connecting device. Example: connection terminal.
Y Electrically controlled mechanical device. Example: solenoid valve, hydraulic valve.
Circuit diagrams, compilation

Circuit diagrams are attached as an appendix in the following order.
Circuit diagram basic machine, drawing number A49226.0100. The
circuit contains pages for several machine models, those applying to
DCT 80-90 are listed here.
Sheet Designation
0.0-1 Cross-reference list
0.1-1 Truth table opt.
1.0-1 Circuit, drivetrain, engine
1.0-2E1 Circuit, Cummins QSB6.7 engine
1.0-2E2 Circuit, Cummins QSB6.7 engine
2.0-1 Circuit, drivetrain gearbox
4.0-1 Circuit, brake system
4.8-1 Circuit, brake oil cooling
7.0-1 Circuit, electric servo levers
7.0-2 Circuit, electric servo joystick
7.0-4 Circuit, accessory attachment
7.0-5 Circuit, accessory attachment
7.2-1 Circuit, lift/lower electric servo
7.2-6 Circuit, mast valves
7.7-1 Circuit, tilt electric servo

E Schematics – Common electrics E:9
Sheet Designation
7.7-2 Circuit, tilt indication
7.9-1 Circuit, twistlock
8.2-1 Circuit, bypassing
9.0-1 Circuit, std. opt.
9.1-1 Circuit, optional equipment
9.1-2 Circuit, hour counter
9.3-1 Circuit, seat heating
9.3-2 Circuit, air suspension seat
9.4-1 Circuit, climate system
9.4-2 Circuit, climate system
9.4-3 Circuit, condenser chassis
9.5-1 Circuit, wipers
9.6-1 Circuit, work lights 20'-40'
9.6-2 Circuit, work lights, carriage
9.6-3 Circuit, work lights, mast
9.6-4 Circuit lighting
9.6-7 Circuit, direction indicators & hazard
9.6-8 Circuit, interior lighting
9.6-9 Circuit, work lights, option
9.6-10 Circuit, work lights, option
9.6-11 Circuit, entry lighting
9.6-12 Circuit, aux. lights, attachment
9.6-13 Circuit, work lights, option, hood lamp
9.6-14 Circuit, work lights, option carriage
9.7-1 Circuit, alarm, audible signals
9.7-2 Circuit, back-up alarm
9.7-3 Circuit, compressor horn
9.7-4 Circuit for horn, servo panel
9.8-1 Circuit, radio
9.8-2 Circuit, printer
9.9-1 Circuit, rearview mirror heating
9.9-2 Circuit, camera
9.10-1 Circuit, cab tilt/sliding cab
9.14–1 Circuit, central lubrication
10.4-1 Circuit, hydr. pump disengagement
10.6-1 Circuit, hydraulic oil cooling
11.5-1 Circuit, current

Sheet Designation
11.5-6 Circuit, emergency stop switch current
11.5-7 Circuit 24/12V
11.5-8 Circuit 24V socket
11.5-9 Circuit, option, ground power
11.5-10 Circuit, option, ground
11.5-11 Circuit, option, ground
11.6-1 Circuit CAN bus ground
Circuit diagram Yuchai YC6A240-30 and Dana HR32000, drawing

number A59539.0100.
Sheet Designation
1.0_1A1 Circuit Yuchai YC6A240-30
1.0_1A2 Circuit Yuchai YC6A240-30
2.0_1A1 Circuit Dana HR32335
2.0_1A2 Circuit Dana HR32335
Circuit diagram for side lift attachment, drawing number A50400.0100.
Sheet Designation
0.0_1 Cross-reference list
7.4_1 Circuit, side shift
7.5_1 Circuit, spreading
7.5_2 Circuit, spreading buzzer
7.5_3 Circuit, spreading sensors
7.8_1 Circuit, levelling
7.9_1 Circuit, open/lock
7.9_2 Circuit, open/lock sensors
7.9_3A Circuit, indicator lights
7.9_3B Circuit, indicator lights
7.9_4 Circuit, alignment sensors
7.9_5A Circuit, alignment sensors
7.9_5B Circuit, alignment sensors
9.6_1 Circuit, work lights, carriage/attachment
9.14_1 Circuit, central lubrication
11.5_1 Circuit, current
11.5_2 Circuit, current
11.6_1 Circuit, CAN bus

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E Schema – Komponentförteckning / E Schematics – List of Components 1
NUMBER SVENSKA ENGLISH
A 32 Kretskort elcentral Printed circuit board, Junction box
A 685 Reglerenhet termostat AC Control unit, termostat AC
A 779 Reglersystem återladdning (EC) Control system, recharging (EC)
A 782 Logik interface 2 drivmotorer Logic (interface) two main motors (EC)
A 783 Logik interface gaspådrag Logic (interface) throttle
A 784 Logik interface bromsregl Logic (interface) brake control
A 785 Logik interface styrsystem Logic (interface) control system
A 786 Servoförstärkare styrsystem Servo amplifier steering system
A 799 Logik allm (option) Logic, general (option)
A 806 Aggregat klimatanläggning Aggregate, air conditioner
A 810 Kondensor AC, fläkt Condensor AC, fan
A 827 Växellåda Gearbox
A 900 Radio/bandspelare Radio/tape recorder
A 905 Kommunikationsradio Communication radio
A 907 Monitor Monitor
A 908 Kamera Camera
A 909 Skrivare Printer
A 911 Dataterminal Dataterminal
A 912 Alkolås Interlock device
A 940 Logik batterivakt Logic switch , battery watch
A 950 Logik transistortändning Logic transistor ignition
A 955 Logik övervarvningsskydd (LPG) Logic overspeed protection (LPG)
A 960 Logik rev-spärr/aut-vxl Logic unit, reversing interlock/automatic
gear changing
A 961 Motor/kupevärmare Engine- and cab heater
B 649 Termostat klimatannläggning Thermostat, air condition
B 690 Fartreglage (EC) Speed control (EC)
B 697 Elbroms Electric brake
B 751 Givare varvtal turbin Transmitter, speed turbin
B 752 Givare varvtal inre växellåda Transmitter, speed internal gear chain
B 753 Varvtalsgivare motor Transmitter, engine revolution
B 754 Givare lufttryck Transmitter, air pressure
B 755 Givare hydraulfilter indikering Transmitter, hydraulics filter indication
B 756 Temperatur kylvätska motor Transmitter, engine coolant temperature
B 757 Bränslenivågivare Transmitter, fuel level
B 758 Varvtalsgivare v-låda Transmitter, gear box revolution
B 759 Nivåindikator kylvätska Transmitter, coolant level
B 760 Givare rev-spärr/aut-vxl trans Transmitter, reversing interlock / automatic
gear change system (on gearbox output
shaft)
B 761 Givare rev-spärr/aut-vxl motor Transmitter, reversing interlock / automatic
gear changing system (engine speed)
B 762 Givare temp,spolkrets bromsar Transmitter, brake flushing circuit

B 763 Givare nivå hydraulolja Transmitter, hydraulic fluid level
B 764 Givare servotryck växellåda Transmitter, gear box servo pressure
B 765 Givare oljetryck v-låda Transmitter, oil pressure gear box
B 766 Givare oljetemp. v-låda Transmitter, oil temperature gear box
B 767 Givare oljetryck motor Transmitter, oil pressure engine
B 768 Givare oljetryck hydraulik Transmitter, hydraulic pressure
B 769 Givare ändläge Transmitter, end position
B 770 Givare rattutslag Transmitter, steering wheel angle
B 771 Givare vinkel Transmitter, angle
B 772 Givare temp bromsolja Transmitter, temperature brake fluid
Verkstadmanual / Workshop Manual – DCT 80–-90 VDCT01.02SE/GB
B 773 Givare närvaro Transmitter, presence
B 774 Givare utomhustemp Transmitter, ambient temperature
B 775 Givare temp klimatanläggning Transmitter, temperature air condition
B 776 Givare temp hydraulolja Transmitter, hydraulic temperature
B 777 Givare läge Transmitter, position
B 778 Givare drivbrytning Transmitter, drive break
B 789 Givare allmän Transmitter, common
B 902 Högtalare Loud speaker
B 7224 Givare, mätläge våg Sensor, measurepoint scale
B 7225 Givare, rotationsstopp Sensor, rotation stop
B 7226 Givare, tryck lyftcylinder Sensor, pressure lift cylinder
B 7227 Givare, tryck klämma Sensor, pressure clamp
B 7228 Givare lyfthöjd analog Sensor lift height analogue
B 7229 Givare tiltvinkel analog Sensor tilt angle analogue
B 7230 Givare ultraljud last position Sensor, ultrasonic load position
B 7231 Givare, Over Height, Ben uppe Sensor, Over Height, Leg upper position
B 7232 Givare,IR Last position Givare,IR Load position
B 7233 Givare lambda sond Sensor lambda sond
B 7234 Givare vatten i bränsle Transmitter water in fuel
B 7235 Givare temp avgaser Sensor exhaust temperature
B 7236 Givare tryck avgaser Sensor exhaust pressure
C 821 KONDENSATOR CAPACITOR
D 740 FleetManager kontrollenhet FleetManager control unit
D 742 FleetManager kortläsare FleetManager card device
D 743 FleetManager accelerations givare FleetManager acceleration sensor
D 744 Galvaniskt isolerad CAN brygga Galvanic insulated CAN bridge
D 780 Reglersystem drivmotor Control system traction motor
D 781 Reglersystem pumpmotor Control system pump motor
D 790 Elektronisk kontrollenhet ECU, hytt Electronic Control Unit ECU, cab
D 791 Elektronisk kontrollenhet aggregat Electronic Control Unit, attachment
D 792 Elektronisk kontrollenhet styrning Electronic Control Unit, steering system
D 793 Elektronisk kontrollenhet växellåda Electronic Control Unit, gearbox
D 794 Elektronisk kontrollenhet motor Electronic Control Unit, engine
D 796 Elektronisk kontrollenhet, lasthantering Electronic Control Unit, Loadhandling
D 797 Elektronisk kontrollenhet, ram Electronic Control Unit, frame
D 798 Elektronisk kontrollenhet, stolvändning Electronic Control Unit, seat rotation
D 2000 Elektronisk kontrollenhet, proportionalventil Electronic control unit, propotional valve
D 9001 Åkerströms fjärrkontroll Åkerströms Remote Control

E 400 G-lampa vä fram Light bulb, roading light left hand front
E 400 G-lampa hö fram Light bulb, roading light right hand rear
E 401 G-lampa vä bak Light bulb, roading light left hand front
E 401 G-lampa hö bak Light bulb, roading light right hand rear
E 402 G-lampa fjärrljus Light bulb, distance light
E 403 G-lampa lastljus Light bulb, mast light
E 404 G-lampa arbetsljus Light bulb, working light
E 405 G-lampa backljus Light bulb, rear light
E 406 G-lampa cont belysning vänster Container light left-hand
E 406 G-lampa cont belysning höger Container light right-hand
E 408 G-lampa park ljus vä fram Light bulb, parking light, left-hand forward
E 408 G-lampa park ljus hö fram Light bulb, parking light, right-hand forward
E 429 G-lampa cigarettändare belysning Light bulb, cigarett lighter illumination

E 431 G-lampa instrument belysning Light bulb, instrument illumination
E 432 G-lampa handsfack belysning Light bulb, glove pocket light
E 433 G-lampa instegs belysning Light bulb, step-in lighting
E 434 G-lampa innerbelysning Light bulb, interior lighting
E 435 G-lampa låsbelysning Light bulb, reading lighting
E 436 G-lampa identifikationsljus Light bulb, identification light
E 437 G-lampa identifikationsljus/takskylt Light bulb, identification light/roof sign
E 438 G-lampa motorrumsbelysning Light bulb, engine compartment light
E 439 Nummerskyltsbelysning Light license plate
E 440 G-lampa värmereglage belysning Light bulb, heating control light
E 456 G-lampa backljus blackout IR vänster Light bulb, rear light blackout IR left-hand
E 456 G-lampa backljus blackout IR höger Light bulb, rear light blackout IR right-hand
E 458 G-lampa fram blackout vänster Light bulb, roading light blackout left-hand
E 458 G-lampa fram blackout höger Light bulb, roading light blackout right-hand
E 459 G-lampa fram blackout IR vänster Light bulb, roading light blackout IR left-
hand
E 459 G-lampa fram blackout IR höger Light bulb, roading light blackout IR right-
hand
E 460 G-lampa arb.belysning hytt blackout IR vä Light bulb, working light cab blackout IR left
E 460 G-lampa arb.belysning hytt blackout IR hö Light bulb, working light cab blackout IR
right
E 461 G-lampa arb.bel. bom 20' blackout IR vä Light bulb, working light boom20' b.out IR
left
E 461 G-lampa arb.bel. bom 20' blackout IR hö Light bulb, working light boom20' b.out IR
right
E 462 G-lampa arb.bel. bom 40' blackout IR vä Light bulb, working light boom40' b.out IR
left
E 462 G-lampa arb.bel. bom 40' blackout IR hö Light bulb, working light boom40' b.out IR
right
E 464 G-lampa cont belysning IR vänster Light bulb,Container light IR left-hand
E 464 G-lampa cont belysning IR höger Light bulb,Container light IR right-hand
E 669 Värmare kupe/ motor diesel Heater compartment/engine diesel
E 802 Eluppvärmd backspegel Electrical heated observation mirror
E 803 Eluppvärmd stol Electrical heated seat
E 804 Cigarettändare Cigarett lighter
E 805 Elvärme hytt Electrical heating cab
E 808 Eluppvärmd lufttorkare Electrical heater air dryer
E 835 Tändstift Ignition plug
E 888 Lufttork, kompressor Air Dryer, Compressor
E 962 Logik slitageind kol elmotor Logic indication of wear, brush electrical
motor
E 4370 Sökljus Search light
E 8092 Eluppvärmd ruta Electrical heated window
F 51 Säkringshållare 1-polig Fuse holder, 1-pole
F 62 Batterihandske 2-polig Battery connector, 2-pole
F 64 Batterihandske 4-polig Battery connector, 4-pole
G 30 Batteri Battery
G 658 Generator (extra) Alternator extra
G 659 Generator utan laddregulator Alternator without loading regulator
G 660 Generator med laddregulator Alternator with loading regulator
G 662 Laddregulator Loading regulator
H 410 G-lampa broms ljus vä fram Light bulb, brake light, left-hand forward
H 410 G-lampa broms ljus hö fram Light bulb, brake light, right-hand forward
H 411 G-lampa broms ljus vä bak Light bulb, brake light, left-hand rear
H 411 G-lampa broms ljus hö bak Light bulb, brake light, right-hand rear
H 412 G-lampa bak ljus vä bak Light bulb, rear light, left-hand rear
H 412 G-lampa bak ljus hö bak Light bulb, rear light right-hand rear
H 413 G-lampa bak ljus vä fram (VBFS) Light bulb, rear light, left-hand forward
(VBFS)
H 413 G-lampa bak ljus hö fram (VBFS) Light bulb, rear light,right-hand forward
(VBFS)
H 416 G-lampa sidomarkering vä fram Light bulb, side position light, left-hand
forward
H 416 G-lampa sidomarkering vä bak Light bulb, side position light, left-hand rear
H 417 G-lampa sidomarkering hö fram Light bulb, side position light, right -hand
forward
H 417 G-lampa sidomarkering hö bak Light bulb, side position light, right-hand
rear
H 420 G-lampa positionsljus vänster Light bulb, position light, left-hand
H 421 G-lampa positionsljus höger Light bulb, position light, right-hand
H 422 G-lampa körvisare vä fram Light bulb, direction indicator left-hand
forward
H 423 G-lampa körvisare hö fram Light bulb, direction indicator right-hand
forwrd
H 426 G-lampa körvisare vä bak Light bulb, direction indicator left-hand rear
H 427 G-lampa körvisare hö bak Light bulb, direction indicator right-hand

rear
H 428 G-lampa roterande varningsljus Light bulb, flashing beacon lamp
H 445 G-lampa körvisare vä (extra) Light bulb, extra direction indicator left
H 446 G-lampa körvisare hö (extra) Light bulb, extra direction indicator right
H 451 G-lampa dimbakljus vänster Light bulb, fog light rear left
H 452 G-lampa dimbakljus höger Light bulb, fog light rear right
H 453 G-lampa bromsljus/körvisare vänster Light bulb, brake light/dir. indicator left-hand
H 453 G-lampa bromsljus/körvisare höger Light bulb, brake light/dir. indicator right-
hand
H 454 G-lampa bromsljus blackout vänster Light bulb, brake light blackout left-hand
H 454 G-lampa bromsljus blackout höger Light bulb, brake light blackout right-hand
H 457 G-lampa positionsljus blackout vänster Light bulb, position light blackout left-hand
H 457 G-lampa positionsljus blackout höger Light bulb, position light blackout right-hand
H 463 G-lampa bak ljus vänster bak, blackout Light bulb, rear light left-hand rear, blackout
H 463 G-lampa bak ljus höger bak, blackout Light bulb, rear light right-hand rear,
blackout
H 465 G-lampa röd saxagregat ute Light-bulb, red extender exended
H 466 G-lampa orange vertikalhålning på Light bulb, orange vertical hold on
H 467 G-lampa grön klämtryck OK Light bulb, green clamp pressure OK
H 468 G-Lampa Röd Maxlast Light bulb,Red Overload
H 500 Kont lampa körvisare Indicating lamp, direction indicator
H 501 Kont lampa körvisare (extra) Indicating lamp, direction indicator extra
H 503 Varn lampa oljetryck motor Warning lamp, oil pressure engine
H 504 Kont lampa helljus Indicating lamp, main beam
H 505 Varn lampa laddning Warning lamp, loading
H 506 Varn lampa laddning (extra) Warning lamp, loading extra
H 507 Varn lampa färdbroms Warning lamp, brake
H 508 Varn lampa parkerings broms Warning lamp, parking brake
H 509 Varn lampa nivå kylvatten Warning lamp, coolant level
H 510 Kont lampa diff spärr Indicating lamp, diff. interlock
H 512 Varn lampa temp momentförst Warning lamp, temperature converter
H 514 Kont lampa överväxel Indicating lamp, overdrive clutch
H 519 Kont lampa halvljus Indicating lamp, dipped lights
H 524 Kont lampa luftfilter Indicating lamp, air filter
H 525 Kont lampa UNIKAT Indicating lamp, UNIKAT
H 528 Kont lampa förvärmning Indicating lamp, preheating
H 530 Kont lampa framhjuls styrning Indicating lamp, forward wheel steering
H 531 Kont lampa 4-hjuls styrning Indicating lamp, 4-wheel steering
H 532 Kont lampa crab styrning Indicating lamp, crab steering
H 533 Kont lampa hyd.pump Indicating lamp, emergency hyd. pump
H 547 Varn lampa centralvarning Warning lamp, central warning
H 549 Varn lampa oljetryck v-låda Warning lamp, oil pressure gear box
H 550 Varn lampa hyttlåsning Warning lamp, cab lock
H 551 Varn lampa temp v-låda Warning lamp, temperature gear box
H 552 Varn lampa bromstryck Warning lamp, brake pressure
H 554 Varn lampa temp spolkrets bromsar Warning lamp, temp. cooling system
brakes
H 555 Varn lampa temp kylvatten mot Warning lamp, temperature coolant engine
H 556 Varn lampa låsning vändskiva Warning lamp, interlocking of turntable

H 560 Varn lampa temp drivmotor el Warning lamp, temperature, drive motor
H 561 Varn lampa temp pumpmotor el Warning lamp, temperature, pump motor
H 562 Varn lampa öppen twistlock Warning lamp, unlocked twist lock
H 563 Varn lampa låst twistlock Warning lamp, locked twist lock
H 564 Varn lampa anliggning Warning lamp, alignement
H 565 Varn lampa temp motor el Warning lamp ,temperature motor
H 569 Kont lampa elvärme Indicating lamp, electric heater
H 569 Kont lampa elvärme Indicating lamp, electric heater
H 570 Varn lampa överkoppling säkerhetssystem Warning lamp, by-pass safety system
H 571 Kont lampa bränslenivå Indicating lamp, fuel level

H 572 Varningslampa lyfthöjd Warning lamp lifting height
H 573 Kontroll lampa motor information Indicator lamp engine information
H 574 Kontroll lampa stödben nere Indicator lamp support jacks down
H 575 Kontroll lampa stödben ur arb.läge Indicator lamp support jacks out of working
pos
H 576 Kontroll lampa anliggning främre ben Indicator lamp, alignment front legs
H 577 Kontroll lampa anliggning bakre ben Indicator lamp, alignment rear legs
H 578 Kontroll lampa klämläge främre ben Indicator lamp, clamp position front legs
H 579 Kontroll lampa klämläge bakre ben Indicator lamp, clamp position rear legs
H 580 Kontroll lampa främre ben uppe Indicator lamp, front legs upper position
H 581 Kontroll lampa främre ben nere Indicator lamp, front legs lower position
H 582 Varningslampa överlast Warning lamp overload
H 583 Kontroll lampa anliggning ett ben Indicator lamp, alignment one leg
H 584 Kontroll lampa anliggning alla ben Indicator lamp, alignment all legs
H 599 Kont lampa option Indicating lamp, option
H 850 Signalhorn Horn
H 853 Summer Buzzer
H 965 Backvarnare Reversing alarm
H 5000 Kont lampa tryck lyfttång Indicating lamp, pressure lift tong
H 5001 Varn lampa, Over Height ben uppe Warn. Lamp, Over Height leg upper pos
H 9003 Varningssignal aut. rörelse Warning alarm aut. movement
K 300 Relä hel/halvljus Relay, main/dipped beam
K 301 Relä dimljus Relay, fog light
K 302 Relä fjärrljus Relay, distance light
K 303 Relä lastljus Relay, mast light
K 304 Relä arbetsljus Relay, working light
K 305 Relä backljus Relay, reversing light
K 306 Relä helljus Relay, main beam
K 307 Relä halvljus Relay, dipped beam
K 308 Relä bromsljus Relay, brake light
K 309 Relä parkeringsbroms Relay, parking light
K 310 Relä körvisare vä Relay, direction indicator left
K 311 Relä körvisare hö Relay, direction indicator right
K 312 Relä startelement Relay,element preheater
K 313 Relä vändbar förarstol Relay, rotating driver´s seat (VBFS)
K 314 Relä parkeringsbroms Relay, parking brake
K 315 Relä tändningslås Relay, ignition key
K 316 Relä torkare Relay, wiper
K 317 Relä strålkastartorkare Relay, roading lights wiper
K 318 Relä AT-regulator Relay, AT-regulator
K 319 Relä varningsblinkers Relay, hazard blinkers
K 320 Relä elektrisk stopp Relay, electical stop
K 321 Relä intervalltorkare Relay, intermittent wiper
K 322 Relä kylvätskenivå Relay, coolant level
K 323 Relä blinkers Relay, blinkers
K 324 Relä rangespärr Relay, range interlock
K 325 Relä blinkande bromsljus (back) Relay, flashing brake lights (reversing)
K 326 Relä blinkande bromsljus (runt) Relay, flashing hazard brake lights
K 327 Relä växel neutral Relay, gear neutral
K 328 Relä växelskifte Relay, gear shift
K 329 Relä växel hög/låg Relay, high/low gear
K 330 Relä startspärr Relay, start interlock
K 331 Relä drivning fram Relay, forward driving
K 332 Relä drivning bak Relay, reversing driving
K 333 Tidrelä förvärmning Time relay, automatically preheating
K 334 Relä frikoppling/drivbrytning Relay, free wheel/drive disconnection
K 335 Relä växelventil 1:a (diesel, gas) Relay, gear change valve 1-gear
(diesel,LPG)
K 336 Relä växelventil 2:a (diesel, gas) Relay, gear change valve 2-gear
(diesel,LPG)
K 337 Relä drivriktning motor Relay, motor drive direction
K 338 Relä kylfläkt drivmotor Relay, cooling fan drive motor
K 339 Relä kylfläkt elskåp Relay, cooling fan electrical box
K 340 Tidrelä fördröjt tillslag Time relay, start delay
K 341 Tidrelä fördröjt frånslag Time relay, stop delay
K 342 Relä drivning 2/4 hjul Relay, switching 2/4 WD
K 343 Relä dimbakljus Relay, fog light rear
K 344 Relä momentförstärkare Relay, torque amplifier
K 345 Relä låsning vändskiva Relay, interlocking of turntable
K 346 Relä frikoppling stollåsning Relay, releasing of seat interlocking
K 347 Relä stolvändning/ljussignal Relay, multifunction, seat rotation/light
signal
K 348 Relä fläktmotor värmare Relay, fan heating
K 349 Relä fartreglage Relay, speed control
K 350 Relä pumpkontaktor/pumpkontroll Relay, pump contactor/pump control
K 351 Relä hyttlyft upp Relay, cab hoist up
K 352 Relä hyttlyft ner Relay, cab hoist down
K 353 Relä säkerhetsslinga Relay, safety loop
K 354 Relä styrsystem Relay, signal control system
K 355 Relä sensorstyrning Relay, sensor control
K 356 Skiftrelä längskörning/tvärskörning Shift relay, length/sideways driving
K 357 Relä roterande varningsljus Relay, hazard beacon
K 358 Relä komressor luft Relay, compressor air
K 359 Relä Hydrauloljekylare Relay hydraulic oil cooler
K 360 Relä startsolenoid Relay, starting solenoid
K 361 Relä kompressor AC Relay, compressor air conditione
K 362 Relä vattenventil AC Relay, water valve air conditioner
K 363 Relä kondensor AC Relay, condenser air conditione
K 364 Relä stolsbrytare Relay seat switch
K 365 Relä fönsterhiss upp Relay, electrical screen elevator up
K 366 Relä fönsterhiss ner Relay, electrical screen elevator down
K 367 Relä styrning Relay, steerin
K 368 Relä lågt bromstryck Relay, low brake pressure
K 369 Relä centralsmörjning Relay, central lubrication
K 370 Relä centralsmörjning, aggregat Relay, central lubrication, attatchment
K 371 Relä lyfthöjd Relay, liftheight
K 372 Relä blinkande varn.ljus, höjdbegränsn. Relay, flashing beacon, lifting height limiter
K 373 Relä bakljus Relay light

K 375 Huvudkontaktor reglersystem Main contactor, operating control
K 376 Kontaktor fram reglersystem Contactor, forward operating control
K 377 Kontaktor bak reglersystem Contactor, reversing operating control
K 378 Kontaktor by-pass Contactor, ¿by-pass¿ operating control/
reglersystem/Fältförsvagning Field weakening
K 379 Kontaktor pumpmotor Contactor, pump motor
K 380 Kontaktor Contactor
K 381 Kontaktor återladdning Contactor, recharging
K 382 Relä, förbikoppling säkerhetssystem Relay, by-pass safety system
K 383 Relä, Stolsvärme Relay, heated seat
K 384 Relä vattenseparator Relay, waterseparator
K 385 Relä bränslepump insprutning Relay, fuel injection pump
K 386 Relä, hög motortemperatur. Relay, high motor temperature
K 387 Relä alternativ gaspedal Relay alternative throttle pedal
K 388 Relä, Extra färdriktningsväljare Relay, Extra direction selector
K 389 Relä, Pausvärme Relay, Paus heat
K 399 Relä option Relay, option
K 3001 Relä rotation Relay, rotation
K 3002 Relä tilt Relay, tilt
K 3003 Relä sidoföring Relay, side shifting
K 3004 Relä längdinställning Relay, length adjustment
K 3005 Relä twist lock Relay, twist lock
K 3006 Relä spridning Relay, spreading
K 3007 Relä lyft/sänk Relay, lifting/lowering
K 3008 Relä hydraulfunktion extra Relay, extra hydraulic function
K 3009 Relä manöverbrytare hydr Relay, operating switch
K 3010 Relä bromsljus vxl std/blackout Relay, brake light shift std/blackout
K 3011 Relä backljus vxl std/blackout Relay, reversing light shift std/blackout
K 3012 Relä arb.bel hytt vxl std/blackout Relay, working light cab, shift std/blackout
K 3013 Relä arb.bel. bom 20' vxl std/blackout Relay,working light boom20' shift std/b.out
K 3014 Relä arb.bel. bom 40' vxl std/blackout Relay,working light boom40' shift std/b.out
K 3015 Relä vxl bromsljus/blinkers vä Relay, shift brake light/direction indicator
left
K 3015 Relä vxl bromsljus/blinkers hö Relay, shift brake light/direction indicator
right
K 3016 Relä signalhorn relay, horn
K 3017 Relä containerbelysning Relay, Container light
K 3018 Relä containerbelysning IR Relay, Container light IR
K 3305 Relä VBFS, backljus Relay, rotating driver´s seat, reversing light
K 3306 Relä VBFS, helljus Relay, rotating driver´s seat, main beam
K 3307 Relä VBFS, halvljus Relay, rotating driver´s seat, dipped beam
K 3308 Relä VBFS, bromsljus Relay, rotating driver´s seat, brake light
K 3310 Relä VBFS, körvisare vä Relay, rotating driver´s seat, direction
indicator left
K 3311 Relä VBFS, körvisare hö Relay, rotating driver´s seat, direction
indicator right
K 3330 Relä, säkerhetsbälte Relay, seat belt
K 3331 Relä VBFS, drivning fram Relay, rotating driver´s seat, forward driving
K 3332 Relä VBFS, drivning bak Relay, rotating driver´s seat, reversing
driving
K 3349 Relä VBFS, fartreglage Relay, rotating driver´s seat, speed control
K 3404 Relä VBFS, mastljus Relay, rotating driver´s seat, mast light
K 3405 Relä,backalarm Relay,reversealarm
K 3412 Relä bak ljus Relay, rotating driver´s seat, rear light
K 3768 Relä oljetryck hydraulik Relay, hydraulic pressure
K 3769 Relä, blockering av hyttilt Relay, blocking of cab tilt
K 3770 Relä anliggning Relay, alignment
K 3771 Relä Krok Relay, Hook
K 3772 Relä laddsignal (D+) Relay, charge signal (D+)
K 3773 Relä 12V för minne radio Relay 12V for radio memory
K 3774 Relä kylfläkt olja Relay, cooling fan oil
K 3776 Relä värmare ruta Relay heated window
K 93774 Relä hållkrets Relay, Holdcircuit
L 830 Tändspole Ignition coil
M 608 Pumpaggregat hyttlyft Pump unit, cab hoist
M 609 Ställmotor gaspådrag Regulating motor, throttle
M 612 Ställmotor recirkulation Regulating motor, re-circulation
M 650 Torkarmotor fram
M 651 Vindrutespolarmotor Washer motor
M 652 Strålkastarmotor Light motor
M 653 Strålkastarspolarmotor Light washer motor
M 654 Startmotor Starter motor
M 655 Kylfläkt drivmotor (EC) Cooling fan, main motor (EC)
M 656 Kylfläkt elskåp (EC) Cooling fan, electrical box (EC)
M 657 Fläktmotor värme Heating fan
M 661 Fönsterhissmotor Screenelevator motor
M 663 Doseringspump klimatanläggning Dosage pump, air condition
M 664 Cirk pump klimatanläggning Circulating pump, air condition
M 666 Fläktmotor cirkulation Circulation fan
M 667 Cirkulationspump värmesystem Circulation pump heating system
M 668 Kylfläkt hydraulolja Cooling fan, hydraulic oil
M 670 Kompressor Compressor
M 671 Doseringspump diesel Dosage pump diesel
M 672 Spjäll motor, ECC Draught valve motor, ECC
M 674 Kylfläkt bromsolja Cooling fan, brake fluid
M 675 Motor, Stolsvändning Motor, Seat rotation
M 677 Motor Låsning stolsvridning Motor Locking revolving seat
M 693 Pump centralsmörjning Pump, central lubrication
M 694 Styrmotor Steering motor
M 695 Drivmotor (EC) Drive motor (EC)
M 696 Pumpaggregate nödstyrning Pump, emergency steering
M 698 Pumpmotor (EC) Pump motor (EC)
M 9000 Motor höj/sänkbar stolspelare Motor rise/lower seat column
P 700 Hastighetsmätare Speedometer
P 701 Mätare oljetemp v-låda Gear box oil temperature gauge
P 702 Klocka Clock
P 703 Varvtalsmätare Engine rev meter
P 704 Tryckluftsmätare Air pressure gauge
P 705 Mätare oljetryck v-låda Gear box oil pressure gauge
P 706 Termometer temp kylvätska motor Temperature gauge, engine coolant
P 707 Bränslemätare Fuel gauge
P 708 Timräknare Hour meter
P 709 Kapacitetsmätare batteri Capacity gauge, battery
P 710 Tidur motor/kupevärmare Timer, engine- and cab heater
P 711 Räknare, impuls Counter, impulse
P 712 Mätare oljetryck motor Motor oil pressure gauge
P 714 Mätare, temp. Hydraulolja Hydraulic fluidtemperature, guage
P 715 Extra instrument allm Extra instrument, general
P 795 Display Display
Q 144 Batterifrånskiljare Battery disconnecting switch
R 807 Potentiometer Potentiometer
R 820 Motstånd Resistor
R 825 Reglage spakstyrning Controls, (steering with control levers).
R 828 Shuntmotstånd Shunt-resitor
R 8071 Potentiometer lyft/sänk Potentiometer lift/lower
R 8072 Potentiometer tilt Potentiometer tilt
R 8073 Potentiometer sidoföring Potentiometer side shifting
R 8074 Potentiometer spridning Potentiometer spreading
R 8075 Potentiometer extra Potentiometer extra
R 8076 Potentiometer mast in/ut Potentiometer reach in/out
R 8077 Potentiometer höger framhjul Potentiometer right front wheel
R 8078 Potentiometer vänster framhjul Potentiometer left front wheel
R 8079 Potentiometer höger bakhjul Potentiometer right rear wheel
R 8080 Potentiometer vänster bakhjul Potentiometer left rear wheel
R 8081 Potentiometer tiltvinkel Potentiometer tilt angle
R 8082 Potentiometer fläkthastighet, ECC Potentiometer fan speed, ECC
R 8083 Potentiometer temperatur, ECC Potentiometer temperature, ECC
R 8084 Potentiometer spjäll, ECC Potentiometer draught valve, ECC
R 8085 Potentiometer rotation Potentiometer rotation
R 8086 Potentiometer sax Potentiometer extender
R 8087 Potentiometer klämma Potentiometer clamp
R 8088 Potentiometer skevning Potentiometer levelling
R 8089 Potentiometer kroklåsning Potentiometer flaps
S 100 Strömställare ljus Switch, light
S 101 Strömställare omk hel/halvljus Switch, main/dipped beam
S 102 Strömställare dimljus Switch, fog light
S 103 Strömställare fjärrljus Switch, distance light
S 104 Strömställare lastljus Switch, mast lights
S 105 Strömställare arbetsljus Switch, working lights
S 106 Strömställare containerljus Switch, container light
S 107 Strömställare park broms Switch, parking brake
S 108 Strömställare centr smörjning Switch, central lubricator
S 109 Strömställare varningsljus Switch, hazard lights
S 110 Strömställare rot varningsljus Switch, rotating hazard beacon
S 111 Strömställare fönsterhiss Switch, window regulator
S 112 Strömställare kylanläggning (AC) Switch, air conditioner (AC)
S 113 Strömställare styrning alt Switch, alternative steering
S 114 Strömställare läsbelysning Switch, reading light
S 115 Strömställare instr belysning Switch, instrument illumination
S 116 Strömställare innerbelysning Switch, interior lighting
S 117 Strömställare värme Switch, heating
S 118 Strömställare fläktm värme Switch, heater fan
S 119 Strömställare vindrutetorkare Switch, wiper
S 120 Strömställare spolare Switch, washer
S 121 Strömställare blackout Switch, blackout
S 122 Strömställare nöd hydraulpump Switch, emergency hydraulic pump
S 123 Strömställare backspegel Switch, observation mirror
S 124 Strömställare kallstart Switch, cold start
S 125 Strömställare avgasbroms Switch, exhaust brake
S 126 Strömställare diff spärr/broms Switch, diff. Block
S 127 Strömställare värmesystem diesel Switch, heating system diesel
S 128 Strömställare kraftuttag sida Switch, power take off side
S 129 Strömställare kraftuttag bak Switch, power take off rear
S 130 Strömställare hög/lågväxel Switch, high/low gear
S 131 Strömställare färdväljare fram Switch, gear selector forward
S 132 Strömställare färdväljare bak Switch, gear selector rear
S 135 Strömställare växelväljare Switch, gear shift
S 136 Strömställare framhjuls styrning Switch, forward wheel steering
S 137 Strömställare 4-hjuls styrning Switch, 4-wheel steering
S 138 Strömställare crab styrning Switch, crab steering
S 139 Strömställare defroster Switch, defroster
S 141 Strömställare Stegbelysning Switch, Steplight
S 142 Strömställare fot Switch, foot
S 143 Strömställare sitsvärme Switch, seat heater
S 145 Strömställare AT-regulator Switch, AT-regulator
S 147 Strömställare körvisare Switch, direction indicators
S 149 Strömställare signalhorn Switch, horn
S 150 Strömställare startlås/ellas Switch, main key switch
S 152 Strömställare intervalltorkare Switch, intermittent wiper
S 156 Strömställare kupevärmare Switch, cab heating
S 157 Strömställare stoltilt Switch, seat tilt
S 158 Strömställare dimbakljus Switch, rear fog light
S 159 Strömställare extra fram/back väljare Switch, extra direction selector
S 160 Strömställare komb fram/back Switch, combi-forward/reverse
S 161 Strömställare komb signal, ljus hel/halv Switch, combi-horn, light main/dipped
spol,torkare m intervall körvisare beam, washer, wiper (intermittent), direction
indicator
S 162 Strömställare komb signal ljus hel/halv, Switch, combi horn, light main/dipped
spol, torkare m 2 int, fram/bacK beam, washer, wiper w 2int., forward/revers
S 163 Strömställare start på 2-an Switch, start 2nd gear

S 165 Strömställare stolvärme Switch, seat heater
S 166 Strömställare låsning vändskiva Switch, interlocking of turntable
S 167 Strömställare luftfjädring Switch, pneumatic springing
S 168 Strömställare låsn stol Switch, interlocking of seat
S 169 Strömställare stolsvändning Switch, reversible seat
S 170 Strömställare förångare (LPG) Switch, evaporator (LPG)
S 171 Strömställare v-skiva upp/ner Switch, fifth wheel up/down
S 172 Strömställare v-skiva fr/back Switch, fifth wheel forward/reverse
S 173 Strömställare v-skiva skevning Switch, fifth wheel, levelling
S 174 Strömställare,utskjut Switch, projecting
S 175 Strömställare hyttlyft upp Switch, cab hoist up
S 176 Strömställare hyttlyft ner Switch, cab hoist down
S 177 Strömställare hyttskjutning Switch, cab movement
S 178 Strömställare nollställning Switch, reset
S 179 Strömställare Aut/man växling Switch Aut/man gearshifting
S 180 Strömställare fyrhjulsdrift Switch, 4-WD
S 190 Strömställare klimatanläggning Switch, air conditioner
S 191 Strömställare recirkulation Switch, re-circulation
S 192 Strömställare vattenavskiljare
S 195 Strömställare joy-stick X Switch, joy-stick X
S 196 Strömställare joy-stick X+Y Switch, joy-stick X+Y
S 197 Strömställare längs/tvärskörning Switch, length/sideways driwing
S 198 Strömställare flytläge skevning Switch, equalizing fifth wheel
S 199 Strömställare option Switch, option
S 200 Brytkontakt lampa park broms Contact, breaking,warning lamp,parking
brake
S 201 Brytkontakt lampa färdbroms Contact, breaking, warning lamp, brake
S 202 Brytkontakt lampa oljetryck motor Contact, breaking, warning lamp, oil
pressure engine
S 204 Brytkontakt tryck ackumulator Contact, breaking, pressure
accumulatortank
S 205 Brytkontakt innerbelysning Contact, breaking, interior lighting
S 206 Brytkontakt handskfack belysning Contact, breaking, glove
S 207 Slutkontakt diff spärr Contact, making, diff. interlock
S 208 Slutkontakt lampa temperatur spolkrets Contact, making, warning lamp temperature
bromsar brake
S 214 Slutkontakt överväxel Contact, making, over drive
S 215 Slutkontakt temp motor Contact, making, temperature engine
S 216 Slutkontakt bromsljus Contact, making, brake lights
S 217 Slutkontakt backljus Contact, making, reversing light
S 218 Slutkontakt AT-regulator Contact, making, AT-control
S 219 Slutkontakt lampa luftfilter Contact, making, indicating light air filter
S 220 Brytkontakt drivning Contact, breaking, drive cut off
S 221 Slutkontakt temp växellåda Contact, making, temperature gear box
S 222 Slutkontakt lampa temp moment - Contact, making, warning lamp temperature
förstärkare torque amplifier.
S 223 Släpkontakt signal Contact, brush, horn
S 224 Slutkontakt insprutningspump Contact, making, injection pump
S 225 Brytkontakt säkerhetsbälte Contact, breaking, seat belt
S 228 Slutkontakt hyttlåsning Contact, making, cab locking
S 229 Slutkontakt stolslåsning Contact, making, seat locking
S 230 Brytkontakt stol Contact, breaking, seat
S 231 Slutkontakt fotkontroll stolvändning Contact, making, seat rotation, foot switch
S 232 Brytkontakt lampa luftanslutning släp Contact, breaking, warning lamp air
connection
S 233 Slutkontakt lampa låsning vändskiva Contact, warning, interlocking of turntable
S 235 Slutkontakt sidoskjutning stol Contact, making, side shifting of seat
S 236 Slutkontakt vattennivå Contact, water level
S 239 Brytkontakt termisk Contact, breaking, thermic
S 240 Slutkontakt termisk Contact, making, thermic
S 241 Brytkontakt lampa luftmatning släp Contact, breaking, warning lamp air supply
to trailer
S 242 Slutkontakt lampa oljetryck v-låda Contact, making, warning lamp, oil
pressure gear box
S 243 Brytkontakt tryck kylmedia AC Contact, breaking, coolant pressure (air
condition)
S 244 Slutkontakt hydraulik aktiverad Contact, making, hydraulics
S 245 Slutkontakt hydraultryck styrning Contact, making, hydraulic pressure control
S 246 Slutkontakt tryck kylmedia Contact, pressure refrigerant

S 250 Manöverbrytare Operating Switch
S 251 Slutkontakt vändbar förarstol Contact, making, VBFS
S 260 Slutkontakt lyft steg 1 Contact, making, hoist step 1
S 261 Slutkontakt lyft steg 2 Contact, making, hoist step 2
S 262 Slutkontakt tilt Contact, making, tilting
S 263 Slutkontakt gaffelspridning Contact, making, fork positioning
S 264 Slutkontakt sidoföring Contact, making, sideshift
S 265 Slutkontakt stativ in/ut Contact, making, lifting mast in-out
S 266 Brytkontakt hyttdörr Contact, breaking cab door
S 267 Slutkontakt bromstryck Contact, making, brake pressure
S 268 Slutkontakt kompressor Contact, making, Compressor
S 269 Slutkontakt sax inne Contact, making extender in
S 270 Slutkontakt överlastskydd Contact, making, overload protection
S 271 Slutkontakt, filter växellåda Contact, making, filter gearbox
S 299 Slut/brytkontakt option Contact, making/braking option
S 720 Givare vändbar förarstol Transmitter, revolving driver´s seat (VBFS)
S 800 Startelement Start element

S 815 Manöverspak Control lever
S 840 Strömfördelare Distributor
S 1001 Strömställare, TW Switch, TW
S 1002 Strömställare, lossa TW Switch, unlocking of TW
S 1003 Strömställare, låsa TW Switch, locking of TW
S 1004 Strömställare, stopp vid 30'-35' Switch, stop at 30 -35¿
S 1005 Strömställare, förbikoppling av Switch, overriding of the safety system
säkerhetssystem
S 1006 Strömställare, fällning främre ben Switch, front legs down
S 1007 Strömställare, fällning bakre ben Switch, rear legs down
S 1008 Strömställare, klämma/lossa ben Switch, clamping/-releasing legs
S 1009 Strömställare, Motor information Switch, Engine information
S 1010 Srömställare, tilt av hytt Switch, tilt of cab
S 1011 Strömställare IR ljus Switch IR light
S 1012 Strömställare utskjut 20¿-40¿ Switch, Extension 20¿-40¿
S 1013 Strömställare stödben Switch, Support jacks
S 1014 Strömställare förbikoppling rotationstopp Switch, over ride rotation stop
S 1015 Strömställare förbikoppling höjdbeg/tp-beg Switch, over ride height limit/tp-limit
S 1017 Strömställare diagnostik öka/minska Switch, diagnostics increase/decrease
S 1018 Strömställare diagnostik on/off Switch, diagnostics on/off
S 1019 Strömställare rastvärme Switch, paus heat
S 1020 Strömställare automatisk släpp/kläm Switch automatic release/clamp funktion
funktion
S 1021 Strömställare sax Switch extender
S 1022 Strömställare vertikalhållning Switch, vertical position
S 1023 Strömställare låsning övre arm Switch, lock upper arm
S 1024 Strömställare Korta Armen av/på Switch, Short Arm on/off
S 1025 Strömställare pappersfunktioner av/på Switch, paper funktions on/off
S 1026 Strömställare omkoppling Switch, switch papper/bale clamp
pappers/klämmagregat
S 1027 Strömställare lyfthöjdsförval Switch, lift height selection
S 1028 Strömställare lyfthöjdsförval öka Switch, lift height selection increase
S 1029 Strömställare lyfthöjdsförval minska Switch, lift height selection decrease
S 1030 Strömställare läraringång givare ultraljud Switch, teaching ultrasonic sensor
S 1031 Strömställare, Over Height Upp/Ned Switch, Over Height Up/Down
S 1032 Brytare backljus Switch reverse light.
S 1033 Flytta korta armen Move short arm
S 1034 Strömställare förbikoppling startspärr Switch Override Start interlock
S 1035 Strömställare Val av klämtryck Switch, Clamp pressure selection
S 1036 Strömställare Korta Armen av/på Switch , Short Arm on/off
S 1037 Strömställare låsning skevning Switch, lock levelling
S 1038 Strömställare Övre armpar/Sidoföring Switch Upper arms/Sideshift
S 1039 Strömställare Inching Switch, Inching
S 1040 Switch stopp motor Switch, Stop engine
S 1041 Strömställare motorrumsbelysning Switch, light engine compartment
S 1042 Strömställare höjdjustering stol Switch, Seat height level
S 1043 Strömställare längdjustering stol Switch, Seat for/aft adjustment
S 1044 Strömställare Tankväljare Switch, Tankselector
S 1045 Strömställare Avstängning backalarm Switch, Rev. Alarm on/off
S 1046 Strömställare eluppvärmd ruta Switch electrical heated shield
S 1047 Henrik testar en brytare!
S 1048 Strömställare fjärrstyrning Switch remote control
S 1049 Strömställare styrning spegel Switch mirror control
S 1440 Huvudströmbrytare
S 7200 Givare, axeltryck höger Sensor, axle pressure right
S 7201 Givare, axeltryck vänster Sensor, axle pressure left
S 7202 Givare, anliggning vänster fram Sensor, alignment left front
S 7202 Givare, anliggning höger fram Sensor, alignment right front
S 7203 Givare, anliggning vänster bak Sensor, alignment left rear
S 7203 Givare, anliggning höger bak Sensor, alignment right rear
S 7204 Givare, öppen vänster twistlock Sensor, unlocked twistlock left
S 7204 Givare, öppen höger twistlock Sensor, unlocked twistlock right
S 7205 Givare, låst vänster twistlock Sensor, locked twistlock left
S 7205 Givare, låst höger twistlock Sensor, locked twistlock right
S 7206 Givare, gaffel aggregat Sensor, fork attachment
S 7207 Givare, 2WD/4WD Sensor, 2WD/4WD
S 7208 Givare, hytt i körläge Sensor, Cab in drive position
S 7209 Givare, oljefilter indikering Sensor, Oil filter indication
S 7210 Givare, hytt i transportläge Sensor, Cab in transportation position
S 7211 Givare, lyfthöjd Sensor, lifting height
S 7212 Givare, körläge Sensor, driving position
S 7213 Givare, Anliggning främre ben Sensor, Alignment front legs
S 7214 Givare, Anliggning bakre ben Sensor, Alignment rear legs
S 7215 Givare, kläm främre ben Sensor, Clamp front legs
S 7216 Givare, kläm bakre ben Sensor, Clamp rear legs
S 7217 Givare, främnre knä Sensor, front knee
S 7218 Givare, bakre knä Sensor, rear knee
S 7219 Givare, främre ben Sensor, front legs
S 7220 Givare, bakre ben Sensor, rear legs
S 7221 Givare, styraxel Sensor, steering axle
S 7222 Givare, stödben uppe Sensor, brace up
S 7223 Givare, stödben nere Sensor, brace down
U 741 FleetManager batterifilter FleetManager battery filter
U 823 Signalomvandlare höger Signal amplifier, right
U 824 Signalomvandlare vänster Signal amplifier, left
U 901 Spänningsomvandlare Voltage converter
U 910 Spänningsomvandlare 80V/24V Voltage converter 80 V / 24 V
U 941 Laddningsutjämnare Even charger
V 665 Diod Diode
V 8090 Laser, pappersaggretgat Lase, Pulp an Paper
W 903 Antenn radio Aerial, radio
W 906 Antenn kommunikationsradio Aerial, communication radio
W 8093 Genomföring, kablage Lead-through, harness
X 37 Terminal stomanslutning Earthing terminal on chassis
X 39 Terminal minusanslutning Terminal, negative terminal
X 72 Stickuttag 2-polig Outlet, 2-pole
X 77 Stickuttag 7-polig Outlet, 7-pole
X 78 Stickuttag extra 7-polig Outlet, extra, 7-pole
Y 600 M-ventil avgasbroms Solenoid valve, exhaust brake
Y 601 M-ventil diff spärr Solenoid valve, diff. interlock
Y 602 M-ventil broms Solenoid valve, brake
Y 603 M-ventil värme Solenoid valve, heater
Y 604 M-ventil kraftuttag sida Solenoid valve, power take off, side
Y 605 M-ventil kraftuttag bak Solenoid valve, power take off, rear
Y 606 M-ventil 2/4 hjulsdrift Solenoid valve, 2/4WD
Y 607 M-ventil hög/låg växel Solenoid valve, high/low gear
Y 610 M-ventil hydraulsystem allm Solenoid valve, hydraulics, general
Y 611 M-ventil flödesbegränsning Solenoid valve, flow restriction
Y 613 M-ventil momentförstärkare Solenoid valve, torque amplifier
Y 614 M-ventil rangespärr Solenoid valve, ranging interlock
Y 615 M-ventil hjulvridning Solenoid valve, wheel turning
Y 616 M-ventil kallstart Solenoid valve, cold start aid
Y 617 M-ventil AT-regulator by-pass Solenoid valve, AT-regulator ¿by-pass¿
Y 618 M-ventil vatten klimatanläggning Solenoid valve, water air conditioner
Y 620 M-ventil vändskiva upp Solenoid valve, fifth wheel up
Y 621 M-ventil vändskiva ner Solenoid valve, fifth wheel down
Y 622 M-ventil vändskiva fram Solenoid valve, fifth wheel forward
Y 623 M-ventil vändskiva bak Solenoid valve, fifth wheel rear
Y 624 M-ventil skevning hö Solenoid valve, levelling right hand
Y 625 M-ventil skevning vä Solenoid valve, levelling left hand
Y 626 M-ventil AT-regulator Solenoid valve, AT-regulator
Y 627 M-ventil vakuum Solenoid valve vacuum
Y 628 M-ventil bränsleblandning Solenoid valve fuelmixture
Y 630 M-ventil v-låda fram Solenoid valve, gear box, forward gear
Y 631 M-ventil v-låda back Solenoid valve, gear box, rear gear
Y 632 M-ventil v-låda spole 1 Solenoid valve, gear box, 1 gear
Y 635 M-ventil klämtryck Solenoid valve, clamping pressure
Y 636 M-ventil styrning Solenoid valve, steering
Y 637 M-ventil flytläge skevning Solenoid valve, equalizing fifth wheel
Y 638 M-ventil stopp insprut pump Solenoid valve, stop injection pump
Y 639 M-ventil låsning orbitrol ls Solenoid valve, locking LS orbitrol
Y 640 M-ventil gasol Solenoid valve, LPG
Y 641 M-ventil förångare (LPG) Solenoid valve, evaporator (LPG)
Y 642 M-ventil park broms Solenoid valve, parking brake
Y 643 M-ventil låsning stol (VBFS) Solenoid valve, seat locking (VBFS)
Y 644 M-ventil låsning vändskiva Solenoid valve, fifth wheel locking
Y 645 Magnetkoppling komp AC Magnetic clutch, compressor AC
Y 646 M-ventil stolsvändning Solenoid valve, seat rotation
Y 647 M-ventil stolstilt Solenoid valve, seat tilt
Y 648 M-ventil luftfjädring Solenoid valve, pneumatic springing
Y 673 Vatten ventil motor, ECC Water valve motor, ECC
Y 676 M-ventil Broms stolsvändning Solenoid valve Brake seat turning
Y 699 M-ventil option Solenoid valve, option
Y 826 Ventil spakstyrning Valve, (steering with control levers).
Y 6001 M-ventil blockering höger Solenoid valve, blocking right
Y 6002 M-ventil blockering vänster Solenoid valve, blocking left
Y 6003 M-ventil inkoppling av hydraulik till topplyft Solenoid valve, activation of toplift
hydraulics
Y 6004 M-ventil sänk Solenoid valve, lower
Y 6005 M-ventil lyft Solenoid valve, lift
Y 6006 M-ventil bom ut Solenoid valve, boom out
Y 6007 M-ventil bom in Solenoid valve, boom in
Y 6008 M-ventil vridning medsols Solenoid valve, rotation clockwise
Y 6009 M-ventil vridning motsols Solenoid valve, rotation counter-clockwise
Y 6010 M-ventil tilt ut Solenoid valve, tilt out
Y 6011 M-ventil tilt in Solenoid valve, tilt in
Y 6012 M-ventil tilt Solenoid valve, tilt
Y 6013 M-ventil fällning främre ben Solenoid valve, lowering front legs
Y 6014 M-ventil fällning bakre ben Solenoid valve, lowering rear legs
Y 6015 M-ventil klämma/lossa ben Solenoid valve, clamping/releasing legs
Y 6016 M-ventil Hyttskjutning fram Solenoid valve, cab movement forward
Y 6017 M-ventil Hyttskjutning bak Solenoid valve, cab movement reverse
Y 6018 M-ventil spridning ut Solenoid valve, spreading out
Y 6019 M-ventil spridning in Solenoid valve, spreading in
Y 6020 M-ventil sidoföring vänster Solenoid valve, side shift left
Y 6021 M-ventil sidoföring höger Solenoid valve, side shift right
Y 6022 M-ventil extra hydraulfunktion ut Solenoid valve, extra hydraulic function out
Y 6023 M-ventil extra hydraulfunktion in Solenoid valve, extra hydraulic function in

Y 6024 M-ventil stativ ut Solenoid valve, mast out
Y 6025 M-ventil stativ in Solenoid valve, mast in
Y 6026 M-ventil höger framhjul styrning vänster Solenoid valve, right front wheel, steering
left
Y 6027 M-ventil höger framhjul styrning höger Solenoid valve, right front wheel, steering
right
Y 6028 M-ventil vänster framhjul styrning vänster Solenoid valve, left front wheel, steering left
Y 6029 M-ventil vänster framhjul styrning höger Solenoid valve, left front wheel, steering
right
Y 6030 M-ventil höger bakhjul styrning vänster Solenoid valve, right rear wheel, steering
left
Y 6031 M-ventil höger bakhjul styrning höger Solenoid valve, right rear wheel, steering
right
Y 6032 M-ventil vänster bakhjul styrning vänster Solenoid valve, left rear wheel, steering left
Y 6033 M-ventil vänster bakhjul styrning höger Solenoid valve, left rear wheel, steering
right
Y 6034 M-ventil skevning Solenoid valve, levelling
Y 6035 M-ventil skevning höger Solenoid valve, levelling right
Y 6036 M-ventil skevning vänster Solenoid valve, levelling left
Y 6037 M-ventil kylfläkt Solenoid valve, Cooling fan
Y 6038 M-ventil frikoppling koppling Solenoid valve, lockup clutch
Y 6039 M-ventil öppna twistlock Solenoid valve, unlocked twist lock
Y 6040 M-ventil låsa twistlock Solenoid valve, locked twist lock
Y 6041 M-ventil nöd, twistlock Solenoid valve, emergency, twistlock
Y 6042 M-ventil mellan bom Solenoid valve, middle boom
Y 6043 Magnetventil, fällning torn (RTCH) Solenoid valve, boom lowering (RTCH)
Y 6044 M-ventil blockering twistlock Solenoid valve, blocking twistlock
Y 6045 M-ventil blockering lyft Solenoid valve, blocking lift
Y 6046 M-ventil utskjut Solenoid valve, projecting
Y 6047 M-ventil, hyttilt upp Solenoid valve, cab tilt up
Y 6048 M-ventil, hyttilt ner Solenoid valve, cab tilt down
Y 6049 M-ventil, kylkrets broms Solenoid valve, cooling cicuit brake
Y 6050 M-ventil blockering utskjut Solenoid valve, blocking projecting
Y 6051 M-ventil, regenerering höger Solenoid valve, regeneration right
Y 6052 M-ventil, regenerering vänster Solenoid valve, regeneration left
Y 6053 M-ventil, körläge Solenoid valve, driving position
Y 6054 M-ventil, klämma ihop Solenoid valve, clambing in
Y 6055 M-ventil, klämma isär Solenoid valve, clambing out
Y 6056 M-ventil, främre knä ut Solenoid valve, front knee out
Y 6057 M-ventil, främre knä in Solenoid valve, front knee in
Y 6058 M-ventil, bakre knä ut Solenoid valve, rear knee out
Y 6059 M-ventil, bakre knä in Solenoid valve, rear knee in
Y 6060 M-ventil, främre ben upp Solenoid valve, front legs up
Y 6061 M-ventil, bakre ben upp Solenoid valve, rear legs up
Y 6062 M-ventil, urkoppling hydraulpump Solenoid valve interruption hydraulic pump
Y 6063 M-ventil, stödben upp Solenoid valve, brace up
Y 6064 M-ventil, stödben ner Solenoid valve, brace down
Y 6065 M-ventil, frikoppling vridbroms Solenoid valve, lockup rotation brake
Y 6066 M-ventil, v-låda, drivning Solenoid valve, gearbox, drive
Y 6067 M-ventil, v-låda, oljetryck till 1:a/3:e växeln Solenoid valve, gearbox,oilpressure to
1st/3rd gear
Y 6068 M-ventil sax/rotation Solenoid valve externder/rotation
Y 6069 M-ventil, v-låda, oljetryck till 2:a/4:e växeln Solenoid valve, gearbox,oilpressure to
2nd/4th gear
Y 6070 M-ventil Over Height upp Solenoid valve, Over Height up
Y 6071 M-ventil Over Height ner Solenoid valve, Over Height down
Y 6072 M-ventil klämtryck Solenoid valve clamp pressure
Y 6073 Propertional ventil, Opti speed Proportional valve, Opti speed
Y 6074 M-ventil, v-låda, växelväljare för 2:a/4:e Solenoid valve, gearbox, gearswitch for
växeln 2nd/4th gear
Y 6075 M-ventil, v-låda, växelväljare för 1:a/3:e Solenoid valve, gearbox, gearswitch for
växeln 1st/3rd gear
Y 6076 M-ventil blockering sänk Solenoid valve, blocking lower
Y 6077 M-ventil Inching Solenoid valve, Inching
Y 6078 M-ventil,Avstängning Övre klämarm Solenoid valve, upper arm off
Y 6079 M-Ventil, Sidoföring/Övre armar Solenoid valve, Sideshift/Upper arms
Y 6080 M-ventil, aktivering hyttkörning Solenoid valve, activate sliding cab
Y 6081 M-ventil, ackumulatorladdning Solenoid valve, accumulator charge
Y 6082 M-ventil tryckbegränsning Solenoid valve, pressure restriction
Z 822 Signalfilter Signal filter


F:1
F Technical data
Contents F Technical data

Technical data.................................................................................................... F:3
Data .................................................................................................................F:3
Volumes ...........................................................................................................F:4
Specification for lifting capacity and dimensions..............................................F:6
Oils and lubricants, recommendation...............................................................F:8
Tightening torques, recommendations...........................................................F:10
Tightening torque, connections for air conditioning .......................................F:11
Tightening torque, ORFS connections ...........................................................F:12
Unit explanations ...........................................................................................F:13
Conversion SI-units........................................................................................F:14
Conversion table length .................................................................................F:15
Conversion table area....................................................................................F:15
Conversion table volume ...............................................................................F:15
Conversion table weight.................................................................................F:15
Conversion table pressure .............................................................................F:16

F:2

F Technical data – Technical data F:3
F Technical data
Data
The machine's weights and dimensions vary depending on how the
machine is equipped. Detailed information regarding this is given in the
product specification and data sheet for the machine in question.
1. Engine Yuchai YC6A240-30

Cummins QSB6.7
Power acc. to ISO 3046 (net power) 164 kW at 2200 rpm 164 kW at 2200 rpm
Torque ISO 3046 800 Nm at 1500 rpm 949 Nm at 1500 rpm
Max. rotation speed 2200 rpm 2200 rpm
Number of cylinders 6 cylinders 6 cylinders
Alternator, output 2640 W 2240 W
System voltage, voltage-capacity 24 V (2x12 V / 135 Ah)
2. Transmission Dana HR32000

No. of gears, forward - reverse 3 – 3
3. Power transmission
Drive axle, type Kessler D81
Kessler D91
4. Brakes
Service brake system – actuated wheel Wet Disc Brake - drive wheel
Parking brake system – actuated wheel Spring brake - drive wheel
5. Steering
Steering system Hydraulic servo
6. Wheels
Dimensions, front and rear 12.00x24
14.00x24
Tyre pressure, also see pressure plate 1.0 MPa
Tyre type, front and rear Inflated. Spare and replacement tyres must be from a manu-
facturer approved by Cargotec.
9. Cab Spirit Delta
Equivalent sound pressure level Yuchai YC6A240-30

in cab according to EN12053 with Cummins QSB6.7
LpAZ 67 dB(A)
measurement uncertainty σR=2.5 dB. LpAZ 65 dB(A)
Measurement value with standard
engine.
Whole-body vibrations according 0.4 - 0.7 m/s2
to EN13059 with measurement
uncertainty k=0.3 x measured value.

F:4 F Technical data – Technical data
9.6 Frame, body, cab and accessories, lighting system

Lamp Output (W) Socket
Check lamps 1.2 W2x4.6d
Interior lighting 10 S8.5
Tail lights 5 BA15s
Brake light 21 BA15s
Direction indicators 21 BA15s
Position lamps 5 W2.1x9.5d
Headlights (high and low beams) 75/70 P43t-38 (H4)
Back-up lights 70 PK22s (H3)
Work lights 70 PK22s (H3)
35 D1S Xenon tubes. Cartridge and
Work lights, Xenon ballast replaced complete.
Revolving beacon 70 PK22s (H3)
Volumes
Any deviation from this table must be approved in writing by Cargotec.
1.2 Engine, fuel system Yuchai YC6A240-30

Cummins QSB6.7
Fuel tank, volume 380 l
Fuel quality Diesel according to:
EN590,
ASTM D 975 No 1-D,
ASTM D 975 No 2-D.
1.7 Engine, cooling system
Coolant volume 32 l 29 l
Coolant, filling point Volvo Penta Coolant VCS, ES Compleat, Premix
ready-mixed.
See Oils and lubricants, recommendation, page F:8.
CAUTION
Risk of engine damage and damage to the cooling system if
different types of coolant are mixed.
When changing and topping up coolant, the same type of
coolant must be used as was used before.
1.8 Engine, lubrication system

Oil type, quality See Oils and lubricants, recommendation, page F:8.
Oil volume, incl. filter 24 l 20 l
2.6 Transmission, lubrication HR32000

system
Oil type See Oils and lubricants, recommendation, page F:8.
Oil volume 32 l

3.3 Power transmission, drive axle Kessler D81 Kessler D91

Oil grade See Oils and lubricants, recommendation, page F:8.
Oil volume, differential 42 l 54 l
Oil volume, hub reduction 2x4 l 2x4 l
7 Load handling

Refrigerant, air conditioning R134a
Refrigerant volume See air conditioning plate
Lubricant, air conditioning ZEXEL PAG oil ZXL100
Washer fluid, volume 5 l
Hydraulic oil tank, volume 320 l
Hydraulic oil system, volume 450 l

Specification for lifting capacity and

dimensions
β α
A2
100 100
H4
H5
B S
H3
R1
R2
H6
H8
H10
100
014020
100
L3 L2 A1
L
DCT80 DCT90
E5 E6 E7 E8 E5 E6 E7 E8
Lifting capacity
Classed [kg x 103] 8 9
Centre of gravity distance (L4 [mm]) 1220 1220
Number of containers, 8'6” container 5 6 7 8 5 6 7 8
Number of containers, 9'6” container 5 5 6 7 5 5 6 7
Dimensions
Truck length (L [mm]) 6900 6900
Truck width (B [mm]) 4050 4100
Height, base machine Spirit Delta (H6 [mm]) 3940 4000
Seat height (H8 [mm]) 2800 2860
Spacing drive axle - attachment front section 1185 1185
(L2 [mm])
Wheelbase (L3 [mm]) 4550 4550
Track (front - rear) (S [mm]) 3270 – 2250 3270 – 2200
Slewing radius, outer (R1 [mm]) 6750 7000
Slewing radius, inner (R2 [mm]) 1150 1500

DCT80 DCT90
E5 E6 E7 E8 E5 E6 E7 E8
Ground clearance, min. [mm] 250 300
Minimum aisle width for 90° stacking, 20' 10600 10850
container (A1 [mm])
Minimum aisle width for 90° stacking, 40' 14200 14350
container (A2 [mm])
Standard Duplex mast
Lifting height (H4 [mm]) 15220 16220 18720 21220 15280 16280 18780 21280
Mast height, min. (H3 [mm]) 8540 9040 10290 11540 8600 9100 10350 11600
Mast height, max. (H5 [mm]) 15040 16040 18540 21040 15100 16100 18600 21100
Mast tilting, forward - backward (α - ß [mm]) 3 – 3 3 – 3
Attachment
Height under twistlock (H10 [mm]) 2220 2280
Height under lifting hooks (H10 [mm]) - -
Side shift ± (V1 [mm]) 600 600
Weight
Service weight [kg x 103] 35.5 36.1 37.6 39.1 36.4 37.0 38.5 40.0
Axle pressure front, (without load) [kg x 103] 22.7 23.3 24.8 26.3 22.9 23.5 25.0 26.5
Axle pressure front, (with classified load) [kg x 34.9 35.5 37.0 38.5 36.7 37.3 38.8 40.3
103]
Axle weight rear, (without load) [kg] 12800 13500
Axle weight rear, (with classed load) [kg] 8600 8700

Oils and lubricants, recommendation

The service intervals specified by Cargotec in the maintenance manual
only apply if oils are selected in accordance with the table below. The
table indicates recommended viscosity for different oil types, and
grades, depending on the outdoor temperature.
Any deviation from this table must be approved in writing by Cargotec,

and may mean changed service intervals.
Oil type, quality ºC -20 -10 0 +10 +20 +30 +40

ºF -4 +14 +32 +50 +68 +86 +104
1.8 Engine, lubrication system
Yuchai YC6A240-30 SAE 15W-40 (motor oil)
API CH-4 or ACEA E5 SAE 15W-30 (motor oil)
SAE 10W-30 (motor oil)

Cummins QSB6.7
API CH-4 or ACEA E5 SAE 5W-30 (motor oil)
2.6 Transmission, lubrication system

GM Allison C-4 SAE 50
John Deere J20 C, D SAE 40
Caterpillar TO-4 SAE 30
MIL-PRF-2104G
SAE 20
NOTE SAE 10W
Engine oil or GL-5 oil must not be used. SAE 0W-20
3.3 Power transmission, drive axle

API GL-5 SAE 80W-140
SAE 75W-90
DIN 51524 Part 3 HVLP ISO VG 68
ISO VG 46 HV
ISO VG 32
NOTE
Oil filters shall always be changed in connection with oil change.
Change interval for engine oil requires that the sulphur content in
the fuel does not exceed 0.5%.
*) The oil in the brake system must meet one of the quality requirements
as well as be a UTTO oil (Universal Tractor Transmission Oil).
ACEA = Association des Constructeurs Européenne d'Automobiles
API = American Petroleum Institute

Lubricating grease
Use a universal grease type EP according to NLGI Grade 2 (EP2) for

all lubrication points except hoisting equipment and slide plates.
For hoisting equipment use a universal grease type EP according to

NLGI Grade 2 (EP2) with 3-5% molybdenum sulphide content.
For slide plates use a lubricant approved by Cargotec. Order from

Cargotec Spare Parts Department. 0.65 kg cartridge for grease gun,
part no. 923110.0360 and 5 kg can part no. 923595.0003.
NOTE
Select lubrication class according to the prevailing climate.
Contact grease
Contact grease 923836.0552.
Sealant silicone
Sealant silicone 923107.0308.
Silicone adhesive
Silicone adhesive 923854.0100.
Coolant
Use ready-mixed recommended coolant. Choose the mixture of

coolant that is adapted for the right temperature.
NOTE
It is important that the coolant is mixed correctly all year round to
ensure adequate corrosion protection. The corrosion-protective
properties decline with time which is why the coolant has to be
changed in accordance with specified intervals.
CAUTION

Tightening torques, recommendations

The tightening torques in the following table are recommendations
when tightening bolts and nuts.
When torque-tightening using a machine, for example, bolt runner, the
tightening torque should be reduced by approx. 5%.
For soft surfaces (lower hardness than 200 HB), use washer under
both bolt head and nut. As an alternative, flange bolt or flange nut
can be used.
Tighten to the prescribed torque without stopping.
Recommended tightening torque may vary depending on surface
treatment. Certain combinations of nut and bolt require lubrication in
accordance with the table below.
Condi- Screw Nut Lubrication

tion
1 untreated untreated oil
2 bright galvanised untreated or bright galvanised dry or oil
3 hot-galvanised untreated dry or oil
Quality 8.8 10.9 12.9

Condition 1 2 3 1 1
Fine M-thread
M81 27 Nm 24 Nm 30 Nm 39 Nm 46 Nm
M101.25 54 Nm 48 Nm 61 Nm 78 Nm 91 Nm
M121.25 96 Nm 85 Nm 108 Nm 135 Nm 162 Nm
M161.5 230 Nm 205 Nm 260 Nm 323 Nm 388 Nm
M181.5 330 Nm 294 Nm 373 Nm 466 Nm 559 Nm
M-thread
M4 3.2 Nm 2.9 Nm 3.6 Nm 4.6 Nm 5.5 Nm
M5 6.4 Nm 5.7 Nm 7.2 Nm 9.1 Nm 11 Nm
M6 11 Nm 9.8 Nm 12.5 Nm 16 Nm 19 Nm
M8 26 Nm 24 Nm 30 Nm 38 Nm 45 Nm
M10 52 Nm 47 Nm 59 Nm 74 Nm 89 Nm
M12 91 Nm 81 Nm 103 Nm 128 Nm 154 Nm
M16 220 Nm 198 Nm 250 Nm 313 Nm 375 Nm
M20 430 Nm 386 Nm 490 Nm 620 Nm 732 Nm
M24 750 Nm 668 Nm 848 Nm 1050 Nm 1270 Nm
M30 1480 Nm 1317 Nm 1672 Nm 2080 Nm 2500 Nm
UNC-thread
1/4 12.5 Nm 11.1 Nm 14.1 Nm 17.6 Nm 20 Nm
5/16 25 Nm 22.3 Nm 28.3 Nm 35 Nm 42 Nm
3/8 44 Nm 39 Nm 50 Nm 62 Nm 73 Nm
7/16 70 Nm 62 Nm 79 Nm 100 Nm 118 Nm
1/2 107 Nm 95 Nm 121 Nm 151 Nm 178 Nm
9/16 153 Nm 136 Nm 173 Nm 216 Nm 255 Nm
5/8 210 Nm 187 Nm 237 Nm 298 Nm 353 Nm

Quality 8.8 10.9 12.9

3/4 370 Nm 390 Nm 418 Nm 524 Nm 619 Nm
7/8 594 Nm 528 Nm 671 Nm 839 Nm 990 Nm
1 889 Nm 791 Nm 1005 Nm 1260 Nm 1480 Nm
1 1/8 1260 Nm 1120 Nm 1424 Nm 1780 Nm 2100 Nm
1 1/4 1760 Nm 1565 Nm 1990 Nm 2490 Nm 2940 Nm
1 3/8 2320 Nm 2065 Nm 2620 Nm 3280 Nm 3870 Nm
1 1/2 3060 Nm 2720 Nm 3455 Nm 4320 Nm 5100 Nm
Tightening torque, connections for air

conditioning
O-ring couplings cooling hoses
Hose diameter Thread Tightening torque

mm inch inch Nm
6 1/4" 7/16" 7-13 Nm
10 3/8" 5/8" 14-20 Nm
10 3/8" 11/16" 14-20 Nm
12 1/2" 3/4" 14-26 Nm
16 5/8" 7/8" 27-41 Nm
19 3/4" 1 1/16" 34-46 Nm
Pressure switch 3/8" 7-13 Nm
7/16"
The above values should be considered guidelines and may vary

depending on installation.

Tightening torque, ORFS connections

Pipe and hose fitting
Pipe diameter Tightening torque

mm inch Nm
6 1/4 23-25
8 5/16
33-38
10 3/8
12 1/2 51-57
14 -
15 - 80-90
16 5/8
18 3/4
120-130
20 -
22 7/8
150-170
25 1"
28 -
30 - 180-200
32 1"1/4
35 -
200-240
38 1"1/2
Wrench size Tightening torque

mm inch Nm
17 11/16 23-25
22 13/16 33-38
24 15/16 51-57
36 1 3/8 120-130
41 1 5/8 150-170

Material fitting
UNF-UN Metric-ISO BSSP

Thread (inch) Tightening torque Thread Tightening torque Thread (inch) Tightening torque (Nm)
(Nm) (mm) (Nm)
7/16-20 21 10x1 20 1/8-28 20
1/2-20 27 12x1.5 35 1/4-19 35
9/16-18 40 14x1.5 45 3/8-19 70
3/4-16 78 16x1.5 55 1/2-14 100
7/8-14 110 18x1.5 68 3/4-14 190
1"1/16-12 180 20x1.5 80 1"-11 300
1"3/16-12 230 22x1.5 98 1"1/4-11 330
1"5/16-12 285 26x1.5 170 1"1/2-11 400
1"5/8-12 320 27x2 180
1"7/8-12 400 33x2 310
42x2 330
48x2 400
Unit explanations
Unit Abbreviation
Newton metre Nm
Kgf/m kpm
Kilo pascal kPa
Mega pascal MPa
Kilowatt kW
Kilojoule kJ
British thermal unit Btu
Calorie ca
Inch in
Feet ft
Yard yd
Mile mile
Centimetre cm
Metre m
Kilometre km

Conversion SI-units
Recalculation Recalculation
SI-unit factor Non-SI factor SI
Torque
Nm x 10.2 = kg·cm x 0.8664 = lb·in
Nm x 0.74 = lbf·ft x 1.36 = Nm
Nm x 0.102 = kg·m x 7.22 = lb·ft
Pressure (Pa = N/m2)
kPa x 4.0 = in.H2O x 0.249 = kPa
kPa x 0.30 = in.Hg x 3.38 = kPa
kPa x 0.145 = psi x 6.89 = kPa
bar x 14.5 = psi x 0.069 = bar
kp/cm 2 x 14.22 = psi x 0.070 = kp/cm2
N/mm 2 x 145.04 = psi x 0.069 = bar
MPa x 145 = psi x 0.00689 = MPa
Power (W = J/s)
kW x 1.36 = hp (cv) x 0.736 = kW
kW x 1.34 = bhp x 0.746 = kW
kW x 0.948 = Btu/s x 1.055 = kW
W x 0.74 = ft·lb/s x 1.36 = W
Energy (J = Nm)
kJ x 0.948 = Btu x 1.055 = kJ
J x 0.239 = calorie x 4.19 = J
Speed and acceleration
m/s2 x 3.28 = ft/s2 x 0.305 = m/s2
m/s x 3.28 = ft/s x 0.305 = m/s
km/h x 0.62 = mph x 1.61 = km/h
Horsepower/torque
Bhp x 5252 rpm= TQ (lb·ft) TQ x rpm 5252 = bhp
Temperature
ºC = (ºF – 32)/1.8 ºF = (ºC x 1.8) + 32
Flow factor
l/min (dm3 /min) x 0.264 = US gal/min x 3.785 = litre/min

Conversion table length

Unit cm m km in ft yd mile
cm 1 0.01 0.00001 0.3937 0.03281 0.01094 0.000006
m 100 1 0.001 39.37 3.2808 1.0936 0.00062
km 100000 1000 1 39370.7 3280.8 1093.6 0.62137
in 2.54 0.0254 0.000025 1 0.08333 0.02777 0.000015
ft 30.48 0.3048 0.000304 12 1 0.3333 0.000189
yd 91.44 0.9144 0.000914 36 3 1 0.000568
mile 160930 1609.3 1.6093 63360 5280 1760 1
1 mm = 0.1 cm – 1 mm = 0.001 m
Conversion table area

Unit cm2 m2 km2 a ft2 yd2 in2
cm2 1 0.0001 - 0.000001 0.001076 0.000012 0.155000
m2 10000 1 0.000001 0.01 10.764 1.1958 1550.000
km2 - 1000000 1 10000 1076400 1195800 -
a 0.01 100 0.0001 1 1076.4 119.58 -
ft2 - 0.092903 - 0.000929 1 0.1111 144.000

yd2 - 0.83613 - 0.008361 9 1 1296.00
in2 6.4516 0.000645 - - 0.006943 0.000771 1
1 ha = 100 a – 1 mile2 = 259 ha = 2.59 km2
Conversion table volume

Unit cm3 = cc m3 l in3 ft3 yd3
cm3 = ml 1 0.000001 0.001 0.061024 0.000035 0.000001
m3 1000000 1 1000 61024 35.315 1.30796
dm3 (l) 1000 0.001 1 61.024 0.035315 0.001308
in3 16.387 0.000016 0.01638 1 0.000578 0.000021
ft3 28316.8 0.028317 28.317 1728 1 0.03704
yd3 764529.8 0.76453 764.53 46656 27 1
1 gal (US) = 3785.41 cm3 = 231 in3 = 0.83267 gal (UK)
Conversion table weight

Unit g kg t oz lb
g 1 0.001 0.000001 0.03527 0.0022
kg 1000 1 0.001 35.273 2.20459
t 1000000 1000 1 35273 2204.59
oz 28.3495 0.02835 0.000028 1 0.0625
lb 453.592 0.45359 0.000454 16 1
1 tonne (metric) = 1.1023 ton (US) = 0.9842 ton (UK)

Conversion table pressure

Unit kp/cm2 bar Pa = N/m2 kPa lbf/in2 lbf/ft2
kp/cm2 1 0.98067 98066.5 98.0665 14.2233 2048.16
bar 1.01972 1 100000 100 14.5037 2088.6
Pa = N/m2 0.00001 0.001 1 0.001 0.00015 0.02086
kPa 0.01020 0.01 1000 1 0.14504 20.886
lbf/in2 0.07032 0.0689 6894.76 6.89476 1 144
lbf/ft2 0.00047 0.00047 47.88028 0.04788 0.00694 1
kg/cm2 = 735.56 Dry (mmHg) = 0.96784 atm

G:1
Contents G Terminology and index

Terminology and index .....................................................................................G:3
Terminology..................................................................................................... G:3
Index ............................................................................................................... G:5

G:2

G Terminology and index – Terminology and index G:3

Terminology
Explanations
Term Description
Accumulator Reservoir that stores (accumulates) pressure for, i.e. hydraulic functions.
Attachment Part of the machine that grips the load when lifting.
Anti-corrosion agent Prevents oxidation, in simple terms, rustproofing.
Working hydraulics All load handling functions, that is, lift and lower, tilt, side shift, spreading (extension)
and levelling.
Wheelbase Distance between drive axle and steering axle.
Bar Unit to express pressure.
Battery disconnector Cuts off power supply from battery.
Daily inspection Actions that should be performed daily to ensure the machine's functionality.
Decitonne Tenth of a tonne, measure of machine's lift capacity.
Display "Window" showing digital information, i.e. on steering wheel panel in the cab.
Operating time Number of hours machine has been in operation, shown on hour meter in cab.
Drive axle Driving axle that receives the torque from the drive-train.
Drive-train Parts in machine involved in power transmission; engine, torque converter, transmission,
propeller shaft, and drive axle with differential and hub reduction.
ECC Electric Climate Control. Air conditioning system with thermostat-controlled cooling,
dehumidification and heating.
EHC Electric Heat Control. Heating system with thermostat-controlled heating.
Electrolyte level Fluid level in battery cells.
Expansion tank Tank for coolant.
Fixed displacement Non-adjustable volume (capacity) in a pump.
Hanging load Lifted load.
FMI Fault Message Identifier.
Main fuse Located by battery. Breaks the current to all systems in the whole machine.
Hydraulic oil Oil for hydraulic system. See specifications in operator's manual.
Hydraulic oil pump Pump in hydraulic system.
Hydraulic system System that uses oil pressure to transfer power to different functions.
Indicator Manual "sensor", for example, shows that a filter is clogged and needs to be changed.
Refrigerant Fluid/gas in air conditioning. Must only be handled by authorised trained personnel.
Low-emission engine Engine with low emissions of hazardous substances. Manufactured in accordance
with regulations.
LC Load centre.
Lift capacity Indicates machine's maximum lift capacity.
Lifting point Attaching point for lift device when lifting an object.
Trolley Lifts the load, located on the mast.
Solenoid valve An electro-magnetically controlled valve. See also proportional valve.
Control valve Valves that can be used to control something, for example, to release pressure and thus
lower a boom or a fork.
Machine model Machine type. Specified, for example: DCT 80-90. See also type designation.

G:4 G Terminology and index – Terminology
Term Description
Environmental waste Used oils, filters, etc., must be handled according to governing national laws and
regulations.
Torque converter Hydraulic, variable clutch.
Hub reduction Type of final drive (often next to drive wheel) that reduces rpm and increases torque
from the drive-train.
Pilot oil pressure A low control pressure to, for example, a valve.
Planetary gear Type of transmission with the gears in constant mesh.
Product alternative One of several alternatives is selected for a machine, e.g. engine alternative.
Proportional valve An electro-magnetically controlled valve. If a voltage is applied, the valve is activated
in proportion to the voltage amplitude. In simple terms, infinitely variable valve, as
opposed to on/off valve. For example, found on transmission's valve housing.
Frame member Structural members in the frame.
Recirculation Circulate over and over again.
Serial number Unique machine designation. On the machine plate.
Service position How machine should be safely positioned before service may be started.
Servo A small movement by the user results in a large angle, i.e. servo steering.
Servo pressure A low control pressure to control a higher pressure, for example, to a valve.
Side lift Attachment. See attachment
Side shift Parallel sideways movement of attachment.
Levelling Attachment is tilted, for example if load stands on uneven ground.
Spirit Delta Enclosed type of cab.
SPN Suspect Parameter Number.
Spreading (positioning) Widening of attachment.
Mast Carrier of trolley, attachment and load.
Dust reservoir The air filter collects the coarsest particles in a dust reservoir, which is emptied
automatically during operation.
Steering axle Wheel axle with steering.
Buzzer Acoustic alarm to catch the operator's attention.
Option Extra equipment for machine.
Tilting Load is leaned forward or backward.
Transmission oil Oil for transmission and torque converter. See specifications in operator's manual.
Securing machine for transport Actions before transporting machine.
Twistlocks Two lock pins, one in each corner of the attachment, pushed down in corresponding
holes in container and twisted to lock the container when lifting.
Type designation Indicates machine type and capacity. See also machine model.
Maintenance Periodic maintenance actions so that machine functions safely and for a long service life.
Wet brakes Brake discs in oil bath.

Valve slide Moveable part in valve. Determines oil's path.

G Terminology and index – Index G:5
Index Cab structure and suspension . . . . . . . . . . . . 9:80

Cab substructure . . . . . . . . . . . . . . . . . . 9:80
CAB, menu 1. . . . . . . . . . . . . . . . . . . . 8:37
CAB, menu 2. . . . . . . . . . . . . . . . . . . . 8:38
A CAB, menu 3. . . . . . . . . . . . . . . . . . . . 8:39
CAB, menu 4. . . . . . . . . . . . . . . . . . . . 8:40
About the documentation . . . . . . . . . . . . . A:12 CAB, menu 5. . . . . . . . . . . . . . . . . . . . 8:41
About the Workshop Manual . . . . . . . . . . . . . A:3 CAB, menu 6. . . . . . . . . . . . . . . . . . . . 8:42
Accelerator . . . . . . . . . . . . . . . . . . . . 1:20 CAB, menu 7. . . . . . . . . . . . . . . . . . . . 8:43
Accumulator . . . . . . . . . . . . . . . . . 4:10, 10:5 CAB, menu 8. . . . . . . . . . . . . . . . . . . . 8:44
Accumulator charging valve . . . . . . . . . . . . . 4:7 Cabin fan . . . . . . . . . . . . . . . . . . . . . 9:32
Accumulator drain valve . . . . . . . . . . . . . . . 10:3 Cable harness . . . . . . . . . . . . . . . . . . 11:25
Accumulator lift . . . . . . . . . . . . . . . . . . . 7:30 Calibrate DRIVE-TRAIN . . . . . . . . . . . . . . 8:114
Air cleaning system . . . . . . . . . . . . . . . . . 1:23 Calibration . . . . . . . . . . . . . . . . . . . . 8:112
Air distributor . . . . . . . . . . . . . . . . . . . . 9:50 CAN bus . . . . . . . . . . . . . . . . . . . . 11:34
Air intake and exhaust outlet . . . . . . . . . . . . . 1:23 CAN bus drive-train . . . . . . . . . . . . . . . . 11:38
Air suspension . . . . . . . . . . . . . . . . . . . 9:17 CAN/POWER . . . . . . . . . . . . . . . . . . . 8:11
Alternator . . . . . . . . . . . . . . . . . . . . . 11:6 CAN/POWER, menu 1 . . . . . . . . . . . . . . . 8:11
Arm rest . . . . . . . . . . . . . . . . . . . . . . 9:18 CAN/POWER, menu 10 . . . . . . . . . . . . . . . 8:20
ATTACH . . . . . . . . . . . . . . . . . . . . . . 8:76 CAN/POWER, menu 11 . . . . . . . . . . . . . . . 8:21
ATTACH, menu 1 . . . . . . . . . . . . . . . . . . 8:76 CAN/POWER, menu 12 . . . . . . . . . . . . . . . 8:21
ATTACH, menu 10 . . . . . . . . . . . . . . . . . 8:81 CAN/POWER, menu 13 . . . . . . . . . . . . . . . 8:22
ATTACH, menu 2 . . . . . . . . . . . . . . . . . . 8:76 CAN/POWER, menu 7 . . . . . . . . . . . . . . . 8:17
ATTACH, menu 3 . . . . . . . . . . . . . . . . . . 8:77 Central lubrication . . . . . . . . . . . . . . . . . 9:87
ATTACH, menu 4 . . . . . . . . . . . . . . . . . . 8:77 Chassis . . . . . . . . . . . . . . . . . . . . . . 9:84
ATTACH, menu 5 . . . . . . . . . . . . . . . . . . 8:78 CLIMATE . . . . . . . . . . . . . . . . . . . . . 8:45
ATTACH, menu 6 . . . . . . . . . . . . . . . . . . 8:78 CLIMATE, menu 1 . . . . . . . . . . . . . . . . . 8:45
ATTACHMENT . . . . . . . . . . . . . . . . . . 8:104 CLIMATE, menu 5 . . . . . . . . . . . . . . . . . 8:47
CLIMATE, menu 6 . . . . . . . . . . . . . . . . . 8:48
CLIMATE, menu 7 . . . . . . . . . . . . . . . . . 8:49
B CLIMATE, menu 8 . . . . . . . . . . . . . . . . . 8:50
Back rest cushion . . . . . . . . . . . . . . . . . . 9:15 Common electrics . . . . . . . . . . . . . . . 11:3, E:6
Back-up alarm . . . . . . . . . . . . . . . . . . . 9:71 Common hydraulics . . . . . . . . . . . . . . 10:3, E:3
Back-up lights . . . . . . . . . . . . . . . . . . . 9:64 Communication. . . . . . . . . . . . . . . . . . 11:34
Batteries. . . . . . . . . . . . . . . . . . . . . . 11:4 Communication between PC and machine . . . . . . 11:39
Battery disconnector . . . . . . . . . . . . . . . . 11:3 Complete machine . . . . . . . . . . . . . . . . . 0:3
Body structure . . . . . . . . . . . . . . . . . . . 9:85 Compressor . . . . . . . . . . . . . . . . . . . . 9:39
Brake cylinder . . . . . . . . . . . . . . . . . . . 4:26 Compressor air-suspension seat . . . . . . . . . . . 9:17
Brake lights . . . . . . . . . . . . . . . . . . . . 9:63 Condenser . . . . . . . . . . . . . . . . . . . . . 9:43
Brake oil filter . . . . . . . . . . . . . . . . . . . 4:6 Container counter. . . . . . . . . . . . . . . . . . 7:75
Brake pedal . . . . . . . . . . . . . . . . . . . . 4:3 Control breaker . . . . . . . . . . . . . . . . 9:10, 11:3
Brake valve . . . . . . . . . . . . . . . . . . . . 4:14 Control levers . . . . . . . . . . . . . . . . . . . 7:4
Brakes . . . . . . . . . . . . . . . . . . . . . . 4:3 Control system . . . . . . . . . . . . . . . . 8:3, D:95
Break contact (opening switch) brake pressure . . . . . 4:19 Control system, engine . . . . . . . . . . . . . . . 1:30
Break contact (opening switch) parking brake . . . . . 4:36 Control system, transmission . . . . . . . . . . . . . 2:18
Breather filter hydraulic oil tank . . . . . . . . . . . 10:24 Control unit KID . . . . . . . . . . . . . . . . . 11:24
Bumper . . . . . . . . . . . . . . . . . . . . . . 9:16 Control unit KIT. . . . . . . . . . . . . . . . . . 11:23
Buzzer, automatic spread 20'-40' . . . . . . . . . . . 7:56 Control unit, attachment . . . . . . . . . . . . . . 11:19
Bypass . . . . . . . . . . . . . . . . . . . . . . 8:7 Control unit, cab . . . . . . . . . . . . . . . . . 11:17
Bypass valve, cooler . . . . . . . . . . . . . . . 10:23 Control units . . . . . . . . . . . . . . . . . . . 11:16
Control valve, attachment . . . . . . . . . 7:33, 7:48, 7:67
Control valve, lift and tilt . . . . . . . . . . . . 7:14, 7:60
Controls and instruments . . . . 1:20, 2:9, 4:3, 7:4, 8:4, 9:3
C Coolant . . . . . . . . . . . . . . . . . . . . . . 1:26
CAB . . . . . . . . . . . . . . . . . . . . . . . 8:37 Cooler hydraulic oil . . . . . . . . . . . . . . . . 10:20
Cab frame . . . . . . . . . . . . . . . . . . . . . 9:80 Cooling fan . . . . . . . . . . . . . . . . 1:26, 10:21
Cab interior . . . . . . . . . . . . . . . . . . . . 9:81 Cooling system . . . . . . . . . . . . . . . . 1:25, 2:17

Counterweights. . . . . . . . . . . . . . . . . . . 9:86 Foreword . . . . . . . . . . . . . . . . . . . . . A:3

Frame control unit . . . . . . . . . . . . . . . . 11:18
Frame, body, cab and accessories . . . . . . . . . . 9:3
D FREELIFT . . . . . . . . . . . . . . . . . . . . . 8:90
Fresh air filter . . . . . . . . . . . . . . . . . . . 9:28
Defroster nozzles . . . . . . . . . . . . . . . . . . 9:51
Fresh air filter or recirculation damper . . . . . . . . . 9:29
Diagnostics . . . . . . . . . . . . . . . . . . . . 8:9
Fuel system . . . . . . . . . . . . . . . . . . . . 1:21
Direction indicators . . . . . . . . . . . . . . . . . 9:64
Fuel tank . . . . . . . . . . . . . . . . . . . . . 1:21
Disc pack . . . . . . . . . . . . . . . . . . . . . 4:26
Fuses . . . . . . . . . . . . . . . . . . . . . . . 11:3
Distribution block . . . . . . . . . . . . . . . . . . 9:90
Distribution of electricity . . . . . . . . . . . . . . . 11:7
Doors . . . . . . . . . . . . . . . . . . . . . . . 9:80
Drive axle . . . . . . . . . . . . . . . . . . . . . 3:4 G
Drive axle block . . . . . . . . . . . . . . . . . . 4:18 Gear pump with fixed displacement . . . . . . . . . . 10:6
DRIVE-TRAIN . . . . . . . . . . . . . . . . . . 8:108 Gear selector and multi-function lever . . . . . . . 2:9, 9:8
General safety information . . . . . . . . . . . . . . B:3
Glass/windows/mirrors . . . . . . . . . . . . . . . 9:73
E
EL-STEERING . . . . . . . . . . . . . . . . . . . 8:90
Electric protection. . . . . . . . . . . . . . . . . . 11:3 H
ELECTRIC SERVO . . . . . . . . . . . . . . . . . 8:98 Headlights . . . . . . . . . . . . . . . . . . . . . 9:63
Electronic box . . . . . . . . . . . . . . . . . . 11:14 Heat exchanger heat . . . . . . . . . . . . . . . . 9:35
Electronic box frame . . . . . . . . . . . . . . . 11:15 Heat exchanger, cooling . . . . . . . . . . . . . . . 9:49
Electronic box, cab . . . . . . . . . . . . . . . . 11:14 Heating coil . . . . . . . . . . . . . . . . . . . . 9:16
ELSERV. . . . . . . . . . . . . . . . . . . . . . 8:69 Heating, ventilation and air conditioning . . . . . . . . 9:21
ELSERV, menu 1 . . . . . . . . . . . . . . . . . . 8:69 Hood engine compartment . . . . . . . . . . . . . . 9:85
ELSERV, menu 10 . . . . . . . . . . . . . . . . . 8:74 Horn . . . . . . . . . . . . . . . . . . . . . . . 9:70
ELSERV, menu 11 . . . . . . . . . . . . . . . . . 8:74 Hoses, pipes and valves . . . . . . . . . . . . . . 10:13
ELSERV, menu 12 . . . . . . . . . . . . . . . . . 8:74 HYD . . . . . . . . . . . . . . . . . . . . . . . 8:51
ELSERV, menu 13 . . . . . . . . . . . . . . . . . 8:75 HYD, menu 1 . . . . . . . . . . . . . . . . . . . 8:51
ELSERV, menu 2 . . . . . . . . . . . . . . . . . . 8:69 HYD, menu 4 . . . . . . . . . . . . . . . . . . . 8:52
ELSERV, menu 7 . . . . . . . . . . . . . . . . . . 8:73 Hydraulic cylinders . . . . . . . . . . . . . . . . 10:29
ELSERV, menu 8 . . . . . . . . . . . . . . . . . . 8:74 Hydraulic oil . . . . . . . . . . . . . . . . . . . 10:26
ELSERV, menu 9 . . . . . . . . . . . . . . . . . . 8:74 Hydraulic oil filter . . 4:30, 7:30, 7:40, 7:57, 7:62, 7:74, 10:24
Emergency stop switch voltage (15E) . . . . . . . . 11:11 Hydraulic oil pump . . . . . . . . . . . . 4:6, 4:30,
Engine . . . . . . . . . . . . . . . . . . . . 1:3, D:9 5:3, 7:10, 7:32, 7:47, 7:59, 7:66
ENGINE . . . . . . . . . . . . . . . . . . . . . . 8:55 Hydraulic oil tank . . . . . . . . . . . . . . . . . . 10:5
Engine control unit . . . . . . . . . . . . . . 1:30, 11:21
ENGINE, menu 1 . . . . . . . . . . . . . . . . . . 8:55
ENGINE, menu 10 . . . . . . . . . . . . . . . . . 8:60 I
ENGINE, menu 2 . . . . . . . . . . . . . . . . . . 8:55
ENGINE, menu 3 . . . . . . . . . . . . . . . . . . 8:56 I/O . . . . . . . . . . . . . . . . . . . . . . . . 8:94
ENGINE, menu 4 . . . . . . . . . . . . . . . . . . 8:57 Ignition . . . . . . . . . . . . . . . . . . . . . . 1:20
ENGINE, menu 5 . . . . . . . . . . . . . . . . . . 8:57 Ignition voltage (15) . . . . . . . . . . . . . . . . . 11:9
ENGINE, menu 6 . . . . . . . . . . . . . . . . . . 8:58 Initiation . . . . . . . . . . . . . . . . . . . . . . 8:95
ENGINE, menu 7 . . . . . . . . . . . . . . . . . . 8:59 Instrument and control panels . . . . . . . . . . . . 9:81
ENGINE, menu 8 . . . . . . . . . . . . . . . . . . 8:59 Insulation . . . . . . . . . . . . . . . . . . . . . 9:82
ENGINE, menu 9 . . . . . . . . . . . . . . . . . . 8:60 Intercooler . . . . . . . . . . . . . . . . . . . . . 1:24
Entertainment and communication . . . . . . . . . . 9:72 Interior fittings, plastic . . . . . . . . . . . . . . . . 9:82
Environment . . . . . . . . . . . . . . . . . . . B:20 Interior fittings, textile . . . . . . . . . . . . . . . . 9:82
Error code menu . . . . . . . . . . . . . . . . . . 8:4 Interior lighting . . . . . . . . . . . . . . . . . . . 9:66
Error codes . . . . . . . . . . . . . . . . . . . . D:3
Exhaust system . . . . . . . . . . . . . . . . . . 1:23
Expansion valve . . . . . . . . . . . . . . . . . . 9:46 L
EXT-ATTACH . . . . . . . . . . . . . . . . . . . 8:90
Levelling. . . . . . . . . . . . . . . . . . . . . . 7:63
EXTRA . . . . . . . . . . . . . . . . . . . . . . 8:89
Lift and lower. . . . . . . . . . . . . . . . . . . . 7:8
Lift cylinder . . . . . . . . . . . . . . . . . . . . 7:15
Lift, tilt and attachment control valve. . . . . 7:40, 7:56, 7:74
F Lighting system. . . . . . . . . . . . . . . . . . . 9:59
Feedback . . . . . . . . . . . . . . . . . . . . A:13 LIGHTS . . . . . . . . . . . . . . . . . . . . . . 8:25
Fine filter hydraulic oil . . . . . . . . . . . . . . . 10:27 LIGHTS, menu 1 . . . . . . . . . . . . . . . . . . 8:25
Fire extinguisher . . . . . . . . . . . . . . . . . . 9:10 LIGHTS, menu 10 . . . . . . . . . . . . . . . . . 8:32
Flashing hazard lights . . . . . . . . . . . . . 9:64, 9:70 LIGHTS, menu 11. . . . . . . . . . . . . . . . . . 8:33
Flex plates . . . . . . . . . . . . . . . . . . . . . 2:10 LIGHTS, menu 12 . . . . . . . . . . . . . . . . . 8:33
Floor covering . . . . . . . . . . . . . . . . . . . 9:82 LIGHTS, menu 13 . . . . . . . . . . . . . . . . . 8:34
Footsteps and hand rail . . . . . . . . . . . . . . . 9:85 LIGHTS, menu 14 . . . . . . . . . . . . . . . . . 8:36

LIGHTS, menu 15 . . . . . . . . . . . . . . . . . 8:36 R

LIGHTS, menu 2 . . . . . . . . . . . . . . . . . . 8:25
Radiator and expansion tank . . . . . . . . . . . . . 1:25
LIGHTS, menu 3 . . . . . . . . . . . . . . . . . . 8:26
Reading instructions . . . . . . . . . . . . . . . . A:4
LIGHTS, menu 4 . . . . . . . . . . . . . . . . . . 8:27
Reading-lamp . . . . . . . . . . . . . . . . . . . 9:83
LIGHTS, menu 5 . . . . . . . . . . . . . . . . . . 8:28
Rear view mirror . . . . . . . . . . . . . . . . . . 9:79
LIGHTS, menu 6 . . . . . . . . . . . . . . . . . . 8:29
Rear window . . . . . . . . . . . . . . . . . . . . 9:79
LIGHTS, menu 7 . . . . . . . . . . . . . . . . . . 8:29
Redundant CAN bus . . . . . . . . . . . . . . . 11:36
LIGHTS, menu 8 . . . . . . . . . . . . . . . . . . 8:30
Redundant voltage feed of control units . . . . . . . . 11:7
LIGHTS, menu 9 . . . . . . . . . . . . . . . . . . 8:31
Relief valve, attachment . . . . . . . 7:39, 7:56, 7:74, 10:3
Lines . . . . . . . . . . . . . . . . . . . . . . . 9:90
Revolving beacon. . . . . . . . . . . . . . . 9:64, 9:71
Link arm . . . . . . . . . . . . . . . . . . . . . . 5:11
Rim . . . . . . . . . . . . . . . . . . . . . . . . 6:16
Load carrier . . . . . . . . . . . . . . . . . . . . 7:64
RMI . . . . . . . . . . . . . . . . . . . . . . . . 8:94
Load handling . . . . . . . . . . . . . . . . . . . 7:3
Roof window . . . . . . . . . . . . . . . . . . . . 9:79
Load retention valve . . . . . . . . . . . . . . . . 7:61
Running lights . . . . . . . . . . . . . . . . . . . 9:63
Lock cylinder . . . . . . . . . . . . . . . . . . . . 7:68
Lock mechanism . . . . . . . . . . . . . . . . . . 7:69
Lubrication system . . . . . . . . . . . . . . . . . 2:13
S
Safety . . . . . . . . . . . . . . . . . . . . . . . B:3
M Safety and emergency equipment. . . . . . . . . . . 9:10
Safety instructions . . . . . . . . . . . . . . . . . B:4
Main beam, side lift attachment . . . . . . . . . . . . 7:51 Safety valves. . . . . . . . . . . . . . . . . . . . 10:3
Main valve . . . . . . . . . . . . . . . . . . . . 10:14 Schematics . . . . . . . . . . . . . . . . . . . . E:3
Make-contact (closing switch) brake lights . . . . . . . 4:21 Seat . . . . . . . . . . . . . . . . . . . . . . . 9:11
Make-contact (closing switch) water in fuel . . . . . . . 1:22 Seat belt. . . . . . . . . . . . . . . . . . . . . . 9:10
Mast . . . . . . . . . . . . . . . . . . . . 7:16, 7:62 Seat buzzer . . . . . . . . . . . . . . . . . . . . 9:10
Mast position sensor . . . . . . . . . . . . . . . . 7:25 Seat cushion . . . . . . . . . . . . . . . . . . . . 9:14
Mechanical seat adjustment . . . . . . . . . . . . . 9:18 Sensor cab temperature . . . . . . . . . . . . . . . 9:53
Moisture filter . . . . . . . . . . . . . . . . . . . 9:45 Sensor fuel level . . . . . . . . . . . . . . . . . . 1:22
Monitoring . . . . . . . . . . . . . . . . . . . . . 8:7 Sensor hydraulic oil temperature . . . . . . . . . . 10:21
MOVE-CAB . . . . . . . . . . . . . . . . . . . . 8:90 Sensor twistlocks . . . . . . . . . . . . . . . . . . 7:72
Sensor, alignment . . . . . . . . . . . . . . . . . 7:71
Sensor, ambient temperature . . . . . . . . . . . . . 9:54
N Sensor, engine temperature . . . . . . . . . . . . . 9:38
Sensor, operator-in-seat . . . . . . . . . . . . . . . 9:19
NO (normally open) switch, disengagement . . . . . . 2:18 Sensor, temperature outlet fan . . . . . . . . . . . . 9:52
Nut, washer and clamp . . . . . . . . . . . . . . . 6:17 Sensor, temperature refrigerant . . . . . . . . . . . . 9:48
Service indicator . . . . . . . . . . . . . . . . . . 8:8
Setup . . . . . . . . . . . . . . . . . . . . . . . 8:95
O Side shift . . . . . . . . . . . . . . . . . . . . . 7:31
Side shift cylinder . . . . . . . . . . . . . . . . . . 7:37
Oil cooler . . . . . . . . . . . . . . . . . . 2:15, 2:17 Side window . . . . . . . . . . . . . . . . . . . . 9:76
OLS . . . . . . . . . . . . . . . . . . . . . . . 8:89 Signalling system . . . . . . . . . . . . . . . . . . 9:68
OPT . . . . . . . . . . . . . . . . . . . . . . . 8:90 SLIDING-CAB . . . . . . . . . . . . . . . . . . 8:112
Other . . . . . . . . . . . . . . . . . . . . . . 10:29 Solenoid valve parking brake . . . . . . . . . . . . . 4:31
Other functions . . . . . . . . . . . . . . . . . . . 7:75 Speed limitation . . . . . . . . . . . . . . . . . . 8:7
Spreader beam . . . . . . . . . . . . . . . . . . . 7:49
Spreading (positioning) . . . . . . . . . . . . . . . 7:41
P Spreading cylinder . . . . . . . . . . . . . . . . . 7:49
Start battery . . . . . . . . . . . . . . . . . . . . 11:4
Paint/coatings . . . . . . . . . . . . . . . . . . . 9:91 Start/stop . . . . . . . . . . . . . . . . . . . . . 1:31
Parking brake caliper . . . . . . . . . . . . . . . . 4:34 Starter motor . . . . . . . . . . . . . . . . . . . . 1:31
Parking brake disc . . . . . . . . . . . . . . . . . 4:35 Steering . . . . . . . . . . . . . . . . . . . . . . 5:3
Parking brake pads . . . . . . . . . . . . . . . . . 4:34 STEERING . . . . . . . . . . . . . . . . . . . 8:108
Parking brake system . . . . . . . . . . . . . . . . 4:29 Steering axle cradle . . . . . . . . . . . . . . . 5:11, 6:4
Parking brake unit . . . . . . . . . . . . . . . . . 4:32 Steering cylinder . . . . . . . . . . . . . . . . . . 5:9
Passenger seat. . . . . . . . . . . . . . . . . . . 9:18 Steering valve . . . . . . . . . . . . . . . . . . . 5:7
Pipes and hoses . . 4:26, 4:36, 5:12, 7:30, 7:39, 7:56, Stopping device . . . . . . . . . . . . . . . . . . 1:31
7:62, 7:74, 10:4–10:5, 10:12–10:13, 10:27 Suspension . . . . . . . . . . . . . . . . . . . . 6:3
Position sensor, spreading . . . . . . . . . . . . . . 7:56 Switch, automatic spreading . . . . . . . . . . . . . 7:7
Power assisted system . . . . . . . . . . . . . . . 5:3 Switch, direction indicators . . . . . . . . . . . . . . 9:9
Power transmission . . . . . . . . . . . . . . . . . 3:3 Switch, lock twistlock . . . . . . . . . . . . . . . . 7:5
Power-assisted brake system . . . . . . . . . . . . 4:5 Switch, spreading 20\q-40\q . . . . . . . . . . . . . 7:6
Pressure limiting valve . . . . . . . . . . . . . . . 10:4 Switch, stop at 30\q . . . . . . . . . . . . . . . . . 7:6
Pressure reducer . . . . . . . . . . . . . . . . . . 7:11
Pressure switch . . . . . . . . . . . . . . . . . . 9:45
Preventive maintenance . . . . . . . . . . . . . . . C:1
Priority valve . . . . . . . . . . . . . . . . . . . . 5:4
T
Propeller shaft . . . . . . . . . . . . . . . . . . . 3:3 Tail lights . . . . . . . . . . . . . . . . . . . . . 9:63
Pump unit . . . . . . . . . . . . . . . . . . . . . 9:89 Tanks and accumulators . . . . . . . . . . . . . . . 10:5
Pumps . . . . . . . . . . . . . . . . . . . . . . 10:6 Technical data . . . . . . . . . . . . . . . . . . . F:3

Temperature control, cleaning and hydraulic oil . . . . 10:18 V

Terminal console . . . . . . . . . . . . . . . . . . 9:83
Terminology . . . . . . . . . . . . . . . . . . . . G:3 Valve block brake system . . . . . . . . . . . 4:27, 4:36
Terminology and index . . . . . . . . . . . . . . . G:3 VBFS . . . . . . . . . . . . . . . . . . . . . . . 8:89
Tilt . . . . . . . . . . . . . . . . . . . . . . . . 7:58 Voltage converter . . . . . . . . . . . . . . . . . 11:13
Tilt cylinder . . . . . . . . . . . . . . . . . . . . 7:61 Voltage feed . . . . . . . . . . . . . . . . . . . . 11:7
Torque converter/Clutch system . . . . . . . . . . . 2:10
TRANSM . . . . . . . . . . . . . . . . . . . . . 8:62
TRANSM, menu 1 . . . . . . . . . . . . . . . . . 8:62 W
TRANSM, menu 10 . . . . . . . . . . . . . . . . . 8:67
TRANSM, menu 11 . . . . . . . . . . . . . . . . . 8:67 Warning parking brake . . . . . . . . . . . . . . . 9:71
TRANSM, menu 12 . . . . . . . . . . . . . . . . . 8:67 Washer motor and reservoir . . . . . . . . . . . . . 9:55
TRANSM, menu 13 . . . . . . . . . . . . . . . . . 8:67 Water valve . . . . . . . . . . . . . . . . . . . . 9:38
TRANSM, menu 14 . . . . . . . . . . . . . . . . . 8:68 Wheel brakes . . . . . . . . . . . . . . . . . . . 4:24
TRANSM, menu 2 . . . . . . . . . . . . . . . . . 8:63 Wheel hub . . . . . . . . . . . . . . . . . . . 5:12, 6:8
TRANSM, menu 3 . . . . . . . . . . . . . . . . . 8:63 Wheel spindle . . . . . . . . . . . . . . . . . 5:12, 6:6
TRANSM, menu 4 . . . . . . . . . . . . . . . . . 8:64 Windscreen . . . . . . . . . . . . . . . . . . . . 9:74
TRANSM, menu 5 . . . . . . . . . . . . . . . . . 8:65 Wings . . . . . . . . . . . . . . . . . . . . . . . 9:85
TRANSM, menu 6 . . . . . . . . . . . . . . . . . 8:66 Wiper front . . . . . . . . . . . . . . . . . . . . . 9:55
TRANSM, menu 7 . . . . . . . . . . . . . . . . . 8:66 Wiper motor front . . . . . . . . . . . . . . . . . . 9:56
TRANSM, menu 8 . . . . . . . . . . . . . . . . . 8:66 Wiper motor rear . . . . . . . . . . . . . . . . . . 9:58
TRANSM, menu 9 . . . . . . . . . . . . . . . . . 8:66 Wiper motor roof . . . . . . . . . . . . . . . . . . 9:57
Transmission. . . . . . . . . . . . . . . . . 2:3, D:59 Wiper rear . . . . . . . . . . . . . . . . . . . . . 9:55
Transmission cable harness . . . . . . . . . . . . . 2:18 Wiper roof . . . . . . . . . . . . . . . . . . . . . 9:55
Transmission control unit . . . . . . . . . . . 2:18, 11:20 Wiper/washer system . . . . . . . . . . . . . . . . 9:55
Trolley. . . . . . . . . . . . . . . . . . . . 7:26, 7:37 Work lights, front wing . . . . . . . . . . . . . . . . 9:67
Twistlock overcentre valve . . . . . . . . . . . . . . 7:68 Working lights, attachment . . . . . . . . . . . . . . 9:67
Twistlocks . . . . . . . . . . . . . . . . . . 7:64, 7:69 Working lights, cab . . . . . . . . . . . . . . . . . 9:66
Tyres . . . . . . . . . . . . . . . . . . . . . . . 6:15 Working lights, mast. . . . . . . . . . . . . . . . . 9:64
Tyres and rims . . . . . . . . . . . . . . . . . . . 6:13 Writing desk . . . . . . . . . . . . . . . . . . . . 9:83


last page
Cargotec Sweden AB
Cargotec improves the efficiency of cargo flows by offering solutions for Torggatan 3
the loading and unloading of goods on land and at sea – wherever cargo SE-340 10, Lidhult, Sweden
is on the move. Cargotec’s main daughter brands for cargo handling
Hiab, Kalmar and MacGregor are global market leaders in their fields. tel. +46 372 260 00
Cargotec’s global network offers extensive services that ensure the fax +46 372 263 90
continuous, reliable and sustainable performance of equipment. www.cargotec.com

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Empty Container Handler 8-9

9 Frame, body, cab and accessories

G Terminology and index

Workshop Manual DCT 80-90 VDCT01.02GB

VDCT01.02GB Workshop Manual DCT 80-90

Cargotec will not accept any responsibility in the event of a modification

About machine version

Cargotec reserves the right to make changes to specifications and

All duplication by any means, such as copying, printing, etc., is

Workshop Manual DCT 80-90 VDCT01.02GB

Read operator's manual

Read the operator's manual

Read the Maintenance manual

refers to important information in the Maintenance manual.

Read the Maintenance manual

VDCT01.02GB Workshop Manual DCT 80-90

The workshop manual's contents

The workshop manual is divided into the following sections.

Workshop Manual DCT 80-90 VDCT01.02GB

Function group structure

The function groups are intended to be used as search terms in

The maintenance manual and workshop manual contain different

References between sections in the same manual are indicated with

References between Maintenance manual and Workshop manual are

VDCT01.02GB Workshop Manual DCT 80-90

References between different information types

The basic rule of searching for information is to use the function

Function descriptions Hydraulic diagrams

Diagnostics Wiring diagrams

• From Function description to Component description, to enable

Workshop Manual DCT 80-90 VDCT01.02GB

Product alternatives and optional equipment

Special equipment is not described in the manual. If uncertain as

Equivalent information for different product alternatives is described

Optional equipment refers to options that can be added to standard

Information on auxiliary equipment is described in separate segments

VDCT01.02GB Workshop Manual DCT 80-90

The machine card indicates of which drawings the machine consists.

If the information on the machine card is not of any assistance, contact

Workshop Manual DCT 80-90 VDCT01.02GB

The function descriptions describe the function in a logical flow from

The function descriptions use symbols to illustrate components such

Example of function description

VDCT01.02GB Workshop Manual DCT 80-90

Symbol explanation function descriptions

Workshop Manual DCT 80-90 VDCT01.02GB

About the documentation

Always indicate publication number when ordering.

For publication number, see machine card.

VDCT01.02GB Workshop Manual DCT 80-90

Your feedback is important to be able to improve the information.

To: Cargotec Sweden AB

Date: .................................... - .................. - ..................

Section / page number: ................................................................................................................................

Workshop Manual DCT 80-90 VDCT01.02GB

VDCT01.02GB Workshop Manual DCT 80-90

Workshop Manual DCT 80-90 VDCT01.02GB

VDCT01.02GB Workshop Manual DCT 80-90

In this publication Cargotec has documented and warned for situations

A near accident is a warning!

Workshop Manual DCT 80-90 VDCT01.02GB

Service position is used for service, maintenance and other situations

Service position entails:

Machine with trolley and attachment in totally lowered