DCT80 Workshop Manual

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
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.
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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

001128
The symbol to the left is used in certain cases on the machine and refers to important information in the Maintenance manual.
Read the Maintenance manual
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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 B C 0 1 2 3 4 5 6 7 8 9 10 11 12 D E F G Foreword Safety Preventive maintenance Complete machine Engine Transmission Power transmission Brakes Steering Suspension Load handling Control system Frame, body, cab and accessories Common hydraulics Common electrics Common pneumatics Error codes Schematics Technical data Terminology and index Error code information and instructions for reading error code information. Wiring diagrams, hydraulic diagrams and list of electrical components. Technical data, conversion tables, information for conversion of units. General terminology and abbreviations, explanation of terms and abbreviations that can appear in the sections, index for headings in the manual. Technical description, comprehensive function descriptions and a description of the function of components included in the machine, divided into function groups. The components used for each respective function are described under each subfunction. Consequently, common components are described in several locations, but in general under the first function to use the component. 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 only has a description what is unique for the new function. Work instructions for corrective maintenance (replacement of components). General information about the workshop manual's purpose, contents and reading instructions as well as survey for feedback of views and any inaccuracies. Keep in mind for your safety. Reference to maintenance manual: Preventive maintenance.
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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.
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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 (Technical description)
Hydraulic diagrams (Section E)
Component descriptions (Technical description, normally in Workshop manual)
Error codes (Section D)
Diagnostics (Technical description, group 8.4)
Wiring diagrams (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.
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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
000264
Optional equipment
Optional equipment refers to options that can be added to standard 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.
Symbol for optional equipment
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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.
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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
D11 11 D12 2 C
P ACK M
14
D790-2
P
B T
10, 13
D797-1
5 4
9
Pa
D9
2
8
C 12
Pa
LB P T P T
015034
B
8
P os
1
F r k la r in g
H y d ra u lo lje p u m p b ro m s o c h s ty rn in g p u m p a r o lja fr n h y d ra u lo lje ta n k e n . Ven och Ven in te tilb lo c k p rio rite tilb lo c k k r v e r 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 b ro m s a r n r s ty rn in g e n h y d ra u lk ra ft.
S ig n a lb e s k r iv n in g
S e try c k s k y lt p v n s te r ra m b a lk . -
H n v is n in g
H y d ra u lo lje p u m p b ro m s o c h s ty rn in g , b e s k riv n in g , s id a 4 :8
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 . 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 . B ro m s v e n tile n s ty r try c k fr n 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. D riv a x e lb lo c k e t f rd e la r b ro m s try c k e t till h ju lb ro m s a rn a .
4 5
S e try c k s k y lt p v 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 B ro m s v e n til, b e s k riv n in g , s id a 4 :1 8
6
014621
Example of function description 1. Hydraulic line - Hydraulic force: solid double line - Hydraulic control signal: dashed double line) 2. Flag measuring outlet (Check point), indicates that there is measuring outlet for checking the hydraulic pressure Flag diagnostic test, indicates that the signal can be checked with diagnostics, see section 8 Control system, group 8.4 Diagnostics Illustration of function, (applied brake) Reference to description of component 7. 8. 9. 6. Signal description, reference value for signal out from component Description of the component's function Position number, reference to position in illustration Position number in illustration, reference to row in table - Electric power: solid single line - Electrical control signal: dashed single line
3.
10. Electrical wiring
4. 5.
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A:11
Symbol explanation function descriptions
1 3
2 4
Symbol explanation function descriptions

The following symbols are used in function descriptions. The symbols are based on standard symbols for wiring and hydraulic diagrams. 1. 2. Electric control signal Electric force Hydraulic control signal Hydraulic force Hydraulic motor Hydraulic oil pump with variable displacement Hydraulic oil pump with fixed displacement Electric motor Accumulator
3. 4. 5.
6. 7. 8. 9.
10
10. Disc brake 11. Filter 12. Radiator 13. Bulb 14. Control and monitoring system, two control units with CAN bus 15. Restriction 16. Adjustable restriction 17. Inductive position sensor 18. Electrically controlled servo valve 19. Thermal bypass valve 20. Temperature-controlled switch 21. Temperature sensor 22. Pressure sensor 23. Pressure-controlled switch 24. Hydraulic cylinder 25. Double-acting hydraulic cylinder 26. Spring brake cylinder 27. Valve block 28. Shuttle valve 29. Non-return valve
11
12
D790-1
13
14
D797-F
15 17 19 21
C C
16 18 20 C 22 24
Pa
23 Pa
25
26
27
014726
28
29
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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.
VDCT01.02GB
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 information
Name / Publication number: ............................................................................................................................. Section / page number: ................................................................................................................................ ................
Suggestions, views, remarks, etc.
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
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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
VDCT01.02GB
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VDCT01.02GB
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.
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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:
009797
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).
Machine with trolley and attachment in totally lowered position
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B:5
Hydraulic and brake systems, depressurising

1 2 Machine in service position, see Service position, page B:4. 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.
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.
"$&
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B:6
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.
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B:7
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.
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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.
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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.
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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.
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B:11
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.
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B:12
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.
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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.
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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).
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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.
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Tensioned springs
Examples of tensioned springs: 1. 2. 3. 4. Torque springs in, e.g. pedals Thrust spring (cup springs) in parking brake cylinder Lock rings 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.
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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. Workshop Manual DCT 80-90
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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.
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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.
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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.
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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.
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C Preventive maintenance
The information is available in the Maintenance Manual
See Maintenance Manual DCT 8090, section C Preventive maintenance. For information on how to order the Maintenance Manual, see the section A Foreword.
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0 Complete machine
Contents 0 Complete machine

Complete machine..............................................................................................0:3
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0 Complete machine
Complete machine, description
Kalmar DCT 80-90 is a forklift truck for empty container handling. The machine has a lifting capacity of 8-9 tonnes depending on the model. The engine is a straight six-cylinder, four-stroke, turbocharged low-emission diesel engine with a unit injector, air to air intercooling and electronically controlled fuel injection. The transmission is hydromechanical with gear wheels constantly engaged and has three gears in each direction. Engine power is transmitted using a torque converter. The power transmission consists of a propeller shaft and one rigid drive axle with differential and hub reduction. Drive takes place on the front wheels.
The service brakes are wet multiple disc brakes which are attached to the drive wheel hub. The parking brake is the disc brake type and operates on the drive axle input shaft. Steering operates on the rear wheels with a double acting hydraulic cylinder. The steering axle is suspended in the frame with pendulum 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. Side shifting is moving the side lift attachment sideways along the trolley. Spreading is adjusting the width between the Twistlocks on the side lift attachment. Tilt is used to angle the load in the longitudinal direction of the truck with the help of the mast. Load securing is to lock the load to the side lift attachment.

1. 2. 3. 4. 5. 6. 7. Steering axle Engine Frame Drive axle Mast Side lift attachment Cab
"
The control system consists of functions for warning the operator of dangerous situations and faults. The control system has diagnostic 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.
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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 012 contain descriptions of the various functions of the machine.
Troubleshooting procedure
1 Check that there is battery voltage available. 2 Battery disconnector, must be in position 1. Battery voltage, should be 2230 V. Fuses, check that they are intact.
Check that all oil and fluid levels are normal. Fuel Engine oil Transmission oil Hydraulic oil Coolant Washer fluid
3 4
Check if there are error codes. 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.
If there is no error code or the problem persists, use the function description for the function affected in section 012. 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).
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Troubleshooting without an error code, example

1 2 Choose suitable section 012 to locate the function and subfunction that have caused the symptom. Read the function description for the function in question to get an overall understanding of which components are affected and how these interact. 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. The fault is probably between the two units where the signal is incorrect. Start by checking the component that should be sending the signal. 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.
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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 4 Follow the instructions in the field "Action". 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. Use the function group to find more information if needed. In section 012 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.
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Table Example of error code information in error code list
Code
34
Description
Signal error from parking brake switch, indicates released and applied at same time or nothing at all.
Limitation
Parking brake cannot be released.
Action
Check cabling between the control unit and the component with diagnostic menu. Check component.
Connections and components

D791-1/K8:5 S107, K8:13 S107
Diagnostic menu
HYD, menu 5
Function group
4.1.2 Parking brake control
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Troubleshooting cable harnesses NOTE

Perform troubleshooting for all cables in the same way to avoid damage to control units, components or measuring equipment. 1 2 3 Study the circuit diagram in question, check where the suspected cable is connected and if, and if so where, it is spliced. Turn off the system voltage with the battery disconnector. 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. b. Measure resistance between connections to the component in the connector at the control unit or component. The resistance must correspond with the component. Otherwise there may be an open circuit or short circuit in cable harness and/or component.
Check if there is a short circuit to the frame: a. b. c. Unplug the connector at both the control unit and the component in question. Measure the resistance in one cable at a time. Measure between the cable and a frame-connected part of the machine. The multimeter should show infinite resistance.
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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 2 Depressurise the hydraulic and brake systems, see section B Safety. Study the hydraulic diagram in question, check between which components the suspect hose is connected and if, and if so where, it is spliced. 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).
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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
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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 97/68/EC) (stage III in accordance with directive
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.
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1 Engine Engine
Engine alternative Yuchai YC6A240-30, functional description

rpm kph
0 P I II III
.
C bar
11 D11
1, 6 D1 5, 7, 19 D6 D790-2 D795 D797-1 18, 22
D790-1 2, 12, 23
4, 8, 17, 21 D20 D8
3, 13, 16, 24 D794 D3

H2O H2O
20
15
14
Pos
1
Explanation
The ignition key lock sends a voltage signal to Control unit, cab (D790-1) when the ignition key is turned to position 1.
Signal description
U = 24 V
Reference
Ignition key lock, description, page 1:20 D1: Diagnostic menu, see section 8 Control system, group 8.4.1.5 CAN/POWER, menu 5 and 8.4.6.4 ENGINE, menu 4
Control unit, cab (D790-1) sends Ignition on over the CAN bus. When required, the Control unit, engine (D794) activates the preheating coil. Status signal is also sent to Control unit, frame (D797-1). Control unit, frame (D797-1) sends preheating active on the CAN bus. Control unit KIT (D790-2) activates indicator light, preheating. The ignition key lock sends a voltage signal to Control unit KIT (D790-2) when the ignition key is turned to start position. Control unit KIT (D790-2) sends a start signal on the CAN bus. Control unit, frame (D797-1) supplies voltage to Relay, starter motor (K360) on the starter motor.
Checked by control system, error shown with error code. U = 24 V
Section 11 Common electrics, group 11.5.3.1 Control unit, cab Section 11 Common electrics, group Frame control unit (D797-1) D3: Diagnostic menu, see section 8 Control system, group 8.4.6.5 ENGINE menu 5
D3: Diagnostic menu, see section 8 Control system, group 8.4.6.5 ENGINE menu 5 Section 11 Common electrics, group 11.5.3.11 Control unit, KIT Ignition key lock, description, page 1:20 D6: Diagnostic menu, see section 8 Control system, group 8.4.6.4 ENGINE menu 4
5 6
Section 11 Common electrics, group 11.5.3.11 Control unit, KIT Section 11 Common electrics, group 11.5.3.2 Frame control unit D8: Diagnostic menu, see section 8 Control system, group 8.4.6.5 ENGINE menu 5
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SENSORS
10
1 Engine Engine
1:5
Pos
9
Explanation
The starter motor cranks the engine.
Signal description
-
Reference
Starter motor, description, page 1:31 D8: Diagnostic menu, see section 8 Control system, group 8.4.6.5 ENGINE menu 5
10
The engine's sensor sends signals to Control unit, engine (D794) that controls the injectors so the engine starts. The accelerator pedal sends a voltage signal proportional the depression to Control unit, cab (D790-1).
Checked by control system, error shown with error code. U = 0.5-4.5 V Lower voltage than 0.5 V and higher voltage than 4.5 V is used to detect faults in cable harnesses and controls. Checked by control system, error shown with error code. Low level: U = 24 V
Section 11 Common electrics, group 11.5.3.10 Control unit, engine Section 9 Frame, body, cab and accessories, group 9.1 Controls and instruments D11: Diagnostic menu, see section 8 Control system, group 8.4.6.1 ENGINE menu 1 Section 11 Common electrics, group 11.5.3.1 Control unit, cab Section 11 Common electrics, group 11.5.3.10 Control unit, engine Cooling system, description, page 1:25
11
12
Control unit, cab (D790-1) sends a message with the rpm request on the CAN bus. Control unit, engine (D794) increases the engine speed. Make-contact (closing switch) coolant level sends a voltage signal to Control unit frame front (D797-F) if the coolant level is low in the expansion tank. Make-contact (closing switch) water in fuel (B760) sends a ground signal to Control unit, engine (D794) if there is too much water in the fuel prefilter. Control unit, frame (D797-1) is used to supply voltage for the signal. Control unit, engine (D794) sends engine data and warning messages on the CAN bus.
13 14
15
Water in fuel: U = 0 V
Make-contact (closing switch) water in fuel, description (engine alternative Yuchai YC6A240-30), page 1:22
16
Checked by control system, error shown with error code.
Section 11 Common electrics, group 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 9 and 8.4.6.10 ENGINE, menu 10 Section 11 Common electrics, group 11.5.3.2 Frame control unit Section 11 Common electrics, group 11.5.3.12 Control unit, KID Section 11 Common electrics, group 11.5.3.11 Control unit, KIT Sensor, fuel level, description, page 1:22 D20: Diagnostic menu, see section 8 Control system, group 8.4.3.7 CAB, menu 7
17
Control unit, frame (D797-1) sends lamp information on the CAN bus. Control unit KID (D795) shows engine data via display figures. Control unit KIT (D790-2) activates warning lamps when necessary. Sensor fuel level (B757) sends a voltage signal proportional to the fuel level in the tank to Control unit, frame rear (D797-R).
Checked by control system, error shown with error code. U = 0.5-4.5 V Lower voltage than 0.5 V and higher voltage than 4.5 V is used to detect faults in cable harnesses and controls. Checked by control system, error shown with error code. -
18 19 20
21
The frame control unit (D797-1) transmits fuel level on the CAN bus. Control unit KID (D795) shows the fuel level in the operating menu for the engine.
Section 11 Common electrics, group 11.5.3.2 Frame control unit Section 11 Common electrics, group 11.5.3.12 Control unit, KID
22
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1 Engine Engine
Pos
23
Explanation
If the rotation speed of the output shaft is so high that it corresponds with the limit for the machine's speed limitation then Control unit, cab (D790-1) sends reduce engine speed on the CAN bus. Control unit, engine (D794) limits the engine speed.
Signal description
Reference
Section 11 Common electrics, group 11.5.3.1 Control unit, cab
24
Section 11 Common electrics, group 11.5.3.10 Control unit, engine
VDCT01.02GB
1 Engine Engine
1:7
Engine alternative Cummins QSB6.7 function description

C
.
bar
0 P I II III
rpm kph
D5
10
<
1,5 D1 11, 19 D11 D790-2 2,6
D10 D14 3, 12, 14, 20 D794
D790-1
17 D12 D7
D797-1
D795
15, 18
D16 D4 4 SENSORS 9 8
Pos
1
H2O
13
D8
16
015016
Explanation
The ignition key lock sends a voltage signal to Control unit, cab (D790-1) when the ignition key is turned to position 1 or preheating mode. Cab control unit (D790-2) sends ignition on over the CAN bus. If the key is turned to the preheating mode, then preheating is also sent on the CAN bus.
Signal description
U = 24 V
Reference
Ignition key lock, description, page 1:20 D1: Diagnostic menu, see section 8 Control system, group 8.4.1.5 CAN/POWER, menu 5 and 8.4.6.4 ENGINE, menu 4
Section 11 Common electrics, group 11.5.3.11 Control unit, KIT
If preheating has been activated with the start key or automatically, then the engine control unit (D794) feeds voltage to the preheating relay and through this also the preheating coil (E800). The preheating coil heats the primary air to the engine. The ignition key lock sends a voltage signal to Control unit KIT (D790-2) when the ignition key is turned to start position. Control unit KIT (D790-2) sends a start signal on the CAN bus.
U = 24 V
4 5
U = 24 V
D4: Diagnostic menu, see section 8 Control system, group 8.4.6.5 ENGINE menu 5 Ignition key lock, description, page 1:20 D5: Diagnostic menu, see section 8 Control system, group 8.4.6.4 ENGINE menu 4
Section 11 Common electrics, group 11.5.3.11 Control unit, KIT
VDCT01.02GB
1:8
1 Engine Engine
Pos
7
Explanation
The starter motor is controlled by the engine control unit (D794) through starter relays and receives signals from the cab control unit KCU (D790-1) over the CAN bus. The starter motor cranks the engine.
Signal description
U = 24 V
Reference
The engine's sensor sends signals to Control unit, engine (D794) that controls the injectors so the engine starts. The accelerator pedal sends a voltage signal proportional the depression to Control unit, cab (D790-1).
Section 11 Common electrics, group 11.5.3.10 Control unit, engine Accelerator pedal, replacement, page 1:20 D10: Diagnostic menu, see section 8 Control system, group 8.4.6.1 ENGINE menu 1
10
U = 0.2-4.8 V Lower voltage than 0.2 V and higher voltage than 4.8 V is used to detect malfunction in cable harnesses and controls. Checked by control system, error shown with error code.
11
Control unit, cab (D790-1) sends a message with the rpm request on the CAN bus.
Section 11 Common electrics, group 11.5.3.1 Control unit, cab D11: Diagnostic menu, see section 8 Control system, group 8.4.6.1 ENGINE menu 1 Section 11 Common electrics, group 11.5.3.10 Control unit, engine D11: Diagnostic menu, see section 8 Control system, group 8.4.6.1 ENGINE menu 1
12
Control unit, engine (D794) increases the engine speed.
13
Make-contact (closing switch) coolant level sends a voltage signal to Control unit, engine (D794) if the coolant level is low in the expansion tank. Control unit, engine (D794) sends engine data and warning messages on the CAN bus.
U = 24 V
Cooling system, description, page 1:25
14
Section 11 Common electrics, group 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 and 8.4.6.9 ENGINE, menu 9 Section 11 Common electrics, group 11.5.3.12 Control unit, KID Sensor, fuel level, description, page 1:22 D16: Diagnostic menu, see section 8 Control system, group 8.4.3.7 CAB, menu 7
15 16
Control unit KID (D795) shows engine data via display figures. Sensor fuel level (B757) sends a voltage signal proportional to the fuel level in the tank to Control unit, frame (D797-1).
R = 0-70 ohm A warning message appears on the display if the amount of fuel in the tank is less than 15% for more than 40 seconds. Checked by control system, error shown with error code. -
17
The frame control unit (D797-1) transmits fuel level on the CAN bus. Control unit KID (D795) shows the fuel level and the machine speed in the operating menu for the engine.
Section 11 Common electrics, group 11.5.3.2 Frame control unit Section 11 Common electrics, group 11.5.3.12 Control unit, KID
18
VDCT01.02GB
1 Engine Engine
1:9
Pos
19
Explanation
If the rotation speed of the output shaft is so high that it corresponds with the limit for the machine's speed limitation then Control unit, cab (D790-1) sends reduce engine speed on the CAN bus. Control unit, engine (D794) limits the engine speed.
Signal description
Reference
20
Engine alternative Yuchai YC6A240-30, component placement

1 2 3 4 14 13 12 5
8 10 9
11
1. 2. 3. 4. 5. 6. 7.
Engine alternative Yuchai YC6A240-30, left-hand side (in the machine's direction of travel) Make-contact (closing switch), low coolant level (B759) Expansion tank Thermostat housing Connection radiator outlet Coolant pump Connection cab heating Drain radiator 8. 9. Connection radiator inlet Oil filter
10. Relay, starter motor (K360) 11. Starter motor (M654) 12. Connection exhaust system 13. Turbocharger 14. Air cleaner connection
VDCT01.02GB
014622
1:10
1 Engine Engine
1 2 3 4 5
10 9 8
1. 2. 3. 4. 5. Filling point engine oil Connection intercooler Relay preheating (K312) Preheating coil (E8000) Oil dipstick engine
7
6. 7. 8. 9.
6
Control unit, engine (D794) Fuel filter Connection intercooler Fuel pump
Engine alternative Yuchai YC6A240-30, right-hand side (in the machine's direction of travel)
10. Alternator
VDCT01.02GB
014641
1 Engine Engine
1:11
Engine alternative Cummins QSB6.7, component placement

4 3 2 1 5
10
7 8 9
Engine alternative Cummins QSB6.7, left side (in machine's direction of travel) 1. 2. 3. 4. 5. Oil dipstick engine Filling point engine oil Outlet exhaust system Outlet coolant to radiator Alternator 6. 7. 8. 9. Connections cab heating Coolant inlet Oil filter Starter motor
015097
10. Crankcase ventilation
VDCT01.02GB
1:12
1 Engine Engine
6 5 4
3 2 1
14
13
12 8 9 10
Engine alternative Cummins QSB6.7, right side (in machine's direction of travel) 1. 2. 3. 4. 5. 6. 7. Alternator Outlet coolant to radiator Turbo air inlet Turbo air outlet Oil dipstick engine Filling point engine oil Fuel filter 8. 9. Air inlet
Engine control unit (D794)
10. Drain engine oil 11. Vibration damper (rubber) 12. Fan drive 13. Water pump 14. Drive belt tensioner
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015096
11
1 Engine Engine
1:13
Components on the machine, component placement

1 2
0 P I II III
12
11
10
1. 2. 3. 4. 5. 6. Accelerator pedal (B690) Ignition key lock (S150) Control unit KIT (D790-2) Control unit, KID (D795) Control unit, cab (D790-1) Diagnostic socket drive-train
9
7. 8. 9.
8
Control unit, transmission (D793) Fuel tank Sensor fuel level (B757)
10. Control unit, frame front (D797-1) 11. Water in fuel sensor (B760) 12. Fuel pre-filter
VDCT01.02GB
014697
1:14
1 Engine Engine
Engine and transmission, separation (engine alternative Yuchai YC6A240-30)

Separation
1 2 3 Machine in service position, see section B Safety. Attach hoisting equipment to the engine. Disconnect the requisite hoses and cables before separating engine and transmission.
NOTE
Drain and collect liquids before detaching hoses.
Use a jack to secure the transmission.
Remove the cover washer on the clutch housing so that the flex plate's attaching bolts are accessible.
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1 Engine Engine
1:15
6 7 8
Remove the cover washer. Rotate the engine so that the bolts in the flex plate can be removed. Remove the screws for the flex plate. The flex plate has eight fastening points against for the flywheel on the engine.
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: 100120 Nm. M14: 140160 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.
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1:16
1 Engine Engine
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.
VDCT01.02GB
1 Engine Engine
1:17
Engine, replacement (engine alternative Cummins QSB6.7 )

Separation
1 2 3 Machine in service position, see section B Safety. Attach hoisting equipment to the engine. Disconnect the requisite hoses and cables before separating engine and transmission. If the engine is replaced the cooling unit must be removed.
NOTE
009088
Drain and collect liquids before detaching hoses. 4 5 Remove the radiator. Use a jack to secure the transmission.
Remove the screws holding the cover plate to the flywheel on the left side of the engine.
008314
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
008315
Do not lift the engine or transmission.
VDCT01.02GB
1:18
1 Engine Engine
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.
Transmission guide stud
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007769
1 Engine Engine
1:19
17 Lift the engine into place. Guide the stud through the flywheel and out through the hole in the flywheel housing. 18 Install the screws which fix the transmission and engine, but do not tighten the screws fully. Leave about a millimetre between the engine and transmission to facilitate installation of the screws for the flex plate/flywheel. 19 Remove the stud through the hole in the flywheel housing.
008319
20 Fit the screws that secure the flex plate by the flywheel in two steps. The first step without tightening the screws, then rotate the flywheel a further turn. Tighten to a torque of 35 Nm (oiled screw).
NOTE
Turn the engine over to access each screw on the flex plate.
008315
NOTE
The engine must be loosened from the engine mounts and separated from the transmission to remove a dropped bolt. Secure the bolt in the socket when installing. 21 Fit the bolts that secure the transmission and engine. Tighten to a torque of 52 Nm (oiled screw).
008275
22 Measure and check that the engine is centred in the frame. 23 Fit the screws in the engine bracket. Tighten to a torque of 169 Nm (oiled screw). 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.
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1:20
1 Engine Controls and instruments
1.1 Controls and instruments

1.1.1 Ignition
Ignition key lock, description
P 0 I No function. Stop position. Everything switched off, the key can be removed. 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
1 2 3 4 5 6 7 Machine in service position, see section B Safety. Pull one edge of the cover away to facilitate access to the accelerator pedal. Disconnect the cable harness from the connector. Unscrew the connector from the accelerator pedal. Replace the accelerator pedal. Fit in the reverse order. Calibrate the accelerator pedal. See section 8 Control system, group 8.5.2.3 Calibrate DRIVE-TRAIN.
1. 2.
Brake pedal Accelerator
Accelerator pedal, calibration

See section 8 Control system, group 8.5.2.3 Calibrate DRIVE-TRAIN.
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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 2 1
1. 2. 3.
Sensor fuel level Filling point fuel Fuel tank
015051
VDCT01.02GB
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 2 1
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 be checked via the diagnostic menu. See section 8 Control system, group 8.4.3.7 CAB, menu 7.
1. 2. 3.
Sensor fuel level Filling point fuel Fuel tank
015051
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).
Make-contact (closing switch) water in fuel, (engine alternative Yuchai YC6A240-30)
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014134
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 dust reservoir can be emptied without opening the air cleaner.
2 3
008040
Combustion in the engine requires air. Free unobstructed flow for fresh air and exhaust gases is essential for efficient engine operation. Particles are collected in the filter material when the air filters clean the air to the engine. Over time, a great deal of particle matter is collected and the filter does not let through sufficient air for efficient combustion, the filter must then be changed. The filter indicator measures the negative pressure on the engine side of the filter. When the filter is clogged the negative pressure is higher and the indicator indicates that it is time to replace the filter. As an option the machine can be equipped with a raised air intake.
Air cleaning system, overview 1. 2. 3. Dust reservoir Air cleaner 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 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!
1. 2. 3.
End pipe Silencer Exhaust pipe
014700
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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.
1 2 4 3
1. 2. 3. 4.
Intercooler Transmission oil cooler Radiator Condenser AC
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014686
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. 2. 3. 4. Coolant is circulated through the cylinder head, engine block and oil cooler by the coolant pump. The thermostat directs the heated coolant back to the coolant pump or through the radiator. The cooling fan blows air through the radiator. 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. Transmission oil (cooled in its own part of the cooling unit), see also section 2 Transmission, group 2.6.3 Oil cooler. Charge air (cooled in the upper part of the cooler unit), see also Intercooler, description, page 1:24.
1 2 4 3
See also Cooling system, description, page 1:25. For more information, see supplier documentation, engine.
1. 2. 3. 4.
Intercooler Transmission oil cooler Radiator Condenser AC
014686
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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. 1 2 3 4 5 Machine in service position, see section B Safety. Open the hood. Remove the cap on the expansion tank. Place a receptacle under the radiator and engine. (The cooling system holds about 40 l.) Drain the cooling system. Open the drain cock on the bottom of the radiator. Collect the coolant in the receptacle.
Drain cock coolant radiator. 6 7 8 Connect a hose to the drain cock on the engine and route the other end to the receptacle. Open the drain cock on the engine. Once all the coolant has drained out, close drain cocks.
Drain cock coolant engine, the illustration shows the tap closed.
VDCT01.02GB
014698
1 Engine Coolant
1:27
Fill the new premixed coolant of the correct type in the expansion tank. For volume and quality, see section F Technical data.
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.
C
A B C
014191
13 Check the level in the expansion tank, fill if necessary. 14 Close the hood. 15 Check the coolant level again after 10 operating hours.
Position for coolant reservoir (expansion tank) Filling point Sight glass, level check
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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. 1 2 3 4 5 Machine in service position, see section B Safety. Open the hood. Remove the cap on the expansion tank. Place a receptacle under the radiator and engine. (The cooling system holds about 40 l.) Drain the cooling system. Open the drain cock on the bottom of the radiator. Collect the coolant in the receptacle.
014698
6 7
Open the drain on the engine. Once all the coolant has drained out, close drain cocks.
Drain point coolant.
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015538
1 Engine Coolant
1:29
Fill the new premixed coolant of the correct type in the expansion tank. For volume and quality, see section F Technical data.
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.
C
1. 2. 3.
014191
13 Close the hood. 14 Check the coolant level again after 10 operating hours.
Position for coolant reservoir (expansion tank) Filling point Sight glass, level check
VDCT01.02GB
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.
VDCT01.02GB
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.
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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
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VDCT01.02GB
2 Transmission Transmission
2:3
2 Transmission
Transmission, general
The workshop manual only describes components and work descriptions that concern installation in the machine. For descriptions and instructions for the transmission'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.
Transmission, function description
. 4
1 23 D 23 6,24 5 D 5 D 1
D 1
D 7 9 0 -1 D 793 D 10
D 7 9 0 -2 D 794
2,7
D 795 D 7 9 7 -F
20
11,17,19,21,27 D 12 D 8 8
2 =
22
26 D 25
D 9
10
2 =
25 4 16 15 3 14 13
!&#
18
12
Pos
1
Explanation
The gear selector sends a voltage signal to Control unit KIT (D790-2).
Signal description
Forward, Conn. F: U = 24 V Reverse, Conn. R: U = 24 V
Reference
Section 9 Frame, body, cab and accessories, group 9.1 Controls and instruments D1: Diagnostic menu, see section 8 Control system, group 8.4.7.2, TRANSM menu 2
Control unit KIT (D790-2) transmits the selected direction of travel (forward or reverse) on the CAN bus.
Section 11 Common electrics, group 11.5.3.11 Control unit, KIT D1: Diagnostic menu, see section 8 Control system, group 8.4.7.2, TRANSM menu 2
The transmission's oil pump pumps oil when the engine is running.
VDCT01.02GB
2:4
Pos
4 5
Explanation
The transmission's oil filter cleans the oil from impurities. The accelerator pedal transmits a signal to Control unit, cab (D790-1).
Signal description
U = 0.5-4.5 V
Reference
Section 1 Engine, group 1.1.2 Accelerator pedal D5: Diagnostic menu, see section 8 Control system, group 8.4.6.1 ENGINE menu 1
Control unit, cab (D790-1) transmits the desired throttle application on the CAN bus. Control unit KIT (D790-2) sends the selected shifting program on the CAN bus. Sensor, oil pressure transmission (B765) sends a voltage signal proportional to the oil pressure to Control unit, transmission (D793). Sensor, turbine speed (B751) sends Control unit, transmission (D793) a pulse signal with frequency proportional to turbine speed. Sensor, oil temperature (B766) sends a voltage signal proportional to the transmission oil temperature to Control unit, transmission (D793). Control unit, transmission (D793) supplies voltage to the solenoid and servo valves in order to obtain the desired function. Solenoid valve clutch forward, (Y630) or Solenoid valve clutch reverse (Y631) is activated to select direction of travel. Solenoid valve clutch gear 1 (Y6067-1), or Solenoid valve clutch gear 2 (Y6069). Engine power is transferred to the transmission's output shaft. Control unit, transmission (D793) controls gear shifting according to selected shifting program. The oil cooler cools the transmission oil. A thermostat senses the oil's temperature and directs the oil back to the transmission if the oil is cold. Control unit, transmission (D793) transmits temperature and speed data on the CAN bus. Control unit KID (D795) shows transmission information in operating menus. Sensor, turbine speed (B751) indicates that the machine's speed exceeds the speed limit, sends Control unit, transmission (D793) requests for reduced engine speed on the CAN bus. Control unit, engine (D794) reduces the engine speed.
Checked by control system, error shown with error code. Checked by control system, error shown with error code. Checked by Control unit, transmission, error shown with error code. Checked by Control unit, transmission, error shown with error code. Checked by Control unit, transmission, error shown with error code. Checked by Control unit, transmission, error shown with error code. Checked by Control unit, transmission, error shown with error code. See also, Actuated valves in selected gear, page 2:5
Section 11 Common electrics, group 11.5.3.1 Control unit, cab Section 11 Common electrics, group 11.5.3.11 Control unit, KIT Transmission, component location, page 2:8
Transmission, component location, page 2:8
10
11
Section 11 Common electrics, group 11.5.3.9 Control unit, transmission
12 13 14 15 16
17
Checked by Control unit, transmission, error shown with error code. -
Section 11 Common electrics, group 11.5.3.9 Control unit, transmission Oil cooler, description, page 2:17
18
19
Checked by control system, error shown with error code. Checked by control system, error shown with error code. -
Section 11 Common electrics, group 11.5.3.9 Control unit, transmission Section 11 Common electrics, group 11.5.3.12 Control unit, KID Transmission, component location, page 2:8
20
21
22
Section11 Common electrics, group 11.5.3.10 Control unit, engine
VDCT01.02GB
2:5
Pos
23
Explanation
If the declutch pedal (S220-1) is depressed, it sends a voltage signal to Control unit, cab (D790-1).
Signal description
U = 24 V
Reference
Section 9 Frame, body, cab and accessories, group 9.1 Controls and instruments D23: Diagnostic menu, see section 8 Control system, group 8.4.7.1, TRANSM menu 1
24 25
Control unit, cab (D790-1) transmits declutch drive on the CAN bus. Make-contact (closing switch) declutch (S220-2) sends a voltage signal to Control unit, frame front (D797-F) if the brake pressure is high enough to allow declutch of the drive.
Checked by control system, error shown with error code. Brake pressure above 0.2 MPa: Conn 1, U = 24 V Conn 2, U = 24 V Brake pressure below 0.2 MPa: Conn 1, U = 24 V Conn 2, U = 0 V
Section 11 Common electrics, group 11.5.3.1 Control unit, cab Make-contact (closing switch) declutch, description, page 2:18 D25: Diagnostic menu, see section 8 Control system, group 8.4.7.1, TRANSM menu 1
26
Control unit, frame front (D797-F) sends declutch approved on the CAN bus. Control unit, transmission (D793) supplies voltage to valve block transmission control so that drive is declutched.
Checked by control system, error shown with error code. Checked by Control unit, transmission, error shown with error code.
Section 11 Common electrics, group 11.5.3.2 Control unit, frame front Section 11 Common electrics, group 11.5.3.9 Control unit, transmission
27
Table Actuated valves in selected gear
Y6067-1
Gear 1 Gear 2 Gear 3 On Off Off
Y6069
On On Off
VDCT01.02GB
2:6
Shifting transmission, function description

21 24 5 25 23 26 3 4 6 7 9 10 11 15 18 14 17
Pa
22 2 8
Pos
1 2
12
Signal description
30.4 l/min at 685 rpm
16
19
Reference
-
20
Explanation
Bottom strainer oil sump, separates particles from the oil before the pumps. The transmission's oil pump feeds the transmission with control pressure for control of the transmission. The oil filter cleans the oil. The bypass valve in the filter bracket leads the oil past the filter if the resistance through the filter becomes too high. The pressure regulator releases pressure to the torque converter if the pressure becomes too high. When the reverse direction of travel is selected Solenoid valve, clutch reverse (Y631) is supplied with voltage. The solenoid valve opens and directs pressure to valve slide clutch reverse. Valve slide clutch reverse pressurises drive clutch reverse and modulation valve forward. Drive clutch reverse locks the transmission in reverse drive when the clutch is pressurised. Modulation valve forward drains the pressure to drive clutch forward at the same rate as the driving clutch reverse is pressurised. When the forward direction of travel is selected Solenoid valve, clutch forward (Y630) is supplied with voltage. The solenoid valve opens and directs pressure to valve slide clutch forward. Valve slide clutch forward pressurises drive clutch forward and modulation valve reverse. Drive clutch forward locks the transmission in forward drive when the clutch is pressurised. Modulation valve reverse drains the pressure to drive clutch reverse at the same rate as the driving clutch forward is pressurised.
3 4
Opening pressure: 410-450 kPa
Opening pressure: 2200 kPa
7 8 9
Drive reverse: 2200-2600 kPa
10
11 12 13
Drive reverse: 2200-2600 kPa
VDCT01.02GB
014699
Rev
13
Fwd
1st
2nd
3rd
2:7
Pos
14 15
Explanation
Solenoid valve gear selection 1 (Y6067-1) pressurises valve slide gear selection 1. Valve slide gear selection 1 pressurises drive clutch gear 1 and cuts off the pressure to the gears. Drive clutch gear 1 locks the transmission in gear position 1 when the clutch is pressurised. Solenoid valve gear selection 2 (Y6069) pressurises valve slide gear selection 2. Valve slide gear selection 1 pressurises drive clutch gear 1 and cuts off the pressure to the gears. Drive clutch gear 2 locks the transmission in gear position 2 when the clutch is pressurised. 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. Sensor, oil pressure transmission (B765) sends a voltage signal proportional to the oil pressure in the transmission to Control unit, transmission (D793). Sensor, oil temperature (B766) sends a voltage signal proportional to the oil temperature to Control unit, transmission (D793). The safety valve leads the oil back to the sump if the pressure to the torque converter becomes too high. The torque converter transmits the engine's power to the transmission. The transmission oil cooler cools the oil. The oil is distributed to different lubrication points in the transmission.
Signal description
-
Reference
Transmission, component location, page 2:8 -
16 17 18
Transmission, component location, page 2:8 -
19 20
21
22
23
Opening pressure: 900 kPa
24 25 26
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2:8
Transmission, component location
1 15 16 14
13 17 12 11
1. 2. 3. 4. 5. 6. 7. 8. 9. Transmission oil cooler Oil pump transmission Oil filter transmission Sensor turbine speed (B751) Solenoid valve clutch reverse (Y631) Solenoid valve clutch gear 1 (Y6067-1) Drain plug and strainer transmission oil Solenoid valve clutch gear 2 (Y6069) Solenoid clutch forward (Y630)
7 10 9 8
014685
10. Valve block transmission control 11. Return from the transmission oil cooler 12. Breather filter transmission 13. Outlet to transmission oil cooler 14. Sensor oil temperature (B766) 15. Thermostat 16. Sensor, oil pressure transmission (B765) 17. Output shaft
VDCT01.02GB
2 Transmission Controls and instruments
2:9
11 6
10 7 9 8
1. 2. 3. 4. 5. 6. Accelerator pedal (B690) Control unit KIT (D790-2) Control unit, KID (D795) Multi-function lever (S162) Control unit, cab (D790-1) Diagnostic socket drive-train 7. 8. 9. Fuse transmission (F51-3) Control unit, transmission (D793) Declutch pedal (S220-1)
014694
10. Make-contact (closing switch) declutch (S220-2) 11. Frame control unit (D797-1)
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.
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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. 1 Machine in service position, see section B Safety. 2 Remove the cover plate.
3 4 5 6 7
Remove the cover plate and rotate the engine so that each bolt to the flex plate can be removed. Remove the screws for the flex plate. Attach the transmission to an overhead crane. Remove the bolts holding together the transmission and engine. Carefully separate the transmission and engine.
8 9
Remove the bolts holding the flex plate to the transmission. Replace the flex plate. Tighten the screws fixing the flex plate to the transmission to 40 Nm (oiled screws).
10 Apply lubricating grease to the converter connection - both on the engine and the gearbox. Insert a stud into one of the nuts on the flexible plate as a guide when the engine is installed. 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.
VDCT01.02GB
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. 1 Machine in service position, see section B Safety. 2 3 Remove the cover plate. Remove the screws for the flex plate. Rotate the engine for each bolt to the flex plate that has to be removed. 4 Attach the transmission to an overhead crane.
008314
5 6
Remove the bolts holding together the transmission and engine. Carefully separate the transmission and engine.
008275
7 8 9
Remove the bolts holding the flex plate to the transmission. Replace the flex plate. Tighten the screws fixing the flex plate to the transmission to 40 Nm (oiled screws). Apply lubricating grease to the converter connection - both on the engine and the gearbox. Insert a stud into one of the nuts on the flexible plate as a guide when the engine is installed.
Flex plate attachment.
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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).
008275
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. 12 Fit the screws that fasten the gearbox and engine and tighten them to 52 Nm (oiled screw).
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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 2 3 Operate and warm up the transmission oil. Machine in service position, see section B Safety. Remove the drain plug (position 2) and and let the oil drain into the receptacle. 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 6 Replace the strainer gasket. 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. 7 Remove the filter holder (position 1) and replace the oil filter. Tighten until it makes contact and then another two-thirds of a turn.
1
4
2 3
1. 2. 3. Oil filter holder Oil plug Strainer
014693
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2:14
2 Transmission Lubrication system
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.
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.
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 C. Use the oil temperature operating menu to check transmission oil temperature.
a b
Operating menu, oil temperature a b Transmission oil temperature Hydraulic oil temperature
000356
014193
13 Check the oil level. Fill to the MAX mark.
Oil level, checking
NOTE
Read the safety instructions for oil before working, see section B Safety. The transmission's oil filler pipe and dipstick are located under the engine hood in front of the cab.
VDCT01.02GB
2 Transmission Oil cooler
2:15
Check the oil level with the engine at idle, transmission in neutral position and at operating temperature (approx. 85 C 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
A. Oil dipstick transmission oil B. Oil filling transmission oil
Work carefully when filling transmission oil to prevent other fluids or particles from contaminating the oil. Other fluids or particles in the transmission oil means a risk of transmission damage.
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 operating temperature more quickly. For more information, see supplier documentation, transmission.
1 2 4 3
1. 2. 3. 4.
Intercooler Radiator, transmission oil Radiator, engine Condenser (for AC)
014686
VDCT01.02GB
2:16
2 Transmission Oil cooler
Thermostat transmission oil cooler, replacement
NOTE
Read the safety instructions for oil before working, see section B Safety. 1 2 3 4 5 Machine in service position, see section B Safety. Drain the oil from the transmission, see Oil and oil filter, changing, page 2:13. Loosen the cover plug and remove the thermostat. Check the O-ring and the spring in the bottom, replace as necessary. Fit the new thermostat, and the cover plug.
014550
IMPORTANT
It is very important that the thermostat is turned with the temperature bulb facing out as shown.
6 7 8 Fill with transmission oil; see Oil and oil filter, changing, page 2:13. Start the engine and check for leaks. Check the transmission oil level, see Oil level, checking, page 2:14.
VDCT01.02GB
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.
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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.
10 1 3 5 9 8
1 2 3 4 5 6
009865
1. 2. 3. 4. 5. 6. 7. 8. 9.
Connection brake cooling, return from wheel brake Connection brake cooling, return to radiator and tank Connection brake cooling, to wheel brake Connection brake cooling, from accumulator charging valve Connection brake cylinder, to wheel brake Connection brake pressure, from brake valve Make-contact (closing switch), declutch (S220-2) Make-contact (closing switch), brake light (S216) 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.
VDCT01.02GB
3:1
3 Power transmission
Contents 3 Power transmission

3 3.2 3.3 Power transmission ...........................................................................................3:3 Propeller shaft..................................................................................................3:3 Drive axle .........................................................................................................3:4
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3:2
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3 Power transmission Power transmission
3:3
3 Power transmission
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

1 2 Machine in service position, see section B Safety. Clean the contact surfaces (cross-toothed) on the drive axle and gearbox.
3 4
Fit the propeller shaft in position with the coupling upward. Fit the propeller shaft's attaching bolts. Tightening torque: 98 Nm (oiled bolt). Retighten the attaching bolts after 50 operating hours.
005193
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3:4
3 Power transmission Drive axle
3.3 Drive axle

Drive axle, general
The workshop manual only describes components and work descriptions that concern installation in the machine. For descriptions and instructions for the drive axle'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.
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 2 3 4 Remove the mast, see section 7 Load handling, group 7.2 Lifting/lowering. Park the machine with blocks behind the steering wheels. Depressurise the hydraulic systems, See section B Safety. Turn the start key to position 0 and switch off the main power.
Insert wedges between the steering axle and the frame.
VDCT01.02GB
3:5
Detach the hydraulic hoses (position 1) and cable harness (position 2) from the distribution block.
NOTE
Plug all connections immediately to protect the hydraulic system from impurities.
2
1. Hydraulic hoses 2. Cables
004501
Remove the cover (position 3) on the parking brake.
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). Detach the hydraulic hose (position 6) from the parking brake.
004505
NOTE
5 4
4. Lock nut 5. Release screw 6. Hydraulic hose, parking brake
004506
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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
Attaching bolts drive axle
VDCT01.02GB
3:7
16 Undo the hydraulic hoses on the drive axle.
NOTE
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.
VDCT01.02GB
3:8
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
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. 33 Check for leaks.
VDCT01.02GB
004501
4:1
4 Brakes
Contents 4 Brakes
4 Brakes..................................................................................................................4:3 4.1 Controls and instruments .................................................................................4:3 4.1.1 Brake pedal .................................................................................................4:3 4.3 Power-assisted brake system ..........................................................................4:5 4.3.1 Hydraulic oil pump.......................................................................................4:6 4.3.2 Brake oil filter ..............................................................................................4:6 4.3.3 Accumulator charging valve ........................................................................4:7 4.3.4 Accumulator ..............................................................................................4:10 4.3.5 Brake valve ...............................................................................................4:14 4.3.6 Drive axle block .........................................................................................4:18 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
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4 Brakes Brakes
4:3
4 Brakes
4.1.1 Brake pedal Brake pedal, checking and adjustment
1 2 Clean the floor round the brake pedal and check that nothing is obstructing the movement of the brake pedal. 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. 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 5 6 Lubricate the pedal hinge with "EP2" universal grease. Check that the rubber pad on the brake pedal is intact and that the tread pattern is not worn away. Replace if necessary. 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
Read the safety instructions for oil before working, see section B Safety. 1 2 3 Switch off the engine and switch off the system voltage. Depressurise the brake and hydraulic systems, see section B Safety. Detach the brake valve from the brake pedal. Secure the brake valve on the cab's underside and remove the brake valve attaching bolt.
VDCT01.02GB
4:4
4 Brakes Brake pedal
Remove the panel around the steering wheel shaft.
NOTE
There is a variant available with adjustable steering wheel shaft.
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.
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 8
Detach the declutch pedal from the brake pedal. Remove the brake pedal. Remove the brake pedal's attaching bolt and lift away the brake pedal.
9 Mounting of steering wheel shaft and steering valve in pedal assembly.
Transfer the pedal rubber to the new pedal.
10 Fit the new brake pedal. Fit the pedal and fit the pedal's attaching bolts. 11 Connect the steering valve to the brake pedal. 12 Connect the brake valve to the brake pedal. 13 Fit the clutch pedal to the brake pedal. 14 Close accumulator drain valve.
NOTE
Check that the accumulator drain valve is fully closed and tighten the lock ring. 15 Lubricate and adjust the brake pedal, see Brake pedal, checking and adjustment, page 4:3.
VDCT01.02GB
"$'
4 Brakes Power-assisted brake system
4:5
4.3 Power-assisted brake system

Power-assisted brake system, function description
14 D11 11 D12 2 C
P
D790-2
P
B T
10, 13
D797-1
5 4
9
Pa
D9
C 12 P a
ACK M LB P T P T
8 7
B
Pos
1
Explanation
Hydraulic oil pump for the brakes and steering pumps oil from the hydraulic oil tank. Valve block accumulator charging and priority valves direct the pressure to the Valve block brakes when the steering does not require hydraulic power. Valve block brakes leads the oil on to accumulators and drive axle block. The accumulators store hydraulic oil pressure. The brake valve directs pressure from the accumulators to the brake cylinder proportional to the pressure on the pedal. Drive axle block distributes the brake pressure to the wheel brakes. The brake cylinder compresses the discs in the brake unit which stops the machine. The wheel brakes brake the machine.
Signal description
See the pressure plate on the left-hand frame beam. -
Reference
Hydraulic oil pump, general, page 4:6
Accumulator charging valve, description, page 4:7
Valve block brake system, description, page 4:27 Accumulator, description, page 4:10 Brake valve, description, page 4:14
4 5
6 7
Drive axle block, description, page 4:18 Wheel brakes, description, page 4:24
Wheel brakes, description, page 4:24
VDCT01.02GB
015034
4:6
4 Brakes Hydraulic oil pump
Pos
9
Explanation
Make-contact (closing switch) brake light (S216) makes the circuit and sends the voltage signal to the Frame control unit (D797-1) when the brake cylinders are pressurised.
Signal description
Brake pressure above 0.2 MPa: Conn. 1, U = 24 V Conn. 2, U = 24 V Brake pressure below 0.2 MPa: Conn. 1, U = 24 V Conn. 2, U = 0 V
Reference
Make-contact (closing switch) brake lights, description, page 4:21 D8: Diagnostic menu, see section 8 Control system, group 8.4.5.4 HYD, menu 4
10
The frame control unit (D797-1) supplies power to the brake light lamps. Brake light lamps (H411L and H411R) come on.
Controlled by control system, error shown with error code. U = 24 V
Section 11 Common electrics, group 11.5.3.2 Frame control unit Section 9 Frame, body, cab and accessories, group 9.6.4 Brake lights D11: Diagnostic menu, see section 8 Control system, group 8.4.2.8 LIGHTS, menu 8
11
12
Break contact (opening switch) brake pressure (S204) breaks the circuit and sends the voltage signal to the Frame control unit (D797-1) if the pressure in the accumulators is low.
Brake pressure above 11.5 MPa: Conn. 1, U = 24 V Conn. 2, U = 24 V Brake pressure below 11.5 MPa: Conn. 1, U = 24 V Conn. 2, U = 0 V
Brake pressure NC switch, description, page 4:19 D9: Diagnostic menu, see section 8 Control system, group 8.4.5.4 HYD, menu 4
13
The frame control unit (D797-1) transmits a warning about low brake pressure on the CAN bus. Control unit KIT (D790-2) activates Warning lamp brake pressure.
Controlled by control system, error shown with error code. Controlled by control system, error shown with error code.
Section 11 Common electrics, group 11.5.3.2 Frame control unit Section 11 Common electrics, group 11.5.3.11 Control unit, KIT
14
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.
VDCT01.02GB
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.
1 2 3
The accumulator charging valve distributes the oil from the hydraulic oil pump brakes and steering between pressure storage and cooling of the wheel brakes. The accumulator charging valve stores pressure 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 13 12 11 10 9 8 7

015032
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 6 to pressure storage. There are measuring points on the accumulator charging valve for measuring control pressure (position 4), servo pressure (position 9), accumulator charging pressure (position 10) and pump pressure brakes and steering (position 13). The pressure is individual for each machine and can be found on the pressure plate of the left front wing.
Valve block accumulator charging and priority valve (a part of the main valve) 1. 2. 3. 4. 5. 6. 7. 8. 9. Feed from the hydraulic oil pump brake and steering [P] Adjuster screw control pressure Return to filter [D] Measuring outlet control pressure [LSM] Connection brake cooling [SPOL] Connection control valve, pilot pressure [LSO] Feed control valve [O] Adjuster screw pressure accumulator charging 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]
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4:8
Accumulator charging, checking and adjustment
NOTE
Read the safety instructions for oil before working, see section B Safety. 1 2 Operate and warm up the machine so that the oil in the hydraulic system reaches operating temperature, at least 50 C. Machine in service position, see section B Safety. Depressurise the hydraulic systems, See section B Safety.
C
Operating menu, hydraulic oil temperature
000475
4 5
Connect a pressure gauge (0-25 MPa) to the accumulator charging pressure measuring outlet on the accumulator charging valve. Start the engine and run it at idle.
Measuring outlet accumulator charging pressure [ACC M] 6 Close accumulator drain valve.
Close the accumulator drain valve
VDCT01.02GB
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014653
4:9
7 8
Check that the pressure slowly rises to the specified accumulator charging pressure on the pressure plate. Brake repeatedly and check at which pressure the accumulator charging valve switches to charging. The valve must switch to charging at 130.5 MPa.
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.
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 59 until the pressure is correct. 12 Depressurise the hydraulic systems, See section B Safety. 13 Remove the pressure gauge and fit the protective cap on the measuring outlet.
Open the accumulator drain valve.
"$&
015028
015021
VDCT01.02GB
4:10
4 Brakes Accumulator
14 Close accumulator drain valve.
NOTE
Check that the accumulator drain valve is fully closed and tighten the lock ring.
Close accumulator drain valve.
"$'
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 hydraulic's reducing valve.
009869
Brake system accumulators
NOTE
If the accumulator delivers low oil pressure, the pumps may be damaged and the hydraulic functions may stop working.
VDCT01.02GB
4:11
Accumulator, checking
NOTE
Read the safety instructions for oil before working, see section B Safety. 1 2 Operate and warm up the machine so that the oil in the hydraulic system reaches operating temperature, at least 50 C. Machine in service position, see section B Safety. Depressurise the hydraulic systems, See section B Safety. The accumulators can be tested with separate test equipment or in the machine. Primarily, separate test equipment should be used since it is faster and more accurate. Test equipment can be ordered from Cargotec. Test with test equipment: continue with step 4. Test in machine: continue with step 6.
C
000475
3 4
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.
Pressure plate, gas pressure brake accumulators
015030
Checking in the machine
2 1
Detach one of the accumulators from the distribution block. Plug the connection on the distribution block with a plug that can withstand high pressure. Plug the connection on the accumulator to protect against impurities.
1. 2. 3.
Clamp Screw Distribution block
009871
VDCT01.02GB
4:12
Connect a pressure gauge (0-25 MPa) to the accumulator charging pressure measuring outlet on the Valve block accumulator charging and priority valve. Turn on the main electric power and start the engine.
Measuring outlet accumulator charging pressure [ACC M] 10 Close the accumulator charging valve and charge the accumulator until the accumulator charging valve changes to cooling.
014653
NOTE
Check that the accumulator drain valve is fully closed and tighten the lock ring. 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.
"$'
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. 14 Depressurise the hydraulic systems, See section B Safety. 15 Mark up and disconnect the tested accumulator. Plug the connections. Connect the other accumulator to the distribution block. 16 Repeat steps 6-13. 17 Depressurise the hydraulic systems, See section B Safety.
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. 19 Turn on the main electric power and start the engine.
VDCT01.02GB
4:13
20 Close the accumulator drain valve so that the accumulators charge.
NOTE
Check that the accumulator drain valve is fully closed and tighten the lock ring. 21 Check that the accumulators' connections are sealed tightly. 22 When the accumulators are fully charged, switch off the engine and turn the start key to position I.
"$'
23 Check that at least 8 brake applications (pedal depressions) can be performed before the pressure drops to 10 MPa. At 11.5 MPa the warning lamp for low brake pressure must be switched on.
Accumulator, replacement
NOTE
Read the safety instructions for oil before working, see section B Safety. 1 2 3 4 Machine in service position, see section B Safety. Switch off the engine and switch off the main electric power. Depressurise the hydraulic systems, See section B Safety. Detach the accumulator's clamp and remove the bolt. Detach the accumulator from the distribution block.
2 1
NOTE
Hold the block firmly so that the other accumulator does not work loose. 6
009871
Bend the clamp away and remove the accumulator. Fit the new accumulator.
1. 2. 3.
Clamp Screw Distribution block 8 9
NOTE
Check that the seal is intact, clean and fitted in the correct position. Secure the accumulator's clamp and tighten the bolt. Close accumulator drain valve.
NOTE
Check that the accumulator drain valve is fully closed and tighten the lock ring. 10 Turn on the main electric power and start the engine. 11 Check that the accumulator's connection is sealed tightly. 12 Check precharging and function, see Accumulator, checking, page 4:11 steps 18-22.
"$'
VDCT01.02GB
4:14
4 Brakes Brake valve
4.3.5 Brake valve

Brake valve, description
3 2 1
The brake valve, which is located on the underside of the cab underneath the brake pedal, controls the hydraulic pressure to the brakes. A lever transfers pedal force to the valve. 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).
1. 2. 3.
Inlet from accumulator [P] Return connection [T] Outlet to brake cylinders [B]
009872
Brake valve, checking
NOTE
C
000475
Connect a pressure gauge (025 MPa) to the measuring outlet for brake pressure on the distribution block on the front axle.
VDCT01.02GB
4:15
NOTE
Check that the accumulator drain valve is fully closed and tighten the lock ring. 6 7 8
"$'
Start the machine and run it at idle until the accumulators are charged and the accumulator charging valve changes to cooling. Press down the pedal completely and read off the pressure. Compare with the pressure plate on the left-hand frame member. Turn off engine.
Close the accumulator drain valve 9 Depress the pedal fully and keep it pressed down, check the pressure. The brake pressure must correspond with the value specified on the pressure plate and must not decrease from this value for 15 seconds. 10 Release the pedal, the brake pressure must decrease to 0 MPa immediately. Otherwise the brake valve is not sealed and could cause the brakes to remain applied and then overheat during operation. Replace the brake valve if it is not sealed. 11 Depressurise the hydraulic systems, See section B Safety. 12 Remove the pressure gauge and fit the protective cap on the measuring outlet.
Pressure plate, brake pressure 13 Close accumulator drain valve.
015026
NOTE
"$'
VDCT01.02GB
4:16
Brake valve, replacement
NOTE
Read the safety instructions for oil before working, see section B Safety. 1 2 Machine in service position, see section B Safety. Depressurise the hydraulic systems, See section B Safety. Mark up and detach the hydraulic hoses from the brake valve.
B T P
NOTE
Plug all connections immediately to protect the brake system from impurities. 4 Secure the brake valve under the cab.
009875
5 6 7 8
Remove the brake valve's attaching bolt. Remove the brake valve. Transfer the connection adapters to the new brake valve. Install the new brake valve.
NOTE
Remember the spacer ring.
B T P
Connect the hydraulic hoses to the brake valve in accordance with the marking.
NOTE
Check that the O-rings are intact, clean and in the correct position.
004795
10 Lubricate and adjust the brake pedal, see Brake pedal, checking and adjustment, page 4:3.
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4:17
NOTE
Check that the accumulator drain valve is fully closed and tighten the lock ring. 12 Turn on the main electric power and start the engine. Let the engine run at idle speed. 13 Test the brakes a couple of times. 14 Check that the brake valve's connections are sealed tightly.
"$'
15 Bleed the wheel brakes' brake cylinders, see Wheel brakes, bleeding, page 4:25.
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4:18
4 Brakes Drive axle block
4.3.6 Drive axle block

Drive axle block, description
10 1 3 5 9 8 1 and left-hand wheel brakes. The drive axle block is fitted on a bracket 2 above the drive axle differential. 3 The drive axle block has a measuring outlet for brake pressure and
for measuring back pressure in the disc brake's cooling circuit. The drive axle block distributes oil flow and brake pressure to the right
4 5 6
The drive axle block has a bypass valve which leads oil directly from the cooling circuit intake to the cooling circuit return if the resistance in the axle becomes too great. This protects the wheel brake seals, e.g. when the oil is cold. (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.
7 There are two contacts in the drive axle block: brake light NO switch
1. 2. 3. 4. 5. 6. 7. 8. 9.
Connection brake cooling, return from wheel brake Connection brake cooling, return to radiator Connection brake cooling, to wheel brake Connection brake cooling, from accumulator charging valve Connection brake cylinder, to wheel brake Connection brake pressure, from brake valve Make-contact (closing switch), declutch (S220) Make-contact (closing switch), brake light (S216) Measuring outlet, brake pressure
10. Measuring outlet, back pressure brake cooling
VDCT01.02GB
009876
4 Brakes Break contact (opening switch) brake pressure
4:19
4.3.7 Break contact (opening switch) brake pressure

Brake pressure NC switch, description
1 2 3 4 5 11 6 7 9 8
Break contact (opening switch) brake pressure (S204) detects the pressure in the accumulators. Break contact (opening switch) located 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. When the pressure in the feed circuit is high enough to ensure braking of the machine, the sensor closes an electric circuit. This is used to warn for pressure-drop in the brake system. The sensor's opening pressure is chosen so that there is pressure for at least another 8 brake applications without additional feed from the pump after the lamp has illuminated. Break contact (opening switch) brake pressure (S204) voltage fed by Frame control unit (D797-1). When the pressure increases above the cut-off pressure, the voltage signal to the Frame control unit (D797-1) is cut. The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.5.4 HYD, menu 4.
015018
10
Valve block brake system 1. 2. 3. 4. 5. 6. 7. 8. 9. Solenoid valve parking brake (Y642) Accumulator drain valve Pressure limiting valve Connection tank return [T] Switch (NO), parking brake (S200) Brake pressure NC switch (S204) Connection, parking brake caliper [HB] Connection feed from accumulator charging and priority valve [P] Connection, accumulators [ACC]
10. Connection brake valve [P] 11. Connection brake valve [T]
Brake pressure NC switch, adjusting
NOTE
C
000475
VDCT01.02GB
4:20
4 Brakes Break contact (opening switch) brake pressure
Connect a pressure gauge (0-25 MPa) to the accumulator charging pressure measuring outlet on the Valve block accumulator charging and priority valve.
Measuring outlet accumulator charging pressure [ACC M] 5 Close accumulator drain valve.
014653
NOTE
Check that the accumulator drain valve is fully closed and tighten the lock ring. 6 7 8
"$'
Start the engine and fully charge the accumulators (the accumulator charging valve changes to cooling). Stop the engine and turn the start key to position I. Brake several times, stop when the warning lamp for low brake pressure comes on. Read the accumulator charging pressure. The pressure should be approx. 11.5 MPa.
10 If necessary, adjust the warning level by turning the adjusting screw in the rear edge of the sensor, between the contact pins.
NOTE
The setting is very sensitive, turn max. 1/4 turn at a time. 11 Repeat steps 6-10 until the warning lamp illuminates at 11.5 MPa. 12 Seal the adjusting screw with locking fluid. 13 Depressurise the hydraulic systems, See section B Safety. 14 Remove the pressure gauge and fit the protective cap on the measuring outlet.
VDCT01.02GB
4 Brakes Make-contact (closing switch) brake lights
4:21
NOTE
"$'
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). The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.5.4 HYD, menu 4.
009878
Make-contact (closing switch) brake light, checking
NOTE
Read the safety instructions for oil before working, see section B Safety. 1 2 Operate and warm up the machine so that the oil in the hydraulic system reaches operating temperature, at least 50 C. Stop the engine and turn the start key to position I. Brake and check that the brake light is switched on. Depressurise the hydraulic systems, See section B Safety.
C
000475
3 4
VDCT01.02GB
4:22
Connect a pressure gauge (0-25 MPa) to the measuring outlet for brake pressure on the distribution block.
Measuring outlet, brake pressure 6 Close accumulator drain valve.
NOTE
Check that the accumulator drain valve is fully closed and tighten the lock ring. 7 Start the engine.
Close accumulator drain valve. 8
"$'
000144
DIAG HYD 4(6) PRESSURE SWITCHES BRAKE PRESSURE X BRAKE LIGHT PRESS. X DECLUTCH PRESSURE X
Use the display, go to the diagnostic menu, see section 8 Control system, group 8.4.5.4 HYD, menu 4. BRAKE LIGHT PRESS. indicates status for the brake light switch. 1 = Activated switch (brakes applied).
Depress the brake pedal slowly until the brake light is switched on or the status of the input signal changes. Keep the pedal in this position and check the pressure on the pressure gauge. The status should change and the brake light should be switched on when the pressure is approx. 0.2 MPa.
10 Turn off engine. 11 Depressurise the hydraulic systems, See section B Safety. 12 Remove the pressure gauge and fit the protective cap on the measuring outlet.
VDCT01.02GB
4:23
NOTE
"$'
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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. The disc pack performs the braking. The brake cylinder presses the discs in the disc pack together during braking.
Wheel hub and brake, cross-section 1. 2. Disc pack Brake cylinder
VDCT01.02GB
000016
4 Brakes Wheel brakes
4:25
Wheel brakes, bleeding
NOTE
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.
1 2 Machine in service position, see section B Safety. 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 4 Start the machine and depress the brake pedal, keep the pedal depressed. 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 Bleed nipple, brake cylinder, on top of the drive axle at the wheel hub's inner short side (left-hand side). 6 7 Close the bleed nipple. Move the spanner and hose and repeat steps 1-5 on the other side. Check the oil level in the brake system, fill if necessary.
Wheel brake, replacement

See supplier documentation, drive axle.
VDCT01.02GB
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 axle and those fixed to the hub reduction.
Disc pack
000008
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.
Brake cylinder
000007
4.3.10 Pipes and hoses

Piped and hoses, description
See section 10 Common hydraulics, group 10.5.1 Pipes and hoses.
VDCT01.02GB
4 Brakes Valve block brake system
4:27
4.3.12 Valve block brake system

Valve block brake system, description
Solenoid valve parking brake
3 4 5
Solenoid valve parking brake

See Solenoid valve parking brake, description, page 4:31
Accumulator drain valve

The accumulator drain valve (position 2) is located on the valve block brake system and is used to drain the pressure in the accumulators to the tank. The valve opens a connection between the accumulators and the wheel brake's cooling circuit. The oil is drained through the wheel brake to the tank. See section 10 Common hydraulics group 10.2.1 Accumulator drain valve.
11
6 7 9 8
10
Pressure limiting valve

See section 10 Common hydraulics group 10.2.4 Pressure limiting valve.
Break contact (opening switch) parking brake

015018
See Break contact (opening switch) parking brake, description, page 4:36.
Break contact (opening switch) brake pressure

See Brake pressure NC switch, description, page 4:19.
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4:28
4 Brakes Valve block brake system
Valve block brake system, replacement
NOTE
Read the safety instructions for oil before working, see section B Safety. 1 2 3 4 Depressurise the hydraulic systems, See section B Safety. Mark and disconnect the cable harness from the valve block. Mark up and detach the hydraulic hoses from the valve block. Move the components to the new valve and assemble the valve in the reverse order.
NOTE
VDCT01.02GB
"$'
4 Brakes Parking brake system
4:29
4.5 Parking brake system

Parking brake system, function description
D1 1 2 D790-1 3, 8 D7 4 C C
P ACK M
10
D790-2
D797-1
D4 13
7
Pa
GHB P T HB
6 12
11
P
Pos 1 Explanation Switch parking brake (S107) activates the parking brake. The switch uses two signals, one for applied and one for released parking brake. Both signals must be correct to enable release of the parking brake. Signal description Switch activated: Conn. 1, U = 24 V Conn. 7, U = 0 V Switch in home position: Conn. 1, U = 0 V Conn. 7, U = 24 V 2 The cab control unit (D790-1) transmits Activate parking brake on the CAN bus. The frame control unit (D797-1) activates the parking brake solenoid valve (Y642). Controlled by control system, error shown with error code. U = 24 V Section 11 Common electrics, group 11.5.3.1 Control unit, cab Solenoid valve parking brake, description, page 4:31 D7: Diagnostic menu, see section 8 Control system, group 8.4.5.5 HYD, menu 5 4 Solenoid valve parking brake (Y642) acts on the valve slide which drains pressure in the parking brake's brake caliper to tank. The brake caliper is drained of pressure and the spring applies the parking brake. Valve block brake system directs the hydraulic oil to the hydraulic oil tank. Solenoid valve parking brake, description, page 4:31 Reference Section 9 Frame, body, cab and accessories, group 9.1 Controls and instruments D5: Diagnostic menu, see section 8 Control system, group 8.4.5.5 HYD, menu 5
5 6
0 MPa -
Parking brake unit, description, page 4:32 Valve block brake system, description, page 4:27
VDCT01.02GB
015036
4:30
4 Brakes Hydraulic oil pump
Pos 7
Explanation Break contact (opening switch) parking brake (S200) breaks the circuit and sends the voltage signal to the Frame control unit (D797-1) when the pressure drops.
Signal description Applied parking brake: Conn. 1, U = 24 V Conn. 2, U = 0 V Released parking brake: Conn. 1, U = 24 V Conn. 2, U = 24 V
Reference Break contact (opening switch) parking brake, description, page 4:36 D10: Diagnostic menu, see section 8 Control system, group 8.4.5.5 HYD, menu 5
The frame control unit (D797-1) transmits Parking brake applied on the CAN bus. Control unit KIT (D790-2) activates indicator light, parking brake (508). Indicator light parking brake comes on. The hydraulic oil pump pumps hydraulic oil from the hydraulic oil tank. Valve block accumulator charging and priority valve directs oil to charging of the accumulators or the brake system's cooling circuit. The accumulators store the oil pressure used when the parking brake is released.
Controlled by control system, error shown with error code. Controlled by control system, error shown with error code. See pressure plate on left frame beam. See pressure plate on left frame beam.
Section 11 Common electrics, group 11.5.3.2 Frame control unit Section 9 Frame, body, cab and accessories, group 9.1 Controls and instruments Section 11 Common electrics, group 11.5.3.11 Control unit, KIT Hydraulic oil pump, general, page 4:6 Accumulator charging valve, description, page 4:7
10 11 12
13
See pressure plate on left frame beam.
Accumulator, description, page 4:10

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.
4.5.2 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.
VDCT01.02GB
4 Brakes Solenoid valve parking brake
4:31
4.5.3 Solenoid valve parking brake

Solenoid valve parking brake, description
1 2 3 4 5 11 6 7 9 8
Solenoid valve parking brake (Y642) activates the parking brake. The solenoid valve is fitted on the valve block brake system, which is fitted 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 and the parking brake caliper on activation. This means that the parking brake caliper is pressurised and the parking brake is released. When the voltage feed to the solenoid valve is cut off, the connection between the accumulators and parking brake caliper is closed. Instead, a connection between the parking brake caliper and tank is opened and the parking brake is applied. This means that the parking brake is applied if the machine becomes de-energised or if the brake system becomes depressurised. The solenoid valve is supplied with voltage by the frame control unit (D797-1) at activation. The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.5.5 HYD, menu 5.
015018
10
VDCT01.02GB
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. Switch off the engine and turn the start key to position I. 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. Activate the parking brake with the switch for the parking brake and check that the parking brake's brake caliper is applied.
2 3
4.5.4 Parking brake unit

Parking brake unit, description
3 1 2
The parking brake unit keeps the machine stationary when parked. The parking brake unit is fitted on the drive axle input shaft between the propeller shaft and drive axle. The parking brake acts on the universal drive shaft via a disc mounted on the drive axle input shaft and a brake calliper with dry brake pads mounted in a bracket on the drive axle.
NOTE
If the hydraulic pressure in the feed circuit drops, a warning is activated before the pressure drops so low that the parking brake is applied. If the parking brake is applied while the machine is in motion, the brake disc and brake pads must be replaced.
1. 2. 3.
Cover Parking brake caliper Parking brake disc
VDCT01.02GB
009881
4:33
Parking brake unit, checking and adjustment
DANGER
1 2 3 4 5 6 Start the engine and fully charge the accumulators (the accumulator charging valve changes to cooling). Switch off the engine and turn the start key to position I. Release the parking brake. Check that the parking brake caliper can move on the bracket. Check that the brake disc is free from oil and dirt. Remove the cover from the brake calliper and check for oil inside the cover. Oil inside the cover indicates internal leakage.
7 8 9
Loosen the lock nut. Adjust the adjusting screw so that the brakes are applied. Turn back the adjusting screw so that the clearance between pad and disc is 0.50.1 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.
VDCT01.02GB
4:34
4.5.4.1 Parking brake caliper Brake caliper, description

1 2 3 4 5
The brake caliper has a spring section and a hydraulic section. The spring section applies the brake while the hydraulic section is used to release the brake. This means that the parking brake is applied if the brake system loses pressure. This, in turn, means that the machine is braked if a serious fault arises.
1. 2. 3. 4. 5.
Brake pads Release cylinder Thrust spring Slackening screw Adjusting washer
000020
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
1 2 Machine in service position and wheels blocked, see section B Safety. Remove the cover from the brake caliper.
VDCT01.02GB
4:35
3 4 5
Loosen the lock nut. Slacken the adjusting screw to release the brake pads. Remove the split pin and undo the nut on one of the attaching bolts holding the parking brake caliper in place.
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 8 9 Remove the parking brake pads. Clean the brake disc with methylated spirit. 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.
VDCT01.02GB
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
1 2 3 4 5 11 6 7 9 8
Break contact (opening switch) parking brake (S200) detects whether the parking brake is applied or released. The break contact (opening 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. Break contact (opening switch) parking brake (S200) senses the pressure in the parking brake circuit. When the pressure is so high that the parking brake is released, the sensor opens an electric circuit. This is used to indicate that the parking brake is released. Break-contact (opening switch) parking brake light (S200) is supplied voltage by and sends a voltage signal to Frame control unit (D797-1). When the pressure increases above the cut-off pressure, the voltage signal to the Frame control unit (D797-1) is cut. The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.5.5 HYD, menu 5.
10
NOTE
015018
Gears cannot be engaged when the parking brake is applied.

4.5.7 Valve block brake system

Valve block brake system, general
See Valve block brake system, description, page 4:27.
VDCT01.02GB
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
VDCT01.02GB
5:2
VDCT01.02GB
5 Steering Steering
5:3
5 Steering
5.2 Power assisted system
Power assisted system, function description
2 C1
P O LSO
C3
P LS T L R
2 1 4
015017
Pos
1
Explanation
Hydraulic oil pump brake and steering pumps oil to the Valve block accumulator charging and priority valve. Valve block accumulator charging and priority valve gives priority to the oil feed to the control valve over accumulator charging and cooling to the brakes. The steering wheel is turned and acts on the steering valve\qs input shaft. The control valve directs oil pressure from the hydraulic oil pump brake and steering to the steering cylinder.
Signal description
See the pressure plate on the left-hand frame beam. Checked by control system, error shown with error code. -
Reference
Section 10 Common hydraulics, group 10.4.1 Gear pump with fixed displacement Priority valve, description, page 5:4
Steering valve, description, page 5:7
The steering cylinder turns the wheels.
Steering cylinder, description, page 5:9 Hydraulic diagram, see section E Schematics, group 10 Common hydraulics, Hydraulic diagram.

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.
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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 hydraulic oil's cooling circuit.
1 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
5 13 12 11
1. 2. 3. 4. 5. 6. 7. 8. 9.
steering valve's consumption. Pilot pressure compensating means that the priority valve compensates for the pressure drop between the priority valve and steering valve via a separate line.
The priority valve has a built-in pressure limiter on the load signal. The pressure limiter maximises the load signal's pressure.
6 7 10 9 8
015032
Feed from the hydraulic oil pump brake and steering [P] Adjuster screw control pressure Return to filter [D] Measuring outlet control pressure [LSM] Connection brake cooling [SPOL] Connection control valve, pilot pressure [LSO] Feed control valve [O] Adjuster screw pressure accumulator charging Measuring outlet servo pressure [PPM]
10. Measuring outlet accumulator 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]
Control pressure, checking
NOTE
C
000475
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5:5
Connect a pressure gauge (0-25 MPa) to the measuring outlet for steering pressure.
Measuring outlet, control pressure [LSM] 5 6 Close the relief valve attachment and the accumulator drain valve. Start the engine and increase engine speed to approx. 1200 rpm.
Close the accumulator drain valve 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
"$'
014651
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5:6
If necessary, adjust the steering pressure on the valve block accumulator charging and priority valve. Undo the lock nut and adjust the pressure by turning the adjusting screw. Clockwise: reduce pressure. Anticlockwise: increase pressure.
Turn the start key to position 0 and switch off the main power.
10 Depressurise the hydraulic systems, See section B Safety. 11 Remove the pressure gauge and fit the protective cap on the measuring outlet.
Adjuster screw, control pressure 12 Close the relief valve attachment and the accumulator drain valve.
015029
NOTE
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"$'
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.
1 2 3
The load signal generates load-dependent control of oil flow from the priority valve to the steering valve. "Closed centre" means that the steering valve is closed in its neutral position. This is necessary so that signal pressure can be connected to the steering valve. The steering valve consists of a gear pump and a distribution valve. When the steering wheel is turned, oil flows from the main pump over the gear pump to the distribution valve, which 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.
5 4
Connections control valve 1. 2. 3. 4. 5. Steering cylinder left [L] Pilot pressure [LSO] Steering cylinder right [R] Tank return [T] Pressure feed [O]
009887
Steering valve, replacement
NOTE
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5 Steering Steering valve
1 2 3
Stop the engine and turn the start key to position I. Depressurise the hydraulic systems, See section B Safety. Turn the start key to position 0 and switch off the main power.
1. 2.
Water valve 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 7 Remove the steering valve. 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.
VDCT01.02GB
5 Steering Steering cylinder
5:9
10 Close the relief valve attachment and the accumulator drain valve.
NOTE
Check that the accumulator drain valve is fully closed and tighten the lock ring. 11 Turn on the main electric power and start the engine. 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.
"$'
5.2.4 Steering cylinder

Steering cylinder, description
1 2 3
The steering cylinder acts on the wheels via the link arms. The steering cylinder is a double-acting hydraulic cylinder.
1. 2. 3. 4.
Steering cylinder Shaft Lock screw Fastening screw (locked with locking fluid)
009888
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5:10
5 Steering Steering cylinder
Steering cylinder, replacement
NOTE
Read the safety instructions for oil before working, see section B Safety. 1 2 3 4 5 Park the machine with the wheels fully turned so that the steering cylinder can be lifted out to one side. Machine in service position, see section B Safety. Depressurise the hydraulic systems, See section B Safety. Detach the link arms from the steering cylinder. Mark up and detach the hydraulic hoses from the steering cylinder.
NOTE
Plug all connections immediately to protect the brake system from impurities.
1. 2.
Link arm mounting Hydraulic connection 6 7 Remove the steering cylinder's attaching bolts. Replace the steering cylinder. Lift the steering cylinder aside.
NOTE
The steering cylinder is heavy, use lifting equipment. 8 9 Support the new steering cylinder so that the holes in the attaching bolts are lined up directly opposite the holes in the steering axle. 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
Attaching bolts steering cylinder.
VDCT01.02GB
009889
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
1. 2.
Link arm mounting Hydraulic connection 13 Close the relief valve attachment and the accumulator drain valve.
NOTE
Check that the accumulator drain valve is fully closed and tighten the lock ring. 14 Start the engine and check for leaks.
"$'
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.
008854
1.
Link arm
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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.

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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
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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! 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 2 3 4 Machine in service position, see section B Safety. Turn the start key to position 0 and switch off the main power. Support under the steering axle so that it cannot fall over. 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 6 7 8 Remove the pins holding the steering axle. Lift the machine so that the frame is off the steering axle. Support the machine under the frame. 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
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6 Suspension Steering axle cradle
Remove the washers that hold the bushing in place.
2 1
10 Press out the bushing. 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.
3
010121
15 Lubricate and fit the pins at the steering axle's mounts. 16 Remove the lifting equipment from the machine.
1. 2. 3. 4.
Steering axle mounting Rubber bushing Washers Screw
6.2.1 Steering axle cradle

Steering axle cradle, description
1 2 3 4 5 6
The steering axle is pendulum suspended with a double-acting steering cylinder. The design comprises a minimum of moving parts to minimise service points and simplify maintenance. The frame suspension comprises maintenance-free parts.
Steering axle 1. 2. 3. 4. 5. 6. Wheel hub Wheel spindle Link arm Steering axle cradle Steering cylinder Spindle bolt / - bearing
008047
Steering axle cradle, replacement
DANGER
Steering axle and machine are very heavy. Risk of crushing! It is forbidden to go under a machine which has been lifted by a jack etc. For machine weight, see section F Technical data.
1 Clean the steering axle and its surrounding area.
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6 Suspension Steering axle cradle
6:5
2 3 4 5 6 7 8
Stop the engine and turn the start key to position I. Depressurise the hydraulic systems, See section B Safety. Turn the start key to position 0 and switch off the main power. Connect the lifting equipment to the rear section of the machine. Tension the lifting equipment, do not lift so much that the wheels are off the ground. Support the machine's rear section. Detach the hydraulic hoses from the steering cylinder.
NOTE
Plug all connections immediately to protect the hydraulic system from impurities. 9 Remove the pins holding the steering axle.
10 Lift the machine up so that the frame is lifted away from the axle. 11 Lift out the steering axle.
CAUTION
The steering axle may start to roll. Crushing injury! Make sure that the steering axle does not roll away uncontrollably.
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
Check that the O-rings are intact, clean and in the correct position. 18 Remove the lifting equipment from the machine.
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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 8 6 7 9 11
1. 2. 3. 4. 5. 6. 7. 8. 9. Wheel spindle Seal ring Bearing (upper) Protective ring Seal ring Bearing (lower) Circlip Shim Bearing cage
10
10. Screw 11. Grease nipple
009780
Spindle bolt bearing, replacement

1 2 3 4 5 6 Machine in service position, see section B Safety. Raise the machine under the steering axle at the wheel in question. Support the steering axle in a safe way. Remove the steering wheel in question. Clean the wheel spindle and its surrounding area. Detach the link arm from the wheel spindle. Remove the wheel hub and wheel bearing; see Wheel bearing, replacement, page 6:8.
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6 Suspension Wheel spindle
6:7
Remove the six screws holding the bearing cage to the wheel spindle.
8 9
Detach the bearing cage by screwing a screw into the removal hole. 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.
002419
14 From underneath, tap in the outer bearing race of the upper 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, replacement, page 6:8. 23 Connect the link arm to the wheel spindle. 24 Fit the wheel.
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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
3 4 5 6 2 1
The wheel hub holds the wheel in place and allows the wheel to rotate.
7 8 9 10 11
008595
1. 2. 3. 4. 5. 6. 7. 8. 9.
Wheel hub Wheel bolt Wheel nut Hub cap Spacer Nut Washer Bearing Screw
10. Bearing 11. Seal ring
Wheel bearing, replacement

1 2 Raise the machine under the steering axle at the wheel in question. Support under the steering axle in a safe way. Remove the steering wheel in question.
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3 4 5
Clean the hub cover and its surrounding area. Remove the hub cover. Wipe away grease from hub cover and hub nut. Handle it as environmentally hazardous waste.
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 8 9
Bend up the locking washer's tabs, remove the lock nut and locking washer. Tension the lifting equipment so that the hub is unloaded. 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.
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6:10
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".
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18 Fill the empty space in the hub with universal grease "EP2".
19 Fit the hub on the wheel spindle.
20 Install the outer bearing, protecting washer, and bearing nut. Pack the bearing with grease and fit the bearing. Fit the washer and hub nut with the smooth surface in towards the hub. 21 Remove the lifting equipment.
22 Tighten the bearing nut in the following stages. A. Lubricate the thread and the side of the nut facing the bearing with oil (SAE 80W/140). B. Tighten the nut to 250 Nm (oiled screw). C. Rotate the hub 10 revolutions. D. Angle tighten the nut 45. E. Rotate the hub 10 revolutions. F. Angle tighten the nut 45.
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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.
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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.
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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.
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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.
Front wheels
009892
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.
009893
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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
1. 2. 3. 4. 5. 6.
Rim Lock ring Rim edge Tapered rim Wheel nut Wheel bolt
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009899
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.
1. 2. 3. 4. 5. 6.
Rim Lock ring Rim edge Tapered rim Wheel nut Wheel bolt
009899
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6:18
6 Suspension Nut, washer and clamp
Wheel bolt, replacement

1 2 3 Machine in service position, see section B Safety. Raise the machine with a jack positioned under the steering axle. Remove the steering wheel; see Maintenance manual DCT 80-90.
4 5
Knock out the bolt with a sledge hammer. Replace the bolt.
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7 Load handling
Contents 7 Load handling

7 Load handling .....................................................................................................7:3 7.1 Controls and instruments .................................................................................7:4 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 7.2.1 Hydraulic oil pump.....................................................................................7:10 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 7.2.15 Hydraulic oil filter .......................................................................................7:30 7.4 Side shift ........................................................................................................7:31 7.4.1 Hydraulic oil pump.....................................................................................7:32 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 7.4.10 Hydraulic oil filter .......................................................................................7:40 7.5 Spreading (positioning) ..................................................................................7:41 7.5.1 Hydraulic oil pump.....................................................................................7:47 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 7.5.9 Relief valve, attachment ............................................................................7:56 7.5.10 Lift, tilt and attachment control valve .........................................................7:56 7.5.11 Hydraulic oil filter .......................................................................................7:57 7.7 Tilt ..................................................................................................................7:58 7.7.1 Hydraulic oil pump.....................................................................................7:59 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 7.7.10 Hydraulic oil filter .......................................................................................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
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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. 2. Mast position sensor (B7211-2), see Mast position sensor, description, page 7:25. Alignment sensors B7203L and B7203R), see Sensor, alignment, description, page 7:71 and Alignment sensor, checking and adjusting, page 7:71. Locked twistlocks sensors (B7205LL and B7205RL), see Sensor, twistlocks, description, page 7:72 and Twistlocks sensor, checking and adjusting, page 7:73. Damping sensor (B769L, B769R, B777L and B777R), see Position sensor spreading, description, page 7:56.
1
3.
4.
2 3 4
015079
Position sensor overview
Spacing check
1 2 3
51 mm C-C
Machine in service position, see section B Safety. Check that the sensor in question is free of damage and dirt. Check that the distance between the sensor and the indicator is 51 mm. Adjust if necessary.
51 mm
Adjusting position sensor - indicator
009632
VDCT01.02GB
7:4
7 Load handling Controls and instruments

7.1.1 Control levers
Control lever, description
A B C
The control lever (S815) is used to control the mast and attachment. 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 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 description, page 7:41.
The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.9.3 ATTACH, menu 3. C. Lifting/lowering (S815-P1)
015080
Lifting/lowering is controlled by moving the control lever forward (lowering) or rearward (lifting). See Lifting/lowering, function description, page 7:8. 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. The signal can be checked from the diagnostic menu, see section 8 Control system, group 8.4.8.1 ELSERV, menu 1. 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 description, page 7:64. The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.9.5 ATTACH, menu 5.
VDCT01.02GB
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).
A. Lift/lower (R8071-P1). Lifting/lowering is controlled by moving the control lever forward (lowering) or rearward (lifting). See Lifting/lowering, function description, page 7:8. The signal can be checked from the diagnostic menu, see section 8 Control system, group 8.4.8.1 ELSERV, menu 1. 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. The signal can be checked from the diagnostic menu, see section 8 Control system, group 8.4.8.1 ELSERV, menu 1. C. Side shift (R8073-P3). Side shift is controlled by moving the lever forward (left) or backward (right). 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.
"&
It is not possible to use side shift on the side lift attachment if the attachment is in its max or min position. D. Emergency stop switch E. Opening locked twistlocks, attachment (S1002). Pull the switch sideways to open the twistlocks if the conditions for this are met. See Twistlocks, function description, page 7:64. The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.9.5 ATTACH, menu 5.
7.1.2 Switch, lock twistlock

Switch lock twistlocks, description (linear control levers)
Switch (green) for locking twistlocks (S1003). The switch is momentary in position 2. Position 1 - Twistlocks are locked automatically when alignment with the load occurs. The parking brake must be OFF.
009907
Position 0 - Twistlock locking not activated. Position 2 - Twistlocks are locked manually. Button springs back. Twistlocks are opened with the switch on the control lever, see Linear control levers, description, page 7:5. The switch is supplied power by and sends a voltage signal to the cab control unit (D790-1). The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.9.5 ATTACH, menu 5.
VDCT01.02GB
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. 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'. The switch is supplied power by and sends a voltage signal to the cab control unit (D790-1). The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.9.3 ATTACH, menu 3.
009910
7.1.4 Switch, stop at 30\q

Switch stop at 30', description (linear control levers)
35 30-
The switch (green) for spreading stop for the attachment at 30' (S1004) activates the 30-foot stop. When the switch is depressed, the function changes from spreading from 20'40' to stop at 30'. The switch is supplied power by and sends a voltage signal to the cab control unit (D790-1). The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.9.3 ATTACH, menu 3.
VDCT01.02GB
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.
009908
This switch is used to activate automatic spreading. 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. The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.9.3 ATTACH, menu 3.
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.
VDCT01.02GB
7:8
7 Load handling Lift and lower
7.2 Lift and lower

Lifting/lowering, function description
Condition
Control breaker Twistlocks Alignment
Reference value
Not activated Locked or unlocked, not intermediate position Mast down: no contact
Reference
Section 11 Common electrics, group 11.5.1.4 Emergency stop switch voltage Twistlocks, description, page 7:64 Sensor, alignment, description, page 7:71
1b
1a D1
D3 D790-1 D797-1 4 D7 8 C
P2
2, 3, 5
D794
7, 15 D14 14 12, 16 10 12, 16
13
11
Pos
1a
Explanation
The lifting/lowering control lever (R8071-P1) sends the cab control unit (D790-1) a voltage signal proportional to lever movement.
Signal description
U = 0.5-4.5 V Lower: U = <2.5 V Lift: U = >2.5 V 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 harnesses and controls.
Reference
Linear control levers, description, page 7:5 D1: Diagnostic menu, see section 8 Control system, group 8.4.8.1 ELSERV, menu 1
1b
The control lever (S815-P1) sends the cab control unit (D790-1) a voltage signal proportional to lever movement.
US815-P1 = 0.5-4.5 V Lower: US815-P1 = <2.5 V Lift: US815-P1 = >2.5 V 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 harnesses and controls.
Control lever, description, page 7:4 D1: Diagnostic menu, see section 8 Control system, group 8.4.8.1 ELSERV, menu 1
The cab control unit (D790-1) sends the frame control unit (D797-1) a lift/lower request via the CAN bus.
VDCT01.02GB
015074
7 Load handling Lift and lower
7:9
Pos
3
Explanation
Cab control unit (D790-1) voltage feeds the control breaker relay lifting and lowering (K3007).
Signal description
U = 24 V
Reference
Section 11 Common electrics, group 11.5.3.2 Frame control unit D3: Diagnostic menu, see section 8 Control system, group 8.4.1.6 CAN/POWER, menu 6
Control breaker relay lifting and lowering (K3007) makes the ground connection between Frame control unit (D797-1) and Solenoid valve lift (Y6005) and Solenoid valve lower(Y6004). Control unit, cab (D790-1) transmits a request for increased engine speed on the CAN bus. Control unit, engine (D794) increases the engine speed. The frame control unit (D797-1) controls the current proportionally to the lever movement to the solenoid valve lift mast (Y6005) or the Solenoid valve lower (Y6004).
Section 11 Common electrics, group 11.5.1.4 Emergency stop switch voltage (15E)
Checked by control system, error shown with error code. Checked by control system, error shown with error code. I = 380650 mA
Section 11 Common electrics, group 11.5.3.1 Control unit, cab Section 11 Common electrics, group 11.5.3.10 Control unit, engine Section 11 Common electrics, group 11.5.3.2 Frame control unit D7: Diagnostic menu, see section 8 Control system, group 8.4.8.3 ELSERV, menu 3 and 8.4.8.4 ELSERV, menu 4
6 7
Solenoid valve lift (Y6005) or Solenoid valve lower (Y6004) pressurises lift, tilt and the attachment control valve's lift spool with servo pressure. Hydraulic oil pump load handling feeds the lift, tilt and attachment control valve with hydraulic pressure. The lift, tilt and attachment control valve's lift spool change position and then pressurise the lift cylinders and accumulator lifting/lowering. Accumulator lift equalizes the pressure surges that occur in the lift cylinders when the machine is running. The lift cylinders are pressurised and the 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.
Lift, tilt and attachment control valve, description, page 7:14
Section 10 Common hydraulics, group 10.4.1 Gear pump Lift, tilt and attachment control valve, description, page 7:14
10
11
Accumulator lift, description, page 7:30 Lift cylinder, description, page 7:15
12
13
The oil filter cleans the return oil from the lift cylinders before it is collected in the hydraulic oil tank. Damping When the mast is approx. 50 cm from its topmost position, damping is activated. The mast position sensor (B7211-2) sends the frame control unit (D797-1) a voltage signal proportional to the lift height. The control unit then transmits a damping request on the CAN bus.
Section 10 Common hydraulics group 10.6.7 Hydraulic oil filter. Mast position sensor, description, page 7:25 Section 11 Common electrics, group 11.5.3.3 Frame control unit D14: Diagnostic menu, see section 8 Control system, group 8.4.8.15 ELSERV, menu 15.
14
UB771/1 = 5 V UB771/2 = 0 V UB771/3 = 0.5-4.5 V
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7:10
7 Load handling Hydraulic oil pump
Pos
15
Explanation
The frame control unit (D797-1) reduces the control current to the lift solenoid valve (Y6005) or the lower solenoid valve (Y6004).
Signal description
-
Reference
Section 11 Common electrics, group 11.5.3.2 Frame control unit D7: Diagnostic menu, see section 8 Control system, group 8.4.8.3 ELSERV, menu 3 and 8.4.8.4 ELSERV, menu 4
16
Lift speed decreases.
Lift cylinder, description, page 7:15 Hydraulic diagram, see section E Schematics, group 10 Common hydraulics, Hydraulic diagram

See section 10 Common hydraulics, group 10.4.1 Gear pump with fixed displacement.
VDCT01.02GB
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 valve, description, page 7:14.
1 2 3 4
5 13 12 11
1. 2. 3. 4. 5. 6. 7. 8. 9.
6 7 10 9 8
015032
Feed from the hydraulic oil pump brake and steering [P] Adjuster screw control pressure Return to filter [D] Measuring outlet control pressure [LSM] Connection brake cooling [SPOL] Connection control valve, pilot pressure [LSO] Feed control valve [O] Adjuster screw pressure accumulator charging Measuring outlet servo pressure [PPM]
10. Measuring outlet accumulator 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]
VDCT01.02GB
7:12
Servo pressure, check
NOTE
Read the safety instructions for oil before working, see section B Safety. 1 2 Operate and warm up the machine so that the hydraulic oil reaches operating temperature, 50 C. Machine in service position, see section B Safety. Depressurise the hydraulic systems, See section B Safety.
C
000475
Connect a pressure gauge (0-25 MPa) to the measuring outlet for servo pressure.
Measuring outlet, servo pressure [PPM] 5 6 Close the relief valve attachment and the accumulator drain valve. Start the engine and run it at idle.
VDCT01.02GB
"$'
014652
7:13
Check that the servo pressure corresponds with the pressure on the pressure plate.
Pressure plate, servo pressure 8 If necessary, adjust the servo pressure on the valve block accumulator charging and priority valve. Undo the lock nut and adjust the pressure by turning the adjusting screw. Clockwise: reduce pressure. Anticlockwise: increase pressure. 9 Turn the start key to position 0 and switch off the main power.
015022
10 Depressurise the hydraulic systems, See section B Safety. 11 Remove the pressure gauge and fit the protective cap on the measuring outlet.
Adjusting screw, servo pressure 12 Close the relief valve attachment and the accumulator drain valve.
015027
NOTE
"$'
VDCT01.02GB
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 2 3
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 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 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 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 variable pumps. Electrically controlled pressure reducing valves (solenoid valves) convert electric current into a low hydraulic pressure that is proportional to the current, so-called servo pressure. The servo pressure acts on the spring-centred control slide in the control valve for the function in 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.
1. 2. 3. 4.
Solenoid valve, lower (Y6004) Solenoid valve, lift (Y6005) Connection left lift cylinder Connection right lift cylinder
015081
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 Control system, group 8.4.8.4 ELSERV, menu 4.
VDCT01.02GB
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 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.
009916

VDCT01.02GB
7:16
7 Load handling Mast
7.2.9 Mast
Mast, description
1
The mast which has a clear view design lifts the load. The trolley runs 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 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 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, 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. Despite these efforts, problems can arise due to neglected maintenance, improper handling, malfunction or damage to a mast wheel, mast or trolley. For example, lamination or pitting could occur on the mast beam flange. This most often occurs on the inner mast, but could also occur on the outer mast. Repairs to the mast may only by performed on the flanges on the outer and inner mast beams according to special instructions, see Flanges on outer and inner mast beam, repair, page 7:23.
1. 2. 3. 4.
Inner mast Lifting eye Outer mast Lift cylinder
009918
Mast, removing
NOTE
NOTE
It is possible to remove the trolley and the side lift attachment as a unit. 1 2 Remove the side lift attachment; see Side lift attachment, removing, page 7:52. Remove the trolley; see Trolley, removing, page 7:26.
VDCT01.02GB
7:17
3 4 5 6 7
Connect the lifting equipment to the lifting lugs at the top of the mast in a secure manner. Start the engine and tilt the mast forwards as far as possible. Turn off engine. Turn the start key to position I and activate the hydraulic functions to depressurise the hydraulic system. Turn the start key to position 0 and switch off the main power.
009974
Mark up and disconnect the hydraulic connections of the lift cylinders.
NOTE
Plug all connections immediately to protect the hydraulic system 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
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.
VDCT01.02GB
7:18
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!
VDCT01.02GB
009983
7:19
16 Lift aside the mast.
009985
17 Place the mast on the ground and detach the lifting equipment (overhead crane).
009975
VDCT01.02GB
7:20
Mast, installing
NOTE
Read the safety instructions for oil before working, see section B Safety. 1 2 3 4 Turn off engine. Turn the start key to position I and activate the hydraulic functions to depressurise the hydraulic system. Turn the start key to position 0 and switch off the main power. Connect lifting equipment to the mast in a secure manner so the mast does not tip when lifted.
009975
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.
009977
The shafts and bearings mentioned above must NEVER be 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.
VDCT01.02GB
009976
7:21
Suspend the mast vertically. Align the mast and position the shafts in the mast mountings.
009978
8 9
Fasten the shafts with bolts and lock nuts. Start the engine and tilt the mast forwards as far as possible.
10 Turn off engine. 11 Turn the start key to position I and activate the hydraulic functions to depressurise the hydraulic system. 12 Turn the start key to position 0 and switch off the main power.
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
VDCT01.02GB
7:22
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.
VDCT01.02GB
009980
7:23
Flanges on outer and inner mast beam, repair
NOTE
Read the safety instructions for oil before working, see section B 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. 1 Machine in service position, see section B Safety. 2 3 4 5 6 Remove the trolley; see Trolley, removing, page 7:26. Removing the mast, please refer to Mast, removing, page 7:16. Separate the outer and inner mast. Clean the mast components. 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 rear flange. If the measurement exceeds 252 mm for a beam that is supposed to be 250 mm, contact Cargotec. 7
010127C
250 mm
Apply a thin layer of slide grease to the sliding surfaces of the outer mast and reassemble the inner and outer masts. 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, page 7:20. Fit the trolley; see Trolley, installing, page 7:27.
Mast beam size 250 mm. 9
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.
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7:24
Slide plates in inner mast, adjusting
NOTE
If the slide plate extends less than 3 mm from the holder, replace it. 1 2 3 Lubricate the inner sliding surfaces of the outer mast with a thin layer of slide grease. Lift the inner mast 200 mm. Adjust the slide plate in the bottom part of the outer mast so that it lies against or has no more than 0.5 mm play to the outer mast. Use a suitable number of shims in the rear and front of the slide plate so that the slide plate lies evenly against the entire sliding surface. 4 Raise the mast to its end position and check that the slide plates do not pinch too hard against the sliding surface.
010152
Slide plates in outer mast, adjusting
NOTE
If the slide plate extends less than 3 mm from the holder, replace it. 1 2 3 4 Lubricate the outer sliding surfaces of the inner mast with a thin layer of slide grease. Lower the inner mast to its bottom position. Lift the inner mast 200 mm. 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.
VDCT01.02GB
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 2 3
2
NOTE
Check that the cover washer is centred on the clamping screw. Screw in the clamping screw (position 5) so that the wheel is completely locked.
4 5
3
NOTE
Rotate the mast wheel while tightening the clamping screw. 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
010126
Lock the clamping screw with the spring pin.
1. 2. 3. 4. 5. 6. 7.
Impeller Circlip Cover washer Spring pin Clamping screw Inner bearing 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 Control system, group 8.4.8.15 ELSERV, menu 15. For checking and adjusting, see Position sensor, checking and adjustment, page 7:3.
VDCT01.02GB
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 the attachment and trolley. Also located on the trolley are the Attachment control unit (D791-1), attachment control valve and buzzer automatic spreading 20'-40' ( )
2 1
See also Side shift cylinder, description, page 7:37.
4
013589
3
1. 2. 3. 4. Side shift cylinder Control valve, attachment Slide plates Mast wheels
Trolley, removing
NOTE
Read the safety instructions for oil before working, see section B Safety. 1 2 3 4 Remove the side lift attachment; see Side lift attachment, removing, page 7:52. Connect lifting equipment to the trolley in a secure manner. Disconnect the main power supply. Disconnect the trolley cable by undoing the lock plate screws. Undo the connectors and protect the terminals by lubricating them with contact grease. Then loosely insert the connectors.
VDCT01.02GB
009995
7:27
Mark up and disconnect the carriage's hydraulic connections. Let the oil run out.
NOTE
Plug all connections immediately to protect the hydraulic system from impurities. 6 Raise the carriage with the lifting equipment (overhead crane) to slacken the chains.
009987
7 8 9
Undo the nuts and remove the chain tensioners. Start the engine and tilt the mast rearwards. 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
Read the safety instructions for oil before working, see section B Safety. 1 2 3 Park the machine with the mast vertical. Raise the mast high enough to position the carriage in the inner mast and lift it into place. 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. Lower the carriage as far as possible. Turn off engine. Turn the start key to position I and activate the hydraulic functions to depressurise the hydraulic system. Turn the start key to position 0 and switch off the main power.
4 5 6 7
013591
VDCT01.02GB
7:28
Remove the plugs and connect the mast's hydraulic hoses and the carriage wiring.
009987
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. 11 Turn on the power supply and start the engine. 12 Check that the hydraulic connections are sealed tightly. 13 Check the trolley functions.
VDCT01.02GB
009995
7:29
Slide plates in trolley, adjusting and, if necessary, replacing

1 Remove the trolley; see Trolley, removing, page 7:26.
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. Use a gauge in the centre of the beam to measure the interior width of the inner mast.
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).
013593
VDCT01.02GB
7:30
7 Load handling Pipes and hoses
Adjust trolley clearance by removing the screws and adding or removing shims. a. If the width at A and B is the same: Adjust C and D to be equal to or max. 0.5 mm more than A. 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.
2 1
b.
2
1. 2. Screws Shim
013648
Lubricate the inner sliding surfaces of the inner mast with a thin layer of slide grease. Fit the trolley; see Trolley, installing, page 7:27. Lift the trolley all the way up and check that the slide plates do not clamp too hard against the sliding surfaces.
7 8
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.
1. 2.
Accumulator brake system Accumulator lift
014672

See section 10 Common hydraulics group 10.6.7 hydraulic oil filter.
VDCT01.02GB
7 Load handling Side shift
7:31
7.4 Side shift

Side shift, function description
Condition
Control breaker
Reference value
Not activated
Reference
Section 11 Common electrics, group 11.5.1.4 Emergency stop switch voltage
1a 1b D1 D790-1 D797-1 D3 4
P2 P2
2 D791-1 7
3 D7
11
9
T2 A B
Pos
1a
Explanation
The side shift control lever (R8073-P3) sends the cab control unit (D790-1) a voltage signal proportional to lever movement.
Signal description
U = 0.5-4.5 V Left: U = <2.5 V 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.
Reference
Linear control levers, description, page 7:5 D1: Diagnostic menu, see section 8 Control system, group 8.4.9.1 ATTACH, menu 1
1b
US815-P3 = 0.5-4.5 V Right: US815-P3 = <2.5 V 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 faults in cable harnesses and controls.
Control lever, description, page 7:4 D1: Diagnostic menu, see section 8 Control system, group 8.4.9.1 ATTACH, menu 1
Control unit, cab (D790-1) transmits side shift left or right on the CAN bus. The frame control unit (D797-1) activates the solenoid valve for main pump relief (Y6062-2).
Section 11 Common electrics, group 11.5.3.1 Control unit, cab Section 11 Common electrics, group 11.5.3.2 Frame control unit D3: Diagnostic menu, see section 8 Control system, group 8.4.5.6 HYD, menu 6
VDCT01.02GB
015076
10
7:32
Pos
4
Explanation
Solenoid valve, relief main pump (Y6062-2) pressurises the attachment spool in the lift, tilt and attachment control valve with servo pressure. Hydraulic oil pump load handling feeds the lift, tilt and attachment control valve with hydraulic pressure. The control valve lift, tilt and attachment's attachment slide changes position and pressurises the control valve attachment. The attachment control unit (D791-1) activates the solenoid valve for side shift left (Y6020) or the solenoid valve for side shift right (Y6021).
Signal description
-
Reference
Section 10 Common hydraulics, group 10.4.1 Gear pump with fixed displacement
U = 24 V
Section 11 Common electrics, group 11.5.3.5 Control unit, attachment D7: Diagnostic menu, see section 8 Control system, group 8.4.9.11 ATTACH, menu 11 and group 8.4.9.12 ATTACH, menu 12
The solenoid valve for side shift left (Y6020) or the solenoid valve for side shift right (Y6021) pressurises the side shift spool in the attachment control valve. The control valve's side shift slide changes position and pressurises the side shift cylinder. The side shift cylinder pushes in the main beam sideways in relation to the trolley. The oil filter cleans the return oil from the lift cylinders before it is collected in the hydraulic oil tank.
Attachment control valve, description, page 7:33
Attachment control valve, description, page 7:33 Side shift cylinder, description, page 7:37
10
11
Section 10 Common hydraulics group 10.6.7 Hydraulic oil filter.
Hydraulic diagram, see section E Schematics, group 10 Common hydraulics, Hydraulic diagram

VDCT01.02GB
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 attachment. The control valve is located up on the trolley. Solenoid valves control the flow from the valve. The control valve is an electro-hydraulically controlled, proportional and pressure-compensated directional control valve. Electrically 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 a flow limit so that several functions can be used simultaneously. This enables them to control the main flow. The control valve has built-in supply of pilot pressure. This means that the valve has built-in pressure reduction which converts feed pressure to servo pressure for the various functions. Supply of pilot pressure is common for all functions. This reduces pressure variations due to long hoses and reduces the number of hoses to the valve. The attachment control valve is fed by lift, tilt and attachment control valve, see Lift, tilt and attachment control valve, description, page 7:40. The control valve has the following sections:
015084
5 10 6 9 7 8
Side shift Spreading right extension beam, see Attachment control valve, description, page 7:48 Spreading left extension beam, see Attachment control valve, description, page 7:48 Twistlocks, see Attachment control valve, description, page 7:67
1. 2. 3. 4. 5. 6. 7. 8. 9.
Solenoid valve, side shift right (Y6021) Solenoid valve, lock twistlock (Y6040) Solenoid valve spreading in left (Y6019L) Solenoid valve spreading in right (Y6019R) Solenoid valve spreading out right (Y6018R) Solenoid valve spreading out left (Y6018L) Solenoid valve, open twistlock (Y6039) Solenoid valve, side shift left (Y6020) Connection, feed from hydraulic oil pump (P)
Side shift slide

The valve slide controls the direction and speed of side shift. The valve spool is controlled by a solenoid valve for side shift right and a solenoid valve for side shift left.
Solenoid valve, side shift left

The solenoid valve for side shift left controls pressure to the side shift spool so that the side shift spool opens and pressurises the side shift cylinder. Solenoid valve, side shift left is controlled electrically by Solenoid valve, side shift left (Y6020), which is activated by Control unit, attachment (D791-1). The solenoid valve directs servo pressure to the side shift slide in proportion to the control current to the solenoid valve. The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.9.11 ATTACH, menu 11.
10. Connection return to tank (T)
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. The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.9.12 ATTACH, menu 12. Workshop Manual DCT 80-90
VDCT01.02GB
7:34
Control valve attachment, replacement
NOTE
Read the safety instructions for oil before working, see section B Safety. 1 2 3 4 Machine in service position, see section B Safety. Depressurise the hydraulic systems, See section B Safety. Remove the attaching bolts and lift away the plate fitted over the control valve. Mark and disconnect the hydraulic hoses from the control valve.
NOTE
Plug all connections immediately to protect the hydraulic system from impurities. 5 Mark and disconnect the cable harness from the control valve.
VDCT01.02GB
013595
7:35
6 7
Remove the attaching bolts and lift away the valve. Place the valve on a clean and protected surface. Transfer the connection adapters to the new control valve.
NOTE
NOTE
013596
Transfer one connection at a time so that the marking is not mixed up. 8 9 Mark up the solenoid valves on the new control valve. Lift the valve into place and fit the attaching bolts.
10 Connect the cable harness to the control valve according to the marking. 11 Connect the hydraulic hoses to the control valve in according to the marking.
NOTE
Check that the O-rings are intact, clean and in the correct position. 12 Turn on the main electric power and start the engine. 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.
VDCT01.02GB
7:36
Control valve attachment, checking hydraulic pressure
NOTE
Read the safety instructions for oil before working, see section B Safety. 1 2 Operate and warm up the machine so that the hydraulic oil reaches operating temperature, at least 50 C. Turn off engine. Machine in service position, see section B Safety.
C
000475
Connect a pressure gauge (0-25 MPa) to the feed pressure measuring outlet on the control valve attachment.
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. Remove the pressure gauge and fit the protective cap on the measuring outlet.
015085
VDCT01.02GB
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.
VDCT01.02GB
7:38
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. Switch off the engine and switch off the main electric power. Clean and measure the thickness of the lower slide plates.
2 3
NOTE
The thickness of the slide plate should be at least 10 mm. 4 5 Replace the lower slide plates, if necessary, by loosening the attachment's mounting. 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 7 Remove the slide plate and fit a new one. Repeat with the other lower slide plates (4 plates). Reassemble the attachment's mounting.
3 2 3
The illustration shows the slide plates between the attachment and trolley. 1. 2. 3. Upper slide plates Lower slide plates Attachment's fastening
013681
VDCT01.02GB
7 Load handling Relief valve, attachment
7:39
Clean and measure the thickness of the upper slide plates. The upper slide plates can be replaced and adjusted using shims when the attachment is in position in the trolley.
NOTE
The thickness of the slide plate should be at least 10 mm. 9 Remove the counterhold.
10 Loosen the slide plate's attaching bolt slightly so that the slide plate releases from the carriage. 11 Insert the required number of shims to remove the play between attachment and carriage. Alternatively replace the slide plate. 12 Refit the counterhold and tighten the attaching bolt that secures the slide plate.
013682
13 Check the play between side lift attachment and the trolley. The 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. 2. 3. 4. Upper slide plates Shim Counterhold Screw
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. 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.

VDCT01.02GB
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 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 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 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
2
015083
When activating the Solenoid valve hydraulic attachment (Y6062-2) the attachment slide is pressurised and controls the direction and flow of the oil from the hydraulic oil pumps to the attachment control valve.
Solenoid valve hydraulic pressure attachment

Solenoid valve hydraulic pressure attachment (Y6062-2) is activated by the frame control unit (D797-1). The solenoid valve directs servo pressure to the attachment slide which is proportional to the control current to the solenoid valve.
1. 2.
Solenoid valve hydraulic pressure attachment (Y6062-2) Connection feed pressure control valve, attachment

VDCT01.02GB
7 Load handling Spreading (positioning)
7:41
7.5 Spreading (positioning)

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

Reference
Switch spreading 20'-40', description (linear control levers), page 7:6 D1: Diagnostic menu, see section 8 Control system, group 8.4.9.3 ATTACH, menu 3
015077
C
P2
D13 C
23
6 13
T2 B
Pos
1a
Explanation
The switch for spreading 20'-40' (S1012) sends a voltage signal to the cab control unit (D790-1).
Signal description
U = 24 V
1b
The control lever (S815-T1.1 and S815-T1.2) sends a voltage signal to the cab control unit (D790-1). The cab control unit (D790-1) transmits spreading in or out on the CAN bus. The frame control unit (D797-1) activates the solenoid valve for main pump relief (Y6062-2).
Spreading: US815-T4 = 24 V Out: US815-T1.2 = 24 V In: US815-T1.1 = 24V
Control lever, description, page 7:4 D1: Diagnostic menu, see section 8 Control system, group 8.4.9.3 ATTACH, menu 3 Section 11 Common electrics, group 11.5.3.1 Control unit, cab Section 11 Common electrics, group 11.5.3.2 Frame control unit D3: Diagnostic menu, see section 8 Control system, group 8.4.5.6 HYD, menu 6
Solenoid valve, relief main pump (Y6062-2) pressurises the attachment spool in the lift, tilt and attachment control valve with servo pressure. Hydraulic oil pump load handling feeds the lift, tilt and attachment control valve with hydraulic pressure.
Section 10 Common hydraulics, group 10.4.1 Gear pump with fixed displacement
VDCT01.02GB
7:42
Pos
6
Explanation
The control valve lift, tilt and attachment's attachment slide changes position and pressurises the control valve attachment. The attachment control unit (D791-1) activates the Solenoid valve spreading out left (Y6018L) and Solenoid valve spreading out right (Y6018R) or Solenoid spreading in left (Y6019L) and Solenoid valve spreading right (Y6019R). The solenoid valve for spreading out left (Y6018L) or the solenoid valve for spreading in left (Y6019L) pressurises the left spreader spool in the attachment's control valve. The solenoid valve for spreading out right (Y6018T) or the solenoid valve for spreading in right (Y6019T) pressurises the right spreader spool in the attachment's control valve. The control valve's spreader spools change position and direct pressure to the spreader cylinders. Left spreader cylinder pushes left spreader beam in or out in the attachment. Right spreader cylinder pushes right spreader beam in or out in the attachment. The sensor for end position 20'-40' left (B769L) sends a voltage signal to the attachment control unit (D791-1). The attachment control unit (D791-1) reduces the control current to the solenoid valve for spreading out left (Y6018L) or the solenoid valve for spreading in left (Y6019L). The solenoid valve for spreading out left (Y6018L) or the solenoid valve for spreading in left (Y6019L) reduces the pressure to the left spreader spool in the attachment's control valve. The control valve's spreading slide left changes position and lowers the pressure on the left spreading cylinder. Spreader speed decreases. The sensor for end position 20'-40' right (B769R) sends a voltage signal to the attachment control unit (D791-1).
Signal description
-
Reference
I = 350600 mA
Section 11 Common electrics, group 11.5.3.5 Control unit, attachment D8D9: Diagnostic menu, see section 8 Control system, group 8.4.9.17 ATTACH, menu 17 8.4.9.20 ATTACH, menu 20
Attachment control valve, description, page 7:33 D8: Diagnostic menu, see section 8 Control system, group 8.4.9.17 ATTACH, menu 17 and 8.4.9.18 ATTACH, menu 18
Attachment control valve, description, page 7:33 D9: Diagnostic menu, see section 8 Control system, group 8.4.9.19 ATTACH, menu 19 and 8.4.9.20 ATTACH, menu 20
10
Attachment control valve, description, page 7:33 Spreading cylinder, description, page 7:49
11
12
Spreading cylinder, description, page 7:49
13
Sensor directly opposite indicator plate: U > 24 V
Position sensor spreading, description, page 7:56 D13: Diagnostic menu, see section 8 Control system, group 8.4.9.6 ATTACH, menu 6
14
Section 11 Common electrics, group 11.5.3.5 Control unit, attachment D8: Diagnostic menu, see section 8 Control system, group 8.4.9.17 ATTACH, menu 17 and 8.4.9.18 ATTACH, menu 18
15
Control valve attachment, replacement, page 7:34 D8: Diagnostic menu, see section 8 Control system, group 8.4.9.17 ATTACH, menu 17 and 8.4.9.18 ATTACH, menu 18
16
17 18
Sensor directly opposite indicator plate: U = 24 V
Spreading cylinder, description, page 7:49 Position sensor spreading, description, page 7:56 D18: Diagnostic menu, see section 8 Control system, group 8.4.9.6 ATTACH, menu 6
VDCT01.02GB
7:43
Pos
19
Explanation
The attachment control unit (D791-1) reduces the control current to the solenoid valve for spreading out right (Y6018R) or the solenoid valve for spreading in right (Y6019R). The solenoid valve for spreading out right (Y6018R) or the solenoid valve for spreading in right (Y6019R) reduces the pressure to the right spreader spool in the attachment's control valve. The control valve's spreading slide right changes position and lowers the pressure on the right spreading cylinder. Spreader speed decreases. The hydraulic oil filter cleans the return oil from the lift cylinders before it is collected in the hydraulic oil tank.
Signal description
-
Reference
20
Control valve attachment, replacement, page 7:34 D9: Diagnostic menu, see section 8 Control system, group 8.4.9.19 ATTACH, menu 19 and 8.4.9.20 ATTACH, menu 20
21
22 23
Spreading cylinder, description, page 7:49 Section 10 Common hydraulics group 10.6.7 Hydraulic oil filter.
VDCT01.02GB
7:44
30-foot stop, function description

Condition
Control breaker Twistlocks
Reference value
Not activated Unlocked or bypass activated
Reference
Section 11 Common electrics, group 11.5.1.4 Emergency stop switch voltage Twistlocks, description, page 7:64 Section 8 Control system, group 8.2.2 Bypass
2b
2a
D1
D2 1
3035
D790-1 D791-1
4,7,9,11
D5 D8 30' 30'
4,7
Pos
1
4,7
10
Reference
Switch stop at 30', description (linear control levers), page 7:6 D1: Diagnostic menu, see section 8 Control system, group 8.4.9.3 ATTACH, menu 3
Explanation
The switch for stop at 30' (S1004) sends a voltage signal to the cab control unit (D790-1).
Signal description
Switch in on position: Conn. 1: U = 0 V Conn. 5: U = 24 V Switch in off position: Conn. 1: U = 24 V Conn. 5: U = 24 V
2a
U = 24 V DC
2b
The control lever (S815-T1.2) sends a voltage signal to the Cab control unit (D790-1). Control unit, cab (D790-1) sends spreading 30' on the CAN bus. Spreading is activated in the same way as the normal spreading steps 314. When the left spreader beam approaches the 30' mark, the sensor for 30' end position left (B777L) sends a voltage signal to the attachment control unit (D791-1). When the right spreader beam approaches the 30' mark, the sensor for 30' end position left (B777R) sends a voltage signal to the attachment control unit (D791-1).
Spreading: US815-T4 = 24 V Out: US815-T1.2 = 24 V In: US815-T1.1 = 24V
Control lever, description, page 7:4 D2: Diagnostic menu, see section 8 Control system, group 8.4.9.3 ATTACH, menu 3 Section 11 Common electrics, group 11.5.3.1 Control unit, cab Spreading, function description, page 7:41 Position sensor spreading, description, page 7:56 D5: Diagnostic menu, see section 8 Control system, group 8.4.9.6 ATTACH, menu 6
Checked by control system, error shown with error code. Sensor directly opposite indicator plate: U = 24 V
4 5
VDCT01.02GB
014803
7:45
Pos
7
Explanation
The attachment control unit (D791-1) dampens the speed in the same way as in normal spreading, steps 1722. When the left spreader beam is at the 30' mark, the sensor for 20'-40' end position (B769L) sends a voltage signal to the attachment control unit (D791-1). The attachment control unit (D791-1) cuts off the current to the solenoid valve for spreading out left (Y6018L) or the solenoid valve for spreading in left (Y6019L). When the right spreader beam is at the 30' mark, the sensor for 20'-40' end position (B769R) sends a voltage signal to the attachment control unit (D791-1). The attachment control unit (D791-1) cuts off the current to the solenoid valve for spreading out right (Y6018R) or the solenoid valve for spreading in right (Y6019R).
Signal description
-
Reference
Spreading, function description, page 7:41
U=0V
10
11
U=0V
VDCT01.02GB
7:46
Automatic spreading 20-40 foot, function description
Condition
Control breaker Twistlocks Doors Parking brake
Reference value
Not activated Unlocked or bypass activated Closed Released
Reference
Section 11 Common electrics, group 11.5.1.4 Emergency stop switch voltage Twistlocks, description, page 7:64 Section 9 Frame, body, cab and accessories, group 9.10.2 Doors Section 4 Brakes, group 4.5 Parking brake system
D1 1b 1a
D2
D790-1 4, 5, 8
D795 D791-1 9
D10
D8
D11
D13
D9
D12
D5
Pos
1a.
Explanation
Signal description
U = 24 V DC
Reference
1b
The control lever (S815-T1.1 and S815-T1.2) sends a voltage signal to the cab control unit (D790-1). The switch for automatic spreading 20'-40' (S1012-2) sends a voltage signal to the cab control unit (D790-1).
Spreading: US815/T4 = 24 V Out: US815/T1.2 = 24 V In: US815/T1.1 = 24 V
Control lever, description, page 7:4 D1: Diagnostic menu, see section 8 Control system, group 8.4.9.3 ATTACH, menu 3 Switch automatic spreading, description (linear control levers), page 7:7 D2: Diagnostic menu, see section 8 Control system, group 8.4.9.3 ATTACH, menu 3
Switch in on position: US199-2/2 = 0 V US199-2/5 = 24 V Switch in off position: US199-2/2 = 24 V US199-2/5 = 24 V
The cab control unit (D790-1) transmits "automatic spreading out" or "automatic spreading in" on the CAN bus. The attachment control unit (D791-1) activates spreading the same way as in steps 3-14 of normal spreading. The attachment control unit (D791-1) activates the automatic spreading buzzer (H9003).
Checked by control system, error shown with error code. -
Spreading, function description, page 7:41
Buzzer active: U = 24 V
Buzzer automatic spreading 20'-40', description, page 7:56 D5: Diagnostic menu, see section 8 Control system, group 8.4.9.21 ATTACH, menu 21
VDCT01.02GB
009347
10
11
13
12
7:47
Pos
6 7
Explanation
Buzzer automatic spreading (H9003) generates acoustic warning signal. When automatic spreading is active, the KID control unit (D795) activates the Automatic Spreading event menu. When the left spreader beam approaches the 20', 30' ( ) or 40' mark, the sensor for 20'40' end position left (B769L) sends a voltage signal to the attachment control unit (D791-1), which activates damping for the left spreader beam the same way as in steps 16-22 of normal spreading.
Signal description
Buzzer active: U = 24 V -
Reference
Buzzer automatic spreading 20'-40', description, page 7:56 Section 11 Common electrics, group 11.5.3.12 Control unit, KID
Spreading, function description, page 7:41 30-foot stop, function description, page 7:44 D8: Diagnostic menu, see section 8 Control system, group 8.4.9.6 ATTACH, menu 6
When the right spreader beam approaches the 20', 30' ( ) or 40' mark, the sensor for 20'40' end position right (B769R) sends a voltage signal to the attachment control unit (D791-1), which activates damping for the right spreader beam the same way as in steps 16-22 of normal spreading.
Spreading, function description, page 7:41 30-foot stop, function description, page 7:44 D9: Diagnostic menu, see section 8 Control system, group 8.4.9.6 ATTACH, menu 6
10
When the left spreader beam is at the 20', 30' ( ) or 40' mark, the sensor for end position 30' left (B777L) sends a voltage signal to the attachment control unit (D791-1).
11
The attachment control unit (D791-1) cuts off the current to the solenoid valve for spreading out left (Y6018L) or the solenoid valve for spreading in left (Y6019L). When the right spreader beam is at the 20', 30' ( ) or 40' mark, the sensor for end position 30' right (B777R) sends a voltage signal to the attachment control unit (D791-1).
I = 0 mA
12
13
The attachment control unit (D791-1) cuts off the control current the solenoid valve for spreading out right (Y6018R) or the solenoid valve for spreading in right (Y6019R).
I = 0 mA
Section 11 Common electrics, group 11.5.3.5 Control unit, attachment D13: section 8 Control system, group 8.4.9.19 ATTACH, menu 16 and 8.4.9.20 ATTACH, menu 20 Hydraulic diagram, see section E Schematics, group 10 Common hydraulics, Hydraulic diagram

VDCT01.02GB
7:48
7.5.2 Control valve, attachment

Attachment control valve, description
Spreader slide
5 10 6 9 7 8
Spreading is controlled by two identical sections in the attachment control valve, one for the right spreader beam and one for the left spreader beam. Both beams are controlled in the same way, which is why they are described together below. For a more detailed description of the valve and component locations, see Attachment control valve, description, page 7:33.
Spreader slide
The valve slides control the direction and speed of the spreading. Each valve slide is controlled by two solenoid valves, one for spreading out and one of spreading in.
Solenoid valve for spreading out

The solenoid valves for spreading out control the pressure to the 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.
015084
The signal can be checked with diagnostic menu. 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 19
1. 2. 3. 4. 5. 6. 7. 8. 9.
Solenoid valve for spreading in

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, spreading in right (Y6019R) are activated by the attachment control unit (D791-1). The solenoid valve controls the servo pressure to spreader slide proportionally toward the control current. 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.
VDCT01.02GB
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 description, page 7:64.
014737
Spreader beam slide plates, adjusting/replacing

1 2 Park the machine with the attachment lowered as far as possible and spreading extended approx. 1000 mm. Switch off the engine and switch off the main electric power.
013683
1000 mm
VDCT01.02GB
7:50
7 Load handling Spreader beam
Unscrew the nuts and bolts (position 1) that secure the slide plates.
013684
Remove the slide plates and shims from the main beam. Lift the extension section slightly so that the slide the plates are unloaded.
Right side
Left side
VDCT01.02GB
013686
013685
7 Load handling Main beam, side lift attachment
7:51
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.
Right side
Left side
013688
013687
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
VDCT01.02GB
7:52
Side lift attachment, removing
NOTE
NOTE
It is possible to remove the trolley and the side lift attachment as a unit. 1 2 3 4 5 Park the machine with the mast vertical and the attachment in its lowest position. Turn off engine. Connect lifting equipment (overhead crane) to the attachment in a secure manner. Start the engine and lift slightly with the lifting equipment (overhead crane). Let the machine stand with the ignition on for a while. Turn off engine.
014819
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 8 9
Fasten the side shift cylinder. Turn the start key to position I and activate the hydraulic functions to depressurise the hydraulic system. Turn the start key to position 0 and switch off the main power.
VDCT01.02GB
009997
7:53
10 Mark up and detach hydraulic connections from the side lift attachment and the side shift cylinder.
NOTE
009952
11 Detach the cable harness of the attachment from the attachment control unit. Undo the connectors and protect the terminals by lubricating them with contact grease. Then loosely insert the connectors. 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
VDCT01.02GB
7:54
Side lift attachment, installing
NOTE
Read the safety instructions for oil before working, see section B Safety. 1 2 3 4 5 6 Park the machine with the mast vertical. Lower the trolley to its lowest position. Turn off engine. Turn the start key to position I and activate the hydraulic functions to depressurise the hydraulic system. Turn the start key to position 0 and switch off the main power. Lift the side lift attachment into place.
Lifting points side lift attachment 7 8 Fit the lifting carriage's front panels to fix the side lifting attachment in position. Check that the side lift attachment runs correctly in the trolley; see Slide plates between trolley and attachment, adjustment, page 7:38.
013680
Clean and apply a layer of lubricating grease to the side shift cylinder shaft prior to installation.
10 Connect the side shift cylinder to the side lift attachment. Align the side shift cylinder, press in the shaft and secure with the circlips.
NOTE
Use an anti-recoil plastic or copper mallet. If necessary, detach the hydraulic connections on the side shift cylinder to make it possible to adjust cylinder length.
VDCT01.02GB
013654
7:55
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. 13 Turn on the power supply and start the engine. 14 Check that the hydraulic connections are sealed tightly. 15 Check the functions of the side lift attachment.
009952
16 Check the 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
VDCT01.02GB
7:56
7 Load handling Position sensor, spreading
7.5.6 Position sensor, spreading

Position sensor spreading, description
3 4 5
The spreading position sensors indicate the position of the spreader beams. The position sensors are used to control spreading so that the twistlocks fit the container. The 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 5 4 3
With the 30 feet stop option, two extra sensors are fitted, Sensor end 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'. The signals can be checked via the diagnostic menu. See section 8 Control system, group 8.4.9.6 ATTACH, menu 6.
2
1. 2. 3. 4. 5. Sensor, end position 20' and 40' Sensor end position 30' Indicator plate 20' Indicator plate 30' Indicator plate 40'
013676
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.



Lift, tilt and attachment control valve, general
See Lift, tilt and attachment control valve, description, page 7:40. Workshop Manual DCT 80-90
VDCT01.02GB
7 Load handling Hydraulic oil filter
7:57

VDCT01.02GB
7:58
7 Load handling Tilt
7.7 Tilt
Tilt, function description
Condition
Control breaker
Reference value
Not activated
Reference
1b
1a D1
D3 D790-1 4 D797-1 2, 3 5 9
D5 6 C
P2
10
A B
11
9
015075
10
Pos
1a
Explanation
The tilt control lever (R8072-P2) sends the cab control unit (D790-1) a voltage signal proportional to lever movement.
Signal description
U = 0.5-4.5 V Out: U = <2.5 V 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 faults in cable harnesses and controls.
Reference
Linear control levers, description, page 7:5 D1: Diagnostic menu, see section 8 Control system, group 8.4.8.1 ELSERV, menu 1
1b
US815-P2 = 0.5-4.5 V In: US815-P2 <2.5 V 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 faults in cable harnesses and controls.
Control lever, description, page 7:4 D1: Diagnostic menu, see section 8 Control system, group 8.4.8.1 ELSERV, menu 1
The cab control unit (D790-1) transmits tilt in or tilt out on the CAN bus. Cab control unit (D790-1) voltage feeds control breaker relay tilt (K3002).
Section 11 Common electrics, group 11.5.3.1 Control unit, cab Section 11 Common electrics, group 11.5.3.2 Frame control unit D5: Diagnostic menu, see section 8 Control system, group 8.4.1.6 CAN/POWER, menu 6
VDCT01.02GB
7:59
Pos
4
Explanation
Control breaker relay tilt (K3002) makes the ground connection between Frame control unit (D797-1) and to Solenoid valve tilt in (Y6011) and Solenoid valve tilt out (Y6010). The frame control unit (D797-1) controls the current proportionally to the lever movement to Solenoid valve tilt in (Y6011) or Solenoid valve tilt out (Y6010). The solenoid valve for tilt in (Y6011) or the solenoid valve for tilt out (Y6010) pressurises the tilt spool in the lift, tilt and attachment control valve. The hydraulic oil pumps pump oil from the hydraulic oil tank. The control valve's tilt spool changes position and pressurises the load retention valve. The load retention valve opens and directs the pressure on to the tilt cylinders. The tilt cylinders angle the mast in relation to the frame. The oil filter cleans the return oil from the lift cylinders before it is collected in the hydraulic oil tank.
Signal description
-
Reference
Section 11 Common electrics, group 11.5.1.4 Emergency stop switch voltage (15E)
I = TDB mA
Section 11 Common electrics, group 11.5.3.2 Frame control unit D5: Diagnostic menu, see section 8 Control system, group 8.4.8.5 ELSERV, menu 5 and 8.4.8.6 ELSERV, menu 6
7 8
Section 10 Common hydraulics, group 10.4.1 Gear pump with fixed displacement Lift, tilt and attachment control valve, description, page 7:60 Load holding valve, description, page 7:61
10
Tilt cylinder, description, page 7:61 Mast, description, page 7:16
11

VDCT01.02GB
7:60
7 Load handling 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. Control valve lift, tilt and attachment is a part of the main valve, see section 10 Common hydraulics, group 10.5.4 Main valve. The main valve is located on the lifting beam in front of the gearbox in the engine compartment. Tilt is controlled by a separate section of the lift, tilt and attachment control valve. See also Lift, tilt and attachment control valve, description, page 7:14. For more information about tilting, see Tilt, function description, page 7:58.
Tilt slide
4 3
1. 2. 3. 4. Solenoid valve, tilt in (Y6011) Solenoid valve, tilt out (Y6010) Connection rod side tilt cylinders Connection piston side tilt cylinders
015082
When the solenoid valves are activated, the tilt spool is pressurised and controls the direction and flow of oil from the hydraulic oil pumps to the tilt cylinders.
Solenoid valve, tilt out

On machines with electric servo, the solenoid valve tilt out is controlled electrically with Solenoid valve tilt out (Y6010) 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. The signal can be checked from the diagnostic menu, see section 8 Control system, group 8.4.8.6 ELSERV, menu 6.
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. The signal can be checked from the diagnostic menu, see section 8 Control system, group 8.4.8.5 ELSERV, menu 5.
VDCT01.02GB
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.
Load retention valve
009929
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.
1 2
3
1. 2. 3. Tilt cylinder Mast Lower mast mounting in frame
009930

VDCT01.02GB
7:62
7.7.8 Mast
Mast, description
See Mast, description, page 7:16.


VDCT01.02GB
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
VDCT01.02GB
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

Condition
Control breaker Alignment
Reference value
Not activated Full alignment or bypass activated
Reference
Section 11 Common electrics, group 11.5.1.4 Emergency stop switch voltage Twistlocks, description, page 7:69 Section 8 Control system, group 8.2.2 Bypassing
1 2b 2a D2 3
D1
7, 20 D790-1 D797-1 D790-2 D795 D791-1
6, 19
D8
5, 12, 18
D5
9 C C
P2 P2 A
D12 13
D17 16
17
10
21
11
T2
14
15
D4
VDCT01.02GB
015078
16 D17
17
7 Load handling Twistlocks
7:65
Pos
1
Explanation
The switch for locking the twistlocks (S1003) (automatic mode) sends a voltage signal to the cab control unit (D790-1). The switch for opening the twistlocks (S1002) sends a voltage signal to the 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.
Signal description
U = 24 V
Reference
Switch lock twistlocks, description (linear control levers), page 7:5 D1: Diagnostic menu, see section 8 Control system, group 8.4.9.5 ATTACH, menu 5
2a
U = 24 V
Switch lock twistlocks, description (linear control levers), page 7:5 D2: Diagnostic menu, see section 8 Control system, group 8.4.9.5 ATTACH, menu 5
2b
The control lever (S815-T2) sends a 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.
US815/T2 = 24 V
Control lever, description, page 7:4 D2: Diagnostic menu, see section 8 Control system, group 8.4.9.3 ATTACH, menu 3
Control unit, cab (D790-1) transmits "open twistlocks" or "lock twistlocks" on the CAN bus. The alignment left sensor (B7203L) and alignment right sensor (B7203R) detect position and send a voltage signal to the attachment control unit (D791). The attachment control unit (D791-1) activates the alignment indicator light on the mast's lamp panel and sends alignment on the CAN bus. Control unit KID (D795) activates the event menu for alignment. Control unit KID (D790-2) activates the indicator light for alignment on the cab's light panel. The frame control unit (D797-1) activates the solenoid valve for main pump relief (Y6062-2).
Checked by control system, error shown with error code. Sensor directly opposite indicator plate: U = 24 V
Section 11 Common electrics, group 11.5.3.1 Control unit, cab. Sensor, alignment, description, page 7:71 D4: Diagnostic menu, see section 8 Control system, group 8.4.9.6 ATTACH, menu 6 Section 11 Common electrics, group 11.5.3.5 Control unit, attachment D5: Diagnostic menu, see section 8 Control system, group 8.4.9.10 ATTACH, menu 10
U = 24 V
6 7
Section 11 Common electrics, group 11.5.3.12 Control unit, KID Section 11 Common electrics, group 11.5.3.11 Control unit, KIT Section 11 Common electrics, group 11.5.3.2 Frame control unit D8: Diagnostic menu, see section 8 Control system, group 8.4.5.6 HYD, menu 6
U = 24 V
Solenoid valve, relief main pump (Y6062-2) pressurises the attachment spool in the lift, tilt and attachment control valve with servo pressure. The load handling hydraulic oil pump pumps oil from the hydraulic oil tank to the lift, tilt and attachment control valve with hydraulic pressure. The control valve lift, tilt and attachment's attachment slide changes position and pressurises the control valve attachment. The attachment control unit (D791-1) activates the "open twistlocks" solenoid valve (Y6039) or the "lock twistlocks" solenoid valve (Y6040). The "open twistlocks" solenoid valve (Y6039) or the "lock twistlocks" solenoid valve (Y6040) pressurises the twistlock spool with servo pressure.
10
See the pressure plate on the left-hand frame beam.
Section 10 Common hydraulics, group 10.4.2 Axial piston pump with variable displacement
11
Lift, tilt and attachment control valve, description, page 7:40 Section 11 Common electrics, group 11.5.3.5 Control unit, attachment D12: Diagnostic menu, see section 8 Control system, group 8.4.9.9 ATTACH, menu 9
12
U = 24 V
13
VDCT01.02GB
7:66
Pos
14
Explanation
The twistlock spool of the control valve changes position and pressurises the lock cylinders via the overcentre valve. The overcentre valve prevents the uncontrolled opening or closing of the twistlocks. The lock cylinders rotate the twistlocks. The "unlocked twistlocks" sensor (B7204 L and R) or the "locked twistlocks" sensor (B7205 L and R) sends a signal to the attachment control unit (D791-1). The attachment control unit (D791-1) voltage feeds the unlocked twistlocks 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. Control unit KID (D795) activates the event menu for twistlocks. Control unit KIT (D790-2) supplies voltage to Indicator light "unlocked twistlocks" or Indicator light "locked twistlocks" on the cab lamp panel. The oil filter cleans the return oil from the lift cylinders before it is collected in the hydraulic oil tank.
Signal description
-
Reference
Attachment control valve, description, page 7:67 Twistlock overcentre valve, description, page 7:68 Lock cylinder, description, page 7:68 Sensor, twistlocks, description, page 7:72 D17: Diagnostic menu, see section 8 Control system, group 8.4.9.7 ATTACH, menu 7 Section 11 Common electrics, group 11.5.3.5 Control unit, attachment D5: Diagnostic menu, see section 8 Control system, group 8.4.9.10 ATTACH, menu 10
15
16 17
18
U = 24 V
19
Checked by control system, error shown with error code. Checked by control system, error shown with error code. -
Section 11 Common electrics, group 11.5.3.12 Control unit, KID Section 11 Common electrics, group 11.5.3.11 Control unit, KIT
20
21
7.9.1.1 Hydraulic oil pump Hydraulic oil pump, general

VDCT01.02GB
7:67
7.9.1.2 Control valve, attachment Attachment control valve, description

Twistlocks slide, description
The twistlocks function is regulated by a separate section in the attachment's control valve. For a general description of the valve and component locations, see Attachment control valve, description, page 7:33.
5 10 6 9 7 8
Twistlocks slide, description

The valve spool controls the direction of the lock cylinder. The valve spool is controlled by the "lock twistlocks" solenoid valve (Y6040) and the "open twistlocks" solenoid valve (Y6039).
"Lock twistlocks" solenoid valve, description

The "lock twistlocks" solenoid valve directs pressure to the twistlock spool so that the spool opens and pressurises the lock cylinders. Solenoid valve locked twistlocks (Y6040) is activated by the attachment control unit (D791-1). The solenoid valve guides servo pressure to the twistlock spool. The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.9.9 ATTACH, menu 9.
"Open twistlocks" solenoid valve, description

015084
The "open twistlocks" solenoid valve directs pressure to the twistlock spool so that the spool opens and pressurises the lock cylinders. Solenoid valve open twistlocks (Y6039) is activated by the attachment control unit (D791-1). The solenoid valve guides servo pressure to the twistlock spool. The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.9.9 ATTACH, menu 9.
1. 2. 3. 4. 5. 6. 7. 8. 9.

See Control valve attachment, replacement, page 7:34.
VDCT01.02GB
7:68
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

VDCT01.02GB
7:69
7.9.1.5 Lock mechanism Lock mechanism, description

1 3 2
The lock mechanism transfers the force of the lock cylinders to the twistlocks. Two lock mechanisms, one in the right and one in the left spreader beam, actuate the twistlocks. The lock mechanism runs in the corner box. The lock mechanism consists of a rotary plate with a linkage bearing at which the lock cylinder is attached. The rotary plate rotates the twistlocks.
1. 2. 3.
Linkages Rotary plate Lock cylinder mount
014807
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.
5
1. 2. 3. 4. 5. Unlocked twistlock sensor Sensor, alignment Locked twistlock sensor Lift pin Alignment pin
014716
Twistlocks secure the load and are located out in the corners of the spreader beam's longitudinal section. Twistlocks are manufactured from high-strength steel in accordance with international standards. The lift pins are marked with serial numbers. 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.
VDCT01.02GB
7:70
Twistlocks, replacement
1 2 3 4 5 Machine in service position, see section B Safety. Depressurise the hydraulic systems, See section B Safety. Clean the twistlocks and the surrounding area. Slacken the screws on the clamp holding the twistlocks in place. 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 7
Remove the clamp halves and lift away the twistlock. Fit a new twistlock and secure it with the clamp halves.
NOTE
Remember the washer. 8 9 Check the positions of the parts and that the twistlocks can move. 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.
VDCT01.02GB
014821
7:71
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. The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.9.7 ATTACH, menu 7.
1
1. 2. Sensor, alignment Alignment pin
014813
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. Check that the sensor is free of damage and dirt. Turn the start key to position I and check that the LED on the sensor is unlit. Lower the attachment onto a container and check that the alignment indicator light comes on. Lift the container a little bit so that the alignment indicator light goes out. With the container lifted, check how much alignment pin movement is needed to detect contact (LED on the sensor lights). The movement should be 34 mm.
2 3 4 5
014717
1
Right side 1. 2. Sensor, alignment Alignment pin
VDCT01.02GB
7:72
If necessary, slacken the lock nut and screw the sensor in/out until the distance between the sensor and the alignment pin is 51 mm.
2
Left side 1. 2. Sensor, alignment Alignment pin
014718
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. The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.9.8 ATTACH, menu 8.
1
1. 2. Unlocked twistlock sensor Locked twistlock sensor
VDCT01.02GB
014809
7:73
Twistlocks sensor, checking and adjusting

1 2 3 4 5 Check that the sensors are free of damage and dirt. If necessary, slacken the lock nut and screw the sensor in/out until the distance between the sensor and the indicator plate is 51 mm. Check that the "twistlocks open" indicator light is lit. Lower the attachment over a container and lock the twistlocks. 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 51 mm.
014719
1
Right side 1. 2. Unlocked twistlock sensor Locked twistlock sensor
Check that the "twistlocks locked" indicator light is lit.
2
Left side 1. 2.
Unlocked twistlock sensor Locked twistlock sensor
014720
VDCT01.02GB
7:74
7.9.1.10 Pipes and hoses Piped and hoses, description

7.9.1.11 Relief valve, attachment Relief valve attachment, description

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 Hydraulic oil filter, general

VDCT01.02GB
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.
Condition
Control breaker
Reference value
Not activated
Reference
D1 1, 4, 7 10 D790-1 D797-1 D2 2,8 5 D795 D791-1 3,6,9 D5
Pos
1
Explanation
The attachment is positioned over a container with the functions 7.2 Lifting/lowering, 7.4 Side shift and 7.5 Spreading
Signal description
-
Reference
Lifting/lowering, function description, page 7:8 Side shift, function description, page 7:31 Spreading, function description, page 7:41 D1: Diagnostic menu, see section 8 Control system, group 8.4.8.1 ELSERV, menu 1 and 8.4.8.1 ELSERV, menu 2.
Alignment sensors left and right (B7203L and B7203R) voltage signal to the attachment control unit (D791-1). Control unit, attachment (D791-1) sends alignment on the CAN bus. Twistlocks are rotated to the locked position and are closed with the 7.9.1 Twistlocks function. The sensor for locked twistlocks left (B7205L) and sensor for locked twistlocks right (B7205R) send a voltage signal to the attachment control unit (D791-1).
Sensor, alignment, description, page 7:71 D2: Diagnostic menu, see section 8 Control system, group 8.4.9.7 ATTACH, menu 7 Section 11 Common electrics, group 11.5.3.5 Control unit, attachment Twistlocks, function description, page 7:64
Sensor, twistlocks, description, page 7:72 D5: Diagnostic menu, see section 8 Control system, group 8.4.9.8 ATTACH, menu 8
VDCT01.02GB
015086
7:76
7 Load handling Container counter
Pos
6
Explanation
Control unit, attachment (D791-1) sends locked twistlocks on the CAN bus. The container is lifted with the function 7.2 Lifting/lowering. Alignment sensors left and right (B7203L and B7203R) make and send a voltage signal to the attachment control unit (D791-1). Control unit, attachment (D791-1) sends no alignment on the CAN bus. If the twistlocks remain locked for 8 seconds then Control unit, cab (D790-1) adds one lift to the container counter.
Signal description
Checked by control system, error shown with error code. U=0V
Reference
Section 11 Common electrics, group 11.5.3.5 Control unit, attachment Lifting/lowering, function description, page 7:8 Sensor, alignment, description, page 7:71 D2: Diagnostic menu, see section 8 Control system, group 8.4.9.7 ATTACH, menu 7
7 8
Section 11 Common electrics, group 11.5.3.5 Control unit, attachment Section 11 Common electrics, group 11.5.3.1 Control unit, cab
10
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8 Control system
Contents 8 Control system

8 Control system ...................................................................................................8:3 8.1 Controls and instruments .................................................................................8:4 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
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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.
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8 Control system Controls and instruments

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

The control and monitoring system gives error code information in three levels which are indicated with a symbol in the lower left corner (B) on the display unit. Stop Indicates a serious malfunction that may jeopardise the operator's safety or cause machine failure. The error code must be attended to immediately. Stop working with the machine and contact service immediately.
000350
C D E
The error code is shown automatically on the display.
Warning Indicates malfunction in machine that should be taken care of as soon as possible. After the finished work shift with the machine, contact service as soon as possible. The error code is shown automatically on the display.
C D E
000351
Information Information to the operator that something should be taken care of as soon as possible, e.g., defective light bulb. Take action to fix the cause of the error code as soon as possible. See section 6 Inspection and maintenance in the operator's manual.
C D E
000352
The error code is stored in the error code list under operating menu for service.
Field C: Error code number
C D B E
000389
The control and monitoring system gives error codes from three sub-systems: Machine: Shown with error code number XXX on display. Engine: Shown with error code number XXX/YY on display.
XX/YY
D
001343
NOTE
If several error codes come from the engine, the error code level is shown for the most serious error code.
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8 Control system Error code menu
8:5
XXX/YY
Transmission: Shown with error code number XX/YY on display.
D
001344
Field D: Type of error

1. 2. 3. 4. 5. 6. 7. Temperature too high/too low. Incorrect signal to solenoid valve. Incorrect hydraulic pressure. Incorrect sensor signal. Incorrect signal from control. Incorrect signal to bulb. Incorrect signal, for example, open circuit.
7
000396
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8 Control system Error code menu
Field E: Affected function

1. 2. 3. Attachment Rotation of attachment Side shift, attachment Length adjustment attachment Levelling Twistlocks Forks up/down Tilt forks Side shift forks
4. 5. 6. 7.
8. 9.
10. Spreading forks
10
11
12
11. Rotation forks 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 26. Battery voltage 27. Bulb for lighting
22
23
24
25
26
27
010153
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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. Extreme hazard to personal health and risk of property 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.
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8 Control system Service indicator
8.2.4 Service indicator

Service indicator, resetting
1 2
Machine in service position, see section B Safety. Navigate first to the service menu and press Enter.
000056
Enter the code to reset the service indicator. Code is obtained from Cargotec Support.
1 23 4 5
000060
NOTE
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 changed to indicated interval. To change duration of the service interval, set the desired interval with the plus or minus key.
004908
SERVICE INTERVALL NEXT SERVICE XXXXh SERVICE INTERVALL STORED XXXXh PRESENT XXXXh
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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
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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 CAB Indicates that diagnostic tests are selected. 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 (X) Variable Number of current menu. Every menu group consists of several menus in a loop. 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. 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.
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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 bus communication. Confirm selections with function key for Enter.
005263
DIAGNOSIS CAN/POWER LIGHTS CAB CLIMATE HYD ENGINE TRANSM ELSERV ATTACH OLS EXTRA
8.4.1.1 CAN/POWER, menu 1 PRESENT REDCAN STATUS, COMMUNICATION MODE
005266
DIAG CAN/POWER 1(X) PRESENT REDCAN STATUS COMMUNICATION MODE X NUMBERS OF UNITS X SEGMENT ERROR X
Description: Indicates communication status for the redundant CAN bus. Circuit diagram: Circuit CANBUS ground group 11.6_1 Contact: Function: 11.6.2 Redundant CAN bus Signal value: 3 2 0 OK. Segment check. Error.
PRESENT REDCAN STATUS, NUMBER OF UNITS
005266
Description: Indicates the number of control units, excluding Cab control unit (D790-1) which should be on the current machine. The number is dependent on the installed options. Circuit diagram: Circuit CANBUS ground group 11.6_1 Contact: Function: 11.6.2 Redundant CAN bus Signal value: X Number of nodes that should be in the machine. Number of nodes depends on installed options.
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PRESENT REDCAN STATUS, SEGMENT ERROR
005266
Description: Indicates if there is open circuit on the redundant CAN bus and if there is, where the first open circuit is. If there is open circuit, it is indicated with a number that corresponds to the defective segment on the redundant CAN bus. Circuit diagram: Circuit CANBUS ground group 11.6_1 Contact: Function: 11.6.2 Redundant CAN bus Signal value: 0 >0 No open circuits. 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.
8.4.1.2 CAN/POWER, menu 2 PRESENT REDCAN STATUS, CONNECTED CITIES
005267
DIAG CAN/POWER 2(X) PRESENT REDCAN STATUS CONNECTED CITIES D797-1 D797-2 XX D795 D791-1 XX
Description: Indicates which control units are in contact with the cab control unit (D790-1) via the redundant CAN bus. Circuit diagram: Circuit CANBUS ground group 11.6_1, Attachment DCF90-100/45E 11.6_1 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 0 Communication with the node is OK. No communication and/or there is some node error.
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8.4.1.3 CAN/POWER, menu 3 PRESENT OPTION KDU
DIAG CAN/POWER 3(X) PRESENT OPTION KDU

007183
Description: Indicates which optional control units should be present on the machine and if they have working communication with the cab KCU control unit (D790-1). Circuit diagram: Circuit CANBUS ground group 11.6_1, Circuit Attachment DCF90-100/45E 11.6_1 Contact: Function: 11.6.2 Redundant CAN bus Signal value: 00 10 11 The control unit is not installed on the machine. The control unit is installed on the machine but there is no communication with the cab control unit (D790-1). The control unit is installed on the machine and there is communication with the cab control unit (D790-1).
KDU D797-2 KDU D791-1
XY XY
8.4.1.4 CAN/POWER, menu 4 PRESENT DRIVE-TRAIN CAN BUS STATUS, ENGINE

Description: Indicates status for engine in the drive-train's CAN bus.
005269
DIAG CAN/POWER 4(X) PRESENT DRIVE-TRAIN CAN BUS STATUS ENGINE X TRANSMISSION X
Circuit diagram: Circuit CANBUS ground group 11.6_1, Circuit Attachment DCF90-100/45E group 11.6_1, Circuit engine QSB6.7 group 1.0_2E1, Circuit Yuchai YC6A240-30 group 1.0_1A1 Contact: Cummins QSB6.7 to D794/46 and 37 : CAN J1939 from D790-1/K13:1 and K13:2
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: 1 0 Communication with the node is OK. No communication and/or there is some node error.
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.
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PRESENT DRIVE-TRAIN CAN BUS STATUS, TRANSMISSION
005269
DIAG CAN/POWER 4(X) PRESENT DRIVE-TRAIN CAN BUS STATUS ENGINE X TRANSMISSION X
Description: Indicates status for transmission in the drive-train's CAN bus. Circuit diagram: Circuit CAN-BUS ground group 11.6_1, circuit Transmission group 2.0_1, Circuit Yuchai YC6A240-30 group 1.0_1A2 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: 1 0 Communication with the node is OK. No communication and/or there is some node error.
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.
8.4.1.5 CAN/POWER, menu 5 IGNITION, KEY IN
007126
DIAG CAN/POWER IGNITION KEY IN RELAY K315-1 RELAY K315-2
5(X) X XY XY
Description: Indicates if ignition is switched on (key in ignition key lock). Circuit diagram: Circuit power group 11.5_3 Connection: signal from S150/15 to digital in D790-1/K11:1 Function: 11.5.1.3 Ignition voltage Signal value: 1 0 Input signal active. No signal.
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IGNITION, RELAY K315-1
007126
5(X) X XY XY
Description: Control current to Relay, ignition voltage (K315-1), 15-voltage. Circuit diagram: Circuit power 11.5_3 Connection: output signal from D790-1/K10:10 to K315-1 Function: 11.5.1.3 Ignition voltage (15) Signal value: 00 01 No output signal and open circuit in the circuit. 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 11 Output signal active, short-circuiting. 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
007126
5(X) X XY XY
Description: Control current to Relay, ignition voltage (K315-2) (15-voltage). Circuit diagram: Circuit power 11.5_3 Connection: output signal from D790-1/K10:16 to K315-2 Function: 11.5.1.3 Ignition voltage (15) Signal value: 00 01 No output signal and open circuit in the circuit. 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 11 Output signal active, short-circuiting. 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.
8.4.1.6 CAN/POWER, menu 6 EMERGENCY STOP, SW

Description: Indicates if switch, emergency stop switch, is activated.
007127
DIAG CAN/POWER 6(X) EMERGENCY STOP, SW X RELAY K3009-1 XY FEEDBACK X RELAY K3009-2 XY
Circuit diagram: Circuit power control breaker group 11.5_6 Connection: signal from S250/2 to digital in D790-1/K8:4 Function: 11.5.1.4 Emergency stop switch voltage (15E) Signal value: 1 0 Input signal active. No signal.
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EMERGENCY STOP, RELAY K3009-1
007127
Description: Status for control current to relay K3009-1, for emergency stop switch voltage, 15E voltage. Circuit diagram: Circuit power control breaker group 11.5_6 Connection: signal from D790-1/K10:11 to K3009-1/86 Function: 11.5.1.4 Emergency stop switch voltage (15E) Signal value: 00 01 No output signal and open circuit in the circuit. 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 11 Output signal active, short circuit. 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.
EMERGENCY STOP, FEEDBACK
007127
Description: Feedback signal from control breaker relay (K3009-1), indicates that relay is working normally. Circuit diagram: Circuit power control breaker group 11.5_6 Contact: Signal from K3009-1/87 via F58-3/8 to digital in D790-1/K11:13 Function: 11.5.1.4 Emergency stop switch voltage (15E) Signal value: 1 0 Input signal active. No signal.
EMERGENCY STOP, RELAY K3009-2
007127
Description: Status of the control current to the control breaker relay (K3009-2), Control breaker relay lifting/lowering (K3007) and Control breaker relay tilt (K3002),15E-voltage. Circuit diagram: Circuit power control breaker group 11.5_6 Contact: signal from D790-1/K10:12 to K3009-2/86, K3002/86 and K3007/86. Function: 11.5.1.4 Emergency stop switch voltage (15E) Signal value: 00 01 No output signal and open circuit in the circuit. 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 11 Output signal active, short circuit. 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.
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8.4.1.7 CAN/POWER, menu 7 790-1 CAB, POWER

Description: Ignition voltage (15) to Control unit, cab (D790-1).
005271
DIAG CAN/POWER 7(X) 790-1 CAB POWER XX.XXV 5V REF X.XXV
Circuit diagram: Circuit power group 11.5_1, 11.5_4 Connection: 15-voltage from K315-1/87 via F54/4 and F58-5/1, F58-5/2 to D790-1/K1:2, D790-1/K1:3 and D790-1/K1:4 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.
005271
DIAG CAN/POWER 7(X) 790-1 CAB POWER XX.XXV 5V REF X.XXV
Circuit diagram: Circuit climate group 9.4_1, 9.4_2 (contact 1, 2), Circuit drivetrain engine group 1.0_1 (contact 3), Circuit electric servo levers 7.0_1 (contact 4), Circuit electric servo joystick 7.0_2 (contact 5) Contact: 1. 2. 3. 4. 5. signal from digital out D790-1/K4:5 to Y672/10 and Y673/10 signal from digital out D790-1/K5:11 to S118/1, S139/1 and S117/1 signal from digital out D790-1/K5:13 to B690-1/1 signal from digital out D790-1/K7:2 to R8071/1, R8072/1, R8073/1 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).
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8.4.1.8 CAN/POWER, menu 8 790-1 CAB, 24V SENSOR SUPPLY

Description: 24 V voltage feed to components in cab.
005275
DIAG CAN/POWER 8(X) 790-1 CAB 24V SENSOR SUPPLY XY 24V SUPPLY,RPM>500 XY
Circuit diagram: 1. 2. Circuit wiper group 9.5_1 Circuit drivetrain transmission group 2.0_1, Circuit extra 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 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 Circuit alarm, audible signals group 9.7_1 Circuit wiper group 9.5_1
3. 4. 5.
6. 7. 8. 9.
10. Circuit wiper group 9.5_1 Contact: 1. 2. signal from digital out D790-1/K4:14 to M650-1/53a 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 signal from digital out D790-1/K6:13 not connected signal from digital out D790-1/K7:12 not connected 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 signal from digital out D790-1/K9:1 not connected signal from digital out D790-1/K10:1 not connected signal from digital out D790-1/K11:12 to S230/2 signal from digital out D790-1/K12:1 to M650-2/53a
3. 4. 5.
6. 7. 8. 9.
10. signal from digital out D790-1/K12:3 to M650-3/53a Function: 1. 2. 3. 4. 5. 9.5.5 Wiper motor front 2.0 Transmission, 9.3 Seat, 9.6 Lighting 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 9.3.14 Sensor operator in seat 9.5.7 Wiper motor rear
6. 7. 8. 9.
10. 9.5.6 Wiper motor roof
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Signal value: 01 Normal mode function off. 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 11 Output signal active, short circuit. It can also be an open circuit as this cannot be detected. Normal mode function on. Output signal active, circuit OK or open circuit. Open circuit cannot be detected.
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790-1 CAB, 24V SUPPLY,RPM>500

Description: Voltage feed when engine speed is higher than 500 rpm.
005275
DIAG CAN/POWER 8(X) 790-1 CAB 24V SENSOR SUPPLY XY 24V SUPPLY,RPM>500 XY
Circuit diagram: Circuit hour meter group 9.1_2, Circuit air suspension seat group 9.3_2 Connection: signal from digital out D790-1/K10:9 to P708/+ and K358/86 Function: 9.3.6 Compressor air-suspension seat, 11.1.1 Hour meter Signal value: 00 01 No output signal and open circuit in the circuit. 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 11 Output signal active, short circuit. 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.
8.4.1.9 CAN/POWER, menu 9 795 DISPLAY, RED. POWER

Description: Redundant voltage to Control unit KID (D795).
DIAG CAN/POWER 795 DISPLAY RED.POWER LE X
9(X) RI X
Circuit diagram: Circuit canbus ground group 11.6_1 Contact:

005276
LE: redundant feed from D790-1/K11:10 to D795/K1:8 RI: redundant feed from D790-1/K11:8 to D795/K1:7 Function: 11.5.1.2 Redundant voltage feed of control units Signal value: 1 0 Feed active. No feed.
8.4.1.10 CAN/POWER, menu 10 797-1 FRAME, POWER

Description: Ignition voltage (15) to the frame control unit (D797-1).
005277
DIAG CAN/POWER 10(X) 797-1 FRAME POWER XX.XXV RED.POWER LE X RI X POWER 2 X
Circuit diagram: Circuit power group 11.5_1 and 11.5_4 Connection: 15 voltage from K315-1/87 via F54/4 and F58-2/1 to D797-1/K2:1, D797-1/K2:9 and D797-1/K2:10 Function: 11.5.1.3 Ignition voltage (15) Signal value: XX.XXV = voltage on connection. The signal value should be 22-30 V (battery voltage).
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797-1 FRAME, RED. POWER

Description: Redundant voltage to frame control unit (D797-1).
005277
Circuit diagram: Circuit canbus ground group 11.6_1 Contact: 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
Function: 11.5.1.2 Redundant voltage feed of control units Signal value: 1 0 Feed active. No feed.
797-1 FRAME, POWER 2

Description: Battery voltage to the frame control unit (D797-1).
005277
Circuit diagram: Circuit power group 11.5 and 11.5_4 Connection: 15-voltage from K315-1/87 via F54/4 and F58-2/1 to D797-1/K2:11 Function: 11.5.1.3 Ignition voltage (15) Signal value: 1 0 Feed active. No feed.
8.4.1.11 CAN/POWER, menu 11 NOT USED

This menu is not used.
XXXXXXX NOT USED
X(X)
008793
8.4.1.12 CAN/POWER, menu 12 793 TRANSMISSION, POWER

Description: Battery voltage (30) to Control unit, transmission (D793).
005279
DIAG CAN/POWER 12(X) 793 TRANSMISSION POWER XX.XXV IGNITION POWER XX.XXV SENSOR SUPPLY XX.XXV
Circuit diagram: Circuit power group 11.5_1, circuit drivetrain gearbox group 2.0_1, circuit Yuchai YC6A240-30 group 1.0_1A2 Connection: 30-voltage from F54/2 via F58-1/5 to D793/45 Function: 11.5.1.1 Battery voltage (30) Signal value: XX.XXV = voltage on the connection. The signal value should be 22-30 V (battery voltage).
VDCT01.02GB
8:22
793 TRANSMISSION, IGNITION POWER

Description: Ignition voltage (15) to Control unit, transmission (D793).
005279
Circuit diagram: Circuit Yuchai YC6A240-30 group 1.0_1A2, Circuit drivetrain gearbox group 2.0_1, Circuit power group 11.5_1 Connection: 15 voltage from K315/87 via F54/4 and F58-2/6 to D793/20, D793/60 and D793/21 Function: 11.5.1.3 Ignition voltage (15) Signal value: XX.XXV = voltage on the connection. The signal value should be 22-30 V (battery voltage).
793 TRANSMISSION, SENSOR SUPPLY

This menu row is not used.
005279

XXXXXXX NOT USED
X(X)
008793

XXXXXXX NOT USED
X(X)
008793
8.4.1.15 CAN/POWER, menu 15 791-1 ATTACHMENT, EME POWER

Description: Voltage feed to Control unit, attachment (D791-1).
005282
DIAG CAN/POWER 15(X) 791-1 ATTACHMENT(OPT) EME POWER XX.XXV RED.POWER LE X RI X EME POWER 2 X
Circuit diagram: Attachment DCF90/100-45E group 11.5_1, Circuit power control breaker group 11.5_6 Connection: 15E voltage from K3009-1/87 via K3009-2/87, F58-3/1 to D791-1/K2:1, K2:9, K2:10, K2:11 Function: 11.5.1.4 Emergency stop switch voltage (15E) Signal value: XX.XXV = Voltage on the connection. The signal value should be 22-30 V (battery voltage).
VDCT01.02GB
8:23
791-1 ATTACHMENT, RED. POWER
005282
Description: Redundant voltage feed to Control unit, attachment (D791-1). Circuit diagram: Circuit CANBUS ground group 11:6_1, Circuit CANBUS KDU opt. group 11.6_2B, Attachment DCF90/100-45E group 11.6_1 Contact: LE: redundant voltage feed to D791/K2:7 RI: redundant voltage feed to D791/K2:8 Function: 11.5.1.2 Redundant voltage feed of control units Signal value: 1 0 Feed active. No feed.
791-1 FRAME, EME POWER 2
005282
Description: Emergency stop switch voltage (15E) to attachment control unit (D791-1). Circuit diagram: Circuit 11.5_5 Connection: 15E voltage from K3009-1/87 via K3009-2/87, F58-3/1 to D791-1/K2:11 Function: 11.5.1.4 Emergency stop switch voltage (15E) Signal value: 1 0 Feed active. No feed.
8.4.1.16 CAN/POWER, menu 16 791-1 ATTACHMENT (OPT), 24V SENSOR SUPPLY
005283
DIAG CAN/POWER 16(X) 791-1 ATTACHMENT (OPT) 24V SENSOR SUPPLY XY 5V REF X.XXV
Description: Voltage feed to sensors connected to the attachment control unit (D791-1). Circuit diagram: Circuit diagram: Attachment DCF90/100-45E group 7.5_3, 7.9_2, 11.5_2 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: 00 01 No output signal and open circuit in the circuit. 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 11 Output signal active, short circuit. 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.
VDCT01.02GB
8:24
791-1 ATTACHMENT (OPT), 5V REF

005283
DIAG CAN/POWER 16(X) 791-1 ATTACHMENT (OPT) 24V SENSOR SUPPLY XY 5V REF X.XXV
8.4.1.17 CAN/POWER, menu 17 REDCAN STATUS CHECK
DIAG CAN/POWER 17(X) REDCAN STATUS CHECK PRESS ENTER SEGMENT ERROR X
005284
Description: Control function from the redundant CAN bus. Cab control unit (D790-1) performs a segment check to verify that all control units are in contact and are connected in the correct order. The control system indicates the fault by numbering the cables between the control units (segments) from 1 onwards. Segment 1 is 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 diagram attachment DCF90/100-45E group 11.6_1 Contact: Function: 11.6.2 Redundant CAN bus
015052
D790-1
CAN L CAN R
D791
CAN L CAN R
D797-1
CAN L CAN R
1 4
CAN R CAN L
2 3
D795
Segment numbering with maximum number of control units.
Signal value: 0 >0 No errors. X > 0, the number indicates defective segment. Use the circuit diagram to find the defective segment.
VDCT01.02GB
8 Control system LIGHTS
8:25
8.4.2 LIGHTS
LIGHTS, description
This group covers lighting.
005285
Confirm selections with function key for Enter.
8.4.2.1 LIGHTS, menu 1 MAIN LIGHT, SWITCH

Description: Signal from headlights switch.
DIAG LIGHTS MAIN LIGHT SWITCH
1(X) X
005286
Circuit diagram: Circuit lighting group 9.6_4 Connection: signal from S100/1 to digital in D790-1/K6:5 Function: 9.6.1 Headlights. Signal value: 1 0 Input signal active. No signal.
8.4.2.2 LIGHTS, menu 2 PRESENT OUTPUT SIGNAL, SIDE LIGHTS

Description: Voltage feed to side running lights.
DIAG LIGHTS 2(X) PRESENT OUTPUT SIGNAL

005287
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 and H417-2 Function: 9.6.2 Running lights Signal value: 00 01 No output signal and open circuit in the circuit. 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 11 Output signal active, short circuit. 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.
SIDE LIGHTS REAR LIGHTS
XY XY
VDCT01.02GB
8:26
PRESENT OUTPUT SIGNAL, REAR LIGHTS

Description: Voltage feed to tail lights.
DIAG LIGHTS 2(X) PRESENT OUTPUT SIGNAL

005287
Circuit diagram: Circuit lighting group 9.6_6 Connection: digital out from D797-1/K1:33 to H412L and H412R Function: 9.6.3 Tail lights Signal value: 00 01 No output signal and open circuit in the circuit. 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 11 Output signal active, short circuit. 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.
SIDE LIGHTS REAR LIGHTS
XY XY
8.4.2.3 LIGHTS, menu 3 HEAD LIGHTS, SWITCH

Description: Lighting headlights front, switch.
005288
DIAG LIGHTS HEAD LIGHTS SWITCH HEAD LE/RI DIMMED LE/RI
3(X) X XY XY
Circuit diagram: Circuit lighting group 9.6_4 Connection: from S162:56A to digital in D790-2/K3:9 Function: 9.6.1 Headlights Signal value: 1 0 Input signal active. No signal.
HEADLIGHTS, HEAD LE/RI

Description: Voltage feed to headlights, high beam.
005288
3(X) X XY XY
Circuit diagram: Circuit lighting group 9.6_5 Connection: digital out from D797-1/K1:15 to E402L-1 and E402R-1 Function: 9.6.1 Headlights Signal value: 00 01 No output signal and open circuit in the circuit. 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 11 Output signal active, short circuit. 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.
VDCT01.02GB
8:27
HEADLIGHTS, DIMMED LE/RI

Description: Voltage feed to headlights, low beam.
005288
3(X) X XY XY
Circuit diagram: Circuit lighting group 9.6_5 Connection: digital out from D797-1/K1:28 to E400L and E400R Function: 9.6.1 Headlights Signal value: 00 01 No output signal and open circuit in the circuit. 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 11 Output signal active, short circuit. 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.
8.4.2.4 LIGHTS, menu 4 PRESENT INPUT SIGNAL, HAZARD SWITCH

Description: Signal from switch, flashing hazard lights (Hazard).
005289
DIAG LIGHTS 4(X) PRESENT INPUT SIGNAL HAZARD SWITCH X FLASH.SW. LE X RI X
Circuit diagram: Circuit blinkers & hazard group 9.6_7 Connection: signal from S109/1 to digital in D790-1/K5:6 Function: 9.7 Signalling system Signal value: 1 0 Input signal active. No signal.
PRESENT INPUT SIGNAL, FLASH.SW.

Description: Signal from switch, direction indicators.
005289
DIAG LIGHTS 4(X) PRESENT INPUT SIGNAL HAZARD SWITCH X FLASH.SW. LE X RI X
Circuit diagram: Circuit blinkers & hazard group 9.6_7 Contact: 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: 1 0 Input signal active. No signal.
VDCT01.02GB
8:28
8.4.2.5 LIGHTS, menu 5 PRESENT OUTPUT SIGNAL HAZARD/FLASHER, LEFT F/R

Description: Voltage feed to direction indicator, left-hand side.
005290
DIAG LIGHTS 5(X) PRESENT OUTPUT SIGNAL HAZARD/FLASHER LEFT F/R XY RIGHT F/R XY
Circuit diagram: Circuit blinkers & hazard group 9.6_7 Connection: digital out from D797-1/K1:30 to H422 and H426 Function: 9.6.6 Direction indicators, 9.6.7 Flashing hazard lights (Hazard) Signal value: 00 01 No output signal and open circuit in the circuit. 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 11 Output signal active, short circuit. 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.
PRESENT OUTPUT SIGNAL HAZARD/FLASHER, RIGHT F/R

Description: Voltage feed to direction indicator, right-hand side.
005290
DIAG LIGHTS 5(X) PRESENT OUTPUT SIGNAL HAZARD/FLASHER LEFT F/R XY RIGHT F/R XY
Circuit diagram: Circuit blinkers & hazard group 9.6_7 Connection: digital out from D797-1/K1:31 to H423 and H427 Function: 9.6.6 Direction indicators, 9.6.7 Flashing hazard lights (Hazard) Signal value: 00 01 No output signal and open circuit in the circuit. 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 11 Output signal active, short circuit. 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.
VDCT01.02GB
8:29
8.4.2.6 LIGHTS, menu 6 ROTATION BEACON, SWITCH

Description: Signal from switch, revolving beacon.
005291
DIAG LIGHTS ROTATION BEACON SWITCH OUTPUT
6(X) X XY
Circuit diagram: Circuit lighting group 9.6_4 Connection: from S110/1 to digital in D790-1/K6:4 Function: 9.6.8 Revolving beacon Signal value: 1 0 Input signal active. No signal.
ROTATION BEACON, OUTPUT

Description: Voltage feed to revolving beacon.
005291
DIAG LIGHTS ROTATION BEACON SWITCH OUTPUT
6(X) X XY
Circuit diagram: Circuit lighting group 9.6_4 Connection: digital out from D790-1/K2:5 to H428 Function: 9.6.8 Revolving beacon Signal value: 01 Normal mode function off. 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 11 Output signal active, short circuit or open circuit. Normal mode function on. Output signal active, circuit OK.
8.4.2.7 LIGHTS, menu 7 PRESENT INPUT SIGNAL, BRAKE LGT SWITCH

Description: Signal from make-contact (closing switch) brake lights.
005292
DIAG LIGHTS 7(X) PRESENT INPUT SIGNAL BRAKE LGT SWITCH X REVERSE LGT SIGNAL X
Circuit diagram: Circuit lighting group 9.6_5 Connection: from S216/2 to digital in D797-1/K1:20 Function: 4.3.8 Make-contact (closing switch) brake lights Signal value: 1 0 Input signal active. No signal.
VDCT01.02GB
8:30
PRESENT INPUT SIGNAL, REVERSE LGT SIGNAL
005292
DIAG LIGHTS 7(X) PRESENT INPUT SIGNAL BRAKE LGT SWITCH X REVERSE LGT SIGNAL X
Description: Signal from Control unit, transmission (D793) when reverse gear is activated. Circuit diagram: Circuit Lighting group 9.6 Contact: Function: 9.6.5 Back-up lights Signal value: 1 0 Input signal active. Output signal "reverse gear active" from Control unit, transmission (D793). No signal.
8.4.2.8 LIGHTS, menu 8 PRESENT OUTPUT SIGNAL, BRAKE LGT

Description: Voltage feed to brake lights.
005293
DIAG LIGHTS 8(X) PRESENT OUTPUT SIGNAL BRAKE LGT LE XY RI XY REV. LGT LE XY RI XY REVERSE ALARM XY
Circuit diagram: Circuit lighting group 9.6_6 Contact: 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: 00 01 No output signal and open circuit in the circuit. 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 11 Output signal active, short circuit. 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.
VDCT01.02GB
8:31
PRESENT OUTPUT SIGNAL, REV. LGT

Description: Voltage feed to back-up lights.
005293
Circuit diagram: Circuit lighting group 9.6_6 Contact: 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: 00 01 No output signal and open circuit in the circuit. 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 11 Output signal active, short circuit. 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.
PRESENT OUTPUT SIGNAL, REVERSE ALARM

Description: Voltage feed to reverse alarm.
005293
Circuit diagram: Circuit back-up alarm group 9.7_2 Connection: digital out from D797-1/K1:10 to H965 Function: 9.7.5 Reverse alarm Signal value: 00 01 No output signal and open circuit in the circuit. 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 11 Output signal active, short circuit. 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.
8.4.2.9 LIGHTS, menu 9 CAB LIGHT, MANUAL SWITCH

Description: Signal from switch, lighting cab.
005294
DIAG LIGHTS CAB LIGHT MANUAL SWITCH DOOR SWITCH OUTPUT
9(X) X X XXX
Circuit diagram: Circuit interior lighting group 9.6_8 Connection: signal from D790-2/K8:11 to digital in D790-1/K11:2 Function: 9.6 Lighting system Signal value: 1 0 Input signal active. No signal.
VDCT01.02GB
8:32
CAB LIGHT, DOOR SWITCH

Description: Signal from break contact (opening switch) door.
005294
9(X) X X XXX
Circuit diagram: Circuit interior lighting group 9.6_8 Connection: signal from S266-LE or S266-RI (connected in parallel) to digital in D790-1/K11:3 Function: 9.10.2 Doors Signal value: 1 0 Input signal active. No signal.
CAB LIGHT, OUTPUT

Description: Voltage feed to interior lighting cab.
005294
9(X) X X XXX
Circuit diagram: Circuit interior lighting group 9.6_8 Connection: digital out from D790-1/K11:6 to E434-1 Function: 9.6.11 Interior lighting Signal value: XXX = 0-255 = 0-24 V (255 means 24 V which corresponds to battery voltage).
8.4.2.10 LIGHTS, menu 10 WORKING LIGHT MAST, SWITCH

Description: Signal from switch for working light, mast.
005295
DIAG LIGHTS 10(X) WORKING LIGHT MAST SWITCH X OUTPUT LE/RI XY
Circuit diagram: Circuit working light mast group 9.6_3 Connection: signal from S105-3/1 to digital in D790-1/K6:3 Function: 9.6 Lighting system Signal value: 1 0 Input signal active. No signal.
WORKING LIGHT MAST, OUTPUT

Description: Voltage feed to working light, mast.
005295
DIAG LIGHTS 10(X) WORKING LIGHT MAST SWITCH X OUTPUT LE/RI XY
Circuit diagram: Circuit working light mast group 9.6_3 Connection: digital out from D797-1/K1:1 to E404L-1 and E404R-1 Function: 9.6.9 Working light, mast Signal value: 00 01 No output signal and open circuit in the circuit. 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 11 Output signal active, short circuit. 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.
VDCT01.02GB
8:33
8.4.2.11 LIGHTS, menu 11 WORKING LIGHT EXTRA OUTPUT, D797-1 C1 P42
005296
DIAG LIGHTS 11(X) WORKING LIGHT EXTRA OUTPUT D797-1 C1 P42 XY D797-2 C1 P42 XY
Description: Voltage feed to auxiliary working light. Circuit diagram: Circuit working light option group 9.6_9 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: 00 01 No output signal and open circuit in the circuit. 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 11 Output signal active, short circuit. 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.
WORKING LIGHT EXTRA OUTPUT, D797-2 C1 P42

005296
DIAG LIGHTS 11(X) WORKING LIGHT EXTRA OUTPUT D797-1 C1 P42 XY D797-2 C1 P42 XY
8.4.2.12 LIGHTS, menu 12 WORKING LIGHT CAB, SWITCH

Description: Signal from switch, working lights cab roof
DIAG LIGHTS 12(X) WORKING LIGHT CAB SWITCH X

005297
Circuit diagram: Circuit working lights 20-40 group 9.6_1 Connection: signal from S105-1/1 to digital in D790-1/K6:10 Function: 9.6 Lighting system Signal value: 1 0 Input signal active. No signal.
OUTPUT
20' XY 40' XY
VDCT01.02GB
8:34
WORKING LIGHT CAB, OUTPUT
DIAG LIGHTS 12(X) WORKING LIGHT CAB SWITCH X OUTPUT 20' XY 40' XY
005297
Description: Control of relays for power supply to working lights cab roof. Circuit diagram: Circuit working lights 20-40 group 9.6_1 Contact: 20': digital out from D790-1/K7:8 to K3017-2. K3017-2 voltage feeds E406L-2 and E406R-2 40': digital out from D790-1/K10:8 to K3017-1. K3017-1 voltage feeds E406L-1 and E406R-1
Function: 9.6.10 Work light cab Signal value: 00 01 No output signal and open circuit in the circuit. 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 11 Output signal active, short circuit. 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.
8.4.2.13 LIGHTS, menu 13 WORKING LIGHT ATTACH, SWITCH

Description: Signal from switch, working lights attachment
008895
DIAG LIGHTS 13(X) WORKING LIGHT ATTACH SWITCH X OUTPUT LE XY RI XY
Circuit diagram: Circuit working lights truck group 9.6_2 Connection: signal from S105-2/1 to digital in D790-1/K6:2 Function: 9.6 Lighting system Signal value: 1 0 Input signal active. No signal.
VDCT01.02GB
8:35
WORKING LIGHT ATTACH, OUTPUT

Description: Voltage feed to working light, attachment.
008895
DIAG LIGHTS 13(X) WORKING LIGHT ATTACH SWITCH X OUTPUT LE XY RI XY
Circuit diagram: Attachment DCF 90/100/100-45E group 9.6_1 Contact: 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: 00 01 No output signal and open circuit in the circuit. 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 11 Output signal active, short circuit. 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.
VDCT01.02GB
8:36
8.4.2.14 LIGHTS, menu 14 SWITCH LIGHTS, OUTPUT
DIAG LIGHTS SWITCH LIGHTS OUTPUT
14(X) XXX
Description: Voltage feed to background lighting in switches, panels and keys. 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 group 9.1_1, circuit seat heating group 9.3_1, circuit climate system 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/K6:3 to S105-3 output signal from D790-1/K6:4 to S110 output signal from D790-1/K6:5 to S100 output signal from D790-1/K6:6 to S143 output signal from D790-1/K6:7 to S199-4 output signal from D790-1/K6:8 to S199-3 output signal from D790-1/K6:9 to S199-1 output signal from D790-1/K6:10 to S105-1 output signal from D790-1/K8:10 to S1004 output signal from D790-1/K8:12 to S1003 output signal from D790-1/K8:13 to S107 output signal from D790-1/K8:14 to S199-2 output signal from D790-1/K8:15 to S1012 output signal from D790-1/K5:5 to S109 Function: 9.6.11 Interior lighting Signal value: 50 170 Means 4-5 V. Means 15-16 V.
005300
8.4.2.15 LIGHTS, menu 15 NOT USED

XXXXXXX NOT USED
X(X)
VDCT01.02GB
008793
8 Control system CAB
8:37
8.4.3 CAB
CAB, description
This group covers functions in the cab.
005301
8.4.3.1 CAB, menu 1 WASHER, SWITCH

Description: Signal from gear and multi-function lever switch washer.
005541
DIAG CAB WASHER SWITCH OUTPUT FRONT OUTPUT REAR ROOF
1(X) X XY XY
Circuit diagram: Circuit wiper group 9.5_1 Connection: signal from S162/53C to digital in D790-2/K3:4 Function: 9.5 Wiper/washer system Signal value: 1 0 Input signal active. No signal.
WASHER, OUTPUT FRONT

Description: Voltage feed to windscreen washer motor.
005541
1(X) X XY XY
Circuit diagram: Circuit wiper group 9.5_1 Connection: digital out from D790-1/K10:13 to M651-1 and M651-2 Function: 9.5.4 Washer motor and reservoir Signal value: 01 Normal mode function off. 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 11 Output signal active, short circuit or open circuit. Normal mode function on. Output signal active, circuit OK.
VDCT01.02GB
8:38
WASHER, OUTPUT REAR ROOF
005541
1(X) X XY XY
Description: Grounding of motor washer roof and rear window. The motor is supplied with voltage parallel with Motor windscreen washing, activation is controlled by controlling grounding of the motor. The motor is grounded at windscreen washing if the wiper motor roof or rear window is activated. 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: 00 01 No output signal and open circuit in the circuit. Normal mode function off. No output signal, circuit OK. It can also be a short circuit as this is only detected when the output signal is active. 10 Output signal active, short circuit.
11
Normal mode function on. Output signal active, circuit OK. It can also be an open circuit as this can only be detected when the output signal is missing.
8.4.3.2 CAB, menu 2 FRONT WIPER, SWITCH (1-3)

Description: Signal from multi-function lever, switch wiper function.
005542
DIAG CAB FRONT WIPER SWITCH (1-3) OUTPUT FEEDBACK
2(X) X XY X
Circuit diagram: Circuit wiper group 9.5_1 Contact: 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 2 3 Long interval. Normal interval. Continuous operation.
VDCT01.02GB
8:39
FRONT WIPER, OUTPUT

Description: Voltage feed to wiper front.
005542
2(X) X XY X
Circuit diagram: Circuit wiper group 9.5_1 Connection: digital out from D790-1/K2:1 to M650-1/53 Function: 9.5.5 Wiper motor front Signal value: 01 Normal mode function off. 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 11 Output signal active, short circuit or open circuit. Normal mode function on. Output signal active, circuit OK.
FRONT WIPER, FEEDBACK
005542
2(X) X XY X
Description: Signal from motor wiper front, indicates when the wiper sweep is completed. Circuit diagram: Circuit wiper group 9.5_1 Connection: signal from M650-1/31B to digital in D790-1/K4:13 Function: 9.5.5 Wiper motor front Signal value: 1 0 Input signal active (wiper sweep). No signal (home position).
8.4.3.3 CAB, menu 3 REAR WIPER, SWITCH
005543
DIAG CAB REAR WIPER SWITCH OUTPUT FEEDBACK
3(X) X XY X
Description: Status of rear window wiper switch on Control unit KIT (D790-2). Circuit diagram: Contact: Function: 9.5 Wiper/washer system Signal value: 1 0 Input signal active. Key for continuous/interval pressed down. No signal.
VDCT01.02GB
8:40
REAR WIPER, OUTPUT

Description: Voltage feed to direction windscreen wiper rear.
005543
3(X) X XY X
Circuit diagram: Circuit wiper group 9.5_1 Connection: digital out from D790-1/K2:4 to M650-2/53 Function: 9.5.7 Wiper motor rear Signal value: 01 Normal mode function off. 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 11 Output signal active, short circuit or open circuit. Normal mode function on. Output signal active, circuit OK.
REAR WIPER, FEEDBACK
005543
3(X) X XY X
Description: Signal from motor windscreen wiper rear, indicates when the wiper sweep is completed. Circuit diagram: Circuit wiper group 9.5_1 Connection: signal from M650-2/31b to digital in D790-1/K12:2 Function: 9.5.7 Wiper motor rear Signal value: 1 0 Input signal active (wiper sweep). No signal (home position).
8.4.3.4 CAB, menu 4 ROOF WIPER, SWITCH

Description: Signal from switch, wiper roof.
005544
DIAG CAB ROOF WIPER SWITCH OUTPUT FEEDBACK
4(X) X XY X
Circuit diagram: Contact: Function: 9.5 Wiper/washer system Signal value: 1 0 Input signal active. Key for continuous/interval pressed down. No signal.
VDCT01.02GB
8:41
ROOF WIPER, OUTPUT

Description: Voltage feed to wiper roof.
005544
4(X) X XY X
Circuit diagram: Circuit wiper group 9.5_1 Connection: digital out from D790-1/K10:14 to wiper motor M650-3/53 Function: 9.5.6 Wiper motor roof Signal value: 00 01 No output signal and open circuit in the circuit. 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 11 Output signal active, short circuit. 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.
ROOF WIPER, FEEDBACK
005544
4(X) X XY X
Description: Signal from motor wiper roof, indicates when the wiper sweep is completed. Circuit diagram: Circuit wiper group 9.5_1 Connection: signal from M650-3/31B to digital in D790-1/K12:4 Function: 9.5.6 Wiper motor roof Signal value: 1 0 Input signal active (wiper sweep). No signal (home position).
8.4.3.5 CAB, menu 5 HORN, SWITCH

Description: Signal from switch, horn.
005545
DIAG CAB HORN SWITCH SWITCH 2 OUTPUT
5(X) X X XY
Circuit diagram: Circuit alarm, audible signals group 9.7_1 Connection: signal from S162/H to digital in D790-2/K3:2 Function: 9.7 Signalling system Signal value: 1 0 Input signal active. No signal.
VDCT01.02GB
8:42
HORN, SWITCH 2
005545
5(X)
Description: Signal from horn switch on hydraulic control panel.
X X XY
Circuit diagram: Circuit horn servo panel group 9.7_4 Connection: signal from S149-3 to digital in D790-1/K9:10 Function: 9.7 Signalling system Signal value: 1 0 Input signal active. No signal.
HORN, OUTPUT
Description: Voltage feed to horn.
005545
5(X) X X XY
Circuit diagram: Circuit alarm, audible signals group 9.7_1 and circuit compressor horn group 9.7_3 Connection: digital out D790-1/K11:11 to H850 ( horn, signal to relay K3016/86) Function: 9.7.1 Horn Signal value: 01 Normal mode function off. 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 11 Output signal active, short circuit or open circuit. Normal mode function on. Output signal active, circuit OK. for compressor
8.4.3.6 CAB, menu 6 BUZZER

Description: Voltage feed to buzzer for alarm indication panel, feed.
005546
DIAG CAB BUZZER SWITCH SEAT ALARM OP
6(X) XY X X X
Circuit diagram: Circuit alarm, audible signals group 9.7_1 Connection: digital out from D790-2/K8:4 to H853/1 Function: 9.3 Seats, 1 Engine, 8.2.1 Overload protection Signal value: 00 01 No output signal and open circuit in the circuit. 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 11 Output signal active, short circuit. 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.
VDCT01.02GB
8:43
SWITCH SEAT
Description: Signal from Sensor, operator-in-seat.
005546
6(X) XY X X X
Circuit diagram: Circuit alarm, audible signals group 9.7_1 Connection: signal from S230/1 to D790-1/K11:14 Function: 9.3.14 Sensor operator in seat 1 0 Input signal active. Operator in seat. No signal. No operator in seat.
ALARM
005546
6(X) XY X X X
Description: Status for alarm indication panel, warning from control system. Circuit diagram: Contact: Function: 8.1.2 Information display 1 0 Conditions for activation of buzzer from seat switch and parking brake are fulfilled Conditions for activation of buzzer are not fulfilled.
OP
005546
6(X) XY X X X
8.4.3.7 CAB, menu 7 FUEL, SENSOR VALUE

Description: Signal from sensor fuel level.
009182
DIAG CAB FUEL SENSOR VALUE PROC
7(X) XXXohm XXX
Circuit diagram: Circuit drivetrain engine group 1.0_1 Connection: analogue rheostat signal from B757 to D797-1/K2:15 Function: 1.2.2 Sensor fuel level Signal value: XXXohm = Current resistance value from sensor fuel level in ohm.
FUEL, PROC
009182
DIAG CAB FUEL SENSOR VALUE PROC
7(X) XXXohm XXX
Description: The control system's interpretation of the signal from sensor, fuel tank. Circuit diagram: Contact: Function: 1.2.2 Sensor fuel level Signal value: XXX = 0-100 = 0-100% = Fuel volume in tank.
VDCT01.02GB
8:44
8.4.3.8 CAB, menu 8 SEAT HEATER, SWITCH
005548
DIAG CAB SEAT HEATER SWITCH OUTPUT
8(X)
Description: Signal from switch, seat heating.
X XY
Circuit diagram: Circuit seat heating group 9.3_1 Connection: signal from S143/1 to digital in D790-1/K6:6 Function: 9.3 Seat Signal value: 1 0 Input signal active. No signal.
SEAT HEATER, OUTPUT

Description: Voltage feed to seat heating relay.
005548
DIAG CAB SEAT HEATER SWITCH OUTPUT
8(X) X XY
Circuit diagram: Circuit seat heating group 9.3_1 Connection: digital out from D790-1/K10:7 to K383/86 Function: 9.3.3 Heating coil Signal value: 00 01 No output signal and open circuit in the circuit. 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 11 Output signal active, short circuit. 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.
VDCT01.02GB
8 Control system CLIMATE
8:45
8.4.4 CLIMATE
CLIMATE, description
This group covers the cab's air conditioning.
005302
8.4.4.1 CLIMATE, menu 1 PRESENT INPUT SIGNAL, REQUIRED TEMP

Description: Set value for desired temperature.
005549
DIAG CLIMATE 1(X) PRESENT INPUT SIGNAL REQUIRED TEMP XXX PRESENT TEMP XXX WATER VALVE FEEDB. XXX
Circuit diagram: Circuit climate system group 9.4_1 Connection: signal from S117/3 to analogue in D790-1/K5:8 Function: 9.4 Heating, ventilation and air conditioning Signal value: XXX = 160-280 = 16-28 C = Preset temperature shown in tenths of degrees and adjusted in increments of half degrees (200 = 20 C). Test by increasing or decreasing temperature with the temperature switch on the panel.
PRESENT INPUT SIGNAL, PRESENT TEMP

Description: Signal from sensor cab temperature.
005549
Circuit diagram: Circuit climate system group 9.4_1 Connection: signal from B775-1/2 to input D790-1/K4:8 Function: 9.4.17 Sensor cab temperature Signal value: XXX = Cab's interior temperature in tenths of degrees (200 = 20 C).
PRESENT INPUT SIGNAL, WATER VALVE FEEDB.

Description: Water valve's position (opening in percent).
005549
Circuit diagram: Circuit climate system group 9.4_2 Connection: signal from Y673/9 to analogue in D790-1/K10:4 Function: 9.4.5 Water valve Signal value: XXX = 0-100 = 0-100% = Water valve's opening in %. 0 = Closed. 100 = Fully open.
8.4.4.2 CLIMATE, menu 2 TEMP COIL
005550
DIAG TEMP TEMP TEMP TEMP
CLIMATE COIL COOLANT AMBIENT DE-ICE
2(X) XXX XXX XXX XXX
Description: Temperature of the air out from the fan. The sensor is fitted in the air distributor. Circuit diagram: Circuit climate system group 9.4_1 Connection: signal from B775-2 to input D790-1/K4:10 Function: 9.4.16 Sensor, temperature outlet fan Signal value: XXX = Temperature of the air blown into the cab in tenths of degrees (200 = 20 C).
VDCT01.02GB
8:46
TEMP COOLANT
005550
Description: Coolant temperature, temperature of the engine's coolant. Signal is retrieved from the engine via CAN bus drive-train. Circuit diagram: Circuit climate system group 9.4_1 and 9.4_2 Connection: from engine via CAN bus, see PRESENT INPUT SIGNAL, COOLANT TEMP, page 8:59. Function: 1.7 Cooling system Signal value: XXX = Engine temperature in tenths of degrees (200 = 20 C).
TEMP AMBIENT
005550
Description: Outdoor temperature. Heat radiation from engine and sun may affect the value since the sensor is fitted on the rear of the cab roof. Circuit diagram: Circuit climate system group 9.4_1 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 C).
TEMP DE-ICE
Description: Temperature in refrigerant circuit.
005550
Circuit diagram: Circuit climate system group 9.4_1 Connection: signal from B775-3/2 to input D790-1/K4:11 Function: 9.4.12 Sensor temperature refrigerant Signal value: XXX = Refrigerant temperature in tenths of degrees (200 = 20 C).
8.4.4.3 CLIMATE, menu 3 PRESENT INPUT SIGNAL, PRESSURE SWITCH

Description: Signal from refrigerant pressure switch.
DIAG CLIMATE 3(X) PRESENT INPUT SIGNAL PRESSURE SWITCH X

005551
Circuit diagram: Circuit climate system group 9.4_1 Connection: signal from S246/2 to digital in D797-1/K1:40 Function: 9.4.10 Pressure switch Signal value: 1 0 Input signal active. Press OK. No signal, too high or too low pressure.
VDCT01.02GB
8:47
8.4.4.4 CLIMATE, menu 4 PRESENT INPUT SIGNAL, WATER VALVE
005552
DIAG CLIMATE 4(X) PRESENT INPUT SIGNAL WATER VALVE XX.XXV DRAUGHT VALVE XX.XXV
Description: Signal from water valve, the voltage is a measure of the position. Circuit diagram: Circuit climate system group 9.4_2 Connection: signal from Y673/9 to analogue in D790-1/K10:4 Function: 9.4.5 Water valve Signal value: XX.XXV = 0.50 - 4.50 V
PRESENT INPUT SIGNAL, DRAUGHT VALVE
005552
DIAG CLIMATE 4(X) PRESENT INPUT SIGNAL WATER VALVE XX.XXV DRAUGHT VALVE XX.XXV
Description: Signal from the engine to the air distributor. The voltage is a measure of the damper's position. Circuit diagram: Circuit climate system group 9.4_2 Connection: signal from Y672/9 to analogue in D790-1/K4:7 Function: 9.4.14 Air distributor Signal value: XX.XXV = 0.50 - 4.50 V
8.4.4.5 CLIMATE, menu 5 PRESENT INPUT SIGNAL, REQUIRED TEMP
005553
DIAG CLIMATE 5(X) PRESENT INPUT SIGNAL REQUIRED TEMP XX.XXV REQ. DRAUGHT XX.XXV REQ. FAN SPEED XX.XXV
Description: Signal from switch, temperature. Voltage when the switch is pressed in the voltage level indicates increase or decrease of the temperature. Circuit diagram: Circuit climate system group 9.4_1 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
005553
Description: Signal from switch, air distribution, voltage when switch is pressed in. The voltage level indicates change of air control against windscreen (up) or floor (down). The damper's position changes in steps between windscreen - floor. Circuit diagram: Circuit climate system group 9.4_1 Connection: signal from S139/3 to analogue in D790-1/K5:9 Function: 9.4 Heating, ventilation and air conditioning Signal value: XX.XXV ~ 2.4 / 0 / 5.0 V = Up / - / down.
PRESENT INPUT SIGNAL, REQ. FAN SPEED
005553
Description: Signal from switch, fan speed, switch controls increase or decrease of fan speed. Speed is adjustable steplessly. The voltage level indicates if the speed should be increased or decreased. Circuit diagram: Circuit climate system group 9.4_1 Connection: signal from S118/3 to analogue in D790-1/K5:7 Function: 9.4 Heating, ventilation and air conditioning Signal value: XX.XXV ~ 2.4 / 0 / 5.0 V = Increase / - / decrease. Workshop Manual DCT 80-90
VDCT01.02GB
8:48
8.4.4.6 CLIMATE, menu 6 PRESENT OUTPUT SIGNAL, FAN SPEED
005554
DIAG CLIMATE 6(X) PRESENT OUTPUT SIGNAL FAN SPEED XXX RECIRKULATION XY COMPRESSOR XY
Description: Current control of fan motor, speed is controlled with PWM-control of grounding (of fan motor). Circuit diagram: Circuit climate system group 9.4_2 Connection: analogue out from D790-1/K2:2 to M657/31 Function: 9.4.3 cab fan. Signal value: XXX = 0-255 = Fan speed (255 = max. fan speed).
PRESENT OUTPUT SIGNAL, RECIRCULATION
005554
Description: Voltage feed to motor for fresh air and recirculation damper. Circuit diagram: Circuit climate system group 9.4_2 Connection: digital out from D790-1/K2:3 to M612 Function: 9.4.2 Fresh air and recirculation damper Signal value: 01 Normal mode function off. 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 11 Output signal active, short circuit or open circuit. Normal mode function on. Output signal active, circuit OK.
PRESENT OUTPUT SIGNAL, COMPRESSOR
005554
Description: Voltage feed of AC compressor's electromagnetic clutch. Controls cut-in and cut-out of the compressor. Two outputs are connected in parallel to handle the current intensity. Circuit diagram: Circuit climate system group 9.4_2 Connection: digital out from D797-1/K1:25 and D797-1/K1:29 to M645 Function: 9.4.7 Compressor Signal value: 00 01 No output signal and open circuit in the circuit. 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 11 Output signal active, short circuit. 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.
VDCT01.02GB
8:49
8.4.4.7 CLIMATE, menu 7 OUTPUT WATER VALVE, CLOCKWISE
DIAG CLIMATE 7(X) OUTPUT WATER VALVE CLOCKWISE XY XY ANTI-CLOCKWISE XY XY
Description: Voltage feed to water valve, for opening. The valve is connected to an H-bridge. The signal can only be diagnosed when the valve's position changes. The valve's opening and closing is controlled by the air conditioning's software depending on desired temperature, outside temp. cab temperature and coolant temperature, so it may be difficult to determine whether the valve is working as it should. Circuit diagram: Circuit climate system group 9.4_2 Connection: digital out from D790-1/K4:1 via R3 to Y673/5 and from D790-1/K4:2 via R4 to Y673/6 Function: 9.4.5 Water valve
24V
Signal value: motor runs clockwise row 1: 11 11 row 2: 00 11 00 01 No output signal and open circuit in the circuit. 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 11 Output signal active, short circuit. 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.
0V
H-bridge
005555
OUTPUT WATER VALVE, ANTI-CLOCKWISE
DIAG CLIMATE 7(X) OUTPUT WATER VALVE CLOCKWISE XY XY ANTI-CLOCKWISE XY XY
Description: Voltage feed to water valve, for closing. The valve is connected to an H-bridge. The signal can only be diagnosed when the valve's position changes. The valve's opening and closing is controlled by the air conditioning's software depending on desired temperature, outside temp. cab temperature and coolant temperature, so it may be difficult to determine whether the valve is working as it should. Circuit diagram: Circuit climate system group 9.4_2 Connection: digital out from D790-1/K4:1 via R3 to Y673/5 and from D790-1/K4:2 via R4 to Y673/6 Function: 9.4.5 Water valve
24V
Signal value: motor runs anticlockwise row 1: 00 11, row 2: 11 11 00 01 No output signal and open circuit in the circuit. 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 11 Output signal active, short circuit. 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.
0V
H-bridge
005555
VDCT01.02GB
8:50
8.4.4.8 CLIMATE, menu 8 OUTPUT DRAUGHT VALVE, CLOCKWISE
DIAG CLIMATE 8(X) OUTPUT DRAUGHT VALVE CLOCKWISE XY XY ANTI-CLOCKWISE XY XY
Description: Voltage feed to motor for the air distributor, rotation clockwise. Is connected to an H-bridge. Signal can only be diagnosed when the air distributor's position changes. Circuit diagram: Circuit climate system group 9.4_2 Connection: digital out from D790-1/K4:3 via R5 to Y672/5 and from D790-1/K4:4 via R6 to Y672/6
24V
Function: 9.4.14 Air distributor Signal value: motor runs clockwise row 1: 11 11, row 2: 00 11 00 No output signal and open circuit in the circuit. 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
005556
01
Output signal active, short circuit. 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.
11
0V
H-bridge
OUTPUT DRAUGHT VALVE, ANTI-CLOCKWISE
DIAG CLIMATE 8(X) OUTPUT DRAUGHT VALVE CLOCKWISE XY XY ANTI-CLOCKWISE XY XY
Description: Voltage feed to the motor for the air distributor, rotation anticlockwise. The motor is connected to an H-bridge. The signal can only be diagnosed when the air distributor's position changes. Circuit diagram: Circuit 9.4_2 Connection: digital out from D790-1/K4:3 via R5 to Y672/5 and from D790-1/K4:4 via R6 to Y672/6
24V
Function: 9.4.14 Air distributor Signal value: motor runs anticlockwise row 1: 00 11, row 2: 11 11 00 No output signal and open circuit in the circuit. 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
005556
01
Output signal active, short circuit. 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.
11
0V
H-bridge
VDCT01.02GB
8 Control system HYD
8:51
8.4.5 HYD
HYD, description
This group covers the hydraulic functions.
005303
8.4.5.1 HYD, menu 1 HYDRAULIC OIL, TEMP

Description: Signal from sensor hydraulic oil temperature.
010070
DIAG HYDRAULIC HYDRAULIC OIL TEMP FAN SET OUTPUT + -
1(X) XXX XY X
Circuit diagram: Circuit cooling hydraulic oil group 10.6_1 Connection: signal from B776/1 to temperature in D797-1/K2:13 Function: 10.6.4 Sensor hydraulic oil temperature Signal value: XXX = Temperature in tenths of degrees (200 = 20 C).
HYDRAULIC OIL, FAN

Description: Voltage feed cooling fan hydraulic oil.
010070
1(X) XXX XY X
Circuit diagram: Circuit cooling hydraulic oil group 10.6_1 Connection: digital out from D797-1/K1:14 to M668/1 Function: 10.6.3 Cooling fan Signal value: 01 Normal mode function off. 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 11 Output signal active, short circuit or open circuit. Normal mode function on. Output signal active, circuit OK.
HYDRAULIC OIL, SET OUTPUT +/Description: Functionality test of hydraulic oil cooling fan.
010070
1(X) XXX XY X
Circuit diagram: Circuit cooling hydraulic oil group 10.6_1 Connection: digital out from D797-1/K1:14 to M668/1 is activated or deactivated with +/Function: 10.6.3 Cooling fan Signal value:
8.4.5.2 HYD, menu 2 NOT USED

XXXXXXX NOT USED
X(X)
008793
VDCT01.02GB
8:52

XXXXXXX NOT USED
X(X)
008793
8.4.5.4 HYD, menu 4 PRESSURE SWITCHES, BRAKE PRESSURE
007240
DIAG HYDRAULIC 4(X) PRESSURE SWITCHES BRAKE PRESSURE X BRAKE LIGHT PRESS. X DECLUTCH PRESSURE X
Description: Signal from break contact (opening switch) brake pressure. Circuit diagram: Circuit brake system group 4.0_1 Connection: signal from S204/2 to analogue in D797-1/K1:13 Function: 4.3.7 Normally open (NO) switch, brake pressure Signal value: 1 0 Input signal active. No signal.
PRESSURE SWITCHES, BRAKE LIGHT PRESSURE

Description: Signal from make-contact (closing switch) brake lights.
007240
Circuit diagram: Circuit lighting group 9.6_5 Connection: signal from S216/2 to digital in D797-1/K1:20 Function: 4.3.8 Make-contact (closing switch) brake lights Signal value: 1 0 Input signal active. No signal.
PRESSURE SWITCHES, DECLUTCH PRESSURE

Description: Signal from break contact (opening switch) declutch.
007240
Circuit diagram: Circuit drivetrain gearbox group 2.0_1 Connection: signal from S220-2/2 to analogue in D797-1/K1:27 Function: 2.8.2 Normally closed (NC) switch, disengagement Signal value: 1 0 Input signal active. No signal.
VDCT01.02GB
8:53
8.4.5.5 HYD, menu 5 P-BRAKE, SWITCH
007241
DIAG HYDRAULIC P-BRAKE SWITCH FEEDBACK SWITCH VALVE
5(X) X/Y X XY
Description: Signals from switch parking brake. Two signals, one for released parking brake and one for applied parking brake. Both signals must be valid to enable release of parking brake. Circuit diagram: Circuit brake system group 4.0_1 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 0/1 Open, parking brake released. On, parking brake applied.
P-BRAKE, FEEDBACK SWITCH
007241
5(X) X/Y X XY
Description: Signal from break contact (opening switch) parking brake. Circuit diagram: Circuit brake system group 4.0_1 Connection: signal from S200/2 to analogue in D797-1/K1:41 Function: 4.5.5 Normally open (NO) switch, parking brake Signal value: 1 0 Input signal active. No signal.
P-BRAKE, VALVE
Description: Voltage feed to Solenoid valve parking brake.
007241
5(X) X/Y X XY
Circuit diagram: Circuit brake system group 4.0_1 Connection: digital out from D797-1/K1:34 to solenoid valve Y642/1 Function: 4.5.3 Solenoid valve parking brake Signal value: 00 01 No output signal and open circuit in the circuit. 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 11 Output signal active, short circuit. 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.
VDCT01.02GB
8:54

XXXXXXX NOT USED
X(X)
008793

XXXXXXX NOT USED
X(X)
008793
8.4.5.8 HYD, menu 8 PRESENT OUTPUT SIGNAL, PRESSURE TO ATTACHM. VALVE
010074
DIAG HYDRAULIC 8(X) PRESENT OUTPUT SIGNAL PRESSURE TO ATTACHM. VALVE XY SET OUTPUT + X
Description: Voltage feed to solenoid valve for main pump relief (pressurised attachment). Circuit diagram: circuit disengage. hydr pump group 10.4_1 Connection: digital out from circuit disengage hydraulic pump group D797-1/K1:35 to solenoid valve Y6062-2 Function: 10.4.2 Axial piston pump with variable displacement Signal value: 1 0 Output signal active. No output signal.
PRESENT OUTPUT SIGNAL, PRESSURE TO ATTACHM, SET OUTPUT +/-
010074
DIAG HYDRAULIC 8(X) PRESENT OUTPUT SIGNAL PRESSURE TO ATTACHM. VALVE XY SET OUTPUT + X
Description: Begin sending or cut off hydraulic pressure to the attachment. Circuit diagram: circuit disengage. hydr pump group 10.4_1 Connection: digital out from D797-1/K1:35 to solenoid valve Y6062-2 is activated or deactivated with +/Function: 10.4.2 Axial piston pump with variable displacement Signal value: 1 0 Output signal active. No output signal.
VDCT01.02GB
8 Control system ENGINE
8:55
8.4.6 ENGINE
ENGINE, description
This group covers the engine functions.
005306
8.4.6.1 ENGINE, menu 1 PRESENT INPUT SIGNAL, ACCELERATOR

Description: Signal from accelerator pedal.
006866
DIAG ENGINE 1(X) PRESENT INPUT SIGNAL ACCELERATOR X.XXV REQUIRED SPD PROC XXX REQUIRED SPD RPM XXXX
Circuit diagram: Circuit drivetrain engine group 1.0_1 Connection: signal from B690-1/2 to analogue in D790-1/K6:11 Function: 1 Engine Signal value: X.XXV = 0.50-4.50 V
PRESENT INPUT SIGNAL, REQUIRED SPD PROC
006866
Description: Required engine speed (in percent) which is sent from Control unit, cab (D790-1) to Control unit, engine (D794) via CAN bus drive-train. Circuit diagram: Contact: Function: 1.9 Control system, engine Signal value: XXXX = 0-100%
PRESENT INPUT SIGNAL, REQUIRED SPD RPM
006866
Description: Required engine speed (in percent) which is sent from Control unit, cab (D790-1) to Control unit, engine (D794) via CAN bus drive-train. Circuit diagram: Contact: Function: 1.9 Control system, engine Signal value: XXXX = 0-2010 rpm
8.4.6.2 ENGINE, menu 2 PRESENT INPUT SIGNAL, ENGINE SPEED EDC
005308
DIAG ENGINE 2(X) PRESENT INPUT SIGNAL ENGINE SPEED EDC XXXX ENGINE SPEED TCU XXXX
Description: Engine speed from Control unit, engine (D794) to Control unit, cab (D790-1) via CAN bus drive-train. Actual value for engine speed. Circuit diagram: Contact: Function: 1.9.2 Sensor engine rpm Signal value: XXXX = Active speed in rpm.
VDCT01.02GB
8:56
PRESENT INPUT SIGNAL, ENGINE SPEED TCU
005308
DIAG ENGINE 2(X) PRESENT INPUT SIGNAL ENGINE SPEED EDC XXXX ENGINE SPEED TCU XXXX
Description: Engine speed from Transmission control unit (D793) to Cab control unit (D790-1) via CAN bus drivetrain. Actual value for engine speed. Only used on machines with engine alternative Cummins QSB6.7. Circuit diagram: Contact: Function: 2.2.5 Sensor engine speed and oil temperature transmission Signal value: XXXX = active speed in rpm.
8.4.6.3 ENGINE, menu 3 PRESENT INPUT SIGNAL, PRESENT TORQUE
005309
DIAG ENGINE 3(X) PRESENT INPUT SIGNAL PRESENT TORQUE XXX REQUIRED TORQUE XXX PRES TORQUE @ RPM XXX
Description: Actual torque from Control unit, engine (D794). Percentage torque use of engine's capacity. Circuit diagram: Contact: Function: 1.9 Control system, engine Signal value: XXX = 0-100%
PRESENT INPUT SIGNAL, REQUIRED TORQUE
005309
Description: Requested torque from cab control unit (D790-1) to engine control unit (D794). Only used on machines with engine alternative Cummins QSB6.7. Circuit diagram: Contact: Function: 1.9 Control system, engine Signal value: XXXX = 0-100%
PRESENT INPUT SIGNAL, PRES TORQUE @ PPM
005309
Description: Available torque at current engine speed. Only used on machines with engine alternative Cummins QSB6.7. Circuit diagram: Contact: Function: 1.9 Control system, engine Signal value: XXXX = 0-100%
VDCT01.02GB
8:57
8.4.6.4 ENGINE, menu 4 PRESENT INPUT SIGNAL, PREHEAT SWITCH

009282
DIAG ENGINE 4(X) PRESENT INPUT SIGNAL PREHEAT SWITCH X CRANK ENGINE SWITCH X D+ X
PRESENT INPUT SIGNAL, CRANK ENGINE SWITCH

Description: Signal from ignition key lock, start position.
009282
Circuit diagram: Circuit power group 11.5_3, Circuit drivetrain engine group 1.0_1 Connection: signal from S150/50 to digital in D790-2/K2:1 Function: 1 Engine, 1.11 Start and stop Signal value: 1 0 Input signal active. No signal.
PRESENT INPUT SIGNAL, D+
009282
Description: Signal from alternator, indicates if alternator supplies current. Circuit diagram: Circuit Yuchai YC6A240-30 group 1.0_1A1, circuit engine QSB6.7 group 1.0_2E1 and circuit drivetrain engine group 1.0_1 Connection: from G660/D+ to digital in D797-1/K2:16 Function: 11.4.1 Alternator Signal value: 1 0 Input signal active. No signal.
8.4.6.5 ENGINE, menu 5 PRESENT OUTPUT SIGNAL, PREHEAT

Description: Status for preheating of induction air. Only used on machines with engine alternative Yuchai YC6M360-30.
015098
DIAG ENGINE 5(X) PRESENT OUTPUT SIGNAL PREHEAT X CRANK ENGINE X CRANK ENGINE WIRE XY
Circuit diagram: Connection: controlled by engine's control system Function: 1.10.1 Preheating Signal value: 1 0 Output signal active. No output signal.
VDCT01.02GB
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PRESENT OUTPUT SIGNAL, CRANK ENGINE

Description: Status for start signal to Engine control unit (D794) via the CAN-bus.
015098
Circuit diagram: Connection: controlled by engine's control system Function: 1.11 Start and stop Signal value: 1 0 Output signal active. 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 YC6A240-30 group 1.0_1A1 and Circuit engine QSB6.7 group 1.0_2E1
015098
Connection: digital out D797-1/K1:32 to K360/86 Function: 1.11 Start and stop Signal value: 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 11 Output signal active, short circuit or open circuit. Normal mode function on. Output signal active, circuit OK.
8.4.6.6 ENGINE, menu 6 PRESENT INPUT SIGNAL, OIL PRESSURE
000153
DIAG ENGINE 6(10) PRESENT INPUT SIGNAL OIL PRESSURE XXX BOOST PRESSURE XXX
Description: Engine oil pressure. CAN bus message from Control unit, engine (D794) to Control unit, cab (D790-1). Circuit diagram: see supplier documentation, engine Contact: Function: 1.8 Lubrication system Signal value: XXX = 10 corresponds to 100 kPa.
PRESENT INPUT SIGNAL, BOOST PRESSURE
000153
DIAG ENGINE 6(10) PRESENT INPUT SIGNAL OIL PRESSURE XXX BOOST PRESSURE XXX
Description: Boost pressure. CAN bus message from Control unit, engine (D794) to Control unit, cab (D790-1). Circuit diagram: see supplier documentation, engine Contact: Function: 1.6 Air intake and exhaust outlet Signal value: XXX = 10 corresponds to 100 kPa.
VDCT01.02GB
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8.4.6.7 ENGINE, menu 7 PRESENT INPUT SIGNAL, OIL TEMP
009284
DIAG ENGINE 7(X) PRESENT INPUT SIGNAL OIL TEMP XXX COOLANT TEMP XXX INTAKE MAIN.TEMP XXX
Description: Engine oil temperature. CAN bus message from Control unit, engine (D794) to Control unit, cab (D790-1). Circuit diagram: see supplier documentation, engine. Contact: 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 C.
PRESENT INPUT SIGNAL, COOLANT TEMP
009284
Description: Coolant temperature. CAN bus message from Control unit, engine (D794) to Control unit, cab (D790-1). Circuit diagram: see supplier documentation, engine Contact: Function: 1.7 Cooling system Signal value: XXX = 200 corresponds to 20 C.
PRESENT INPUT SIGNAL, INTAKE MAIN.TEMP
009284
Description: Charge air temperature. CAN bus message from Control unit, engine (D794) to Control unit, cab (D790-1). Circuit diagram: see supplier documentation, engine Contact: Function: 1.6 Air intake and exhaust outlet Signal value: XXX = 200 corresponds to 20 C.
8.4.6.8 ENGINE, menu 8 PRESENT EDC ERROR, NO. OF ACT ERROR
009279
DIAG ENGINE 8(X) PRESENT EDC ERROR NR OF ACT ERROR XX SPN XXXX FMI XX
Description: Number of active error codes from Control unit, engine (D794). Circuit diagram: Contact: Function: 1.9 Control system Signal value: XX = number of active error codes.
VDCT01.02GB
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PRESENT EDC ERROR, SPN
009279
Description: SPN number for the first error code from Control unit, engine (D794). SPN indicates the malfunction area, i.e. what component or signal is defective. Error codes are shown with SPN/FMI in the error code menus. Circuit diagram: Contact: Function: 8.3 Error codes Signal value: XXXX = error code number. Use the error code list; see section D Error codes.
PRESENT EDC ERROR, FMI
009279
Description: FMI number for the first error code from the Control unit, engine (D794). FMI indicates error type, e.g. short circuit or low value. Error codes are shown with SPN/FMI in the error code menus. Circuit diagram: Contact: Function: 8.3 Error codes Signal value: XX = fault type number. Use the error code list; see section D Error codes.
8.4.6.9 ENGINE, menu 9 FUEL CONSUMPTION, MOMENTARILY l/h

Description: Current fuel consumption in litres/hour.
DIAG ENGINE FUEL CONSUMTION MOMENTARILY l/h
9(X) XXX
009280
Circuit diagram: Contact: Function: 1.2 Fuel system Signal value: XXX = fuel consumption in l/h.
8.4.6.10 ENGINE, menu 10 PRESENT INPUT SIGNAL, PRE-HEAT FEEDBACK
!''
DIAG ENGINE 10(X) PRESENT INPUT SIGNAL PRE-HEAT FEEDBACK X WATER IN FUEL SW. X COOLANT LEVEL SW. X
Description: Signal from Control unit, engine (D794) which indicates that preheating is active. Only used on machines with engine alternative Yuchai YC6A240-30. Circuit diagram: Circuit Yuchai YC6A240-30 group 1.0_1A1, circuit mast sensor OLS group 8.2_3 Connection: signal from D794/1:38 to D797-1/K1:36 Function: 1.6 Air intake and exhaust outlet Signal value: 1 0 No signal Input signal active. (Indication that preheating is activated by Control unit, engine (D794) is active.)
VDCT01.02GB
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PRESENT INPUT SIGNAL, WATER IN FUEL SW.
!''
Description: Signal from Control unit, engine (D794) which indicates that there is too much water in the fuel filter. Only used on machines with engine alternative Yuchai YC6A240-30. Circuit diagram: Circuit Yuchai YC6A240-30 group 1.0_1A1, circuit mast sensor OLS group 8.2_3 Connection: signal from D794/1:39 to D797-1/K1:37 Function: 1.2 Fuel system Signal value: 1 0 No signal 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) coolant level (B759), which indicates that the coolant level is low. Only used on machines with engine alternative Yuchai YC6A240-30. Circuit diagram: Circuit Yuchai YC6A240-30 group 1.0_1A1 Connection: signal from B759/2 to digital in D797-1/K1:12 Function: 1.7 Cooling system Signal value: 1 0 No signal Input signal active. Coolant level is low.
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8 Control system TRANSM
8.4.7 TRANSM
TRANSM, description
This group covers transmission functions.
005324
8.4.7.1 TRANSM, menu 1 PRESENT INPUT SIGNAL, BRAKE PEDAL

005325
DIAG TRANSM. 1(X) PRESENT INPUT SIGNAL BRAKE PEDAL X.XXV DECLUTCH SWITCH X DECLUTCH PRESS SW. X
PRESENT INPUT SIGNAL, DECLUTCH SWITCH

Description: Signal from declutch pedal.
005325
Circuit diagram: Circuit drivetrain gearbox group 2.0_1 Connection: signal from S220-1/2 to digital in D790-1/K6:14 Function: 2 Transmission Signal value: 1 0 Input signal active. Declutch pedal depressed. No signal.
PRESENT INPUT SIGNAL, DECLUTCH PRESS SW.
005325
Description: Signal from break contact (opening switch) declutch (pressure switch). Circuit diagram: Circuit drivetrain gearbox group 2.0_1 Connection: signal from S220-2/2 to digital in D797-1/K1:27 Function: 2.8.2 Normally closed (NC) switch, disengagement Signal value: 1 0 Input signal active. No signal.
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8.4.7.2 TRANSM, menu 2 SWITCHES, FORWARD

Description: Signal from gear and multi-function lever (forward).
005326
DIAG TRANSM. SWITCHES FORWARD REVERSE SHIFT MODE
2(X) X X X
Circuit diagram: Circuit drivetrain gearbox group 2.0_1 Connection: signal from S162/F to digital in D790-2/K3:11 Function: 2 Transmission Signal value: 1 0 Input signal active. Travel direction forward selected. No signal.
SWITCHES, REVERSE
Description: Signal from gear and multi-function lever (reverse).
005326
2(X) X X X
Circuit diagram: Circuit drivetrain gearbox group 2.0_1 Connection: signal from S162/R to digital in D790-2/K3:12 Function: 2 Transmission Signal value: 1 0 Input signal active. Travel direction reverse selected. No signal.
SWITCHES, SHIFT MODE
005326
2(X) X X X
Description: Signal from switch, shifting program. Status on CAN bus from Control unit KIT (D790-2). The switches are integrated in Control unit KIT (D790-2). Circuit diagram: Contact: Function: 2 Transmission Signal value: 1 2 4 Shifting program 1 selected. Shifting program 2 selected. Automatic shifting selected.
8.4.7.3 TRANSM, menu 3 PRESENT VALUE, FORWARD

Description: Status for forward direction of travel from Control unit, transmission (D793). Indicates if forward drive is activated in the transmission. Circuit diagram: 005327
DIAG TRANSM. PRESENT VALUE FORWARD REVERSE GEAR
3(X) X X X
Contact: Function: 2.8 Control system, transmission Signal value: 1 0 Output signal for travel direction forward active. No output signal.
VDCT01.02GB
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PRESENT VALUE, REVERSE
005327
3(X) X X X
Description: Status for rearward direction of travel from Control unit, transmission (D793). Indicates if rearward drive is activated in the transmission. Circuit diagram: Contact: Function: 2.8 Control system, transmission Signal value: 1 0 Output signal for travel direction reverse active. No output signal.
PRESENT VALUE, GEAR
005327
3(X) X X X
Description: Current gear, status from Control unit, transmission (D793). Shows which gear is activated in the transmission. Circuit diagram: Function: 2.8 Control system, transmission Contact: Signal value: X = current gear.
8.4.7.4 TRANSM, menu 4 OPERATING STATE, AUT/MAN MODE
005328
DIAG TRANSM. OPERATING STATE AUT/MAN MODE WARNING OPERATING MODE
4(X) X X X
Description: Shows which shifting program is selected automatic or manual. Circuit diagram: Contact: Function: 2.8 Control system, transmission Signal value: 1 0 Automatic. Manual.
OPERATING STATE, WARNING
005328
4(X) X X X
Description: Warning for serious malfunction in transmission from Control unit, transmission (D793). Circuit diagram: Contact: Function: 2.8 Control system, transmission Signal value: 1 0 Active error. No errors.
VDCT01.02GB
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OPERATING STATE, OPERATING MODE
005328
4(X) X X X
Description: Operating mode status for Control unit, transmission (D793), also shown in control unit display. Circuit diagram: Contact: Function: 2.8 Control system, transmission Signal value: 0 1 2 3 4 5 Not used. Manual or automatic shifting, standard mode shown during operation. Not used. Not used. Limp home, reduced capacity due to malfunction in transmission. Shut down, serious transmission malfunction control unit shuts down, likely that malfunction cannot be shown as CAN-bus. Calibration of transmission in progress.
8.4.7.5 TRANSM, menu 5 OPERATING STATE, SHIFT IN PROGRESS
005329
DIAG TRANSM. 5(X) OPERATING STATE SHIFT IN PROGRESS X FAULT X OLD FAULT X
Description: Status for transmission function during operation, shifting in progress. Active during shifting. Circuit diagram: Contact: Function: 2.8 Control system, transmission Signal value: 1 0 Shifting in progress. No activity.
OPERATING STATE, FAULT
005329
Description: Status for transmission's function during operation, active error codes present. Circuit diagram: Contact: Function: 2.8 Control system, transmission Signal value: 1 0 Active error code. No error codes.
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OPERATING STATE, OLD FAULT
005329
Description: Status for transmission's function during operation, there are inactive error codes that have not been acknowledged. Circuit diagram: Contact: Function: 2.8 Control system, transmission Signal value: 1 0 There are inactive error codes that have not been acknowledged. No unacknowledged error codes.
8.4.7.6 TRANSM, menu 6 NOT USED

XXXXXXX NOT USED
X(X)
008793

XXXXXXX NOT USED
X(X)
008793

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X(X)
008793

XXXXXXX NOT USED
X(X)
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XXXXXXX NOT USED
X(X)
008793

XXXXXXX NOT USED
X(X)
008793

XXXXXXX NOT USED
X(X)
008793
8.4.7.13 TRANSM, menu 13 ACT ERROR AREA
005337
DIAG TRANSM. 13(X) ACT ERROR AREA XXX TYPE XXX NUMBER OF OCCU. XXXXX TIME AGO XXXXX
Description: Indicates malfunction area active error, first part of the error code. In the event of several error codes, the most serious error code is shown. Circuit diagram: Contact: Function: 2.8 Control system, transmission Signal value: XXX = First part of error code; see section D Error codes
TYPE
Description: Indicates type of active error.
005337
Circuit diagram: Contact: Function: 2.8 Control system, transmission Signal value: XXX = Second part of error code.
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NUMBER OF OCCU.
Description: Number of times active errors have occurred.
005337
Circuit diagram: Contact: Function: 2.8 Control system, transmission Signal value: XXXXX = Number of times active errors have occurred.
TIME AGO
Description: When latest active error occurred.
005337
Circuit diagram: Contact: Function: 2.8 Control system, transmission Signal value: XXXXX = Operating time in hours since latest error
8.4.7.14 TRANSM, menu 14 MANUAL GEAR SHIFT, GEAR
DIAG TRANSM. 14(X) MANUAL GEAR SHIFT

"
Description: Manual control of the transmission with the plus and minus keys. The menu can be used to rule out mechanical malfunctions in the transmission's gear control. Circuit diagram: Contact: Function: 2.8 Control system, transmission Signal value: X = Selected gear.
GEAR (+/-)
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8 Control system ELSERV
8:69
8.4.8 ELSERV
ELSERV, description
005400
This group covers electric servo functions. Confirm selections with function key for Enter.
8.4.8.1 ELSERV, menu 1 PRESENT INPUT SIGNALS, P1

Description: Signal from control lever P1.
005401
DIAG ELSERVO 1(X) PRESENT INPUT SIGNALS P1 XX.XXV P2 XX.XXV P3 XX.XXV
Circuit diagram: Circuit electric servo levers group 7.0_1, circuit electric servo joystick group 7.0_2 Connection: signal from R8071/3 (S815/8) to analogue in D790-1/K7:3 Function: 7.1.1 Control levers Signal value: XX.XXV = 0.50 - 4.50 V. 2.5 V in zero position.
PRESENT INPUT SIGNALS, P2

005401

005401
8.4.8.2 ELSERV, menu 2 NOT USED

XXXXXXX NOT USED
X(X)
008793
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8.4.8.3 ELSERV, menu 3 OUTPUT LIFT, REFERENCE
005403
DIAG ELSERVO OUTPUT LIFT REFERENCE REQUIRED VALUE FEEDBACK
3(X) XY XXXmA XXXmA
Description: Status for control current to control valve (solenoid valve, lift mast). Circuit diagram: Circuit lift/lower electric servo group 7.2_1 Contact: digital output from D797-1/K1:4 to Y6005/1 Function: 7.2.5 Control valve, lift and tilt Signal value: 00 10 11 No output signal, PWM off. Output signal active, short circuit. 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
005403
3(X) XY XXXmA XXXmA
Description: Reference value for control current to control valve (solenoid valve, lift mast). Circuit diagram: Circuit lift/lower electric servo group 7.2_1 Connection: output signal reference value out from D797-1/K1:16 to Y6005/2 Function: 7.2.5 Control valve, lift and tilt Signal value: XXX = Current value in mA for controlling solenoid valve.
OUTPUT LIFT, FEEDBACK
005403
3(X) XY XXXmA XXXmA
Description: Current value for control current to control valve (solenoid valve, lift mast). Circuit diagram: Circuit lift/lower electric servo group 7.2_1 Connection: output signal, actual value out from D797-1/K1:16 to Y6005/2 Function: 7.2.5 Control valve, lift and tilt Signal value: XXX = Measured current value in mA.
VDCT01.02GB
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8.4.8.4 ELSERV, menu 4 OUTPUT LOWER, REFERENCE
005404
DIAG ELSERVO OUTPUT LOWER REFERENCE REQUIRED VALUE FEEDBACK
4(X) XY XXXmA XXXmA
Description: Status for control current to control valve (solenoid valve, lower mast). Circuit diagram: Circuit lift/lower electric servo group 7.2_1 Contact: digital output from D797-1/K1:4 to Y6004/1 Function: 7.2.5 Control valve, lift and tilt Signal value: 00 10 11 No output signal, PWM off. Output signal active, short circuit. Output signal active, circuit OK.
NOTE
OUTPUT LOWER, REQUIRED VALUE
005404
4(X) XY XXXmA XXXmA
Description: Reference value for control current to control valve (solenoid valve, lower mast). Circuit diagram: Circuit lift/lower electric servo group 7.2_1 Connection: output signal reference value out from D797-1/K1:17 to Y6004/2 Function: 7.2.5 Control valve, lift and tilt Signal value: XXX = Current value in mA for controlling solenoid valve.
OUTPUT LOWER, FEEDBACK
005404
4(X) XY XXXmA XXXmA
Description: Current value for control current to control valve (solenoid valve, lower mast). Circuit diagram: Circuit lift/lower electric servo group 7.2_1 Connection: output signal, actual value out from D797-1/K1:17 to Y6004/2 Function: 7.2.5 Control valve, lift and tilt Signal value: XXX = Measured current value in mA.
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8.4.8.5 ELSERV, menu 5 OUTPUT TILT IN, REFERENCE
005405
DIAG ELSERVO OUTPUT TILT IN REFERENCE REQUIRED VALUE FEEDBACK
5(X) XY XXXmA XXXmA
Description: Status for control current to control valve (solenoid valve, tilt in). Circuit diagram: Circuit tilt electric servo group 7.7_1 Connection: digital out from D797-1/K1:5 to Y6011/1 Function: 7.7.5 Control valve, lift and tilt Signal value: 00 10 11 No output signal, PWM off. Output signal active, short circuit. Output signal active, circuit OK.
NOTE
OUTPUT TILT IN, REQUIRED VALUE
005405
5(X) XY XXXmA XXXmA
Description: Reference value for control current to control valve (solenoid valve, tilt in). Circuit diagram: Circuit tilt electric servo group 7.7_1 Connection: output signal reference value out from D797-1/K1:18 to Y6011/2 Function: 7.7.5 Control valve, lift and tilt Signal value: XXX = Current value in mA for controlling solenoid valve.
OUTPUT TILT IN, FEEDBACK
005405
5(X) XY XXXmA XXXmA
Description: Current value for control current to control valve (solenoid valve, tilt in). Circuit diagram: Circuit tilt electric servo group 7.7_1 Connection: output signal, actual value out from D797-1/K1:18 to Y6011/2 Function: 7.7.5 Control valve, lift and tilt Signal value: XXX = Measured current value in mA.
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8.4.8.6 ELSERV, menu 6 OUTPUT TILT OUT, REFERENCE
005406
DIAG ELSERVO 6(X) OUTPUT TILT OUT REFERENCE XY REQUIRED VALUE XXXmA FEEDBACK XXXmA
Description: Status for control current to control valve (solenoid valve, tilt out). Circuit diagram: Circuit tilt electric servo group 7.7_1 Connection: digital out from D797-1/K1:5 to Y6010/1 Function: 7.7.5 Control valve, lift and tilt Signal value: 00 10 11 No output signal, PWM off. Output signal active, short circuit. Output signal active, circuit OK.
NOTE
OUTPUT TILT OUT, REQUIRED VALUE
005406
Description: Reference value for control current to control valve (solenoid valve, tilt out). Circuit diagram: Circuit tilt electric servo group 7.7_1 Connection: output signal, reference value out from D797-1/K1:19, to solenoid valve Y6010/1 Function: 7.7.5 Control valve, lift and tilt Signal value: XXX = Current value in mA for controlling solenoid valve.
OUTPUT TILT OUT, FEEDBACK
005406
Description: Current value for control current to control valve (solenoid valve, tilt out). Circuit diagram: Circuit tilt electric servo group 7.7_1 Connection: output signal, actual value out from D797-1/K1:19 to solenoid valve Y6010/2 Function: 7.7.5 Control valve, lift and tilt Signal value: XXX = Measured current value in mA.

XXXXXXX NOT USED
X(X)
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X(X)
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8.4.8.13 ELSERV, menu 13 PRESENT INPUT SIGNALS, SPREADER

Description: Signal from switch for spreading the attachment.
007128
DIAG ELSERVO 13(X) PRESENT INPUT SIGNALS SPREADER IN X OUT X PISTOL X UNLOCK TW X
Circuit diagram: Circuit electric servo joystick group 7.0_2 Contact: 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: 1 0 Input signal active. No signal.
PRESENT INPUT SIGNALS, PISTOL

007128
PRESENT INPUT SIGNALS, UNLOCK TW

Description: Signal from control lever to unlock twistlock.
007128
Circuit diagram: Circuit electric servo joystick group 7.0_2 Contact: Signal from S815/20 to digital in D790-1/K7:15 Function: 7.1.1 Control lever Signal value: 1 0 Input signal active. No signal.

XXXXXXX NOT USED
X(X)
008793

XXXXXXX NOT USED
X(X)
008793
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8 Control system ATTACH
8.4.9 ATTACH
ATTACH, description
This group covers attachment functions.
005339
8.4.9.1 ATTACH, menu 1 PRESENT INPUT SIGNALS, P3

005416
DIAG ATTACHMENT 1(X) PRESENT INPUT SIGNALS P3 XX.XXV P4 XX.XXV P7 XX.XXV

005416

005416
8.4.9.2 ATTACH, menu 2 PRESENT INPUT SIGNALS, P5

DIAG ATTACHMENT 2(X) PRESENT INPUT SIGNALS P5 XX.XXV

005417
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8.4.9.3 ATTACH, menu 3 PRESENT INPUT SIGNALS, SPREADER

Description: Signals from switch for spreading the attachment.
005418
DIAG ATTACHMENT 3(X) PRESENT INPUT SIGNALS SPREADER IN X OUT X AUTO 20/40 X 30/35 STOP X
Circuit diagram: Circuit 20-40, 30-35 stop group 7.5-1, circuit electric servo joystick group 7.0_2 Contact: 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: 1 0 Input signal active. No signal.
PRESENT INPUT SIGNALS, AUTO 20/40
005418
Description: Signal from switch automatic spreading 20/40. Circuit diagram: Circuit 20-40 opt. group 7.5_3 Connection: from S1012-2/1 to digital in D790-1/K8:11 Function: 7.5 Spreading Signal value: 1 0 Input signal active. No signal.
PRESENT INPUT SIGNALS, 30/35 STOP
005418
Description: Signal from switch for stop at 30'/35'. Circuit diagram: Circuit 20-40, 30-35 stop group 7.5-1 Connection: from S1004/1 to digital in D790-1/K8:10 Function: 7.5 Spreading Signal value: 1 0 Input signal active. No signal.
8.4.9.4 ATTACH, menu 4 PRESENT INPUT SIGNALS, PISTOL

DIAG ATTACHMENT 4(X) PRESENT INPUT SIGNALS

007130
PISTOL
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8.4.9.5 ATTACH, menu 5 PRESENT INPUT SIGNALS, LOCK CONT

Description: Signal from switch, lock twistlocks.
010079
DIAG ATTACHMENT 5(X) PRESENT INPUT SIGNALS LOCK CONT X UNLOCK CONT X
Circuit diagram: Circuit Twistlock group 7.9_1 Contact: Signal from S1003 to digital in D790-1/K8:12 Function: 7.9.1 Twistlocks Signal value: 1 0 Input signal active. No signal.
PRESENT INPUT SIGNALS, UNLOCK CONT

Description: Signal from control lever to open twistlocks.
010079
DIAG ATTACHMENT 5(X) PRESENT INPUT SIGNALS LOCK CONT X UNLOCK CONT X
Circuit diagram: Circuit Twistlock group 7.9_1 Contact: Signal from S1002 to digital in D790-1/K7:15 Function: 7.1.1 Control levers Signal value: 1 0 Input signal active. No signal.
8.4.9.6 ATTACH, menu 6 PRESENT INPUT SIGNALS, LOW SPEED 20/40
010080
DIAG ATTACHMENT 6(X) PRESENT INPUT SIGNALS LE RI LOW SPEED 20/40 X X 30/35 STOP X X
Description: Signal from spreading position sensor for end position damping 20'/40' right or left. Circuit diagram: Attachment DCF90/100-45E group 7.5_3 Connection: from inductive sensor B769L to digital in D791/K1:12 or from inductive sensor B769R to digital in D791/K1:40 Function: 7.5.6 Position sensor spreading Signal value: 1 0 Input signal active. No signal.
PRESENT INPUT SIGNALS, 30/35 STOP
010080
DIAG ATTACHMENT 6(X) PRESENT INPUT SIGNALS LE RI LOW SPEED 20/40 X X 30/35 STOP X X
Description: Signal from position sensor for end position 30' right or left. Circuit diagram: Attachment DCF90/100-45E group 7.5_3 Connection: from inductive sensor B777L to digital in D791/K1:20 or from inductive sensor B777R to digital in D791/K1:37 Function: 7.5.6 Position sensor spreading Signal value: 1 0 Input signal active. No signal.
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8.4.9.7 ATTACH, menu 7 PRESENT INPUT SIGNALS, ALIGNMENT LE RI

Description: Signals from right and left alignment sensors.
010093
DIAG ATTACHMENT 7(X) PRESENT INPUT SIGNALS ALIGNMENT LE RI X X
Circuit diagram: Attachment DCF90/100-45E group 7.9_5A, 7.9_4 Contact: LE: signal from B7203L to digital in D791/K1:27 RI: signal from B7203R to digital in D791/K1:26 Function: 7.9.1.7 Alignment sensor Signal value: 1 0 Input signal active. No signal.
8.4.9.8 ATTACH, menu 8 PRESENT INPUT SIGNAL LE RI, LOCKED CONT

Description: Signals from sensors locked twistlock right and left.
010082
DIAG ATTACHMENT 8(X) PRESENT INPUT SIGNALS LE RI LOCKED CONT X X UNLOCKED CONT X X
Circuit diagram: Attachment DCF90/100-45E group 7.9_2 Contact: LE: Signal from B7205LL to analogue in (used as digital) D791/K1:23 RI: Signal from B7205RL to analogue in (used as digital) D791/K1:24 Function: 7.9.1.8 Twistlocks sensor Signal value: 1 0 Input signal active. No signal.
PRESENT OUTPUT SIGNAL LE RI, UNLOCKED CONT

Description: Signals from sensors open twistlock right and left.
010082
DIAG ATTACHMENT 8(X) PRESENT INPUT SIGNALS LE RI LOCKED CONT X X UNLOCKED CONT X X
Circuit diagram: Attachment DCF90/100-45E group 7.9_2 Contact: LE: Signal from B7204L to analogue in (used as digital) D791-1/K1:22 RI: Signal from B7204R to analogue in (used as digital) D791-1/K1:41 Function: 7.9.1.8 Twistlocks sensor Signal value: 1 0 Input signal active. No signal.
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8.4.9.9 ATTACH, menu 9 PRESENT OUTPUT SIGNAL, LOCK CONT
010083
DIAG ATTACHMENT 9(X) PRESENT OUTPUT SIGNAL LOCK CONT XY UNLOCK CONT XY
Description: Voltage feed to control valve attachment, locked twistlock. Circuit diagram: Circuit Twistlock group 7.9_1 Connection: digital out from D791/K1:7 to Y6040/1 Function: 7.9.1.2 Attachment control valve Signal value: 00 01 No output signal and open circuit in the circuit. 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 11 Output signal active, short circuit. 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.
PRESENT OUTPUT SIGNAL, UNLOCK CONT

Description: Voltage feed to control valve attachment, open twistlock.
010083
DIAG ATTACHMENT 9(X) PRESENT OUTPUT SIGNAL LOCK CONT XY UNLOCK CONT XY
Circuit diagram: Circuit Twistlock group 7.9_1 Connection: digital out from D791/K1:9 to Y6039/1 Function: 7.9.1.2 Attachment control valve Signal value: 00 01 No output signal and open circuit in the circuit. 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 11 Output signal active, short circuit. 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.
VDCT01.02GB
8:81
8.4.9.10 ATTACH, menu 10 PRESENT OUTPUT SIGNAL, IND. LOCKED CONT
010084
DIAG ATTACHMENT 10(X) PRESENT OUTPUT SIGNAL IND. LOCKED CONT XY IND. UNLOCKED CONT XY IND. ALIGNMENT XY
Description: Voltage feed, indicator light for locked twistlocks - located on carriage. Circuit diagram: Circuit attachment DCF90/100-45E group 11.5_2, 7.9_3A Connection: digital out from D791/K1:29 to H563/1 Function: 7.9.1 Twistlocks Signal value: 00 01 No output signal and open circuit in the circuit. 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 11 Output signal active, short circuit. 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.
PRESENT OUTPUT SIGNAL, IND. UNLOCKED CONT
010084
Description: Voltage feed, indicator light for unlocked twistlocks located on carriage. Circuit diagram: Circuit attachment DCF90/100-45E group 11.5_2, 7.9_3A Connection: digital out from D791/K1:25 to H562/1 Function: 7.9.1 Twistlocks Signal value: 00 01 No output signal and open circuit in the circuit. 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 11 Output signal active, short circuit. 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.
VDCT01.02GB
8:82
PRESENT OUTPUT SIGNAL, IND. ALIGNMENT
010084
Description: Voltage feed, alignment indicator light - located on carriage. Circuit diagram: Circuit attachment DCF90/100-45E group 11.5_2, 7.9_3A Connection: digital out from D791/K1:39 to H564/1 Function: 7.9.1 Twistlocks Signal value: 00 01 No output signal and open circuit in the circuit. 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 11 Output signal active, short circuit. 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.
8.4.9.11 ATTACH, menu 11 OUTPUT SIDE SHIFT LE, REFERENCE
010088
DIAG ATTACHMENT 11(X) OUTPUT SIDESHIFT LE REFERENCE XY REQUIRED VALUE XXX FEEDBACK XXX
Description: Status for control current to attachment control valve for side shift left. Circuit diagram: Circuit attachment DCF90/100-45E group 7.4_1 Connection: digital out from D791-1/K1:32 to Y6020/1 Function: 7.4.2 Control valve attachment Signal value: 00 10 11 No output signal, PWM off. Output signal active, short circuit. Output signal active, circuit OK.
NOTE
OUTPUT SIDE SHIFT LE, REQUIRED VALUE
010088
Description: Reference value for control current to attachment control valve for output signal, side shift left. Circuit diagram: Circuit attachment DCF90/100-45E group 7.4_1 Connection: output signal reference value out from D791-1/K1:18 to Y6020/2 Function: 7.4.2 Control valve attachment Signal value: XXX = Current value in mA for controlling solenoid valve.
VDCT01.02GB
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OUTPUT SIDE SHIFT LE, FEEDBACK
010088
Description: Current value for control current to attachment control valve for side shift left. Circuit diagram: Circuit attachment DCF90/100-45E group 7.4_2 Connection: output signal actual value out from D791-1/K1:18 to Y6020/2 Function: 7.4.2 Control valve attachment Signal value: XXX = Measured current value in mA.
8.4.9.12 ATTACH, menu 12 OUTPUT SIDE SHIFT RI, REFERENCE
010089
DIAG ATTACHMENT 12(X) OUTPUT SIDESHIFT RI REFERENCE XY REQUIRED VALUE XXX FEEDBACK XXX
Description: Status for control current to attachment control valve for side shift right. Circuit diagram: Circuit attachment DCF90/100-45E group 7.4_1 Connection: digital out from D791/K1:33 to Y6021/1 Function: 7.4.2 Control valve attachment Signal value: 00 10 11 No output signal, PWM off. Output signal active, short circuit. Output signal active, circuit OK.
NOTE
OUTPUT SIDE SHIFT RI, REQUIRED VALUE
010089
Description: Reference value for control current to attachment control valve for output signal, side shift right. Circuit diagram: Circuit attachment DCF90/100-45E group 7.4_1 Connection: output signal reference value out from D791-1/K1:18 to Y6021/2 Function: 7.4.2 Control valve attachment Signal value: XXX = Current value in mA for controlling solenoid valve.
OUTPUT SIDE SHIFT RI, FEEDBACK
010089
Description: Current value for control current to attachment control valve for side shift right. Circuit diagram: Circuit attachment DCF90/100-45E group 7.4_1 Connection: output signal, actual value out from D791-1/K1:18 to Y6021/2 Function: 7.4.2 Control valve attachment Signal value: XXX = Measured current value in mA.
VDCT01.02GB
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8.4.9.13 ATTACH, menu 13 NOT USED

XXXXXXX NOT USED
X(X)
008793

XXXXXXX NOT USED
X(X)
008793

XXXXXXX NOT USED
X(X)
008793

XXXXXXX NOT USED
X(X)
VDCT01.02GB
008793
8:85
8.4.9.17 ATTACH, menu 17 OUTPUT SPREAD LE OUT, REFERENCE
010087
DIAG ATTACHMENT 17(X) OUTPUT SPREAD LE OUT REFERENCE XY REQUIRED VALUE XXX FEEDBACK XXX
Description: Status for control current to attachment control valve for spreading, left side out. Circuit diagram: Attachment DCF90/100-45E group 7.5_1 Connection: digital out from D791/K1:3 to Y6018L/1 Function: 7.5.2 Control valve attachment Signal value: 00 10 11 No output signal, PWM off. Output signal active, short circuit. Output signal active, circuit OK.
NOTE
OUTPUT SPREAD LE OUT, REQUIRED VALUE
010087
Description: Reference value for control current to attachment control valve for output signal spreading left side out. Circuit diagram: Attachment DCF90/100-45E group 7.5_1 Connection: output signal, reference value out from D791/K1:16 to Y6018L/2 Function: 7.5.2 Control valve attachment Signal value: XXX = Current value in mA for controlling solenoid valve.
OUTPUT SPREAD LE OUT, FEEDBACK
010087
Description: Current value for control current to attachment control valve for spreading, left side out. Circuit diagram: Attachment DCF90/100-45E group 7.5_1 Connection: output signal, actual value out from D791/K1:16 to Y6018L/2 Function: 7.5.2 Control valve attachment Signal value: XXX = Measured current value in mA.
VDCT01.02GB
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8.4.9.18 ATTACH, menu 18 OUTPUT SPREADER LE IN, REFERENCE
010090
DIAG ATTACHMENT 18(X) OUTPUT SPREADER LE IN REFERENCE XY REQUIRED VALUE XXX FEEDBACK XXX
Description: Status for control current to attachment control valve for spreading, left side in. Circuit diagram: Attachment DCF90/100-45E group 7.5_1 Connection: digital out from D791/K1:2 to Y6019L/1 Function: 7.5.2 Control valve attachment Signal value: 00 10 11 No output signal, PWM off. Output signal active, short circuit. Output signal active, circuit OK.
NOTE
OUTPUT SPREADER LE IN, REQUIRED VALUE
010090
Description: Reference value for control current to attachment control valve for output signal spreading left side in. Circuit diagram: Attachment DCF90/100-45E group 7.5_1 Connection: output signal, reference value out from D791/K1:16 to Y6019L/2 Function: 7.5.2 Control valve attachment Signal value: XXX = Current value in mA for controlling solenoid valve.
OUTPUT SPREADER LE IN, FEEDBACK
010090
Description: Current value for control current to attachment control valve for spreading, left side in. Circuit diagram: Attachment DCF90/100-45E group 7.5_1 Connection: output signal, actual value out from D791/K1:16 to Y6019L/2 Function: 7.5.2 Control valve attachment Signal value: XXX = Measured current value in mA.
VDCT01.02GB
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8.4.9.19 ATTACH, menu 19 OUTPUT SPREAD RI OUT, REFERENCE
010091
DIAG ATTACHMENT 19(X) OUTPUT SPREAD RI OUT REFERENCE XY REQUIRED VALUE XXX FEEDBACK XXX
Description: Status for control current to attachment control valve for spreading, right side out. Circuit diagram: Attachment DCF90/100-45E group 7.5_1 Connection: digital out from D791/K1:5 to Y6018R/1 Function: 7.5.2 Control valve attachment Signal value: 00 10 11 No output signal, PWM off. Output signal active, short circuit. Output signal active, circuit OK.
NOTE
OUTPUT SPREAD RI OUT, REQUIRED VALUE
010091
Description: Reference value for control current to attachment control valve for output signal spreading right side out. Circuit diagram: Attachment DCF90/100-45E group 7.5_1 Connection: output signal, reference value out from D791/K1:17 to Y6018R/2 Function: 7.5.2 Control valve attachment Signal value: XXX = Current value in mA for controlling solenoid valve.
OUTPUT SPREAD RI OUT, FEEDBACK
010091
Description: Current value for control current to attachment control valve for spreading, right side out. Circuit diagram: Attachment DCF90/100-45E group 7.5_1 Connection: output signal, actual value out from D791/K1:17 to Y6018R/2 Function: 7.5.2 Control valve attachment Signal value: XXX = Measured current value in mA.
VDCT01.02GB
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8.4.9.20 ATTACH, menu 20 OUTPUT SPREADER RI IN, REFERENCE
010092
DIAG ATTACHMENT 20(X) OUTPUT SPREADER RI IN REFERENCE XY REQUIRED VALUE XXX FEEDBACK XXX
Description: Status for control current to attachment control valve for spreading, right side in. Circuit diagram: Attachment DCF90/100-45E group 7.5_1 Connection: digital out from D791/K1:4 to Y6019R/1 Function: 7.5.2 Control valve attachment Signal value: 00 10 11 No output signal, PWM off. Output signal active, short circuit. Output signal active, circuit OK.
NOTE
OUTPUT SPREADER RI IN, REQUIRED VALUE
010092
Description: Reference value for control current to attachment control valve for output signal spreading right side in. Circuit diagram: Attachment DCF90/100-45E group 7.5_1 Connection: output signal, reference value out from D791/K1:17 to Y6019R/2 Function: 7.5.2 Control valve attachment Signal value: XXX = Current value in mA for controlling solenoid valve.
OUTPUT SPREADER RI IN, FEEDBACK
010092
Description: Current value for control current to attachment control valve for spreading, right side in. Circuit diagram: Attachment DCF90/100-45E group 7.5_1 Connection: output signal, actual value out from D791/K1:17 to Y6019R/2 Function: 7.5.2 Control valve attachment Signal value: XXX = Measured current value in mA.
VDCT01.02GB
8 Control system OLS
8:89
8.4.9.21 ATTACH, menu 21 PRESENT OUTPUT SIGNAL, BUZZER AUTO 20-40
DIAG ATTACHMENT 21(X) PRESENT OUTPUT SIGNAL

009181
Description: Voltage feed to buzzer, automatic spreading 20'-40'. Circuit diagram: Attachment DCF90/100-45E group 7.5_2 Connection: digital out from D791/K1:28 to H9003/1 Function: 7.5 Spreading Signal value: 01 10 11 No output signal. Error detection only possible when output signal is active. Output signal active, short circuit or open circuit. Output signal active, circuit OK.
BUZZER AUTO 20-40
XY
8.4.10 OLS
OLS, description
005436
8.4.11 EXTRA
EXTRA, description
005440
This menu consists of optional functions: Reversible driver's seat, VBFS 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

008904
DIAGNOSIS EXTRA VBFS EL-STEERING EXT-ATTACH FREELIFT MOVE-CAB OPT I/O RMI
VDCT01.02GB
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8 Control system EXTRA
8.4.11.2 EL-STEERING EL-STEERING, description

008911
8.4.11.3 EXT-ATTACH EXT-ATTACH, description

007625
8.4.11.4 FREELIFT FREELIFT, description

008912
8.4.11.5 MOVE-CAB MOVE-CAB, description

008913
8.4.11.6 OPT OPT, description

This group covers a number of options.
VDCT01.02GB
008914
8:91
OPT, menu 1
OPTION SWITCH, S199-1

Description: Signal from switch S199-1. Circuit diagram: Circuit extra equipment group 9.1_1
005488
DIAG OPTION 1(X) OPTION SWITCH S199-1 X S199-4 X S199-2 X S199-3 X
Connection: signal from S199-1/1 to digital in D790-1/K6:9 Function: Signal value: 1 0 Input signal active. No signal.

005488

005488

005488
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OPT, menu 2
PRESENT OUTPUT SIGNAL CENTRAL LUBRICATION, FRAME
005489
DIAG OPTION 2(X) PRESENT OUTPUT SIGNAL CENTRAL LUBRICATION FRAME XY ATTACHMENT XY
PRESENT OUTPUT SIGNAL CENTRAL LUBRICATION, FRAME

Description: Voltage feed to central lubrication of frame. Circuit diagram: Circuit std. opt. group 9.0_1 and circuit central 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: 00 01 No output signal and open circuit in the circuit. 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 11 Output signal active, short circuit. 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.
PRESENT OUTPUT SIGNAL CENTRAL LUBRICATION, ATTACHMENT
005489
DIAG OPTION 2(X) PRESENT OUTPUT SIGNAL CENTRAL LUBRICATION FRAME XY ATTACHMENT XY
PRESENT OUTPUT SIGNAL CENTRAL LUBRICATION, ATTACHMENT

Description: Voltage feed to central lubrication of attachment. Circuit diagram: Attachment DCF90/100-45E group 9.14_1 Connection: digital out from D791-1/K1:14 to M693/1 Function: 9.14.1 Pump unit Signal value: 01 10 11 No output signal. Error detection only possible when output signal is active. Output signal active, short circuit or open circuit. Output signal active, circuit OK.
VDCT01.02GB
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OPT, menu 3
PRESENT OUTPUT SIGNAL, D797-1 C1 P42

Description: Voltage feed from D797-1/K1:42. Circuit diagram: 005490
DIAG OPTION 3(X) PRESENT OUTPUT SIGNAL D797-1 C1 P42 XY
Connection: digital out D797-1/K1:42 Function: Signal value: 00 01 No output signal and open circuit in the circuit. 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 11 Output signal active, short circuit. 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.
OPT, menu 4
OPT, menu 5

DIAG OPTION 5(X) PRESENT OUTPUT SIGNAL D791-1 C1 P14 XY D791-1 C1 P28 XY
Connection: digital out from D791-1/K1:14 Function: Signal value: 01 10 11 No output signal. Error detection only possible when output signal is active. Output signal active, short circuit or open circuit. Output signal active, circuit OK.
VDCT01.02GB
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DIAG OPTION 5(X) PRESENT OUTPUT SIGNAL D791-1 C1 P14 XY D791-1 C1 P28 XY
Connection: digital out from D791-1/K1:28 Function: Signal value: 00 01 No output signal and open circuit in the circuit. 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 11 Output signal active, short circuit. 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.
8.4.11.7 I/O I/O, description

015099
DIAGNOSIS EXTRA VBFS EL-STEERING EXT-ATTACH FREELIFT I/O RMI MOVE-CAB OPT I/O
8.4.11.8 RMI RMI, description

VDCT01.02GB
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
The settings influence the functions. Adjustments may impair the function.
008891
INIT ELSERVO START CURRENT LIFT STORED VALUE PRESENT VALUE

Menu group
1(X) XXXmA XXXmA
If uncertain, contact Cargotec Service.
Example of initiation menu, start current for lift function. 1. 2.
NOTE
Initiation does not need to be performed in one process but each step can be performed separately, independently of other steps. In order that hydraulic functions shall work satisfactorily and safely, 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:
Menu number. The number of menus depends on the equipment fitted to the machine. For this reason, number of menus is indicated with (X) in this manual. Signal value Actual variable
3. 4.
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] 1 2 t [s]
1. 2. 3. Max. current (END CURRENT) Damping (PROC DAMPING) Start current (START CURRENT)
006299
STORED
States the stored value for the current variable.
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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
1 Engine, speed limitation 1 Engine, automatic engine shut-down on idle 1 Engine, automatic engine speed increase for lifting 2 Transmission, starting gear
Menu
INIT DRIVE-TRAIN, menu 9, page 8:110 INIT DRIVE-TRAIN, menu 11, page 8:110 INIT DRIVE-TRAIN, menu 13, page 8:111 INIT DRIVE-TRAIN, menu 1, page 8:108 INIT DRIVE-TRAIN, menu 10, page 8:110 INIT DRIVE-TRAIN, menu 12, page 8:111 INIT ELSERVO, menu 1, page 8:98 INIT ELSERVO, menu 2, page 8:98
2 Transmission, speed limitation (gear lock-out) 2 Transmission, automatic engine speed reduction for shift forward - reverse 7.2 Lifting/lowering, lift mast
7.2 Lifting/lowering, lower mast Comment: The current value is for unladen machines. When loaded, the current value is controlled by the limited lowering speed. 7.4 Side shift
INIT ELSERVO, menu 3, page 8:99 INIT ELSERVO, menu 4, page 8:99 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 INIT ATTACH, menu 10, page 8:106 INIT ATTACH, menu 11, page 8:106
7.5 Spreading in
INIT ATTACH, menu 12, page 8:107 INIT ATTACH, menu 13, page 8:107 INIT ATTACH, menu 14, page 8:107
7.7 Tilt
INIT ELSERVO, menu 5, page 8:99 INIT ELSERVO, menu 6, page 8:100
VDCT01.02GB
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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
Enter the code for initiation. Code is obtained from Cargotec Support.
1 23 4 5
000060
NOTE
The code determines which service menu is activated (Service, Diagnostic test, Initiation or Calibration). 4 Select group by scrolling with the arrow keys (1 and 2) and confirm with Enter. Each initiation consists of a sequence of a number of menus. The first menu for the selected initiation opens in the display. Select the desired menu with the arrow keys (1 and 2).
007169
INITIATION ELSERVO ATTACHMENT STEERING DRIVE-TRAIN SLIDING-CAB RETURN
Change the current value with the plus and minus keys.
005494
1(X)
NOTE
XXXmA XXXmA
Current values can only be adjusted within specific limits. 6 Use the function key for Enter to store the desired current value setting, "STORED".
VDCT01.02GB
8:98
8.5.1.1 ELECTRIC SERVO INIT ELSERVO
007169
The menu group for this function covers initiation of the electric servo functions for load handling. The settings for lift, lower, tilt in, tilt out are made here. For other load handling functions, see INIT ATTACH, page 8:104.
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
005494
1(X)
Description: Start current for activation of solenoid valve, lift mast (Y6005).
XXXmA XXXmA
PRESENT VALUE: indicates the current value for the start current. Adjust the value with the plus and minus keys. Store the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates stored value for start current. Function: 7.2.5 Control valve, lift and tilt Component: Solenoid valve, lift mast (Y6005) Signal value: XXXmA = 0 - 999 mA.

END CURRENT, LIFT
END CURRENT, LIFT
005495
INIT ELSERVO END CURRENT LIFT STORED VALUE PRESENT VALUE
2(X)
Description: Control current on full lever actuation for the activation of the solenoid valve for mast lift (Y6005).
XXXmA XXXmA
PRESENT VALUE: indicates the current value for max. current. Adjust the value with the plus and minus keys. Store the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates stored value for max. current. Function: 7.2.5 Control valve, lift and tilt Component: Solenoid valve, lift mast (Y6005) Signal value: XXXmA = 0 - 999 mA.
VDCT01.02GB
8:99

START CURRENT, LOWER
START CURRENT, LOWER
005496
INIT ELSERVO START CURRENT LOWER STORED VALUE PRESENT VALUE
3(X)
Description: Start current for activation of solenoid valve, lower mast (Y6004).
XXXmA XXXmA
PRESENT VALUE: indicates the current value for the start current. Adjust the value with the plus and minus keys. Store the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates stored value for start current. Function: 7.2.5 Control valve, lift and tilt Component: Solenoid valve, lower mast (Y6004) Signal value: XXXmA = 0 - 999 mA.

END CURRENT, LOWER
END CURRENT, LOWER
005497
INIT ELSERVO END CURRENT LOWER STORED VALUE PRESENT VALUE
4(X)
Description: Control current on full lever actuation for the activation of the solenoid valve for mast lower (Y6004).
XXXmA XXXmA
PRESENT VALUE: indicates the current value for max. current. Adjust the value with the plus and minus keys. Store the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates stored value for max. current. Function: 7.2.5 Control valve, lift and tilt Component: Solenoid valve, mast (Y6004) Signal value: XXXmA = 0 - 999 mA.

START CURRENT, TILT IN
START CURRENT, TILT IN
007139
INIT ELSERVO START CURRENT TILT IN STORED VALUE PRESENT VALUE
5(X)
Description: Start current for the activation of the solenoid valve for tilt in (Y6011).
XXXmA XXXmA
PRESENT VALUE: indicates the current value for the start current. Adjust the value with the plus and minus keys. Store the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates stored value for start current. Function: 7.7.5 Control valve, lift and tilt Component: Solenoid valve, tilt in (Y6011) Signal value: XXXmA = 0 - 999 mA.
VDCT01.02GB
8:100

END CURRENT, TILT IN
END CURRENT, TILT IN
007140
INIT ELSERVO END CURRENT TILT IN STORED VALUE PRESENT VALUE
6(X)
Description: Control current on full lever actuation for the activation of the solenoid valve for tilt in (Y6011).
XXXmA XXXmA
PRESENT VALUE: indicates the current value for max. current. Adjust the value with the plus and minus keys. Store the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates stored value for max. current. Function: 7.7.5 Control valve, lift and tilt Component: Solenoid valve, tilt in (Y6011) Signal value: XXXmA = 0 - 999 mA.

START CURRENT, TILT OUT
START CURRENT, TILT OUT
007141
INIT ELSERVO START CURRENT TILT OUT STORED VALUE PRESENT VALUE
7(X)
Description: Start current for the activation of the solenoid valve for tilt out (Y6010).
XXXmA XXXmA
PRESENT VALUE: indicates the current value for the start current. Adjust the value with the plus and minus keys. Store the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates stored value for start current. Function: 7.7.5 Control valve, lift and tilt Component: Solenoid valve, tilt out (Y6010) Signal value: XXXmA = 0 - 999 mA.

END CURRENT, TILT OUT
END CURRENT, TILT OUT
007142
INIT ELSERVO END CURRENT TILT OUT STORED VALUE PRESENT VALUE
8(X)
Description: Control current on full lever actuation for the activation of the solenoid valve for tilt out (Y6010).
XXXmA XXXmA
PRESENT VALUE: indicates the current value for max. current. Adjust the value with the plus and minus keys. Store the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates stored value for max. current. Function: 7.7.5 Control valve, lift and tilt Component: Solenoid valve, tilt out (Y6010) Signal value: XXXmA = 0 - 999 mA.
VDCT01.02GB
8:101

START CURRENT, SIDE SHIFT LE/RI
START CURRENT, SIDE SHIFT LE/RI

Description: Start current of activation of solenoid valve for side shift left (Y6020) and solenoid valve for side shift right (Y6021). PRESENT VALUE: indicates the current value for the start current. Adjust the value with the plus and minus keys. Store the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates stored value for start current. Function: 7.4.2 Control valve attachment Component: Solenoid valve for side shift left (Y6020) and solenoid valve for side shift right (Y6021) Signal value: XXXmA = 0 - 999 mA.
007143
INIT ELSERVO 9(X) START CURRENT SIDESHIFT LE/RI STORED VALUE XXXmA PRESENT VALUE XXXmA

END CURRENT, SIDE SHIFT LE/RI
END CURRENT, SIDE SHIFT LE/RI

Description: Control current at full lever actuation for activation of solenoid valve for side shift left (Y6020) and solenoid valve for side shift right (Y6021).
007144
INIT ELSERVO 10(X) END CURRENT SIDESHIFT LE/RI STORED VALUE XXXmA PRESENT VALUE XXXmA
PRESENT VALUE: indicates the current value for max. current. Adjust the value with the plus and minus keys. Store the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates stored value for max. current. Function: 7.4.2 Control valve attachment Component: Solenoid valve for side shift left (Y6020) and solenoid valve for side shift right (Y6021) Signal value: XXXmA = 0 - 999 mA.

START CURRENT, SPREADING IN/OUT
START CURRENT, SPREADING IN/OUT

Description: Start current for activation of solenoid valve for spreading in (Y6019) and solenoid valve for spreading out (Y6018). PRESENT VALUE: indicates the current value for the start current. Adjust the value with the plus and minus keys. Store the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates stored value for start current. Function: 7.5.2 Control valve attachment Component: Solenoid valve for spreading in (Y6019) and solenoid valve for spreading out (Y6018) Signal value: XXXmA = 0 - 999 mA.
007145
INIT ELSERVO 11(X) START CURRENT SPREADING IN/OUT STORED VALUE XXXmA PRESENT VALUE XXXmA
VDCT01.02GB
8:102

END CURRENT, SPREADING IN/OUT
END CURRENT, SPREADING IN/OUT

Description: Control current at full lever actuation for activation of solenoid valve for spreading in (Y6019) and solenoid valve for spreading out (Y6018).
007146
INIT ELSERVO 12(X) END CURRENT SPREADING IN/OUT STORED VALUE XXXmA PRESENT VALUE XXXmA
PRESENT VALUE: indicates the current value for max. current. Adjust the value with the plus and minus keys. Store the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates stored value for max. current. Function: 7.5.2 Control valve attachment Component: Solenoid valve for spreading in (Y6019) and solenoid valve for spreading out (Y6018) Signal value: XXXmA = 0 - 999 mA.

START CURRENT, LIFT 2
START CURRENT, LIFT 2
007147
INIT ELSERVO START CURRENT LIFT 2 STORED VALUE PRESENT VALUE
13(X)
Description: Start current for activation of solenoid valve, lift trolley (Y6022).
XXXmA XXXmA
PRESENT VALUE: indicates the current value for the start current. Adjust the value with the plus and minus keys. Store the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates stored value for start current. Function: 7.2.5 Control valve, lift and tilt Component: Solenoid valve trolley (Y6022) Signal value: XXXmA = 0 - 999 mA.

END CURRENT, LIFT 2
END CURRENT, LIFT 2
007148
INIT ELSERVO END CURRENT LIFT 2 STORED VALUE PRESENT VALUE
14(X)
Description: Control current on full lever actuation for the activation of the solenoid valve for lift trolley (Y6022).
XXXmA XXXmA
PRESENT VALUE: indicates the current value for max. current. Adjust the value with the plus and minus keys. Store the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates stored value for max. current. Function: 7.2.5 Control valve, lift and tilt Component: Solenoid valve trolley (Y6022) Signal value: XXXmA = 0 - 999 mA.
VDCT01.02GB
8:103

START CURRENT, LOWER 2
START CURRENT, LOWER 2
007149
INIT ELSERVO START CURRENT LOWER 2 STORED VALUE PRESENT VALUE
15(X)
Description: Start current for activation of solenoid valve, lower trolley (Y6023).
XXXmA XXXmA
PRESENT VALUE: indicates the current value for the start current. Adjust the value with the plus and minus keys. Store the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates stored value for start current. Function: 7.2.5 Control valve, lift and tilt Component: Solenoid valve, lower trolley (Y6023) Signal value: XXXmA = 0 - 999 mA.

END CURRENT, LOWER 2
END CURRENT, LOWER 2
007150
INIT ELSERVO END CURRENT LOWER 2 STORED VALUE PRESENT VALUE
16(X)
Description: Control current on full lever actuation for the activation of the solenoid valve for lower trolley (Y6023).
XXXmA XXXmA
PRESENT VALUE: indicates the current value for max. current. Adjust the value with the plus and minus keys. Store the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates stored value for max. current. Function: 7.2.5 Control valve, lift and tilt Component: Solenoid valve, lower trolley (Y6023) Signal value: XXXmA = 0 - 999 mA.

DAMP (PROC), LIFT
DAMP (PROC), LIFT
INIT ELSERVO DAMP (PROC) LIFT STORED VALUE PRESENT VALUE

I [mA] 1 2
17(X)
Description: Percentage damping of control current to solenoid valve for mast lift (Y6005) when the mast reaches max height.
XX XX
PRESENT VALUE: indicates the current value for damping. 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 in percent. Function: 7.2.5 Control valve, lift and tilt
007151
3 t [s]
Component: Solenoid valve, lift mast (Y6005) Signal value: XXX = 0 - 100%. 100% means no damping i.e. max. current. 0% means full damping i.e. start current.
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8:104
8.5.1.2 ATTACHMENT INIT ATTACH
007170
This function handles initialization of the attachment functions side shift and spreading.
DANGER
NOTE
INIT ATTACH, menu 1

NOT USED
XXXXXXX NOT USED
X(X)
NOT USED
008793
INIT ATTACH, menu 2

NOT USED
XXXXXXX NOT USED
X(X)
NOT USED
008793
INIT ATTACH, menu 3

NOT USED
XXXXXXX NOT USED
X(X)
NOT USED
008793
INIT ATTACH, menu 4

NOT USED
XXXXXXX NOT USED
X(X)
NOT USED
008793
VDCT01.02GB
8:105
INIT ATTACH, menu 5

START CURRENT, SIDE SHIFT
START CURRENT, SIDE SHIFT
005513
INIT ATTACH START CURRENT SIDESHIFT STORED VALUE PRESENT VALUE
5(X)
Description: Start current of activation of solenoid valve for side shift left (Y6020) and solenoid valve for side shift right (Y6021).
XXXmA XXXmA
PRESENT VALUE: indicates the current value for the start current. Adjust the value with the plus and minus keys. Store the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates stored value for start current. Function: 7.4.2 Control valve attachment 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
005514
INIT ATTACH END CURRENT SIDESHIFT STORED VALUE PRESENT VALUE
6(X) XXXmA XXXmA

Description: Control current at full lever actuation for activation of solenoid valve for side shift left (Y6020) and solenoid valve for side shift right (Y6021). PRESENT VALUE: indicates the current value for max. current. Adjust the value with the plus and minus keys. Store the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates stored value for max. current. Function: 7.4.2 Control valve attachment Component: Solenoid valve for side shift left (Y6020), Solenoid valve for side shift right (Y6021) Signal value: XXXmA = 0 - 999 mA
INIT ATTACH, menu 7

NOT USED
XXXXXXX NOT USED
X(X)
NOT USED
008793
INIT ATTACH, menu 8

NOT USED
XXXXXXX NOT USED
X(X)
NOT USED
008793
VDCT01.02GB
8:106
INIT ATTACH, menu 9

START CURRENT, SPREADER OUT, 20'-40'
START CURRENT, SPREADER OUT, 20'-40'

Description: Start current for activation of solenoid valve for spreading out left (Y6018L) and solenoid valve for spreading out right (Y6018R). PRESENT VALUE: indicates the current value for the start current. Adjust the value with the plus and minus keys. Store the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates stored value for start current. Function: 7.5.2 Control valve attachment
005517
INIT ATTACH 9(X) START CURRENT SPREADER OUT, 20'-40' STORED VALUE XXXmA PRESENT VALUE XXXmA
I [mA] 1 2 3 t [s]
Component: Solenoid valve, spreading out 20'-40' (Y6018) Signal value: XXXmA = 0 - 999 mA
INIT ATTACH, menu 10

END CURRENT, SPREADER OUT, 20'-40'
END CURRENT, SPREADER OUT, 20'-40'

Description: Control current at full lever actuation for activation of solenoid valve for spreading out left (Y6018L) and solenoid valve for spreading out right (Y6018R). PRESENT VALUE: indicates the current value for max. current. Adjust the value with the plus and minus keys. Store the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates stored value for max. current.
005518
INIT ATTACH 10(X) END CURRENT SPREADER OUT, 20'-40' STORED VALUE XXXmA PRESENT VALUE XXXmA
I [mA] 1 2 3 t [s]
Function: 7.5.2 Control valve attachment Component: Solenoid valve for spreading out left (Y6018L) and solenoid valve for spreading out right (Y6018R). Signal value: XXXmA = 0 - 999 mA

DAMP (PROC), SPREADER OUT, 20'-40'
DAMP (PROC), SPREADER OUT, 20'-40'

Description: Percentage damping of control current to solenoid valve for spreading out left (Y6018L) and solenoid valve for spreading out right (Y6018R) when spreading out approaches 40'. PRESENT VALUE: indicates the current value for damping. 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 in percent.
014600
INIT ATTACH 11(X) DAMP PROC SPREADER OUT, 20-40 STORED VALUE XX PRESENT VALUE XX
I [mA] 1 2 3 t [s]
Function: 7.5.2 Control valve attachment Component: Solenoid valve for spreading out left (Y6018L) and solenoid valve for spreading out right (Y6018R). Signal value: XXX = 0 - 100%. 100% means no damping, i.e. max. current. 0% means full damping, i.e. start current
VDCT01.02GB
8:107

START CURRENT, SPREADER IN, 40'-20'
START CURRENT, SPREADER IN, 40'-20'

Description: Start current for activation of solenoid valve for spreading in left (Y6019L) and solenoid valve for spreading in right (Y6019R). PRESENT VALUE: indicates the current value for the start current. Adjust the value with the plus and minus keys. Store the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates stored value for start current. Function: 7.5.2 Control valve attachment
005520
INIT ATTACH 12(X) START CURRENT SPREADER IN, 40'-20' STORED VALUE XXXmA PRESENT VALUE XXXmA
I [mA] 1 2 3 t [s]
Component: Solenoid valve for spreading in left (Y6019L) and solenoid valve for spreading in right (Y6019R). Signal value: XXXmA = 0 - 999 mA

END CURRENT, SPREADER IN, 40'-20'
END CURRENT, SPREADER IN, 40'-20'

Description: Control current at full lever actuation for activation of solenoid valve for spreading in left (Y6019L) and solenoid valve for spreading in right (Y6019R). PRESENT VALUE: indicates the current value for max. current. Adjust the value with the plus and minus keys. Store the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates stored value for max. current.
005521
INIT ATTACH 13(X) END CURRENT SPREADER IN, 40'-20' STORED VALUE XXXmA PRESENT VALUE XXXmA
I [mA] 1 2 3 t [s]
Function: 7.5.2 Control valve attachment Component: Solenoid valve for spreading in left (Y6019L) and solenoid valve for spreading in right (Y6019R). Signal value: XXXmA = 0 - 999 mA

DAMP (PROC), SPREADER IN, 40'-20'
DAMP (PROC), SPREADER IN, 40'-20'

Description: Percentage damping of control current to solenoid valve for spreading in left (Y6019L) and solenoid valve for spreading in right (Y6019R) when spreading in approaches 20'. PRESENT VALUE: indicates the current value for damping. 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 in percent.
014704
INIT ATTACH 14(X) DAMP PROC SPREADER IN, 40-20 STORED VALUE XX PRESENT VALUE XX
I [mA] 1 2 3 t [s]
Function: 7.5.2 Control valve attachment Component: Solenoid valve for spreading in left (Y6019L) and solenoid valve for spreading in right (Y6019R). Signal value: XXX = 0 - 100%. 100% means no damping, i.e. max. current. 0% means full damping, i.e. start current
VDCT01.02GB
8:108
8.5.1.3 STEERING INIT STEERING

8.5.1.4 DRIVE-TRAIN INIT DRIVE-TRAIN

This function covers engine and transmission initiation.
007172
DANGER
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 START IN 1:ST 1=YES 0=NO STORED VALUE PRESENT VALUE
1(X)
Description: Setting to get transmission to always start in 1st gear. PRESENT VALUE: indicates the present speed setting. Change the value using the plus or minus keys. Save the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates saved setting. Function: 2 Transmission Component: Signal value: XXX = 1= yes, XXX = 0 = no
XXX XXX

NOT USED
XXXXXXX NOT USED
X(X)
NOT USED
008793
VDCT01.02GB
8:109

NOT USED
XXXXXXX NOT USED
X(X)
NOT USED
008793

NOT USED
XXXXXXX NOT USED
X(X)
NOT USED
008793

NOT USED
XXXXXXX NOT USED
X(X)
NOT USED
008793

NOT USED
XXXXXXX NOT USED
X(X)
NOT USED
008793

NOT USED
XXXXXXX NOT USED
X(X)
NOT USED
008793

NOT USED
XXXXXXX NOT USED
X(X)
NOT USED
008793
VDCT01.02GB
8:110

OPTION SPEED LIMIT
OPTION SPEED LIMIT
005587
INIT DRIVE-T 9(X) OPTION SPEED LIMIT (km/h) STORED VALUE XXX PRESENT VALUE XXX
Description: Setting of speed limitation. PRESENT VALUE: indicates the current setting. Change the value with the plus and minus keys. Save the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates saved setting. Function: 2 Transmission Component: Signal value: XXX = speed (km/h)

OPTION HIGHEST GEAR AT SPEED LIMIT
OPTION HIGHEST GEAR AT SPEED LIMIT
005588
INIT DRIVE-T 10(X) OPTION HIGHEST GEAR AT SPEED LIMIT STORED VALUE XXX PRESENT VALUE XXX
Description: Setting of highest permissible gear (speed limitation through blocked gears). PRESENT VALUE: indicates the current setting. Change the value with the plus and minus keys. Save the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates saved setting. Function: 2 Transmission Component: Signal value: XXX = gear

OPTION ENGINE SHUT DOWN
OPTION ENGINE SHUT DOWN
005589
INIT DRIVE-T 11(X) OPTION ENGINE SHUT DOWN AT IDLE (sec) STORED VALUE XXX PRESENT VALUE XXX
Description: Setting of idle time prior to automatic engine shutdown. PRESENT VALUE: indicates the current setting. Change the value with the plus and minus keys. Save the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates saved setting. Function: 1 Engine Component: Signal value: XXX = time in seconds before engine shutdown.
VDCT01.02GB
8:111

F-R WITHOUT ENGINE SPEED REDUCTION
F-R WITHOUT ENGINE SPEED REDUCTION

Description: Activation or deactivation of automatic engine speed reduction when changing direction of travel forward - reverse. This makes it possible to change direction of travel without releasing the 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. PRESENT VALUE: indicates the current setting. Change the value with the plus and minus keys. Save the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates saved setting. Function: 2 Transmission Component: Signal value: X = 1, activated X = 0, deactivated
005590
INIT DRIVE-T 12(X) F-R WITHOUT ENGINE SPEED REDUCTION STORED VALUE X PRESENT VALUE X

AUTO ENGINE SPEED AT LIFT
AUTO ENGINE SPEED AT LIFT
005591
INIT DRIVE-T 13(X) AUTO ENGINE SPEED AT LIFT STORED VALUE X PRESENT VALUE X
Description: Activation or deactivation of automatic engine speed increase during lift. PRESENT VALUE: indicates the current setting. Change the value with the plus and minus keys. Save the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates saved setting. Function: 1 Engine Component: Signal value: X = 1, activated X = 0, deactivated
VDCT01.02GB
8:112
8 Control system Calibration
8.5.1.5 SLIDING-CAB NOT USED

XXXXXXX NOT USED
X(X)
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
CALIBRATION SCALE STEERING DRIVE-TRAIN RETURN
SCALE
000062
STEERING
STEERING
000074
DRIVE-TRAIN
DRIVE-TRAIN
This function handles calibration for engine and transmission. The menu loop contains two different calibrations are not linked to each other, see:
000078
Accelerator pedal, calibration, page 8:114
NOTE
VDCT01.02GB
8:113
Calibration menu, explanation
1 5
Calibration menu, explanation

The illustration shows an example of a menu, here for the calibration of the centre position for lever joystick control. The table indicates what a description contains (which follows in the next section):
008892
4
1. 2.
CALIBR STEERING 1(X) STEERING LEVER CENTER POSITION STORED VALUE X.XXV PRESENT VALUE X.XXV
Menu group
Designation: Example
Description
Name of the input signal/control signal affected. A short description of what is calibrated and the meaning of the variables.
Variable (position 5): STEERING LEVER CENTRE POSITION Description: Setting the centre position for lever joystick control (R825). STORED VALUE: Gives the stored signal value for lever steering control (R825), centre position. PRESENT VALUE: Gives the present signal value for lever steering control (R825), centre position. Function: 5.2 Power-assisted steering system Component: Lever joystick control (R825)
Sequence number. The number of menus depends on the equipment fitted to the machine. For this reason, number of menus is indicated with (X) in this manual. Signal value STORED indicates stored value, PRESENT indicates the current value of the signal to be calibrated Heading of menu figure
3. 4.
5.
Name of current function. Indicates the component 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
Enter the code for calibration. Code is obtained from Cargotec Support.
1 23 4 5
000060
NOTE
The code determines which service menu is activated (Service, Diagnostic test, Initiation or Calibration). 4 Select group by scrolling with the arrow keys (1 and 2) and confirm with Enter. Each calibration consists of a sequence of a number of menus. The first menu for the selected calibration opens in the display. Select the next menu with key 1 and 2 (arrow function).
000062
VDCT01.02GB
8:114
8.5.2.3 Calibrate DRIVE-TRAIN Accelerator pedal, calibration

1 Start key in operating position, engine switched off.
DRIVE-TRAIN, menu 1
005532
CALIBR DRIVE-TRN 1(X) ACCELERATOR, RELEASE THE PEDAL STORED VALUE X.XXV PRESENT VALUE X.XXV
Go into the calibration menus and select DRIVE-TRAIN, menu 1, see Calibration, work instructions, page 8:113. ACCELERATOR, RELEASE THE PEDAL 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 4
Release the accelerator pedal. Store the position with function key for Enter.
DRIVE-TRAIN, menu 2
CALIBR DRIVE-TRN 2(X) ACCELERATOR, PRESS THE PEDAL TO FLOOR STORED VALUE X.XXV PRESENT VALUE X.XXV
00
ACCELERATOR, PRESS THE PEDAL TO FLOOR Description: Setting of full-throttle position for Accelerator pedal (B690-1). 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).
6 7
Press the accelerator pedal down fully and keep it down until the position is stored. Store the position with function key for Enter.
VDCT01.02GB
9:1
9 Frame, body, cab and accessories
Contents 9 Frame, body, cab and accessories

9 Frame, body, cab and accessories ...................................................................9:3 9.1 Controls and instruments .................................................................................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
VDCT01.02GB
9:2
9.6.8 9.6.9 9.6.10 9.6.11 9.6.12 9.6.14 9.7 9.7.1 9.7.2 9.7.3 9.7.4 9.7.5 9.8 9.9 9.9.1 9.9.2 9.9.3 9.9.4 9.9.5 9.10 9.10.1 9.10.2 9.10.3 9.11 9.11.1 9.11.2 9.11.3 9.11.4 9.11.5 9.11.7 9.11.8 9.11.9 9.12 9.13 9.13.1 9.13.2 9.13.3 9.13.4 9.14 9.14.1 9.14.2 9.14.3 9.15
Revolving beacon......................................................................................9:64 Working lights, mast ..................................................................................9:64 Working lights, cab ....................................................................................9:66 Interior lighting...........................................................................................9:66 Working lights, attachment ........................................................................9:67 Work lights, front wing ...............................................................................9:67 Signalling system ...........................................................................................9:68 Horn ..........................................................................................................9:70 Flashing hazard lights ...............................................................................9:70 Revolving beacon......................................................................................9:71 Warning parking brake ..............................................................................9:71 Back-up alarm ...........................................................................................9:71 Entertainment and communication ................................................................9:72 Glass/windows/mirrors...................................................................................9:73 Windscreen ...............................................................................................9:74 Side window ..............................................................................................9:76 Roof window..............................................................................................9:79 Rear window .............................................................................................9:79 Rear view mirror ........................................................................................9:79 Cab structure and suspension .......................................................................9:80 Cab frame .................................................................................................9:80 Doors.........................................................................................................9:80 Cab substructure .......................................................................................9:80 Cab interior ....................................................................................................9:81 Instrument and control panels ...................................................................9:81 Interior fittings, plastic ...............................................................................9:82 Interior fittings, textile ................................................................................9:82 Floor covering ...........................................................................................9:82 Insulation ...................................................................................................9:82 Terminal console .......................................................................................9:83 Writing desk...............................................................................................9:83 Reading-lamp ............................................................................................9:83 Chassis ..........................................................................................................9:84 Body structure................................................................................................9:85 Wings ........................................................................................................9:85 Hood engine compartment ........................................................................9:85 Footsteps and hand rail.............................................................................9:85 Counterweights .........................................................................................9:86 Central lubrication ..........................................................................................9:87 Pump unit ..................................................................................................9:89 Distribution block .......................................................................................9:90 Lines..........................................................................................................9:90 Paint/coatings ................................................................................................9:91
VDCT01.02GB
9 Frame, body, cab and accessories Frame, body, cab and accessories
9:3

Controls and instruments, overview
Overview
Overview
15
12 14
13
12
11
10
6
015102
1. 2. 3. 4. 5. 6. 7. 8. 9.
Left instrument panel Gear selector and multi-function lever (S162) Steering wheel panel Steering wheel Switch direction indicators (S161) Panel for hydraulic functions Emergency stop switch for hydraulics (S250) Switch for parking brake (S107) 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)
VDCT01.02GB
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)
24..28 19..23 18
29 30 31 18. Switch for air distribution (S139)

19. Switch for working lights cab roof (S105-1) 20. Switch, work lights on carriage and attachment (S105-2) Auxiliary work lights, carriage and attachment
010907
17 16
Left instrument panel
21. Switch for work lights on mast (S105-3) Auxiliary work lights, mast 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
VDCT01.02GB
9:5
Steering wheel panel
32
33
34
35
36

32. Warning lamp, low battery charging 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. Warning lamp, high coolant temperature 38. Warning light, low oil pressure engine 39. Indicator light for preheating
37..41 42..46 47 48
49
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 63 62 61
54 55 56 60 59 58 57
008132
52. Control system indicator 53. Ignition 54. Switch for defroster 55. Switch, windscreen wiper roof, interval 56. Switch, windscreen wiper roof, continuous 57. Switch, interior lighting 58. Switch, windscreen wiper rear, interval 59. Switch, windscreen wiper rear, continuous 60. Control system function keys 61. Travel direction indicator, Forward Neutral Reverse 62. Shifting program A, automatic shifting 63. Shifting program 1, locked to 1st gear 64. Shifting program 2, locked to 2nd gear
VDCT01.02GB
9:6
Panel for hydraulic functions
Panel for hydraulic functions
$&
65. Lift/lower (R8071)
% 67. Side shift (R8073) % %" %" %!
66. Tilt (R8072)
68. Opening the twistlocks (S1002) 69. Switch, horn (S149) 70. Switch for twistlock, automatic/manual locking (S1003) 71. Switch, spreading 20'-40' (attachment) (S1012) 72. Switch for stopping spreading at 30' (attachment) (S1004) 73. Switch, automatic spreading 20'-40' (S1012-2) 74. Switch for bypassing of hydraulic functions (S1005) Key for bypassing hydraulic functions
&
$'
Panel for hydraulic functions and control lever
$# $& $' % % % $$ $% %
%! & %" %"

"%&
Panel for hydraulic functions and linear control levers
VDCT01.02GB
"%'
9:7
Operating menus, overview
10
11
1. 2. 3. 4. 5. 6. 7. Engine and transmission operating menu Engine operating menu Operating menu for oil temperature Operating menu electrical system Operating menu, container counter Operating menu service interval Operating menu statistics
12
8. 9.
13
Service operating menu
14
Operating menu heating and air conditioning
10. Operating menu, code lock 11. Operating menu statistics, operating hours 12. Operating menu statistics, fuel consumption 13. Operating menu statistics, driving distance 14. Operating menu statistics, lift statistics
Event menus overview
Event menus overview

Side lift attachment with twistlocks
1. 2. 3. 4.
Event menu, twistlock alignment Event menu twistlocks Event menu open door Event menu automatic spreading
VDCT01.02GB
014669
014668
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
2 3
1 0
The following functions are handled by the gear and multi-function lever (position 2).
Movement
Forward/Reverse Inward, handle
Function
Travel direction (for selecting shifting program and travel direction, see section 2 Transmission). Washing of windscreen, roof window and rear window. The signal can be checked via the diagnostic menu. see section 8 Control system, group 8.4.3.1 CAB, menu 1 Windscreen wiper, front. 0 No wiping of front window. If wiper rear or roof are active then these run at slow interval wiping. 1 Slow interval wiping front window, controls slow interval wiping for roof window and rear window. 2 Fast interval wiping front window, controls fast interval wiping for roof window and rear window. 3 - Continuous wiping of front window. If wiper rear or roof are active then these run at fast interval wiping. The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.3.2 CAB, menu 2.
000338
Rotation
Upward Downward
Light signal High beam (on/off) With headlights on: The gear selector multi-function lever are used for switching between high and low beam.
000339
With headlights off: The gear selector and multi-function lever are used to flash with the headlights. The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.2.3 LIGHTS, menu 3. Inward, button Horn (position A). The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.3.5 CAB, menu 5.
VDCT01.02GB
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, replacement, page 9:81. 2 3 4 Undo the attaching bolts (2 x hexagonal socket bolts). Unplug the connector from Control unit KIT (D790-2). Fit a new lever and refit the steering wheel panel.
9.1.22 Switch, direction indicators

Switch, direction indicators, replacement
1 2 Machine in service position, see section B Safety. Remove the steering wheel and separate the steering wheel panel.
3 4 5
Detach the cable harness from the direction indicator. Press together the clips on the direction indicator and detach it from the steering wheel panel. Replace the direction indicator, fitting it in the reverse order.
VDCT01.02GB
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.
VDCT01.02GB
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 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
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.
$
"#
# "
1. 2. 3. 4. 5. 6. 7. Head rest Adjusting arm rest, right Back rest rake adjustment Display of weight setting Seat height adjustment Seat cushion angle adjustment Front/rear adjustment
VDCT01.02GB
9:12
Seat, description (product alternative BE-GE 9200)
2 3
The seat's function is to provide the operator with a good sitting position and contribute to a good work environment. The cab's seat has several adjustment options and fulfils high comfort standards. The seat has the following equipment: mechanical height adjustment arm rest right two-point seat belt seat heating head rest armrest left
5
006825
8 7
Controls 1. 2. 3. 4. 5. 6. 7. 8. Adjusting lumbar support Adjusting arm rest, right Adjusting arm rest, left Back rest rake adjustment Adjusting suspension position Seat cushion angle adjustment Seat height adjustment Front/rear adjustment
The seat is equipped with a sensor that senses the spring deflection of the seat. This is used to activate the buzzer if the operator leaves the seat without applying the parking brake as well as without putting the transmission in neutral position if leaving the seat.
VDCT01.02GB
9:13
Seat, description (product alternative BE-GE 9200 air suspension)
2 3
The seat's function is to provide the operator with a good sitting position and contribute to a good work environment. The cab's seat has several adjustment options and fulfils high comfort standards. The air suspension automatically adjusts seat height and suspension 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:
air suspension (with external compressor) arm rest right three-point seat belt seat heating armrest left head rest
5
006826
8 7
Controls BE-GE 9200 1. 2. 3. 4. 5. 6. 7. 8. Adjusting lumbar support Adjusting arm rest, right Adjusting arm rest, left Back rest rake adjustment Adjusting suspension position Seat cushion angle adjustment Seat height adjustment Front/rear adjustment
The seat is equipped with a sensor that senses the spring deflection of the seat. This is used to activate the buzzer if the operator leaves the seat without applying the parking brake as well as without putting the transmission in neutral position if leaving the seat.
Seat, replacement (product alternative BE-GE 9200)

1 2 Machine in service position, see section B Safety. Slide back the seat to its rear position, remove the front attaching bolts.
VDCT01.02GB
9:14
9 Frame, body, cab and accessories Seat cushion
3 4 5 6
Slide the seat to its front position, remove the rear attaching bolts. Disconnect the seat's connectors from the machine's cabling. Remove the seat. Fit in the reverse order.
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)

1 2 3 Machine in service position, see section B Safety. Loosen the rubber bellows by removing the plastic clips. Unhook the upholstery's rails from the seat frame and remove the upholstery. Remove the padding. If the seat is equipped with seat heater. Unplug the connector for the heating coil before the padding is removed.
5 4
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.
Assemble in reverse order.
1
006276
1. 2. 3. 4. 5.
Plastic clip, rubber bellows Upholstery Seat frame Padding Heating coil
VDCT01.02GB
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)

1 2 Machine in service position, see section B Safety. 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. 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. 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.
3 4
Position the back rest on the seat and fit the attaching bolts, do not tighten them. Then fit the attaching bolts for the seat belt. Tighten the attaching bolts for the seatbelt with a torque of 42 Nm, then tighten the attaching bolts with a torque of 33 Nm.
If the seat is equipped with 3-point seat belt or arm rest. Cut holes in the upholstery for seat belt and arm rest on the new back rest before arm rest or seat belt is installed.
6
8
Fit in the reverse order.
1
1. 2. 3. 4. 5. 6. Attaching bolt back rest Attaching bolt, seat belt Cover, belt guide Attaching bolt, belt guide Arm rest Attaching bolt, arm rest
006278
VDCT01.02GB
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)

1 Machine in service position, see section B Safety. Remove the driver's seat from the frame and lift it out of the machine. See Seat, replacement (product alternative BE-GE 9200), page 9:13. Remove the seat cushion, see Seat cushion, replacement (product alternative BE-GE), page 9:14. Remove the back rest cushion, see Back rest cushion, replacement (product alternative BE-GE), page 9:15. Remove the shock absorber's attaching bolts. Replace the shock absorber. Assemble in reverse order. 2
3 4
1
5 6
006277
3
1. 2. 3. Bumper Attaching bolt Attaching bolt
VDCT01.02GB
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
Compressor air-suspension seat
For location, see Seat, description (product alternative BE-GE 9200 air suspension), page 9:13.
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.
Compressor air-suspension seat
001621
VDCT01.02GB
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.
Passenger seat with bracket
001627
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.
VDCT01.02GB
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 Bang)
DANGER
Sensor, operator-in-seat (S230) is supplied with voltage by and sends a voltage signal to Control unit, cab (D790-1). The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.3.6 CAB, menu 6.
VDCT01.02GB
9:20
9 Frame, body, cab and accessories Sensor, operator-in-seat
Sensor, operator-in-seat, description (product alternative BE-GE)
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 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. 2. Sensor, operator-in-seat, (S230) (product alternative BE-GE) Buzzer (H853)
Sensor, operator-in-seat (S230) is supplied with voltage by and sends a voltage signal to Control unit, cab (D790-1). The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.3.6 CAB, menu 6.
VDCT01.02GB
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
cab can also be equipped with air conditioning (
).
2 4 D C E 3 E
The temperature in the cab is thermostat-controlled by Control unit, cab (D790-1). The cab temperature is regulated to the set temperature. The temperature can be set between 16 and 28 C. The unit is operated with controls on the dashboard panel.
Heating system (EHC)

The heating system (EHC) handles heating and ventilation. (The heating system cannot provide cooling.) The heating system uses heat from the engine's cooling system via a heating coil to heat the ambient air. The fan forces the ambient air through the heating coil on through ducts in the cab interior. It is then directed to the windscreen (defroster) or the feet.
Air conditioning (ECC)
B
The climate control system (ECC) is responsible for heating, ventilation, cooling and dehumidifying. The air is heated in the same way as for the heating system (EHC). During cooling, ambient air is forced through the evaporator, which cools the air. The air can then be directed in the same way as for the heating system.
000762
The function of the air conditioning is to: heat the air when it is cold dehumidify the air when it is damp clean the air of impurities cool the air when it is hot defrost (defroster function)
Outline view, air conditioning 1. 2. 3. 4. 5. 6. A B C D E F G Fluid reservoir/filter dryer with integrated pressure switch Heating coil and evaporator Fan Expansion valve Condenser Compressor High-pressure gas High-pressure fluid Low-pressure fluid Low-pressure gas Outdoor air for cab ventilation Heated or cooled air to the cab Outdoor air for eliminating heat
IMPORTANT
On machines with ECC or AC, it is vital that the engine cooling system is refilled with coolant with the correct concentration of antifreeze. Otherwise there is a risk that the air conditioning system will freeze during usage.
VDCT01.02GB
9:22
Heating, ventilation and air conditioning, function description
2 D
1 D
3 25
26
4 6
C C
D D 7 D790-1 D790-2 D795
D D
D 15 D
D797-1 16 D794 12 D 22
Pa
M
5
C
D 14
23
C
M
13 D
D 19 18 17 20 C
21
24
M
D
M
C
11
007690
10
Pos
1
Explanation
Switch, temperature (S117) sends a voltage signal to Control unit, cab (D790-1).
Signal description
Raise: U = 2.02.5 V Unaffected: U = 0-0.5 V Lower: U = 4.5-5.0 V
Reference
Controls and instruments, overview, page 9:3 D1: Diagnostic menu, see section 8 Control system, group 8.4.4.5, CLIMATE menu 5 Controls and instruments, overview, page 9:3 D2: Diagnostic menu, see section 8 Control system, group 8.4.4.5, CLIMATE menu 5 Controls and instruments, overview, page 9:3 D3: Diagnostic menu, see section 8 Control system, group 8.4.4.5, CLIMATE menu 5 Sensor, cab temperature, description, page 9:53 D4: Diagnostic menu, see section 8 Control system, group 8.4.4.1, CLIMATE menu 1
Switch, fan (S118) sends a voltage signal to Control unit, cab (D790-1).
Raise: U = 2.02.5 V Unaffected: U = 0-0.5 V Lower: U = 4.5-5.0 V
Switch, air distribution (S139) sends a voltage signal to Control unit, cab (D790-1).
Scroll up: U = 2.02.5 V Unaffected: U = 0 V Scroll down: U = 4.5-5.0 V
Sensor, cab temperature (B775-1) sends a voltage signal proportional to the temperature to Control unit, cab (D790-1).
R = 10 k at 25 C
VDCT01.02GB
9:23
Pos
5
Explanation
The outlet fan temperature sensor (B775-2) sends the cab control unit (D790-1) a voltage signal proportional to temperature. Sensor, ambient temperature (B774) sends a voltage signal proportional to the temperature to Control unit, cab (D790-1). Control unit, cab (D790-1) regulates temperature and air distribution with signals from sensors and controls. 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. Control unit, cab (D790-1) controls Water valve (Y673), which routes hot water for heat exchanger heat. The water valve's opening (%) is fed back to the Control unit, cab (D790-1). This gives information for controlling the water valve's position.
Signal description
R = 10 k at 25 C
Reference
Sensor, temperature outlet fan, description, page 9:52 D5: Diagnostic menu, see section 8 Control system, group 8.4.4.2, CLIMATE menu 2
R = 10 k at 25 C
Sensor, ambient temperature, description, page 9:54 D6: Diagnostic menu, see section 8 Control system, group 8.4.4.2, CLIMATE menu 2
Section 11 Common electrics, group 11.5.3.1 Control unit, cab -
U = 0.5-4.5 V
Water valve, description, page 9:38 D9: Diagnostic menu, see section 8 Control system, group 8.4.4.7 CLIMATE, menu 7 and 8.4.4.4 CLIMATE, menu 4
10
Sensor, engine temperature, sends a voltage signal proportional to the engine temperature to Control unit, engine (D794).
Section 1 Engine D10: Diagnostic menu, see section 8 Control system, group 8.4.4.2, CLIMATE menu 2
11
Heat exchanger heat supplies heat to the cab air. The heat is transferred from the engine's cooling system to the cab air. Control unit, engine (D794) transmits engine temperature in the cooling system on the CAN bus. Control unit, cab (D790-1) controls Actuator motor, recirculation (M612) which sets the fresh air or recirculation damper in the required position. Control unit, cab (D790-1) controls Fan motor (M657), which increases the airflow in the cab. Control unit, cab (D790-1) controls Damper motor (Y672), which sets the air distributor to the required position. The air distributor's position is fed back to Control unit, cab (D790-1). This gives information for controlling the air distributor's position.
Heat exchanger heat, description, page 9:35
12
Checked by control system, error shown with error code. Checked by control system, error shown with error code.
Section 11 Common electrics, group 11.5.3.10 Control unit, engine Fresh air filter or recirculation damper, description, page 9:29 D13: Diagnostic menu, see section 8 Control system, group 8.4.4.6, CLIMATE menu 6 D14: Diagnostic menu, see section 8 Control system, group 8.4.4.6, CLIMATE menu 6 Air distributor, description, page 9:50 D15: Diagnostic menu, see section 8 Control system, group 8.4.4.8 CLIMATE, menu 8 and 8.4.4.4 CLIMATE, menu 4
13
14
Checked by control system, error shown with error code. U = 0.5-4.5 V
15
16
The frame control unit (D797-1) controls AC compressor connection.
Section 11 Common electrics, group 11.5.3.3 Frame control unit
VDCT01.02GB
9:24
Pos
17
Explanation
The frame control unit (D797-1) supplies voltage to the compressor's solenoid valve (645).
Signal description
U = 24 V
Reference
Compressor, description (engine alternative Cummins QSB6.7 ), page 9:39 D17: Diagnostic menu, see section 8 Control system, group 8.4.4.6, CLIMATE menu 6
18
The compressor draws gaseous refrigerant from the evaporator, compresses it, and forces it on to the condenser. The condenser cools the refrigerant. The gaseous refrigerant condenses to liquid form and is pumped on in the circuit. The moisture filter absorbs any moisture from the cooling circuit. The fluid reservoir stores the refrigerant. The pressure switch (S246) sends a signal to the frame control unit (D797-1) if the pressure in the system becomes abnormally high or low. The expansion valve adjusts the 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. Sensor, refrigerant circuit temperature, sends a voltage signal proportional to the temperature to Control unit, cab (D790-1). Heat exchanger, cooling, dissipates heat from the cab air. The heat is transferred from the air to the refrigerant and transforms the refrigerant to a gaseous state. The defroster switch on Control unit KIT (D790-2) activates the defroster program for the air conditioning for six minutes. Control unit KID (D795) shows the heating and ventilation settings in the display.
Compressor, description (engine alternative Cummins QSB6.7 ), page 9:39
19
Condenser, description, page 9:43
20
Moisture filter, description, page 9:45
21
U = 24 V
Pressure switch, description, page 9:45 D21: Diagnostic menu, see section 8 Control system, group 8.4.4.3, CLIMATE menu 3
22
Expansion valve, description, page 9:46
23
R = 10 k at 25 C
Sensor, temperature refrigerant, description, page 9:48 D23: Diagnostic menu, see section 8 Control system, group 8.4.4.2, CLIMATE menu 2.
24
Heat exchanger, cooling, description, page 9:49
25
Checked by control system, error shown with error code. Checked by control system, error shown with error code.
Section 11 Common electrics, group 11.5.3.11 Control unit, KIT Section 11 Common electrics, group 11.5.3.12 Control unit, KID
26
VDCT01.02GB
9:25
Heating, ventilation and air conditioning, checking

1 2 Machine in service position, see section B Safety. Navigate to the service menu and press Enter.
000056
Enter the code for diagnostics. Code is obtained from Cargotec Support.
1 23 4 5
000060
NOTE
The code determines which service menu is activated (Service, Diagnostic test, Initiation or Calibration). 4 Select CLIMATE.
004998
Menu 1
000132
DIAG CLIMATE 1(8) PRESENT INPUT SIGNAL REQUIRED TEMP XXX PRESENT TEMP XXX WATER VALVE FEEDB. XXX
Checking the desired temperature, inside temperature sensor and water valve. REQUIRED TEMP: should be 160 (16.0 C) for max. cooling and 280 (28.0 C) for max. heating. The setting is changed with the 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
000133
2(8) XXX XXX XXX XXX
Check of Sensor, temperature outlet fan (B775-2), engine temperature, Sensor, outdoor temperature (B774), and check of Sensor, temperature refrigerant (B775-1). TEMP COIL: temperature that the air has in the air distributor is 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.
VDCT01.02GB
9:26
Menu 3
006865
DIAG CLIMATE 3(X) PRESENT INPUT SIGNAL PRESSURE SWITCH X OPT DOOR SWITCH X
(Only machines with ECC) Checks that the refrigerant circuit is filled. 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
000135
DIAG CLIMATE 4(8) PRESENT INPUT SIGNAL WATER VALVE XX.XXV DRAUGHT VALVE XX.XXV
Checks Water valve (Y673) and Air distributor (Y642). WATER VALVE: should work between 1.0-1.24 V and 2.95-3.2 V. This is checked by turning the temperature control and changing 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
000136
DIAG CLIMATE 5(8) PRESENT INPUT SIGNAL REQUIRED TEMP XX.XXV REQ. DRAUGHT XX.XXV REQ. FAN SPEED XX.XXV
Checks the switches for temperature, air distribution and fan speed. REQUIRED TEMP: home position U = 0 V; raise U = 2-2.5 V; lower U = 4.5-5 V. 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
000137
DIAG CLIMATE 6(8) PRESENT OUTPUT SIGNAL FAN SPEED XXX RECIRKULATION XY COMPRESSOR XY
10 Checks Cab fan (M657), Fresh air and recirculation damper (M612) and Electromagnetic clutch, compressor (M645) . FAN SPEED: increase and decrease fan speed, value should 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.
VDCT01.02GB
9:27
Menu 7
DIAG CLIMATE 7(8) OUTPUT WATER VALVE CLOCKWISE XY XY ANTI-CLOCKWISE XY XY
11 Checks the direction selector for Water valve (Y673). CLOCKWISE: when the temperature is increased and the water 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 "ANTI-CLOCKWISE 11 11".
24V
NOTE
M
The "ones" are only shown for a moment when the water valve changes position, "zeros" are shown when the valve does not change position. The water valve does not open if the engine temperature is low, or if the outdoor temperature is high.
0V
000138
Menu 8
DIAG CLIMATE 8(8) OUTPUT DRAUGHT VALVE CLOCKWISE XY XY ANTI-CLOCKWISE XY XY
12 Checks the direction selector for the air distributor. CLOCKWISE: when the air is directed against the windscreen and 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" and "ANTI-CLOCKWISE 00 11".
24V
NOTE
M
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.
0V
000139
VDCT01.02GB
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.
2
004999
1
Fresh air intake, cab 1. 2. Fresh air filter Fresh air and recirculation damper
VDCT01.02GB
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
Fresh air intake, cab 1. 2. Fresh air filter Fresh air and recirculation damper
VDCT01.02GB
9:30
Motor, fresh air filter or recirculation damper, replacement

1 2 Machine in service position, see section B Safety. Remove the wiper arms.
3 4
Remove the nuts which hold the wiper motor in the protective plate. Remove the protective plate.
Remove the fresh air filter.
VDCT01.02GB
9:31
6 7 8 9
Remove the bolts which secure the arm and motor in the plate. Detach the connector from the motor. Replace the motor. Fit in the reverse order. Tighten the wiper arm to torque 16-20 Nm.
VDCT01.02GB
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. The signal can be checked via the diagnostic menu, section 8 Control system, group 8.4.4.6 CLIMATE, menu 6.
Fresh air intake, cab 1. Cabin fan
003209
Cab fan, replacement

1 2 Machine in service position, see section B Safety. Remove the wiper arms.
VDCT01.02GB
9:33
3 4
Remove the bolts which hold the wiper motor in the protective plate. Remove the protective plate.
Detach the washer hose from the protective plate.
VDCT01.02GB
9:34
Remove the bolts which secure the plate and cab fan.
8 9
Detach the connector from the cab fan. Remove the cab fan.
10 Replace the cab fan. 11 Fit in the reverse order. Tighten the wiper arm to torque 16-20 Nm.
VDCT01.02GB
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
Fresh air intake, cab 1. 2. 3. Heat exchanger heat Heat exchanger, cooling Expansion valve and sensor for refrigerant temperature
003210
Heat exchanger, cooling/heating, replacement
WARNING
Personal injury, environmental damage. Read the safety instructions for refrigerant, see section B Safety.
1 Machine in service position, see section B Safety.
VDCT01.02GB
9:36
Drain the AC system of R134a refrigerant.
IMPORTANT
Working on the air conditioning requires special authorisation.
3 4 5 6 Detach the AC system hoses and the coolant hoses. Remove the wiper arms. Remove the nuts which hold the wiper motor in the protective plate. Remove the protective plate.
Detach the washer hose from the protective plate.
VDCT01.02GB
9:37
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.
VDCT01.02GB
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.
Water valve position under cab floor (from below)
010021
Water valve, replacement

1 2 3 4 5 6 7 8 9 Machine in service position, see section B Safety. Detach the connector from the water valve. Stop the flow of fluid to and from the water valve using hose pinch-off pliers. Detach the coolant hoses from the water valve. Remove the water valve from the cab floor. Replace the water valve. Fit in the reverse order. Check the coolant level. Run the heating system at the highest setting (fully open valve) to vent air from the system.
1. 2.
Water valve 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. The signal can be checked via the diagnostic menu, section 8 Control system, group 8.4.4.2 CLIMATE, menu 2. For location, see section 1 Engine.
VDCT01.02GB
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.
The signal can be checked via the diagnostic menu, section 8 Control system, group 8.4.4.6 CLIMATE, menu 6.
2
015087
1. 2. 3.
Compressor Belt tensioner 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 5
1. 2. 3. 4. 5. Rigging screw (belt tensioner) Compressor Connections Screw and nut Drive belt
009116
VDCT01.02GB
9:40
Compressor, changing (engine alternative Yuchai YC6A240-30)
WARNING
NOTE
For tightening torque of refrigerant hoses and pressure switch, see section F Technical data. 1 2 Machine in service position, see section B Safety. Drain the AC system of R134a refrigerant.
IMPORTANT
3 4 5 Detach the coolant hoses from the compressor. Loosen the belt tensioner so that the drive belt is released. Undo the hose couplings and detach the hoses from the compressor intake and outlet. Plug the connections immediately to prevent contamination. Remove the bolts which secure the compressor. Drain the oil from the old compressor (through the intake and outlet connections) and the hoses. Measure the oil quantity. Drain the oil from the new compressor. Fill the new compressor with the same quantity of oil as was drained from the old compressor - minimum 0.1 litre.
6 7
8 9
10 Fit the new compressor and other equipment in reverse order.
2
015087
11 Check for leaks and refill the AC-system with refrigerant R134a, using the intended equipment. For volume, see the plate for the climate control system.
1. 2. 3.
Compressor Belt tensioner Drive belt
IMPORTANT
NOTE
Fill new oil through the compressor's suction connection.
VDCT01.02GB
9:41
Compressor, replacement (engine alternative Cummins QSB6.7 )
WARNING
NOTE
IMPORTANT
3 4 5 Detach the coolant hoses from the compressor. Loosen the turnbuckle so that the compressor belt is released. Undo the hose couplings and detach the hoses from the compressor intake and outlet. Plug the connections immediately to prevent contamination. Remove the bolts which secure the compressor. Drain the oil from the old compressor (through the intake and outlet connections) and the hoses. Measure the oil quantity. Drain the oil from the new compressor. Fill the new compressor with the same quantity of oil as was drained from the old compressor - minimum 0.1 litre.
6 7 8
009116
4 5
1. 2. 3. 4. 5. Rigging screw (belt tensioner) Compressor Connections Screw and nut Drive belt
10 Fit the new compressor and other equipment in reverse order. 11 Check for leaks and refill the AC-system with refrigerant R134a, using the intended equipment. For volume, see the plate for the climate control system.
IMPORTANT
NOTE
Fill new oil through the compressor's suction connection.
VDCT01.02GB
9:42
Pulley and electromagnetic clutch, replacement

There is no need to drain refrigerant from the system before replacement. 1 Machine in service position, see section B Safety. 2 3 Slacken the belt tensioner and remove the drive belt. Remove the screw from the centre of the pulley.
006263
Remove the locking washer and the outer lock ring.
1. 2.
Lock ring Locking washer 5 Remove the groove.
1.
Groove
VDCT01.02GB
006265
006264
9 Frame, body, cab and accessories Condenser
9:43
Remove the three screws securing the electromagnetic clutch.
006266
7 8
Remove the clutch coil Fit in the reverse order. Check the function.
1.
Electromagnetic clutch
006267
9.4.8 Condenser
Condenser, description
1 2 4 3
The condenser is located on the radiator in the engine compartment. The function of the condenser is to convert the hot, high-pressure gas from the compressor to liquid form. Pipes and cooling fins in the condenser battery absorb the heat, which is dissipated with a fan. The temperature of the refrigerant in the condenser varies from approx. 50 C to 70 C and the pressure varies between 12 and 14 bar, depending on ambient temperature and airflow through the condenser. When the refrigerant has been condensed to liquid, it is directed on to the fluid reservoir/filter dryer.
1. 2. 3. 4.
Intercooler Transmission oil cooler Radiator Condenser
014686
VDCT01.02GB
9:44
9 Frame, body, cab and accessories Condenser
Condenser, replacement
WARNING
NOTE
1 2 4 3
3 4 5 6
014686
IMPORTANT
Detach the inlet and outlet hoses from the condenser. Remove the bolts which secure the condenser at the top edge and lift the condenser out in a suitable way. Replace the condenser, fitting it in the reverse order. Check for leaks and refill the AC-system with refrigerant R134a, using the intended equipment. For volume, see section F Technical data.
1. 2. 3. 4.
Intercooler Transmission oil cooler Radiator Condenser
IMPORTANT
VDCT01.02GB
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. 2. 3.
Moisture filter Pressure switch Sight glass
9.4.10 Pressure switch

Pressure switch, description
NOTE
For tightening torque of refrigerant hoses and pressure switch, see section F Technical data. 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. The signal can be checked via the diagnostic menu, section 8 Control system, group 8.4.4.3 CLIMATE, menu 3. 1. 2. 3. Moisture filter Pressure switch Sight glass
VDCT01.02GB
9:46
9 Frame, body, cab and accessories Expansion valve
Pressure switch, replacement
WARNING
1 2 Machine in service position, see section B Safety. Drain the machine of refrigerant, R134a.
IMPORTANT
3 4 5 1. 2. 3. Moisture filter Pressure switch Sight glass 6 Detach the connector from the pressure switch. Unscrew the pressure switch from its mounting. Replace the pressure switch. Check for leaks and refill the AC-system with refrigerant R134a, using the intended equipment. For volume, see section F Technical data.
IMPORTANT
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.
VDCT01.02GB
9 Frame, body, cab and accessories Expansion valve
9:47
Expansion valve, replacement
WARNING
1 2 Machine in service position, see section B Safety. Drain the AC system of refrigerant.
IMPORTANT
3 4 5 Detach the AC system hoses. Detach the coolant hoses. Remove the heat exchanger for cooling/heating to access the expansion valve, see Heat exchanger, cooling/heating, replacement, page 9:35. Replace the expansion valve. Fit in the reverse order. Check for leaks and refill the AC-system with refrigerant R134a, using the intended equipment. For volume, see section F Technical data.
6 7 8
IMPORTANT
VDCT01.02GB
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 3 2
1. 2. 3. Sensor cab temperature Sensor temperature refrigerant Sensor, temperature outlet fan
005001
Sensor, temperature refrigerant, replacement
WARNING
1 2 Machine in service position, see section B Safety. Drain the AC system of refrigerant.
IMPORTANT
3 4 5 Detach the AC system hoses from the heat exchanger. Detach the coolant hoses from the heat exchanger. Detach the heat exchanger to access the refrigerant temperature sensor, see Heat exchanger, cooling/heating, replacement, page 9:35. Replace the temperature sensor. Fit in the reverse order.
6 7
VDCT01.02GB
9 Frame, body, cab and accessories Heat exchanger, cooling
9:49
Check for leaks and refill the AC-system with refrigerant R134a, using the intended equipment. For volume, see section F Technical data.
IMPORTANT
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
Fresh air intake, cab 1. 2. 3. Heat exchanger heat Heat exchanger, cooling Expansion valve and sensor for refrigerant temperature
003210
Heat exchanger, cooling, replacement

See Heat exchanger, cooling/heating, replacement, page 9:35. Workshop Manual DCT 80-90
VDCT01.02GB
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

1 2 3 4 5 6 Machine in service position, see section B Safety. Remove the dashboard panel. Remove the steering wheel shaft cover. Detach the steering wheel shaft and angle it back against the driver's seat. Remove the lower cover in front of the pedal assembly. Detach the air hoses from the air distributor and detach the connector.
1. 2. 3.
Instrument panel Steering column adjustment Lower protective cover 7 8 Remove the air distributor from its mounting. Replace the air distributor, fitting it in the reverse order.
Air distributor
VDCT01.02GB
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

1 2 3 Machine in service position, see section B Safety. Remove the air damper manually. Remove the bolts which hold the other part of the defroster nozzle in the dashboard.
4 5
Detach the air hose from the defroster nozzle. Replace the defroster nozzle.
VDCT01.02GB
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. 2. 3. Sensor cab temperature Sensor temperature refrigerant Sensor, temperature outlet fan
1 3 2
005001
Sensor, temperature outlet fan, replacement

1 2 3 4 Machine in service position, see section B Safety. Remove the dashboard panel. Remove the lower protective cover in front of the steering wheel shaft. Detach the steering wheel shaft and angle it back against the driver's seat.
1. 2. 3.
Instrument panel Steering column adjustment Lower protective cover 5 6 Detach the temperature sensor from the air distributor. Fit in the reverse order.
Air distributor including temperature sensor.
VDCT01.02GB
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. The signal can be checked via the diagnostic menu, section 8 Control system, group 8.4.4.1 CLIMATE, menu 1.
1 3 2
1. 2. 3. Sensor cab temperature Sensor temperature refrigerant Sensor, temperature outlet fan
005001
Sensor, cab temperature, replacement

1 2 Machine in service position, see section B Safety. Remove the dashboard panel.
3 4 5 6 7
Detach the hose from the temperature sensor. Detach the connector from the temperature sensor. Remove the temperature sensor. Replace the temperature sensor. Fit in the reverse order.
007985
VDCT01.02GB
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. The signal can be checked via the diagnostic menu, section 8 Control system, group 8.4.4.2 CLIMATE, menu 2.
Sensor, ambient temperature
Sensor, ambient temperature, replacement

1 2 3 4 5 Machine in service position, see section B Safety. Detach the connector from the temperature sensor. Remove the temperature sensor from its mounting in the cab. Replace the temperature sensor. Fit in the reverse order.
VDCT01.02GB
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. The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.3.1 CAB, menu 1.
VDCT01.02GB
9:56
9 Frame, body, cab and accessories Wiper motor front
Washer motor and reservoir, replacement

1 2 3 4 5 6 Machine in service position, see section B Safety. Remove the protection over the washer fluid reservoir. Drain the washer fluid from the fluid reservoir. Remove the washer motors from the fluid reservoir. Remove the bolts which secure the fluid reservoir in the cab wall. Replace the washer fluid reservoir. Replace the washer motor, if necessary.
A
A B
Washer fluid reservoir without protective plate. Washer fluid reservoir Washer motors
003619
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. The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.3.2 CAB, menu 2
Wiper motor front, replacement

1 2 3 4 5 Machine in service position, see section B Safety. Remove the wiper arms. Remove the nuts which hold the motor in the protective plate. Remove the protective plate. Detach the washer hose from the protective plate.
6 7 8 9
Remove the nuts which hold the motor in the cab. Detach the connector from the wiper motor. Replace the motor. Fit in the reverse order. Tighten the wiper arms to torque 16-20 Nm.
VDCT01.02GB
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 mounted on the motor. The motor produces the movement of the wiper. The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.3.4 CAB, menu 4.
Wiper motor roof, replacement

1 2 Machine in service position, see section B Safety. Remove the plastic cover.
Detach the washer hose and the connector to the wiper motor.
4 5 6
Undo the lock nut securing the wiper arm and disconnect the washer fluid hose. Remove and replace the wiper motor. Fit in the reverse order. Tighten the wiper arm to torque 16-20 Nm.
VDCT01.02GB
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 mounted on the motor. The motor produces the movement of the wiper. The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.3.3 CAB, menu 3.
Wiper motor rear, replacement

1 2 3 Machine in service position, see section B Safety. Remove the panels behind the driver's seat. Remove the screws holding the motor's plastic cover.
4 5
Detach the connector to the motor. Raise the plastic cover and remove the nut securing the wiper arm. Detach the washer fluid hose.
6 7 8
Remove the screws securing the motor and the lock nut on the motor. Replace the wiper motor. Fit in the reverse order. Tighten the wiper arms to torque 16-20 Nm.
VDCT01.02GB
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 section F Technical data.
D1
D2
D3
D5
D4 13 D13 D8 14 15 D15
8 10
6 D6 17 D17 16 M D16 19 D797-1 D790-1 7, 12 D18

Pa
14
D10 D9 28 D791-1
D790-2 11
D20 D21 D22 D23 D24
18 D29 D30
015047
D25 D26 20
Pos
21
22
23
24
25
26
27
D27
Signal description Reference
29
30
Explanation
The switch for cab roof work lights (S105-1) sends a voltage signal to the cab control unit (D790-1). Switch, working lights attachment (S105-2) sends a voltage signal to Control unit, cab (D790-1). The switch for mast work lights (S105-3) sends a voltage signal to the cab control unit (D790-1). Switch, headlights (S100) sends a voltage signal to Control unit, cab (D790-1). Switch, revolving beacon (S110) sends a voltage signal to Control unit, cab (D790-1).
Switch in ON position: U = 24 V Switch in ON position: U = 24 V Switch in ON position: U = 24 V Switch in ON position: U = 24 V Switch in ON position: U = 24 V
D1: Diagnostic menu, see section 8 Control system, group 8.4.2.12 LIGHTS, menu 12 D2: Diagnostic menu, see section 8 Control system group 8.4.2.13 LIGHTS, menu 13 D3: Diagnostic menu, see section 8 Control system group 8.4.2.10 LIGHTS, menu 10 D4: Diagnostic menu, see section 8 Control system, group 8.4.2.1 LIGHTS, menu 1 D5: Diagnostic menu, see section 8 Control system group 8.4.2.6 LIGHTS, menu 6
VDCT01.02GB
9:60
The door NC switch (S266-LE & S266-RI) sends a voltage signal to the cab control unit (D790-1).
Door open: U = 24 V
Interior lighting cab, description, page 9:66 D6: Diagnostic menu, see section 8 Control system group 8.4.2.9 LIGHTS, menu 9
Control unit, cab (D790-1) transmits "switch on lights" messages on the CAN bus. Multi-function lever (S162) sends a voltage signal to Control unit KIT (D790-2).
Checked by control system, error shown with error code. Lever in high beam position: US162/56a = 24 V
Section 11 Common electrics, group 11.5.3.1 Control unit, cab Gear selector and multi-function lever, description, page 9:8 D8: Diagnostic menu, see section 8 Control system group 8.4.2.3 LIGHTS, menu 3
Lever, direction indicator (S161) sends a voltage signal to Control unit KIT (D790-2). Switch, interior lighting on Control unit KIT (D790-2) sends a voltage signal to Control unit KIT (D790-2). Control unit KIT (D790-2) sends a "switch on lights" message on the CAN bus. Control unit, cab (D790-1) supplies voltage to the lights in and around the cab. The relay for cab roof work lights (K3017-1 and K3017-2) is activated when the cab roof work lights are activated. It supplies voltage to the cab roof work lights (E406L-1 E406R-1, E406L-2 & E406R-2).
Left: US161/6 = 24 V Right: US161/1 = 24 V Checked by control system, error shown with error code. Checked by control system, error shown with error code. Checked by control system, error shown with error code. UK3017/30 = 24 V UK3017/85 = 0 V Cab roof work lights on: UK3017/86 = 24 V UK3017/87 = 24 V Cab roof work lights off: UK3017/86 = 0 V UK3017/87 = 0 V
D9: Diagnostic menu, see section 8 Control system group 8.4.2.4 LIGHTS, menu 4 D10: Diagnostic menu, see section 8 Control system group 8.4.2.9 LIGHTS, menu 9 Section 11 Common electrics, group 11.5.3.11 Control unit, KIT Section 11 Common electrics, group 11.5.3.1 Control unit, cab Working lights, cab, description, page 9:66
10
11
12
13
14
The cab roof work lights (E406L-1 E406R-1, E406L-2 & E406R-2) come on when the cab roof work lights are activated.
Light on: U = 24 V
Working lights, cab, description, page 9:66 D14: Diagnostic menu, see section 8 Control system group 8.4.2.12 LIGHTS, menu 12
15
Back-up lights, white (E405L & E405R) are switched on when reverse gear is selected.
Light on: U = 24 V
Back-up lights, description, page 9:64 D15: Diagnostic menu, see section 8 Control system group 8.4.2.8 LIGHTS, menu 8
16
Revolving beacon (H428) is switched on when the revolving working light is activated.
Light on: U = 24 V
Revolving beacon, description, page 9:64 D16: Diagnostic menu, see section 8 Control system group 8.4.2.6 LIGHTS, menu 6
17
Interior lighting (E434-1) comes on when a door is opened or if activated when the switch on the KIT control unit (D790-2).
Light on: U = 24 V
Interior lighting cab, description, page 9:66 D17: Diagnostic menu, see section 8 Control system, group 8.4.2.9 LIGHTS, menu 9
VDCT01.02GB
9:61
18
The brake light NO switch (S216) sends a voltage signal to the frame control unit (D797-1).
Brake pressure over 0.2 MPa: U = 24 V
Section 4 Brakes, group 4.3.8 Make-contact (closing switch) brake lights D18: Diagnostic menu, see section 8 Control system group 8.4.2.7 LIGHTS, menu 7
19
The frame control unit (D797-1) supplies voltage to the machine lights. The direction indicators (H422, H423, H426 & H427) come on when they or the warning lights are activated.
Checked by control system, error shown with error code. Light on: U = 24 V
Section 11 Common electrics, group 11.5.3.2 Frame control unit Direction indicators, description, page 9:64 D20: Diagnostic menu, see section 8 Control system, group 8.4.2.5 LIGHTS, menu 5
20
21
The running lights (H416-1, H416-2, H417-1 & H417-2) come on together with the headlights.
Light on: U = 24 V
Running lights, description, page 9:63 D21: Diagnostic menu, see section 8 Control system group 8.4.2.2 LIGHTS, menu 2
22
Headlights, low beam (E400L & E400R) are switched on when the headlight is activated.
Light on: U = 24 V
Headlights, description, page 9:63 D22: Diagnostic menu, see section 8 Control system group 8.4.2.3 LIGHTS, menu 3
23
Headlights high beam (E402L-1 & E402R-1) are lit when high beam is activated.
Light on: U = 24 V
Headlights, description, page 9:63 D23: Diagnostic menu, see section 8 Control system, group 8.4.2.3 LIGHTS, menu 3
24
Tail lights, red (H412L & H412R) are switched on when the headlight is activated.
Light on: U = 24 V
Tail lights, description, page 9:63 D24: Diagnostic menu, see section 8 Control system group 8.4.2.2 LIGHTS, menu 2
25
Brake lights (H411L & H411R) are switched on when the brake is activated.
Light on: U = 24 V
Brake lights, description, page 9:63 D25: Diagnostic menu, see section 8 Control system group 8.4.2.8 LIGHTS, menu 8
26
The mast work lights (E404L-1 & E404R-1) come on when activated.
Light on: U = 24 V
Mast working lights, description, page 9:64 D26: Diagnostic menu, see section 8 Control system, group 8.4.2.10 LIGHTS, menu 10
27
The auxiliary mast work lights (E404L-4 & E404R-4) come on when the mast work lights are activated.
Light on: U = 24 V
Mast working lights, description, page 9:64 D27: Diagnostic menu, see section 8 Control system group 8.4.2.11 LIGHTS, menu 11
28
Control unit, attachment (D791-1) supplies voltage to the attachment's lights. The twistlock attachment work lights (E404L-3 & E404R-3) come on when activated.
Checked by control system, error shown with error code. Light on: U = 24 V
Section 11 Common electrics, group 11.5.3.5 Control unit, attachment Working lights, attachment, description, page 9:67 D29: Diagnostic menu, see section 8 Control system, group 8.4.2.13 LIGHTS, menu 13
29
30
The twistlock attachment auxiliary work lights (E404L-5 and E404R-5) come on when activated.
Light on: U = 24 V
Working lights, attachment, description, page 9:67 D30: Diagnostic menu, see section 8 Control system group 8.4.2.11 LIGHTS, menu 11
VDCT01.02GB
9:62
Lighting system, component location

The purpose of the lighting is to increase safety during operation and load handling.
NOTE
It is important that the right type of bulb is used for each area. See section F Technical data. The machine has the following lights:
1 2
3,8,10 12 24 23 22
19, 20, 21
1. 2. 3. 4. 5. 6. 7. 8. 9.
18
17
16
15
11, 13, 14
Mast work lights (E404L-1 & E404R-1) Auxiliary mast work lights (E404L-4 & E404R-4) Relay, cab roof work lights (K3017-1 & K3017-2) Multi-function lever (S162) Control unit KIT (D790-2) Interior lighting (E434-1) Cab roof work lights (E406L-1 & E406R-1) Auxiliary cab roof work lights (E406L-2 & E406R-2) Revolving beacon (H428)
14. Direction indicators, rear (H426 & H427) 15. Door NC (normally closed) switch (S266-LE & S266-RI) 16. Switch, see Controls and instruments, overview, page 9:3 17. Frame control unit (D797-1) 18. Make-contact (closing switch) brake light (S216) 19. Direction indicators, front (H422 & H423) 20. Running lights, front (H416-1 & H417-1) 21. Headlights, low beam (E400L & E400R) Headlights, high beam (E402L-1 & E402R-1) 22. Control unit, attachment (D791-1) 23. Twistlock attachment work lights (E404L & E404R) 24. Auxiliary carriage work lights (E404L-5 & E404R-5)
10. Control unit, cab (D790-1) 11. Running lights, rear (H416-2 & H417-2) 12. Back-up lights, white (E405L & E405R) 13. Tail lights, red (H412L & H412R) Brake lights (H411L & H411R)
VDCT01.02GB
014664
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, section 8 Control system, group 8.4.2.2 LIGHTS, menu 2.
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). The lights and their signal can be checked from the diagnostic menu, section 8 Control system, group 8.4.2.2 LIGHTS, menu 2.
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. The lights and their signal can be checked from the diagnostic menu, see section 8 Control system, group 8.4.2.7 LIGHTS, menu 7 and 8.4.2.8 LIGHTS, menu 8.
VDCT01.02GB
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). The lights and their signal can be checked from the diagnostic menu, see section 8 Control system, group 8.4.2.7 LIGHTS, menu 7 and 8.4.2.8 LIGHTS, menu 8.
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). The lights and their signal can be checked from the diagnostic menu, see section 8 Control system, group 8.4.2.4 LIGHTS, menu 4 and 8.4.2.5 LIGHTS, menu 5
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). The signal can be checked from the diagnostic menu, see section 8 Control system, group 8.4.2.4 LIGHTS, menu 4 and 8.4.2.5 LIGHTS, menu 5.
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). The lights and their signal can be checked from the diagnostic menu, section 8 Control system, group 8.4.2.6 LIGHTS, menu 6.
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).
VDCT01.02GB
9 Frame, body, cab and accessories Working lights, mast
9:65
The lights and their signal can be checked from the diagnostic menu, see section 8 Control system, group 8.4.2.10 LIGHTS, menu 10 and 8.4.2.11 LIGHTS, menu 11 The mast can be equipped with two auxiliary work lights ( ).
VDCT01.02GB
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. The working lights are controlled by selecting with the switch for working lights, cab roof. The signal travels to Control unit, cab (D790-1), which in turn supplies power to the working lights. The lights and their signal can be checked from the diagnostic menu, section 8 Control system, group 8.4.2.12 LIGHTS, menu 12.
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. The lights and their signal can be checked from the diagnostic menu, section 8 Control system, group 8.4.2.9 LIGHTS, menu 9.
VDCT01.02GB
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. The working lights are controlled by selecting with the switch for working lights, attachment. The signal travels to Control unit, cab (D790-1). The lights and their signal can be checked from the diagnostic menu, section 8 Control system, group 8.4.2.13 LIGHTS, menu 13. The attachment can be equipped with two extra working lights ( ).
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). The lights and their signal can be checked from the diagnostic menu, section 8 Control system, group 8.4.2.11 LIGHTS, menu 11.
VDCT01.02GB
9:68
9 Frame, body, cab and accessories Signalling system
9.7 Signalling system

Signalling system, function description
NOTE
It is important that the right type of bulb is used for each area. See section F Technical data.
4 D17 17 D4 6
D2 D3 D1 16 15
7 D6
D6 D15 14 M D14 D10 10 D12

Pos
1
D13 D790-1 D797-1 11
13
D18 18 D790-2 8 D791-1 D795 20

010027
19
5 9 D11
D21 12
21
Description
Switch, revolving beacon (S110) sends a voltage signal to Control unit, cab (D790-1). Switch, flashing hazard lights (Hazard) (S109) sends a voltage signal to Control unit, cab (D790-1). Switch, parking brake (S107) sends a voltage signal to Control unit, cab (D790-1). The horn switch (S149-3) sends a voltage signal to the cab control unit (D790-1). Control unit, cab (D790-1) sends messages about activation on the CAN bus. Multi-function lever (S162) sends a voltage signal to Control unit KIT (D790-2).
Signal description
Switch in ON position: U = 24 V Switch in ON position: U = 24 V Switch in ON position: U = 24 V Switch in ON position: U = 24 V Checked by control system, error shown with error code. Signal button pressed in: US162/H = 24 V
Reference
D1: Diagnostic menu, see section 8 Control system group 8.4.2.6 LIGHTS, menu 6 D2: Diagnostic menu, see section 8 Control system group 8.4.2.4 LIGHTS, menu 4 D3: Diagnostic menu, see section 8 Control system group 8.4.5.4 HYD, menu 4 D4: Diagnostic menu, see section 8 Control system, group 8.4.3.5 CAB, menu 5 Section 11 Common electrics, group 11.5.3.1 Control unit, cab Gear selector and multi-function lever, description, page 9:8 D6: Diagnostic menu, see section 8 Control system group 8.4.3.5 CAB, menu 5
Lever, direction indicator (S161) sends a voltage signal to Control unit KIT (D790-2). Control unit KIT (D790-2) sends messages about activation on the CAN bus. The frame control unit (D797-1) supplies voltage to the machine lights and buzzers.
Left: US161/6 = 24 V Right: US161/1 = 24 V Checked by control system, error shown with error code. Checked by control system, error shown with error code.
D7: Diagnostic menu, see section 8 Control system group 8.4.2.4 LIGHTS, menu 4 Section 11 Common electrics, group 11.5.3.11 Control unit, KIT Section 11 Common electrics, group 11.5.3.2 Frame control unit
VDCT01.02GB
9 Frame, body, cab and accessories Signalling system
9:69
Pos
10
Description
The direction indicators (H422, H423, H426 and H427) come on when the warning lights are activated. The reversing lights (E405L and E405R) come on when reverse gear is selected. Back-up alarm (H965) is activated when reverse gear is selected.
Signal description
Light on: U = 24 V
Reference
Direction indicators, description, page 9:64 D10: Diagnostic menu, see section 8 Control system, group 8.4.2.5 LIGHTS, menu 5
11
Light on: U = 24 V
Back-up lights, description, page 9:64 D11: Diagnostic menu, see section 8 Control system group 8.4.2.8 LIGHTS, menu 8
12
Reverse gear selected: U = 24 V
Reverse alarm, description, page 9:71 D12: Diagnostic menu, see section 8 Control system group 8.4.2.8 LIGHTS, menu 8 Horn, description, page 9:70 D13: Diagnostic menu, see section 8 Control system group 8.4.3.5 CAB, menu 5
13
Horn (H850) sounds when the horn is activated.
Horn active: U = 24 V
14
Revolving beacon (H428) is switched on when the flashing hazard light is activated. Relay loud horn (K3016) is activated when horn is activated.
Light on: U = 24 V
Revolving beacon, description, page 9:64 D14: Diagnostic menu, see section 8 Control system, group 8.4.2.6 LIGHTS, menu 6
15
UK3016/30 = 24 V UK3016/85 = 0 V Horn activated: UK3016/86 = 24 V UK3016/87 = 24 V
Horn, description, page 9:70 D15: Diagnostic menu, see section 8 Control system, group 8.4.2.6 LIGHTS, menu 6
16
Loud horn (H850-1) sounds when the horn is activated. Make-contact (closing switch) operator-in-seat (S230) sends a voltage signal to Control unit, cab (D790-1) when there is a load on the driver's seat. In the event of warnings, Buzzer, cab (H853) is supplied voltage by Control unit KIT (D790-2) to draw the operator's attention to the warning message. In the event of warnings, control unit KID (D795) activates the warning lamp to draw the operator's attention to the warning message. The attachment control unit (D791-1) supplies voltage to the automatic spreading buzzer during automatic spreading. The automatic spreading buzzer (H9003) is activated when automatic spreading 20'-40' is activated.
Horn active: U = 24 V
Horn, description, page 9:70
17
Operator in seat: U = 24 V
9.3.14 Sensor, operator-in-seat, page 9:19 D17: Diagnostic menu, see section 8 Control system group 8.4.3.6 CAB, menu 6
18
D18: Diagnostic menu, see section 8 Control system group 8.4.3.6 CAB, menu 6
19
A clicking sound is audible when then termination resistor is activated. Checked by control system, error shown with error code. Buzzer active: U = 24 V
Section 11 Common electrics, group 11.5.3.12 Control unit, KID
20
Section 11 Common electrics, group 11.5.3.5 Control unit, attachment
21
Section 7 Load handling, group 7.5.10 Buzzer, automatic spreading 20'-40' D21: Diagnostic menu, see section 8 Control system, group 8.4.9.21 ATTACH, menu 21
NOTE
On machines with side lift attachment, an audible signal can also be given with the open twistlock button (S1002) on the panel for hydraulic functions or the open twistlock button on the joystick, provided that the "open twistlocks upon contact" function is not active.
VDCT01.02GB
9:70
9 Frame, body, cab and accessories Horn
Signalling system, component location

The machine has the following signalling systems:
3 4 5
19 18
1. 2. 3. 4. 5. 6. 7. 8. 9. Control unit, KID (D795) Buzzer, cab (H853) Control unit KIT (D790-2) Multi-function lever (S162) Direction indicator lever (S161) Revolving beacon (H428) Reverse alarm (H965) Reversing lights (E405L & E405R)
17
16
15
14
13
12 10,1 1 9 8
11. Control unit, cab (D790-1)
12. Make-contact (closing switch) operator-in-seat (S230) 13. Horn (H850) 14. Switch, see Controls and instruments, overview, page 9:3 15. Loud horn (H850-1) 16. Frame control unit (D797-1) 17. Direction indicators, front (H422 & H423) 18. Control unit, attachment (D791-1) 19. Buzzer automatic spreading (H9003)
Direction indicators, rear (H426 & H427)
10. Relay loud horn (K3016)
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
001247
or from the horn switch ( ). The horn is located under the cab (the air horn is located on the front of the cab). The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.3.5 CAB, menu 5.

Flashing hazard lights, description
See Flashing hazard lights, description, page 9:64.
VDCT01.02GB
014665
9 Frame, body, cab and accessories Revolving beacon
9:71

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. The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.3.6 CAB, menu 6.
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. The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.2.8 LIGHTS, menu 8.
VDCT01.02GB
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.
VDCT01.02GB
9 Frame, body, cab and accessories Glass/windows/mirrors
9:73
9.9 Glass/windows/mirrors
Glass/windows/mirrors, component placement
C D
The windows are designed to both enclose the cab and provide the operator with a good view. Toughened glass windows are standard on all trucks. The roof window is a safety detail and is therefore always 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:
001512
Side windows front, position E Windshield (front window), position B
A
A B C D E Side windows
Windscreen (front window) Roof window Rear window 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 C and +200 C. The hardening properties of the adhesive are extremely dependent on the ambient temperature. An increase of 10 C cuts hardening time in half. Silicone adhesive 923854.0100 is mixed at a ratio of 1:10 in a static mixer. Change mixer after every interruption that lasts more than 5 minutes. The short setting time means that work has to be planned carefully in order to avoid undesired hardening.
Fixing time:
10-20 minutes at 20 C approx. 5 minutes at 60 C
Hardening time:
approx. 24 hours at 20 C approx. 1 hour at 60 C Full strength is obtained after 7 days. In warm climates, it is advantageous to cool the container to increase hardening time. The silicone adhesive should not be used at temperatures above +75 C. In cold climates, the hardening time can be shortened by covering the joints so that cooling is prevented. The window pane can be warmed with defroster or cab heater. The recommended storage temperature is between -30 C and +20 C. Storage in a refrigerator or a colder environment is recommended.
VDCT01.02GB
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. 1 2 3 Machine in service position, see section B Safety. Remove the decor strip. 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 5 Clean all surfaces thoroughly. Remove old remains of silicone with a razor blade or similar. Fit masking tape on the inside and outside of the window panes by the surfaces that are to be glued.
VDCT01.02GB
9 Frame, body, cab and accessories Windscreen
9:75
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
Adjusting side window - cab roof 1. 2. 3. Side window Rubber strip Cab frame/door opening
1,0
Adjusting side window - windscreen 1. 7 8 Masking tape
Fit the decor strip around the whole window pane. 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.
VDCT01.02GB
006269
9:76
9 Frame, body, cab and accessories Side window
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.
006272
IMPORTANT
Mark the window panes with "New adhesive. Do not touch".
14 Remove the masking tape immediately after applying adhesive to avoid edge formation. Hardening time is dependent on ambient temperature, plan the change so that downtime is minimised.
Cardboard tool template for silicone joint scale 1:1
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. 1 2 Machine in service position, see section B Safety. Use special tools to detach the decor strip.
VDCT01.02GB
9:77
3 4
Remove the decor strip which runs around the whole window. Carefully remove any remains of glass from the rubber strip.
Fit the new window, securing it at the bottom edge.
Spray soap solution on the window and rubber strip to facilitate fitting.
VDCT01.02GB
9:78
Thread the rubber strip around the whole window; use special tools.
8 9
Secure the decor strip with a special tool. 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.
VDCT01.02GB
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 C to -45 C (becomes brittle at -110 C, glass conversion temperature 145 C). The roof window has a patented surface layer that increases its 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.
VDCT01.02GB
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 corner. Each insulator mounting has one rubber bushing and one bolt.
1 2
4
Cab Spirit Delta 1. 2. 3. 4. Cab frame Door Cab suspension Cab substructure
003206
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. The signal can be checked via the diagnostic menu. See section 8 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.
VDCT01.02GB
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

1 2 3 Machine in service position, see section B Safety. Remove the steering wheel centre cover. Remove the nut and the steering wheel.
Remove the bolts on the underside of the steering wheel panel.
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9:82
9 Frame, body, cab and accessories Interior fittings, plastic
Remove the bolts on the top of the steering wheel panel.
6 7 8
Unplug the connector from the multi-function levers, ignition key lock, Control unit KIT (D790-2) and Control unit KID (D795). Transfer the components to the new steering wheel cover. Fit in the reverse order.
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.
VDCT01.02GB
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.
VDCT01.02GB
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).
3
1. 2. 3. Frame's rear section with counterweights
4
4. 5. 6.
5
Bracket for front wings Cab mounting (4 points) Steering axle mounting
Engine compartment with mountings for engine and transmission Frame's front section with drive axle mounting
VDCT01.02GB
014666
9 Frame, body, cab and accessories Body structure
9:85
9.13 Body structure

Body structure, description
The body structure's components comprise:
3
1. 2. 3. Counterweight Hood engine compartment 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. Workshop Manual DCT 80-90
VDCT01.02GB
014667
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.
VDCT01.02GB
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 3 Turn the start key to position I. 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. 2. 3. 4. 5. Grease nipple, filling point grease Safety valve Grease nipple, manual lubrication of system Indicator pin Switch, manual operation 4 Fill grease in the pump unit through the filler nipple, see section F Technical data.
VDCT01.02GB
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. 2. 3. Pause time setting (red) Run-time setting (blue) 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 Pause time [hours] 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 A 10 B 11 C 12 D 13 E 14 F 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 Run-time [minutes] 1 2 2 4 3 6 4 8 5 10 6 12 7 14 8 16 9 18 A 20 B 22 C 24 D 26 E 28 F 30
VDCT01.02GB
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. 2. 3. Pump unit Safety valve Distribution block
VDCT01.02GB
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 the whole system. If there is a blockage in the system, this line will be pressurised from the pump to the stop through all distribution blocks on the circuit. This 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.
Example illustration, components central lubrication 1. 2. 3. Pump unit Safety valve Distribution block
9.14.3 Lines
Lines, description
Central lubrication works under very high pressure, only use lines that meet the following specifications.
Main hose
Diameter Explosion pressure 8.4 mm min. 60.0 MPa
VDCT01.02GB
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.
VDCT01.02GB
9:92
VDCT01.02GB
10:1
10 Common hydraulics
Contents 10 Common hydraulics

10 Common hydraulics .........................................................................................10:3 10.2 Safety valves..................................................................................................10:3 10.2.1 Accumulator drain valve ............................................................................10:3 10.2.2 Relief valve, attachment ............................................................................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
VDCT01.02GB
10:2
VDCT01.02GB
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.
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 valve to tank. See section 7 Load handling, group 7.4.7 Relief valve attachment.
Relief valve, attachment. The illustration depicts an open valve.
015019
VDCT01.02GB
10:4
10 Common hydraulics Pressure limiting valve
10.2.3 Pressure limiting valve

Pressure limiting valve, description
1 2 3 4 5 11 6 7 9 8
The pressure limiting valve (position 3) is located on the valve block brake system and protects the brake system against excessive pressure. See section 4 Brakes, group 4.3.12 Valve block brake system.
10
015018

Pipes and hoses, general
See Pipes and hoses, general, page 10:13.
VDCT01.02GB
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.
1. 2. 3. 4. 5.
Hydraulic oil filter cover Hydraulic oil filler plug Sight glass hydraulic oil Breather filter hydraulic oil tank Hydraulic oil drain plugs
008086
10.3.2 Accumulator
Accumulators, description
1 2
Brake system accumulators, see section 4 Brakes, group 4.3.4 Accumulator Accumulator lift, see section 7 Load handling, group 7.2.14 Accumulator lift
Accumulators 1. 2. Brake system accumulators Accumulator lift
014672

See Pipes and hoses, general, page 10:13. Workshop Manual DCT 80-90
VDCT01.02GB
10:6
10 Common hydraulics Pumps
10.4 Pumps
10.4.1 Gear pump with fixed displacement
Gear pump with fixed displacement, description
6 1
The hydraulic system is fed by two gear pumps with fixed 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 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.
000660
3 4
1. 2. 3. 4. 5. 6. Pump housing Outlet Drive wheel Gear cover Intake Trailing gear
The displacement, i.e. how many cubic centimetres of oil that the pump can deliver per pump revolution, differs on the various gear pumps.
NOTE
It is very important that the clearance between the gears and between the gear and the housing is correct. Clearance that is too small creates wear damage. Clearance that is too large reduces the pump's power output.
Hydraulic oil pump brake and steering
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:
014671
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 description, page 10:18.
1. 2.
Hydraulic oil pump for load handling Hydraulic oil pump for brake pressure, steering
VDCT01.02GB
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
Read the safety instructions for oil before working, see section B Safety. 1 2 Operate and warm up the machine so that the oil in the hydraulic system reaches operating temperature, at least 50 C. Machine in service position, see section B Safety. Depressurise the hydraulic systems, see section B Safety.
C
000475
4 5
Connect a pressure gauge (0-25 MPa) to the measuring outlet pump pressure brakes and steering on the main valve. Start the engine and run it at idle.
Measuring outlet, pump pressure brake and steering [PM]
014649
VDCT01.02GB
10:8
Close the accumulator drain valve and check the pump pressure during charging.
NOTE
Check that the accumulator drain valve is fully closed and tighten the lock ring. Check that the pressure rises to the specified feed pressure on the pressure plate. 7
"$'
Depressurise the hydraulic systems, See section B Safety. Remove the pressure gauge and fit the protective cap on the measuring outlet.
Pressure plate, pump pressure brakes and steering 9 Close accumulator drain valve.
015023
NOTE
VDCT01.02GB
"$'
10:9
Load handling hydraulic oil pump, checking

1 2 Operate and warm up the machine so that the oil in the hydraulic system reaches operating temperature, at least 50 C. Machine in service position, see section B Safety. Depressurise the hydraulic systems, See section B Safety.
C
000475
Connect a pressure gauge (0-25 MPa) to the measuring outlet pump pressure load handling on the main valve.
Measuring outlet, pump pressure load handling [P2] 5 6 Close the accumulator drain valve and the attachment relief valve. Start the engine and run it at idle.
"$'
014650
VDCT01.02GB
10:10
7 8 9
Check that the feed pressure corresponds with the pressure plate. Turn off engine. Depressurise the hydraulic systems, See section B Safety.
10 Remove the pressure gauge and fit the protective cap on the measuring outlet.
Pressure plate, feed pressure load handling 11 Close accumulator drain valve.
015024
NOTE
VDCT01.02GB
"$'
10:11
Gear pump with fixed displacement, replacement
NOTE
Read the safety instructions for oil before working, see section B Safety. 1 2 3 4 Machine in service position, see section B Safety. Depressurise the hydraulic systems, See section B Safety. Clean the hydraulic oil pumps and the areas around them. Mark up and detach the hydraulic hoses from the pump.
NOTE
Plug all connections immediately to protect the hydraulic system 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
Check that the O-rings are intact, clean and in the correct position. Fastening screws hydraulic oil pump load handling 7 8 Check the seal between the pump and transmission, replace if necessary. 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. Fastening screws hydraulic oil pump brake and steering If necessary vent the pump before starting the engine by removing the hoses on the pressure side.
NOTE
VDCT01.02GB
10:12
10 Common hydraulics Pipes and hoses
10 Close the accumulator drain valve and the attachment relief valve.
NOTE
Check that the accumulator drain valve is fully closed and tighten the lock ring. 11 Turn on the system voltage and start the engine. 12 Check that the hose connections are tight.
Close the accumulator drain valve 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

VDCT01.02GB
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. 2. 3. 4. 5. 6. To avoid stresses in the connection, there should be a length of straight hose after the connection. The hose must not be twisted. (A twist of 7% reduces service life by 90%.) Minimise the number of bends by using correct couplings. Avoid sharp bends. Keep the hoses clean internally. Leave the plugs in place as long as possible when installing. Check the position of the O-rings and tighten to the correct torque, see section F Technical data.
NOTE
Straight coupling requires a counterhold wrench to prevent damage to the O-ring. 7.
Hose length
The O-rings must not be oiled when fitted.
C/L
Hose length
Hose length is measured on a hose laid out between the sealing surfaces. On angled connections, measure from the sealing surface's centre line [C/L] as illustrated.
Cleanliness
The function and service life of hydraulic components depend to a great extent on how clean the hydraulic oil is. It is therefore very important to prevent dirt from entering the brake and hydraulic system. Some simple advice to keep the hydraulic system clean.
001015
Always clean the area around a component before starting to work. Plug hose connections immediately after disconnecting. If possible, use correct plugs for the connection type. If plugs are missing, use clean plastic bags and cable ties or tape to seal the connection. Never re-use oil that has been drained from the machine. If possible, filter the oil before pouring it into the machine. Oil 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.
C/L line for measuring hose length
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10:14
10 Common hydraulics Main valve
10.5.4 Main valve

Main valve, description
1 2 3 4 5 6 28 27 26 7 8 9 10 11 25 24 23 22 21 20 19
1. 2. 3. 4. 5. 6. 7. 8. 9. Solenoid valve, lower (Y6004) Solenoid valve, lift (Y6005) Adjuster screw max pressure lift Solenoid valve hydraulic pressure attachment (Y6012/Y6062) Solenoid valve, tilt in (Y6011) Solenoid valve, tilt out (Y6010) Adjuster screw max pressure tilt and attachment Feed from the hydraulic oil pump brake and steering [P] Adjuster screw control pressure
12
13 14 15 18 17 16
015031
15. Connection servo valves [PP] 16. Measuring outlet servo pressure [PPM] 17. Adjusting screw accumulator charging pressure 18. Connection valve block brakes, accumulator charging [ACC] 19. Measuring outlet accumulator pressure [ACC M] 20. Adjusting screw servo pressure 21. Measuring outlet pump pressure brake and steering [PM] 22. Connection tilt cylinders, piston side 23. Connection tilt cylinders, rod side 24. Connection control valve, attachment 25. Connection lift cylinders, piston side 26. Feed hydraulic oil pump load handling [P2] 27. Return to filter [D] 28. Measuring outlet, pump pressure load handling [P2]
10. Return to filter [D] 11. Measuring outlet control pressure [LSM] 12. Connection brake cooling [SPOL], to the drive axle block 13. Connection control valve, pilot pressure [LSO] 14. Feed control valve [O]
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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.
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10:16
Main valve, replacement
NOTE
Read the safety instructions for oil before working, see section B Safety. 1 2 3 4 Machine in service position, see section B Safety. Depressurise the hydraulic systems, see section B Safety. Place a container tray under the main valve and remove the cover that sits over the main valve. Mark up and detach the hydraulic hoses from the main valve.
NOTE
Plug all connections immediately to protect the hydraulic system from impurities. 5 6 7 Mark up and detach the wiring from the main valve. Remove the fastening screws and lift off the main valve. Place the valve on a clean and protected surface. Transfer the connection adapters to the new main valve.
NOTE
015103
NOTE
Transfer one connection at a time so that the marking is not mixed up. 8 9 Mark up the solenoid valves on the new main valve. Lift the main valve into place and fit the fastening screws.
Main valve
10 Connect the hydraulic hoses to the main valve in accordance with the marking.
NOTE
Check that the O-rings are intact, clean and in the correct position. 11 Connect the cable harness to the main valve in accordance with the marking.
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10:17
12 Close the accumulator drain valve and the attachment relief valve.
NOTE
Check that the accumulator drain valve is fully closed and tighten the lock ring. 13 Turn on the main electric power and start the engine. 14 Check that the valve\qs hydraulic connections are sealed. 15 Bleed the brakes, see section 4 Brakes, group 4.3.9 Wheel brakes. 16 Check the steering
"$'
Activate the steering gradually to bleed the steering's hydraulic 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
26 Test drive the machine and check that all functions work correctly.
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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
D795 D797-1
D790-2
15
9, 1 1, 14 4
18
2
SPOL
P2
12
D P
M
7 5 6
C 17 8 C
Pos
1
19
C 13
1 20
Signal description
See pressure plate on left frame beam. P < 0.3 MPa
015037
Explanation
Hydraulic oil pump for the brakes and steering pumps oil from the hydraulic oil tank. Valve block accumulator charging and priority valve directs the oil to the steering, charging of the accumulators, hydraulic oil filter or through the hydraulic system's cooling circuit. Excess oil is led to the hydraulic oil filter.
Reference
Gear pump with fixed displacement, description, page 10:6 See section 4 Brakes, group 4.3.3 Accumulator charging valve
VDCT01.02GB
10 Common hydraulics Temperature control, cleaning and hydraulic oil
10:19
Pos
3 4
Explanation
The hydraulic oil filter cleans the oil. Hydraulic oil in the cooling circuit passes through the drive axle block to the wheel brakes. The hydraulic oil cools the wheel brakes. A small amount of oil is guided through the fine filter and back to the hydraulic oil tank. The hydraulic oil cooler cools the oil. The hydraulic oil temperature sensor (B776) sends the frame control unit (D797-1) a voltage signal proportional to the hydraulic oil temperature.
Signal description
-
Reference
Hydraulic oil filter, description, page 10:24 See section 4 Brakes, group 4.3.6 Drive axle block See section 4 Brakes, group 4.3.9 Wheel brakes. Fine filter hydraulic oil, description, page 10:27
5 6 7 8
Hydraulic oil cooler, description, page 10:20 Sensor, hydraulic oil temperature, description, page 10:21 D8: Diagnostic menu, see section 8 Control system, group 8.4.5.1 HYD, menu 1
The frame control unit (D797-1) transmits oil temperature on the CAN bus.
Checked by the control system, error indicated with error code.
Section 11 Common electrics, group 11.5.3.2 Frame control unit D8: Diagnostic menu, see section 8 Control system, group 8.4.5.1 HYD, menu 1 Section 9 Frame, body, cab and accessories, group 9.1 Controls and instruments. Cooling fan, description, page 10:21 D8: Diagnostic menu, see section 8 Control system, group 8.4.5.1 HYD, menu 1
10
The KID control unit (D795) shows oil temperature in the operating menu hydraulic oil temperature. If the hydraulic oil temperature is high, the frame control unit (D797-1) supplies voltage to the Cooling fan (M668).
11
U = 24 V
12
The cooling fan (M668) increases the airflow through the hydraulic oil cooler, thus increasing cooling output If the oil temperature is low or the pressure through the cooler becomes too high, the bypass valve opens and leads the oil past the cooler. If the hydraulic oil temperature is too high, the frame control unit (D797-1) transmits a warning for high hydraulic oil temperature on the CAN bus.
Cooling fan, description, page 10:21
13
P = 0.2 MPa
Bypass valve, cooler, description, page 10:23
14
Checked by the control system; error shown with error code.
Section 11 Common electrics, group 11.5.3.2 Frame control unit D8: Diagnostic menu, see section 8 Control system, group 8.4.5.1 HYD, menu 1 Section 9 Frame, body, cab and accessories, group 9.1 Controls and instruments. Section 11 Common electrics, group 11.5.3.12 Control unit, KID Gear pump with fixed displacement, description, page 10:6 Section 7 Load handling, group7.2.3 Lift, tilt and attachment control valve Hydraulic oil filter, description, page 10:24
15
The KIT control unit (D790-2) activates the hydraulic oil temperature warning light. The KID control unit (D795) shows the error code on the display. The hydraulic oil pump load handling pumps oil to lift, tilt and attachment control valve. Lift, tilt and attachment control valve leads the return oil from load handling to the hydraulic oil filter. The hydraulic oil filter cleans the oil.
16
Checked by the control system; error shown with error code. -
17
18
19
Hydraulic diagram, see section E Schematics group 10 Common hydraulics, Hydraulic diagram. Workshop Manual DCT 80-90
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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
Read the safety instructions for oil before working, see section B Safety. 1 2 3 Machine in service position, see section B Safety. Drain the oil from the hydraulic oil tank, see Hydraulic oil, changing, page 10:26. Mark up and detach the hydraulic hoses from the cooler. Let the oil in the cooler drain into the receptacle.
1 2 3
4 5 6 7
009990
NOTE
Plug all connections immediately to protect the hydraulic system from impurities. Disconnect the cable harness from the cooling fan. Remove the attaching bolts and lift away the cooler. Transfer the cooling fan to the new cooler. Fit the cooler. Connect the cable harness to the cooling fan. Connect the hydraulic hoses to the cooler.
8 9
1. 2. 3.
Cooling fan Hydraulic connections Radiator
NOTE
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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! Leakage and environmental damage! 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. The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.5.1 HYD, menu 1.
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
The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.5.1 HYD, menu 1.
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10:22
10 Common hydraulics Sensor hydraulic oil temperature
Sensor, hydraulic oil temperature, replacement
NOTE
Read the safety instructions for oil before working, see section B Safety. 1 2 3 4 Machine in service position, see section B Safety. Drain the oil from the hydraulic oil tank, see Hydraulic oil, changing, page 10:26. Disconnect the cable harness from Sensor, hydraulic oil temperature (B776). Replace Sensor, hydraulic oil temperature (B776).
NOTE
Check that the O-rings are intact, clean and in the correct position. 5 Connect the cable harness to the sensor.
Sensor, hydraulic oil temperature (B776) 6 Fill oil in the hydraulic oil tank, see Hydraulic oil, changing, page 10:26. The oil level should be visible in the sight glass.
009992
CAUTION
Diagnostic menu HYD, menu 1
VDCT01.02GB
000141
DIAG HYD HYDRAULIC OIL TEMP FAN
1(6) XXX XY
Use the display, go to the diagnostic menu, see section 8 Control system, group 8.4.5.1 HYD, menu 1. TEMP indicates hydraulic oil temperature in C. Check that correct temperature is shown.
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.
Bypass valve
009993
Bypass valve, cooler, replacement
NOTE
IMPORTANT
Ensure cleanliness around the filter and filling point when working on the hydraulic tank. Dirt particles may cause machine damage.
1 2 3 4 Machine in service position, section B Safety. Depressurise the hydraulic systems, See section B Safety. Drain the oil from the hydraulic oil tank, see Hydraulic oil, changing, page 10:26. Disconnect the bypass valve from the tank.
NOTE
Note how the bypass valve faces; the valve is marked with an arrow. 5
009993
Install the new bypass valve, turning the valve to face the same way as the old one. Use Loctite when fitting the bypass valve.
Bypass valve
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10:24
10 Common hydraulics Breather filter hydraulic oil tank
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
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.
VDCT01.02GB
009994
10 Common hydraulics Hydraulic oil filter
10:25
Hydraulic oil filter, replacement
NOTE
IMPORTANT
1 2 On machines with a raised cab: Remove the footstep over the covers and clean the covers and the area around them. Switch off the engine and switch off the main electric power.
3 4 5
Remove the cover plates (position 1) over the hydraulic oil filters. Lift up the filter unit and place it in the receptacle. Let the hydraulic oil drain. Separate the filter unit and remove the filter insert. Handle the filter insert as environmentally hazardous waste. Note the position of the parts.
1. 2. 3. 4.
Hydraulic oil filter cover Filling point hydraulic oil Sight glass hydraulic oil Breather filter hydraulic oil tank 6 7 8 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. Clean the filter holder's parts. Be especially thorough with the magnetic rod. Fit the new filters and assemble the filter units. Install the filter units and the covers. Tighten the screws crosswise.
Magnetic rod
008084
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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 2 Machine in service position, section B Safety. 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
IMPORTANT
1 Machine in service position, see section B Safety. Remove the filler cap and pump out the hydraulic oil into a receptacle. 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. Fit the drain plug when the oil has drained out.
2 3
NOTE
008084
Make sure that the seal washer for the drain plug is fitted as well. 5 If the hydraulic oil filters are to be changed, change them before filling the tank with oil, see Hydraulic oil filter, replacement, page 10:25.
1. 2. 3. 4.
Hydraulic oil filter cover Filling point hydraulic oil Sight glass hydraulic oil Breather filter hydraulic oil tank
VDCT01.02GB
10 Common hydraulics Pipes and hoses
10:27
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

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
VDCT01.02GB
10:28
10 Common hydraulics Fine filter hydraulic oil
Fine filter hydraulic oil, replacement
NOTE
IMPORTANT
1 2 3 4 5 Machine in service position, see section B Safety. Remove the cover. Take out a collection vessel. Lift up the filter insert and place it in the receptacle. Let the hydraulic oil drain. Fit the new filter insert and refit the cover over the fine filter.
VDCT01.02GB
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. 2.
Carefully check the source of the leakage before taking any action. It may be possible to rectify the fault without disassembly. 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. 2. 3. 4. 5. 6. 7. 8. 9.
Piston rod Scraper Cylinder head Piston rod seal O-ring with support ring Cylinder barrel Sleeve coupling Welded cylinder end face Piston
10. Piston seal, double-acting 11. Example of weld
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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 2 3 Remove the cylinder from its mounting and undo the connections. Plug the cylinder connections and hoses without delay. 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.
VDCT01.02GB
10:31
Function and removal of the seals

Piston rod seal
2 1
Piston rod seal

The piston rod seal is the seal that sits in the groove in the cylinder head and seals against the piston rod. This seal is very exposed to wear since it is both a dynamic and a static seal, i.e. it seals against a moving surface on the piston rod while the sealing surface with the cylinder head is fixed. There are different types of piston rod seals: Single V-seal Pre-stressed V-seal with support ring Compressible seal
5
1. 2. 3. 4. 5. 6. Hydraulic pressure Seal lip pressed out toward piston rod Seal lip pressed inward toward cylinder head Sealing surface, piston rod Sealing surface, cylinder head Screwdriver
001497
The single V-seal has a V-shaped section with two lips that seal in opposite directions. The hydraulic pressure acts in the V-shape, 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.
VDCT01.02GB
10:32
2 1
7 6
3 4
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 since the O-ring already presses the sealing lips out toward the sealing surfaces when unloaded. It is just as sensitive to damage as the V-seal. Examine in the same manner. To remove, use a screwdriver to prise the seal outward and bend it up (see illustration). It is extremely important that the screwdriver is always inserted in the V-shape so that it cannot touch and thereby damage a sealing surface. A mark from a screwdriver on a sealing surface can have a devastating effect and cause major leakage.
5
1. 2. 3. 4. 5. 6. 7. Hydraulic pressure Seal lip pressed out toward piston rod Seal lip pressed inward toward cylinder head Sealing surface, piston rod Sealing surface, cylinder head Screwdriver O-ring
001498
2 1 3
The compressible piston rod seal consists of a solid rubber profile and provides a larger sealing surface than the V-seals. To remove, use a screwdriver to prise the seal outward and bend it up (see illustration). With this type of seal with sealing surfaces that cover so much of the seal groove, it is particularly important that marks are not made with the screwdriver.
3 6 4 5
5
1. 2. 3. 4. 5. 6. Hydraulic pressure Seal lip pressed out toward piston rod Seal lip pressed inward toward cylinder head Sealing surface, piston rod Sealing surface, cylinder head Screwdriver
VDCT01.02GB
001499
10:33
Support ring and O-ring
Support ring and O-ring

The support ring and O-ring combination is used for sealing between two fixed surfaces, such as between cylinder barrel and cylinder head. The purpose of the support ring is to lend rigidity to the O-ring so that it is not deformed. The O-ring is pressed against the support ring and the sealing surface by the hydraulic pressure in the cylinder.
3 4 2
When the cylinder head is mounted in the barrel: Take extreme care not to damage the O-ring.
1
1. 2. 3. 4.
Scraper
Hydraulic pressure O-ring Support ring Sealing surface, cylinder head
001506
D+10 1
Scraper
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 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 impair the function of the scraper. To prevent the scraper from bottoming in its recess in the cylinder head, the recess is slightly deeper than the width of the scraper.
2 4 3 D 5
1. 2. 3. 4. 5. 6.
Correct assembly tool Scraper, correctly fitted Cylinder head Clearance between scraper and bottom of cylinder head recess Incorrect assembly tool Deformed scraper
001496
VDCT01.02GB
10:34
1 2
A screwdriver can be used for removal. This must always be applied against the outer edge of the scraper (see illustration). Carefully tap the screwdriver down between the scraper and the cylinder head and then prise out the scraper. Polish away any damage to the cylinder head.
CAUTION
3
No tool may be applied from the inside. This could give rise to burrs on the cylinder head which could in turn damage the piston rod. Burrs may also damage the piston rod seal when fitting the piston.
001551
1. 2. 3.
Screwdriver Scraper Cylinder head
On the single-acting V-seal it is always the long side that seals against the fixed surface and the short side that seals against the moving surface. 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
5
1. 2. 3. 4. 5. 6. Hydraulic pressure Seal pressed out toward cylinder barrel Seal pressed in toward piston Sealing surface, cylinder barrel Sealing surface, piston Screwdriver
VDCT01.02GB
002370
10:35
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.
Double-acting piston seal
002950
Double-acting piston seal

The double-acting seal functions with pressure from both sides, e.g. in a steering cylinder. All of the interior surface of the cylinder barrel is a sealing surface and it is therefore extremely important that it is completely free from damage.
002951
2
1. 2. 3. 4. 5. 6. Variable sealing surface to cylinder barrel Fixed sealing surface with piston Guide ring Support ring Piston head Cylinder barrel
Exercise caution when fitting the piston in the cylinder barrel, making sure that the seal is not damaged by the cylinder barrel threads.
Dismantling:
1 2 3 4 5 Remove guide rings and support rings. Move the seal body over to one side of the sealing groove. Press up the material so that there is a gap between seal and piston. Without damaging the surface of the piston - cut off the seal with a knife. 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 2 All double-acting piston seals are of similar design: a middle seal body, then support rings and farthest out guide rings. 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.
VDCT01.02GB
10:36
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 Locate the damage using your fingertips and fingernails. 2 3 4 Use a small, highly-polished hammer and work the surrounding material inwards towards the damage, starting from the outside. Instead of a small sharp mark there will now be a small uniform concavity in the chromium plating. Polish with emery cloth, progressing from number 240 to 600. Wrap the emery cloth round a file to give it good support. Note that there must always be chromium plating present at the damage. It is important to treat small impact marks before disassembly and assembly to avoid damaging the cylinder head. Repairing larger damage on a piston rod:
002952
5 6
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.
1. 2. 3. 4.
Piston rod Chromium plating Impact mark Highly-polished hammer
VDCT01.02GB
10:37
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 3 4 5 6 7 8 9 Unscrew the connecting nipple for the hydraulic hose. Insert the piston rod with piston crown until the O-ring is visible through the nipple hole. 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. Pull the O-ring up slightly and hold it with a pair of needle-nose pliers. Continue to pull the O-ring out through the hole. Hold the O-ring steady and cut it with a knife. Rotate the piston rod while pulling the O-ring out through the hole. Remove the lock ring from the cylinder barrel.
10 Carefully extract the piston rod from the cylinder barrel.
002953
VDCT01.02GB
10:38
VDCT01.02GB
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
VDCT01.02GB
11:2
VDCT01.02GB
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.
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
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 3 Remove the plastic cover. 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 3 Remove the cover from the electronic box. 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.
VDCT01.02GB
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).
VDCT01.02GB
11 Common electrics Start battery
11:5
Start battery, replacement

1 2 3 4 Machine in service position, see section B Safety. Disconnect the cables from the battery terminals. Start with the negative (minus) cable. Replace the batteries. 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.
VDCT01.02GB
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. The signal can be checked via the diagnostic menu, section 8 Control 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. The signal can be checked via the diagnostic menu, section 8 Control system, section 8.4.6.4 ENGINE, menu 4.
010052
Alternator, replacement
See supplier documentation, engine.
VDCT01.02GB
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 D1 D2 D793 D794 D8 2 3 D3 4 D4
D790-1 5, 6 9 D795 D790-2
D791 8 7 D797-1
0015056
D9
Pos
1
D7
Reference
Section 9 Frame, body, cab and accessories, group 9.10.2 Doors D1: Diagnostic menu, see section 8 Control system, group 8.4.2.9 LIGHTS, menu 9 or 8.4.11.5 MOVE-CAB, menu 1
Explanation
The NC switch, operator's door (S 266-LE) or the NC switch, passenger door (S 266-RI) sends a voltage signal to the cab control unit (D790-1) when the door is opened. The interior lighting switch of the KIT control unit (D790-2) sends a voltage signal to the cab control unit (D790-1). Switch, flashing hazard lights (S109) sends a voltage signal to Control unit, cab (D790-1).
Signal description
U = 24 V
U = 24 V
Section 9 Frame, body, cab and accessories, group 9.6.12 Interior lighting D2: Diagnostic menu, see section 8 Control system, group 8.4.2.13 LIGHTS, menu 13
U = 24 V
Section 9 Frame, body, cab and accessories, group 9.6.7 Flashing hazard lights D3: Diagnostic menu, see section 8 Control system, group 8.4.2.5 LIGHTS, menu 5
When the ignition switch (S150) is turned to position I, it sends a voltage signal to the cab control unit (D790-1). Control unit, cab (D790-1) activates a hold circuit, which activates the control unit's control logic.
U = 24 V
Section 9 Frame, body, cab and accessories, group 9.1 Controls and instruments D4: Diagnostic menu, see section 8 Control system, group 8.4.1.5 CAN/POWER, menu 5
Cab control unit, description, page 11:17
VDCT01.02GB
11:8
11 Common electrics Voltage feed
Pos
6
Explanation
Control unit, cab (D790-1) activates a redundant voltage feed to other control units. Control unit, cab (D790-1) has 4 outputs for redundant voltage feed while other control units have two inputs for redundant voltage feed. In the event of a malfunction of one voltage feed the control unit is supplied by the other feed.
Signal description
UK11:7 = 24 V U
K11:8
Reference
Cab control unit, description, page 11:17
= 24 V
UK11:9 = 24 V UK11:10 = 24 V
Control unit, cab (D790-1) supplies voltage to the control logic of the other control units via the redundant voltage feed.
UK2:7 = 24 V UK2:8 = 24 V UK2:7 = 24 V UK2:8 = 24 V
Frame control unit, description, page 11:18 D7: Diagnostic menu, see section 8 Control system, group 8.4.1.10 CAN/POWER, menu 10 Control unit, attachment, description, page 11:19 D8: Diagnostic menu, see section 8 Control system, group 8.4.1.15 CAN/POWER, menu 15 D9: Control unit KID, description, page 11:24 Diagnostic menu, see section 8 Control system, group 8.4.1.9 CAN/POWER, menu 9
UK2:7 = 24 V UK2:8 = 24 V
VDCT01.02GB
11:9
11.5.1.3 Ignition voltage (15) Ignition voltage (15), function description

Condition
Battery disconnector Redundant voltage feed Redundant CAN bus
Reference value
In position 1 Activated. Communication established.
Reference
Battery disconnector, description, page 11:3 Redundant voltage feed of control units, function description , page 11:7 Redundant CAN bus, description, page 11:36
1 D1 D2 2
+
K315-2 K315-1 D3 3 7 D794 3, 6
D793 4, 5 D8 D790-1 2, 8 9 D795 D790-2 D797-1 D9

Pos
1
015054
10
D10
D791
Explanation
Switch, flashing hazard lights (S109) sends a voltage signal to Control unit, cab (D790-1). When the ignition switch (S150) is turned to position I, it sends a voltage signal to the cab control unit (D790-1). Cab control unit (D790-1) voltage feeds the ignition key lock power relay K315-1 and the ignition voltage relay K315-2 in the frame electronic box. Relay, ignition voltage K315-1 supplies voltage to fuse holder in the cab electronic box and in the frame electronic box. The fuses feed voltage to control units, relays, solenoid valves and other electronic components.
Signal description
U = 24 V
Reference
Section 9 Frame, body, cab and accessories, group 9.6.7 Flashing hazard lights D1: Diagnostic menu, see section 8 Control system, group 8.4.2.5 LIGHTS, menu 5
U = 24 V
Section 9 Frame, body, cab and accessories, group 9.1 Controls and instruments D2: Diagnostic menu, see section 8 Control system, group 8.4.1.5 CAN/POWER, menu 5
U = 24 V
Cab control unit, description, page 11:17 D3: Diagnostic menu, see section 8 Control system, group 8.4.1.5 CAN/POWER, menu 5
U = 24 V
U = 24 V
VDCT01.02GB
11:10
Pos
6
Explanation
Relay, ignition voltage K315-2 supplies voltage to Control unit, engine (D794).
Signal description
U = 24 V
Reference
Control unit, engine, description (engine alternative Yuchaii YC6A240-30), page 11:21. Control unit, engine, description (engine alternative Cummins QSB6.7 ), page 11:22.
The drive-train's CAN-bus establishes communication. Ignition voltage to Control unit, cab (D790-1).
Checked by control system, error shown with error code. UK1:2 = 24 V UK1:3 = 24 V UK1:4 = 24 V
CAN bus drive-train, description, page 11:38
Ignition voltage to the frame control unit (D797-1).
UK2:1 = 24 V UK2:9 = 24 V UK2:10 = 24 V
Frame control unit, description, page 11:18 D9: Diagnostic menu, see section 8 Control system, group 8.4.1.10 CAN/POWER, menu 10 Control unit, transmission, description, page 11:20 D10: Diagnostic menu, see section 8 Control system, group 8.4.1.12 CAN/POWER, menu 12
10
Ignition voltage to Control unit, transmission (D793).
UA1 = 24 V
VDCT01.02GB
11:11
11.5.1.4 Emergency stop switch voltage (15E) Emergency stop switch voltage (15E), function description
Condition
Redundant voltage feed Ignition voltage Control breaker
Reference value
Activated. Activated. Not activated
Reference
Redundant voltage feed of control units, function description , page 11:7 Ignition voltage (15), function description, page 11:9 Section 9 Frame, body, cab and accessories, group 9.1 Controls and instruments
D794 D793 D5 3, 4 K3009-1 6 K3009-2 K3002 K3007
+
D4 D2
D7 D790-1 1, 2, 5 D795 D790-2 7 D791

015055
D797-1
Pos
1
Explanation
Ignition voltage is activated by the cab control unit (D790-1) Control unit, cab (D790-1) supplies voltage to Relay, emergency stop switch voltage (K3009-1) in the frame electronic box.
Signal description
Checked by control system, error shown with error code. UK3009-1/86 = 24 V
Reference
Ignition voltage (15), function description, page 11:9 Cab control unit, description, page 11:17 D2: Diagnostic menu, see section 8 Control system, group 8.4.1.6 CAN/POWER, menu 6
Relay, emergency stop switch voltage (K3009-1) supplies voltage to Relay, emergency stop switch voltage (K3009-2) in the frame electronic box. Relay, emergency stop switch voltage (K3009-1) also sends a voltage signal to the Control unit, cab (D790-1), which verifies that Relay, emergency stop switch voltage (K3009-1) is active but Relay, emergency stop switch voltage (K3009-2) is inactive. This verifies that the emergency stop switch is working.
UK3009-2/87 = 24 V
Electronic box frame, description, page 11:15
UK3009-1/87 = 24 V UK3009-2/87= 0 V
Electronic box frame, description, page 11:15 D4: Diagnostic menu, see section 8 Control system, group 8.4.1.6 CAN/POWER, menu 6
Control unit, cab (D790-1) activates Relay, emergency stop switch voltage (K3009-2) in the electronic box.
UK3009-2/86 = 24 V
VDCT01.02GB
11:12
Pos
6
Explanation
Relay, emergency stop switch voltage K3009-2 supplies voltage to the emergency stop switch circuit.
Signal description
UK3009-2/87 = 24 V
Reference
Electronic box frame, description, page 11:15
The attachment control unit (D791) is voltage fed with emergency stop switch voltage as long as emergency stop switch is not depressed. Attachment control unit D791 is only voltage fed by the emergency stop switch, thus all attachment functions stop if the emergency stop switch is activated. If the emergency stop switch is pressed, ignition voltage to the cab control unit (D790-1) is cut off, thereby cutting off control current to emergency stop switch voltage relay K3009-1, emergency stop switch voltage relay K3009-2, the tilt relay (K3002) and the lift/lower relay (K3007). The power supply to the control units is cut off and the 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 in home position: UK2:1 = 24 V Emergency stop switch in home position: UK2:9 = 24 V Emergency stop switch in home position: UK2:10 = 24 V Emergency stop switch in home position: UK2:11 = 24 V
Control unit, attachment, description, page 11:19 D7: Diagnostic menu, see section 8 Control system, group 8.4.1.15 CAN/POWER, menu 15
Emergency stop switch, checking

1 2 3 4
002084
Start the machine and active any load handling function. Activate lift. Press in the emergency stop switch and check that the lift movement stops. Reset the emergency stop switch (turn in the direction of the arrows) and check that the lift function is working again.
VDCT01.02GB
11:13
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
1 2 3 4 5
Machine in service position, see section B Safety. Remove the covers behind the driver's seat. Detach the electrical cables from the converter. Remove the voltage converter. Fit in the reverse order.
The voltage converter is located diagonally behind the driver's seat.
VDCT01.02GB
11:14
11 Common electrics Electronic box
11.5.2 Electronic box

11.5.2.1 Electronic box, cab Electronic box, cab, description
7 6
The electronic box is mounted on the rear wall of the cab, on the left. Located there are: 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. Control unit cab (D790-1). 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.
1 2 3 4 5
008693
NOTE
This connector is not fitted on the machine if the machine is equipped with voltage converter.
CAUTION
Connector X067 must be used when connecting extra electrical equipment. The use of other connections can lead to overloading of cable harness and product damage.
1. 2. 3. 4.
Control unit, cab (D790-1) Diagnostic socket, machine Diagnostic socket CAN Bus drivetrain 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). Voltage converter Termination resistor Customer accessory connector (X067) 24V/10A and 12V/20A
5. 6. 7.
Customer accessory connector (X067)
Customer accessory connector (X067)

The connector is designed for customer accessories and contains connections for 24 V. On machines with voltage converter 24 V to 12
4
014169
V there is also a connection for 12 V Pin 1. 24 V, ignition voltage, 10 A Pin 2. 24 V, battery voltage, 10 A Pin 3. Ground Pin 4. 12 V, ignition voltage, 20 A
VDCT01.02GB
11 Common electrics Electronic box
11:15
11.5.2.2 Electronic box frame Electronic box frame, description

4 3 2 1 6 5
The electronic box is fitted on the side of the machine. Also located there are: Circuit fuses. Outlet for programming Control unit, transmission (D793) Main fuses. Control unit, transmission (D793) Power relays for voltage feed to the machine's functions.
8 9 10 11 13
1. 2. 3. 4. Circuit fuses, battery voltage (30) F58-3 Circuit fuses, ignition voltage (15) F58-2 Circuit fuses, emergency stop switch voltage (15E) F58-3 Diagnostic socket engine, (Engine alternative Yuchai YC6A240-30) (the connector hangs loose in the electronic box) Main fuses Terminal block Circuit fuse transmission control unit (0.5 A) (F51-3) Tilt in/out relay K3002 Lifting/lowering relay K3007
015057
12
5. 6. 7. 8. 9.
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 3 4 5 6
1.
Termination resistor
VDCT01.02GB
007184
11:16
11 Common electrics Control units
11.5.3 Control units

Control units, location
1 2 3
7
1. 2. 3. 4. Frame control unit (D797-1) Control unit, KID (D795) Control unit KIT (D790-2) Control unit, cab (D790-1)
6
5. 6. 7. 8. Control unit, transmission (D793) Engine control unit, Yuchai (D794) Engine control unit, Cummins (D794) Control unit, attachment (D791-1)
VDCT01.02GB
014680
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.
000041
3 2
1. 2. 3. 4. 5. 6.
5 6
Control unit, cab has four indicator lights that indicate the control unit's function. Lamp 1 Green light on when there is battery voltage to the unit. The light is physically controlled by voltage feed to the control unit. Flashes green when redundant voltage feed to control units and redundant CAN bus communication are active. No power in the system. Green light when power electronics and 15-voltage are supplied voltage. Lamp 3 Long single flash yellow during communication with Control unit, display (D795). This is a basic condition of fault tracing. Short single flash yellow during communication with Control unit, engine (D794) and Control unit, 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.
Connection terminals - fan, working lights, windscreen wiper Connection terminals, other Light 1, battery voltage Light 2, redundant voltage feed, redundant CAN bus and power supply Light 3, communication Light 4, error indication
Lamp 2
Control unit cab, replacement

1 2 3 4 5 6 Machine in service position, see section B Safety. Remove the cover from the electronic box. Detach the connectors from Control unit, cab (D790-1). Replace the control unit. Check that the new control unit corresponds with the machine's forklift number (Z-number). Calibrate the new control unit. See section 8 Control system, group 8.5.2.3 Calibrate DRIVE-TRAIN.
VDCT01.02GB
11:18
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. Lamp 1
3 4
Green light on when there is battery voltage to the unit. The light is physically controlled by voltage feed to the control unit. Flashes green when one or more of the following is missing: redundant voltage feed left, redundant voltage feed right or 15-voltage. Green light when redundant voltage feed left, redundant voltage feed right and 15-voltage are supplied voltage.
Lamp 2
6
1. 2. 3. 4. 5. 6. Light 1, battery voltage
000043
Lamp 3
Single yellow flash during communication with the KID control unit (D795) or cab control unit (D790-1). Double yellow flash during communication with the KID control unit (D795) and the cab control unit (D790-1).
Light 2, redundant voltage feed and power supply Light 3, communication Light 4, error indication Control signals (inputs and outputs) Power supply (redundant voltage feed for control units, redundant CAN bus) and input data Lamp 4
Red light in the event of active error.
Frame control unit, replacement

1 2 3 4 5 6 Machine in service position, see section B Safety. Detach the cables from the frame control unit (D797-1). Replace the control unit. Check that the new control unit corresponds with the machine's forklift number (Z-number). Check the initiation values for attachment functions; see section 8 Control system, group 8.5.1.1 ELSERVO. The control unit is not calibrated.
VDCT01.02GB
11:19
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 3 4
The cab control unit has four indicator lights that indicate the control unit's function. Lamp 1 Green light on when there is battery voltage to the unit. The light is physically controlled by voltage feed to the control unit. Flashes green when one or more of the following is missing: redundant voltage feed left, redundant voltage feed right or 15-voltage. Green light when redundant voltage feed left, redundant voltage feed right and 15-voltage are supplied voltage. Lamp 3 Single yellow flash during communication with the KID control unit (D795) or cab control unit (D790-1). Double yellow flash during communication with the KID control unit (D795) and the cab control unit (D790-1). Lamp 4 Red light in the event of active error.
Lamp 2
6
1. 2. 3. 4. 5. 6. Light 1, battery voltage
Light 2, redundant voltage feed and power supply Light 3, communication Light 4, error indication Control signals (inputs and outputs) Power supply (redundant voltage feed for control units, redundant CAN bus) and input data
000043
Control unit, attachment, replacement

1 2 3 4 5 6 Machine in service position, see section B Safety. Disconnect the cable harness from the control unit. Replace the control unit. Check that the new control unit corresponds with the machine's forklift number (Z-number). Check the initiation values for attachment functions; see section 8 Control system, group 8.5.1.2 ATTACHMENT. The control unit is not calibrated.
VDCT01.02GB
11:20
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 2 3 4 5 Machine in service position. Disconnect the cable harness from Control unit, transmission (D793). Replace the control unit. Check that the new control unit corresponds with the machine's forklift number (Z-number). 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.
VDCT01.02GB
015058
11:21
11.5.3.10 Engine control unit Control unit, engine, description (engine alternative 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 coolant temperature oil pressure oil temperature oil level crankcase pressure water in fuel fuel pressure coolant level
Engine control unit
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.
VDCT01.02GB
11:22
Control unit, engine, description (engine alternative Cummins QSB6.7 )

The engine control unit (D794) is part of drivetrain control and handles engine function, fuel injection, etc.
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 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.
4
010053
engine speed camshaft position boost pressure charge air temperature coolant temperature oil pressure water in fuel fuel pressure coolant level
1. 2. 3. 4.
Connector from Cummins cable harness Connector XD794-3 Connector from Cummins cable harness Connector XD794-3
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.
VDCT01.02GB
11:23
11.5.3.11 Control unit KIT Control unit KIT, description

1 2
The KIT control unit (D790-2) handles functions for the gear and multi-function lever, the direction indicator switch and start key positions II and III. It also handles the key panel for the control system and its panel for warning and indicator lights. Control unit KIT (D790-2) has several individual function keys and indicator lights. See the operator's manual for detailed information on warning and indicator lights and function keys.
1. 2.
Panel, warning and indicator lights Panel for keys
000049
Control unit KIT, replacement

1 2 3 4 5 6 7 Machine in service position, see section B Safety. Remove the steering wheel and separate the steering wheel panel. Detach the KIT control unit (D790-2) from the steering wheel panel. Detach the connector sockets. Remove the warning panel for warning and indicator lights. Fit in the reverse order. The KIT control unit (D790-2) is not calibrated.
VDCT01.02GB
11:24
11.5.3.12 Control unit KID Control unit KID, description

1 2
Control unit KID (D795) displays to the operator information sent by 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.
1. 2.
LCD display Series of diodes that serve as an indicator light for serious malfunction.
000051
Control unit KID, replacement

1 2 3 4 5 6 Machine in service position, see section B Safety. Remove the steering wheel and separate the steering wheel panel. Detach the connector from the KID control unit (D795). Detach the KID control unit (D795) from the steering wheel panel. Fit in the reverse order. The KID control unit (D795) is not calibrated.
VDCT01.02GB
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
X001 X002
Location
Control unit, cab (D790-1) Control unit, cab (D790-1)
Function
Power supply and ground connection 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
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
Instrument illumination Switch, working lights Switch, rotating beacon Switch, headlights Switch, option Seat heater Accelerator Declutch pedal
X007
Control lever Twistlock Spreading (positioning)
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Contact
X008
Location
Function
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
Background illumination, switches Switch, horn
X009-2 X010
Control unit, cab (D790-1) Control unit, cab (D790-1)
Control lever 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
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
Windscreen wiper, rear Windscreen wiper, roof
X013
CAN bus RS232
X015
Control unit KIT (D790-2)
CAN bus Power supply and ground connection Control unit KIT (D790-2)
X016 X017
Control unit KIT (D790-2) Control unit KIT (D790-2)
Ignition Switch, horn Control, windscreen wipers Control, gear Control, high and low beams
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Contact
X018
Location
Control unit KIT (D790-2)
Function
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 Switch flashing hazard lights (Hazard) 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 X049 X050 X051
Electronic box, cab Electronic box, cab Electronic box, cab Electronic box, cab
Termination resistor Termination resistor RS232 Control unit, cab (D790-1) 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
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Contact
X055
Location
Electronic box, cab
Function
Windscreen wiper, roof Power, CD player Power, COM radio
X056
Electronic box, cab
Revolving beacon Working lights, cab
X057 X058
Electronic box, cab Electronic box, cab
Windscreen wiper, rear Motor, windscreen washing Engine heater start inhibitor, bridged
X059 X060
CAN bus CAN bus Interior lighting Engine heater start inhibitor, bridged
X060A
Extension X060
CAN bus Interior lighting Engine heater start inhibitor, bridged
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 X066
Ambient temperature sensor Accelerator Interior lighting
X067 X069
Customisation Sensor, twistlock open/closed Twistlock relay Spreading relay
X070
Electronic box, cab
Sensor twistlocks Spreading relay
X072 X080
To Right Behind Seat Instrument panel, cab
Current outlet Switch, mast/attachment work lights Switch, high beam Switch, rotating beacon Switch, seat heater Switch, seat heater
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Contact
X081
Location
Instrument panel, cab
Function
Switch, seat heater Switch flashing hazard lights (Hazard) Extra sensors Hour counter
X082 X090
Instrument panel, cab Electric servo panel, cab
NC switch, cab doors 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 X168 X201 X203 X204 X205
Electric servo panel, cab Electronic box frame Electronic box frame Electronic box frame Front edge of frame Electronic box frame
Switch, twistlock Power supply attachment control unit Ground connection and power supply, Control unit, transmission (D793) Termination resistor Mast work lights 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 X212
Frame control unit (D797-1) Frame control unit (D797-1)
42-pin connector to 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 X215 X230 X235
Front edge of frame Electronic box frame Beneath driver's seat Front edge of frame
CAN bus, attachment control unit (D791) Power supply attachment control unit Sensor, operator-in-seat Lift/lower valve Tilt valve Mast valves
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Contact
X236 X240 X241 X242
Location
Engine Front edge of frame Front edge of frame Front edge of frame
Function
Low coolant level sensor Voltage feed Option 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 X248 X251 X261 X270
Front edge of frame Front edge of frame Control unit, transmission (D793), electronic box frame Electronic box frame Lamp bracket left front
Brake light forward Mast position sensor 60-pin connector for Control unit, transmission (D793) RS232 Control unit, transmission (D793) High and low beams Direction indicators Side marker lights
X271
Lamp bracket right front
High and low beams Direction indicators Side marker lights
X272
Lamp bracket left rear
Tail lights Brake light Direction indicators Side marker lights
X273
Lamp bracket right rear
Tail lights Brake light Direction indicators Side marker lights
X275
Rear edge of frame
Tail lights Brake light Direction indicators 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 X281
Engine Electronic box frame
Coolant level Diagnostic socket engine
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11:31
Contact
X286
Location
Engine
Function
Resistance, indication preheating active Resistance, indication water in fuel
X287 X301 X400 X401 X403
Engine Mast Attachment control unit (D791) Attachment control unit (D791) Carriage middle
Power supply and ground connection Control unit, engine (D794) Mast position sensor Power supply and ground connection, attachment control unit (D791) CAN bus, attachment control unit 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 X422
Attachment control unit (D791) Attachment control unit (D791)
42-pin connector for Control unit attachment (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 X612 X645 X651 X657 X660 X690 X759 X774 X775 X815 X900 X901
Cab Air conditioning Engine Cab Cab Engine Cab Engine Cab Cab Cab Cab Voltage converter, cab
Revolving beacon Actuator motor, recirculation Compressor air conditioning Motor, windscreen washing Heater fan Alternator Accelerator Coolant level Ambient temperature Temperature sensor, cab, fan, refrigerant Power assisted system CD player Voltage converter 24 V/12 V Socket 24 V
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11:32
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 Temperature Resistance input 0200 . Linear work range with accuracy of 3%. Rheostat input with non-linear work area. The resistance value is equivalent to temperature and the work range of approx. -40 till 150 C. There are two different resistance curves, one for Control unit, cab (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). E.g. fuel level sensor. E.g. hydraulic oil temperature sensor and air conditioning temperature sensor.
Analogue outputs Current feedback voltage out, PWM A modulated signal between 0 V and system voltage, i.e. 24 V. The work range is 0 to 2 A. A modulated signal is a digital signal translated to an analogue (continuous) signal adapted for a purpose, such as solenoid valve control. When the slide in a solenoid valve gets hot, resistance drops. This generates a lower current through the valve spool, which can cause the valve's servo pressure to remain constant. An internal ammeter measures current in the circuit and regulates the voltage level in order to maintain the desired current value in the valve spool. Voltage out, PNP PWM Voltage out, reversed polarity, NPN PWM A modulated signal between 0 V and system voltage, i.e. 24 V. Requires a grounding point as reference. A modulated signal between 0 V and system voltage, i.e. 24 V. Requires 24 V as reference. Hydraulics, e.g. lifting/lowering of the boom. Used when the output signal actuates proportional solenoid valves.
E.g. interior lighting and background illumination in switches. E.g. cab fan.
Digital input signals Digital input signal with pull down and search lighting Digital input signal with pull down Signal in, U < 5 V generates logical zero (0) Signal in, U > 16 V generates logical one (1) If there is no signal in, the input is grounded. Signal in, U < 5 V generates logical zero (0) Signal in, U > 12 V generates logical one (1) If there is no signal in, the input is grounded. Bandwidth 300 Hz, i.e. designed for slow sensors. Digital outputs High side driver, 1.5 A Logical one (1) generates voltage out, U >= 22.5 V Max. load 1.5 A Open load 0.15 A Max. instantaneous current load, 8 A High side driver, 5 A Logical one (1) generates voltage out, U >= 22.5 V Max. load 5 A Open load 0.9 A Max. instantaneous current load, 35 A E.g. working lights and wiper motors. E.g. side marker lights, solenoid valves. E.g. position sensors (inductive sensors) and brake pressure (pressure switches). E.g. input signal from a circuit breaker with search lighting.
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Signal type High side driver, 10 A
Explanation Logical one (1) generates voltage out, U >= 22.5 V Max. load 10 A Open load 1.9 A Max. instantaneous current load, 70 A
Application area E.g. cooling fan. This output is only found on the frame and attachment control units. E.g. air conditioning water valve (works in both directions).
H-bridge
Logical one (1) generates voltage out, U >= 22.5 V or grounded output, U=0V Max. load 0.5 A Open load 0.15 A Max. instantaneous current load, 8 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.
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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.
120 ohm
120 ohm
The CAN bus is a fast control bus with logical hardware circuits. A 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 3 4
that the signal traffic is carried by "twisted pair" cables. that termination resistors (position 1) are necessary (adapted to cables' impedance) so that the pulse train (position 4) should obtain a sharp signal. that the signal valve is given as the potential difference between the cables, CAN + and CAN - (position 2 and 3). form of signal messages.
U [V]
t [S]
Messages are sequential and signal is high (voltage high) or low (voltage low). 1. 2. 3. 4. 5.
Message
Termination resistor (120 ohm) CAN + (voltage high) CAN - (voltage low) Pulse Control unit
A
000026
Message
There are two types of messages:
000027
CAN Standard, has identity field of 11 bits CAN Extended, has identity field of 29 bits
F G
t [S]
Messages are sequential and signal is high (voltage high) or low (voltage low). A B C D E F G Length message Start bit Identity field/Priority Control field (length of data segment) Data segment Checksum for error detection Acknowledge bit
CAN works in messages sent in frames of 8 bytes (64 bits). A complete message is approx. 100 bits long. The illustration depicts how a message is structured.
Start bit (B)

Indicates that the transmission of a frame, i.e. a message, is now beginning.
Identity field (C)

Indicates what kind of information the message contains, e.g. measurement information on engine speed. 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.
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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 U [V]
0,5 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 potential levels. CAN + has a recommended value of 3.5 V and CAN - has 1.5 V. As a worst case scenario, the potential difference can be only 0.5 V and still be approved. In practice, a potential difference of 2 V is recommended for reliable communication. A pulse train can only be observed using an oscilloscope, NOT with a digital multimeter. When a message is sent, all control units in the network listen. Messages are saved in the control unit and relevant information is processed. The control unit that receives the message first confirms receipt (sets an acknowledge bit). The transmitting control unit then knows that the message has been received by at least one control 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).
1,5 V
t [S]
Potential levels CAN + and CAN -
000028
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
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11 Common electrics Redundant CAN bus
11.6.2 Redundant CAN bus

Redundant CAN bus, description
D791
CAN R CAN L
D790-1
CAN R CAN L
D790-2
D795
CAN R CAN L
The redundant CAN bus handles communication between all of the machine's control units except Control unit, transmission (D793) and Control unit, engine (D794). These have a separate CAN bus; see CAN bus drive-train, description, page 11:38.
014682 009752
CAN L
CAN R
D797-1
Outline view, redundant CAN bus
D790-1
CAN L CAN R
D791
CAN L CAN R
D797-1
CAN L CAN R
4
CAN R CAN L
2 3
D795
Segment numbering starts from the CAN-R (right) connection
Redundant CAN bus means that the control units are connected into a network that communicates via a CAN bus (see CAN bus, description, page 11:34) and that there are double communication routes on the network. The network is divided into control units and segments (segments are the cables between the control units). The number of active segments depends on the number of control units the machine has, which depends on the machine's equipment level (options).
D790-1
CAN L CAN R
D791
CAN L CAN R
D797-1
CAN L CAN R
1 4
CAN R CAN L
2 3
015052
The network is built on the CAN kingdom principle, which means that one control unit is central and is the master unit. In this case, it is the cab control unit (D790-1). Other control units in the network are secondary (slaves) and handle special areas, e.g. machine components. The control units have two CAN bus connections - CAN L (left) and CAN R (right). The control units are connected to one another in series in a loop. The redundant CAN bus can handle the loss of a segment. The link is analysed upon start-up. If a segment 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.
D795
Segment numbering
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11 Common electrics Redundant CAN bus
11:37
Connection of redundant CAN bus Condition Reference value

In position 1 Activated.
Reference
Battery disconnector Redundant voltage feed
Battery disconnector, description, page 11:3 Redundant voltage feed of control units, function description , page 11:7
D790-2
S1
5 4
1, 6
D790-1
S4
D795
D791 2
S2
D797-1 3
S3
Pos
1
Explanation
Control unit, cab (D790-1) establishes redundant CAN bus communication by sending a request on the CAN bus via CAN R. The attachment control unit (D791) sends a response back on the CAN bus via CAN L and sends the request on via CAN R. Termination resistors in the control nodes ensure communication segment by segment.
Signal description
Reference
Cab control unit, description, page 11:17 Diagnostic menu, see section 8 Control system, group 8.4.1.1 CAN/POWER, menu 1 and 8.4.1.2 CAN/POWER, menu 2 Control unit, attachment, description, page 11:19 Diagnostic menu, see section 8 Control system, group 8.4.1.1 CAN/POWER, menu 1 and 8.4.1.2 CAN/POWER, menu 2
A clicking sound is audible when then termination resistor is activated.
The frame control unit (D797-1) sends a response back on the CAN bus via CAN L and sends the request on via CAN R. Termination resistors in the control nodes ensure communication segment by segment.
Frame control unit, description, page 11:18 Diagnostic menu, see section 8 Control system, group 8.4.1.1 CAN/POWER, menu 1 and 8.4.1.2 CAN/POWER, menu 2
Control unit KID (D795) sends a response back on the CAN bus via CAN L and sends the request on via CAN R. Termination resistors in the control nodes ensure communication segment by segment.
Control unit KID, description, page 11:24 Diagnostic menu, see section 8 Control system, group 8.4.1.1 CAN/POWER, menu 1 and 8.4.1.2 CAN/POWER, menu 2
VDCT01.02GB
015060
11:38
11 Common electrics CAN bus drive-train
Pos
5
Explanation
The KIT control unit (D790-2) is not connected to the redundant CAN bus. The KIT control unit (D790-2) does not communicate until ignition voltage (15) is activated. If all control units have responded, the cab control unit (D790-1) deactivates the segment to the attachment control 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.
Signal description
A clicking sound is audible when then termination resistor is activated. Checked by control system, error shown with error code.
Reference
Control unit KIT, description, page 11:23
Diagnostic menu, see section 8 Control system, group 8.4.1.1 CAN/POWER, menu 1 and 8.4.1.2 CAN/POWER, menu 2
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
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.
1
1. 2. 3. 4. 5. 6. Redundant CAN bus CAN bus drive-train Control unit, engine (D794) Engine Control unit, transmission (D793) Transmission
VDCT01.02GB
000033
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 electronic box frame. The diagnostic socket for the engine is loose in electronic box frame. 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.
1 2
3
1. 2. 3. Diagnostic socket, machine Diagnostic socket CAN bus drive-train Diagnostic socket engine (loose in electronic box)
015059
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D:1
D Error codes
Contents D Error codes

D 1 2 8 Error codes ........................................................................................................ D:3 Engine................................................................................................................. D:9 Transmission ................................................................................................... D:59 Control system ................................................................................................ D:95
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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. Description, explanation of the error code and when it\qs generated. Limitation, in case of certain error codes certain functions are impaired or limited to protect the machine and operator. Action, information of what should be checked to find the cause of the error code. Diagnostic menu, reference to suitable diagnostic menu to rectify the problem, read signal value or check the function. In addition to the explanation of the display figure, the description of the diagnostic menus contains reference to circuit diagrams that are found in section E Schematics and reference to function group for further information about functions and components. Function group is a reference to which function group the error code is associated. This field is used to search for more 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.
C D B E
000389
B. Error code level (symbol) C. Error code number D. Error cause (symbol) E. Function (symbol)
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Error code menu, description

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

The control and monitoring system gives error code information in three levels which are indicated with a symbol in the lower left corner (B) on the display unit. Stop Indicates a serious malfunction that may jeopardise the operator's safety or cause machine failure. The error code must be attended to immediately. Stop working with the machine and contact service immediately.
000350
C D E
The error code is shown automatically on the display.
Warning Indicates malfunction in machine that should be taken care of as soon as possible. After the finished work shift with the machine, contact service as soon as possible. The error code is shown automatically on the display.
C D E
000351
Information Information to the operator that something should be taken care of as soon as possible, e.g., defective light bulb. Take action to fix the cause of the error code as soon as possible. See section 6 Inspection and maintenance in the operator's manual.
C D E
000352
The error code is stored in the error code list under operating menu for service.
C D B E
000389
The control and monitoring system gives error codes from three sub-systems: Machine: Shown with error code number XXX on display. Engine: Shown with error code number XXX/YY on display.
XX/YY
D
001343
NOTE
If several error codes come from the engine, the error code level is shown for the most serious error code.
VDCT01.02GB
D:5
XXX/YY
Transmission: Shown with error code number XX/YY on display.
D
001344

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

1. 2. 3. Attachment Rotation of attachment Side shift, attachment Length adjustment attachment Levelling Twistlocks Forks up/down Tilt forks Side shift forks
4. 5. 6. 7.
8. 9.
10. Spreading forks
10
11
12
11. Rotation forks 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 26. Battery voltage 27. Bulb for lighting
22
23
24
25
26
27
010153
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D:7
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
The safety menu is shown. Hold Enter depressed for at least two seconds.
1 23 4 5
000060
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 remedied.
001998
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Note error code number (field C) to avoid forgetting. Error code level is shown with a symbol in field B Error code is shown in field C Error cause is shown with a symbol in field D 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.
C D B E
000389
6 7
Use the error code tables to find more information about the error code. After the remedial action, check that no active error codes remain for the function in question.
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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
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20-30 31
Description
Too high value. Too low value. Incorrect data. Electrical problem. Electrical problem. Electrical problem. Electrical problem. Mechanical problem. Mechanical problem or electrical problem. Communication error. Mechanical problem or electrical problem. Unknown malfunction. Component error. Incorrect calibration. Unknown malfunction. Too high value. Too high value. Too low value. Too low value. Communication error.
SAE-text
Data valid, but higher than normal operating range. Data valid, but lower than normal operating range. Intermittent or incorrect data. Abnormally high voltage or short-circuit to higher voltage. Abnormally low voltage or short-circuit to lower voltage. Abnormally low current or open circuit. Abnormally high current or short-circuit to ground. Incorrect response from mechanical system. Abnormal frequency. Abnormal update rate. Abnormally wide variations. Non-identifiable malfunction. Incorrect unit or component. Values outside calibration values. Special instructions. Data valid, but higher than normal operating range. The least serious level Data valid, but higher than normal operating range. Moderately severe level Data valid, but below normal operating range: The least serious level Data valid, but below normal operating range: Moderately severe level Received network data incorrect Reserved for SAE-assignment
FMI is not available or the condition that is identified by the SPN exists.
Not available or condition exists
VDCT01.02GB
D:10
1 Engine Engine
Error codes engine (engine alternative Yuchai YC6A240-30)

Table Error codes Yuchai YC6A240-30
Display
Supplier code
P2135
Description
Limitation
Action

D794/1:79 D794/1:80
Diagnostic menu
29/2
Signal from accelerator pedal, signal 2 and 1 do not correspond. Accelerator pedal, short circuit to voltage. Accelerator pedal, short circuit to ground. Machine speed too high. Speed signal unreasonable. Machine speed does not correspond with values from fuel injection and engine speed. Speed signal wrong. Internal error engine control unit.
Reduced engine power.
Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Ease off throttle or select higher gear. Check the engine speed sensor. Check the speed sensor on the transmission.
29/3
P0223
Reduced engine power. Reduced engine power. Engine speed is limited. Engine speed is limited.
D794/1:80
29/4
P0222
D794/1:80
84/0 84/2
P0501 P0501
D794/1:71
ENGINE, menu 1
84/11
P0510
Engine speed is limited.
Check the engine speed sensor. Check the speed sensor on the transmission.
84/12
P0500
Speed signal wrong.
Check the engine speed sensor. Check the speed sensor on the transmission.
ENGINE, menu 1
91/2
P2135
Signal from accelerator pedal, signal 1 and 2 do not correspond. Accelerator pedal, short circuit to voltage. Accelerator pedal, short circuit to ground. Signal from accelerator pedal and brake pedal not consistent. Sensor pressure fuel filter, unreasonable signal.
Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness between control unit and sensor. Check the sensor.
D794/1:79 D794/1:80
91/3
P0123
Reduced engine power. Reduced engine power. No limitation.
D794/1:79
91/4
P0122
D794/1:79
91/7
P2299
D794/1:79 D794/1:80
95/2
P1017
No limitation.
D794/1:81
VDCT01.02GB
1 Engine Engine
D:11
Display
Supplier code
P1015
Description
Limitation
Action

D794/1:81
Diagnostic menu
95/3
Sensor pressure fuel filter, signal high.
No limitation.
Check the cable harness between control unit and sensor. Check the sensor.
95/4
P1016
Sensor pressure fuel filter, signal low.
No limitation.
D794/1:81
95/7 97/3
P1018 P2267
Fuel filter clogged. Water-in-fuel sensor (B760), short circuit to voltage.
No limitation. No limitation.
Change the fuel filter. Check the cable harness between control unit and sensor. Check the sensor.
D794/1:43 B760/1
ENGINE, menu 10
97/4
P2266
Water-in-fuel sensor (B760), short circuit to ground.
No limitation.
D794/1:43 B760/1
ENGINE, menu 10
97/11 98/2
P2269 P250B
Water in fuel. Sensor engine oil level, unreasonable signal. Sensor engine oil level, short circuit to voltage. Sensor engine oil level, short circuit to ground. Sensor engine oil level, incorrect signal via CAN bus.
Change the fuel prefilter. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Use diagnostic menu to check communication. Check the cable harness between Control unit, cab (D790-1) and Control unit, engine (D794).
D794/1:43 B760/1 -
ENGINE, menu 10 -
98/3
P250D
No limitation.
98/4
P250C
No limitation.
98/12
P250A
No limitation.
D794/1:34 D794/1:35
CAN/POWER, menu 3
100/2
P0521
Sensor engine oil pressure, unreasonable signal.
No limitation.
Check the cable harness between control unit and sensor. Check the sensor. Check the oil level in the engine.
ENGINE, menu 6
100/3
P0523
Sensor engine oil pressure, short circuit to voltage.
No limitation.
ENGINE, menu 6
100/4
P0522
Sensor engine oil pressure, short circuit to ground.
No limitation.
ENGINE, menu 6
VDCT01.02GB
D:12
1 Engine Engine
Display
Supplier code
P0520
Description
Limitation
Action

D794/1:34 D794/1:35
Diagnostic menu
100/12
Sensor engine oil pressure, incorrect signal via CAN bus.
No limitation.
Use diagnostic menu to check communication. Check the cable harness between Control unit, cab (D790-1) and Control unit, engine (D794).
CAN/POWER, menu 3
100/17
P0524
Low engine oil pressure.
Check the oil level in the engine. Change oil filter. Check the system pressure valves and the safety valve in the lubrication system. Check the sensor.
ENGINE, menu 6
102/2
P0236
Sensor boost pressure and sensor air pressure, unreasonable signal combination. Sensor boost pressure, short circuit to voltage.
Check the cable harness between control unit and sensor. Check the sensors.
D794/2:32 36
ENGINE, menu 6
102/3
P0238
D794/2:34
ENGINE, menu 6
102/4
P0237
Sensor boost pressure, short circuit to ground.
D794/2:34
ENGINE, menu 6
102/12
P0235
Sensor boost pressure, incorrect signal via CAN bus.
D794/1:34 D794/1:35
CAN/POWER, menu 3
105/3
P0098
Sensor intake temperature, incorrect signal. Short circuit to voltage. Sensor intake temperature, short circuit to ground.
No limitation.
D794/2:36
ENGINE, menu 7
105/4
P0097
No limitation.
D794/2:36
ENGINE, menu 7
105/12
P0099
Sensor intake temperature, incorrect signal via CAN bus.
No limitation.
D794/1:34 D794/1:35
CAN/POWER, menu 3
VDCT01.02GB
1 Engine Engine
D:13
Display
Supplier code
P2227
Description
Limitation
Action

D794/2:32 2:36
Diagnostic menu
108/2
Sensor air pressure and sensor boost pressure, unreasonable signal combination. Sensor air pressure, short circuit to voltage.
Check the cable harness between control unit and sensor. Check the sensors.
ENGINE, menu 6
108/3
P2229
108/4
P2228
Sensor air pressure, short circuit to ground.
108/12
P0000
Sensor air pressure, incorrect signal via CAN bus.
D794/1:34 D794/1:35
CAN/POWER, menu 3
110/2
P0116
Coolant temperature sensor, the temperature is unreasonable in relation to the oil temperature. Sensor coolant temperature, short circuit to voltage.
D794/2:15
ENGINE, menu 7
110/3
P0118
D794/2:15
ENGINE, menu 7
110/4
P0117
Sensor coolant temperature, short circuit to ground.
D794/2:15
ENGINE, menu 7
110/12
P0115
Sensor coolant temperature, incorrect signal via CAN bus.
D794/1:34 D794/1:35
CAN/POWER, menu 3
VDCT01.02GB
D:14
1 Engine Engine
Display
Supplier code
P0217
Description
Limitation
Action

D794/2:15
Diagnostic menu
110/15
Coolant temperature too high.
No limitation.
Check the coolant 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 control unit and sensor. Check the sensor.
111/2
P2557
Sensor coolant level, unreasonable signal combination. Sensor coolant level, short circuit to voltage. Sensor coolant level, short circuit to voltage. Sensor coolant level, open circuit. Mass air flow sensor, signal deviation too high. Mass air flow sensor, air flow too high. Mass air flow sensor, signal deviation too low. Mass air flow sensor, air flow too low. Sensor fuel pressure, short circuit to voltage.
No limitation.
Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness between control unit and sensor. Check the sensor.
ENGINE, menu 10 ENGINE, menu 10 ENGINE, menu 10 ENGINE, menu 10 -
111/3
P2559
No limitation.
111/4
P2558
No limitation.
111/12
P2556
No limitation.
132/3
P0101
No limitation.
132/3
P0103
No limitation.
132/4
P0101
No limitation.
132/4
P0102
No limitation.
157/3
P0193
D794/2:14
157/4
P0192
Sensor fuel pressure, short circuit to ground.
D794/2:14
157/15
P0191
Sensor fuel pressure, signal deviation too high.
D794/2:14
VDCT01.02GB
1 Engine Engine
D:15
Display
Supplier code
P0191
Description
Limitation
Action

D794/2:14
Diagnostic menu
157/17
Sensor fuel pressure, signal deviation too low.
158/12
P2533
Ignition key lock, open circuit. High battery voltage.
No limitation.
Check the cable harness at the control unit. Check the voltage feed. If equipment for assisted start is connected, disconnect it.
D794/1:40
168/3
P0563
No limitation.
D794/1:2
168/4
P0562
Low battery voltage.
The engine may be difficult to start.
Check and charge the batteries. Check the cable harness to the control unit. Check alternator, battery and cable harness between battery and alternator.
D794/1:2
171/3
P0073
Sensor outdoor temperature, short circuit to voltage. Sensor outdoor temperature, short circuit to ground. Sensor outdoor temperature, incorrect signal via CAN bus.
No limitation.
Check the cable harness at the control unit. Check the cable harness at the control unit. Use diagnostic menu to check communication. Check the cable harness between Control unit, cab (D790-1) and Control unit, engine (D794).
171/4
P0072
No limitation.
171/12
P0071
No limitation.
D794/1:34 D794/1:35
CAN/POWER, menu 3
172/3
P0113
Sensor intake temperature, high signal.
No limitation.
D794/2:36
ENGINE, menu 7
172/4
P0112
Sensor intake temperature, low signal.
No limitation.
D794/2:36
ENGINE, menu 7
174/3
P0183
Sensor fuel temperature, short circuit to voltage.
No limitation.
174/4
P0182
Sensor fuel temperature, short circuit to ground.
No limitation.
VDCT01.02GB
D:16
1 Engine Engine
Display
Supplier code
P0198
Description
Limitation
Action

-
Diagnostic menu
175/3
Sensor engine oil temperature, short circuit to voltage.
No limitation.
ENGINE, menu 7
175/4
P0197
Sensor engine oil temperature, short circuit to ground.
No limitation.
ENGINE, menu 7
175/12
P0195
Sensor engine oil temperature, incorrect signal via CAN bus.
No limitation.
D794/1:34 D794/1:35
CAN/POWER, menu 3
175/17
P0196
High oil temperature.
No limitation.
Check the oil level. Check coolant temperature and level.
ENGINE, menu 7 -
190/7
P0016
Sensor camshaft and sensor crankshaft, unreasonable signal combination.
No limitation.
Check the cable harness between control unit and sensors. Check the sensors.
D794/2:09 D794/2:23
190/11
P0336
Sensor rotation speed crankshaft, irregular signal.
The engine is extremely difficult to start and runs unevenly or stops. Reduced engine power.
D794/2:23
ENGINE, menu 2
190/12
P0008
Sensor camshaft rotation speed, signal error.
No limitation.
D794/2:09
190/12
P0335
Sensor rotation speed crankshaft, no signal.
The engine is extremely difficult to start and runs unevenly or stops. Reduced engine power.
D794/2:23
520/11 520/12
UD13A UD13B
CAN bus, communication error.
No limitation.
D794/1:34 D794/1:35
CAN/POWER, menu 3
VDCT01.02GB
1 Engine Engine
D:17
Display
Supplier code
P0219
Description
Limitation
Action

D794/2:09 D794/2:23
Diagnostic menu
533/15
Engine speed too high.
No limitation.
Check the fuel pressure. Check the cable harness between control unit and sensors. Check sensor camshaft rotation speed and sensor crankshaft.
Engine, menu 2
596/2
P0564
Cruise control input, unreasonable signal.
No limitation.
Check the cable harness at the control unit.
D794/1:31 D794/1:64 D794/1:74 D794/1:46 -
597/2
P0504
The signal from the brake pedal does not correspond with the accelerator pedal. Brake pedal, incorrect signal via CAN bus.
No limitation.
Check the cable harness at the control unit. Use diagnostic menu to check communication. Check the cable harness between Control unit, cab (D790-1) and Control unit, engine (D794).
597/12
P0571
No limitation.
D794/1:34 D794/1:35
CAN/POWER, menu 3
598/2
P0704
Sensor clutch, unreasonable signal. Sensor clutch, incorrect signal via CAN bus.
No limitation.
Check the cable harness at the control unit. Use diagnostic menu to check communication. Check the cable harness between Control unit, cab (D790-1) and Control unit, engine (D794).
598/12
P0704
No limitation.
D794/1:34 D794/1:35
CAN/POWER, menu 3
624/2
P1626
Drive circuit lamp 1, overheating. Drive circuit lamp 2, overheating. Drive circuit lamp 3, overheated. Drive circuit system lamp, overheated. Drive circuit warning lamp, overheated.
No limitation.
Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit.
624/2
P162A
No limitation.
624/2
P162E
No limitation.
624/2
P161C
No limitation.
624/2
P1632
No limitation.
VDCT01.02GB
D:18
1 Engine Engine
Display
Supplier code
P1623
Description
Limitation
Action

-
Diagnostic menu
624/3
Drive circuit lamp 1, short circuit to voltage. Drive circuit lamp 2, short circuit to voltage. Drive circuit lamp 3, short circuit to voltage. Drive circuit system lamp, short circuit to voltage. Drive circuit warning lamp, short circuit to voltage. Drive circuit lamp 1, short circuit to ground. Drive circuit lamp 2, short circuit to ground. Drive circuit lamp 3, short circuit to ground. Drive circuit system lamp, short circuit to ground. Drive circuit warning lamp, short circuit to ground. Drive circuit lamp 1, open circuit. Drive circuit lamp 2, open circuit. Drive circuit lamp 3, open circuit. Drive circuit system lamp, open circuit. Drive circuit warning lamp, open circuit. Internal error engine control unit.
No limitation.
Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Contact Yuchai service.
624/3
P1627
No limitation.
624/3
P162B
No limitation.
624/3
P1619
No limitation.
624/3
P162F
No limitation.
624/4
P1624
No limitation.
624/4
P1628
No limitation.
624/4
P162C
No limitation.
624/4
P161A
No limitation.
624/4
P1630
No limitation.
624/12
P1625
No limitation.
624/12
P1629
No limitation.
624/12
P162D
No limitation.
624/12
P161B
No limitation.
624/12
P1631
No limitation.
630/2 630/4 630/12
P062F P062F P062F
No limitation.
VDCT01.02GB
1 Engine Engine
D:19
Display
Supplier code
P0341
Description
Limitation
Action

D794/2:09
Diagnostic menu
636/11
Sensor rotation speed camshaft, irregular signal.
The engine takes longer to start than normal. The engine is running normally once it has started. The engine takes longer to start than normal. The engine is running normally once it has started. No limitation.
Check the cable harness between control unit and sensor. Check the sensor. Check the cable harness between control unit and sensor. Check the sensor. Use diagnostic menu to check communication. Check the cable harness between Control unit, cab (D790-1) and Control unit, engine (D794).
636/12
P0340
Sensor rotation speed camshaft, no signal.
D794/2:09
639/12
UC029
CAN bus (A), electrical problem.
D794/1:34 D794/1:35
CAN/POWER, menu 3
645/3
P1511
Sensor machine speed, incorrect signal form.
D794/1:71
ENGINE, menu 2
645/4
P1512
D794/1:71
ENGINE, menu 2
645/12
P1513
D794/1:71
ENGINE, menu 2
651/3
P0262
Injector cylinder 1, short circuit to ground.
Engine only runs on 3 cylinders and has reduced power.
Check the cable harness between control unit and injector. Check the injector.
D794/3:04 D794/3:13
651/8
P0261
Injector cylinder 1, short circuit between cables.
D794/3:04 D794/3:13
651/11
P0263
Injector cylinder 1, installation-dependent error.
D794/3:04 D794/3:13
651/11
P0263
Injector cylinder 1, indefinable error.
D794/3:04 D794/3:13
VDCT01.02GB
D:20
1 Engine Engine
Display
Supplier code
P1213
Description
Limitation
Action

D794/3:04 D794/3:13
Diagnostic menu
651/11
No limitation.
651/11
P1214
No limitation.
D794/3:04 D794/3:13
651/11
P1215
No limitation.
D794/3:04 D794/3:13
651/12
P0201
Injector cylinder 1, open circuit.
No limitation.
D794/3:04 D794/3:13
652/3
P0265
D794/3:06 D794/3:11
652/8
P0264
D794/3:06 D794/3:11
652/11
P0266
D794/3:06 D794/3:11
652/11
P0266
D794/3:06 D794/3:11
652/11
P1216
No limitation.
D794/3:06 D794/3:11
652/11
P1217
No limitation.
D794/3:06 D794/3:11
VDCT01.02GB
1 Engine Engine
D:21
Display
Supplier code
P1218
Description
Limitation
Action

D794/3:06 D794/3:11
Diagnostic menu
652/11
No limitation.
652/12
P0202
No limitation.
D794/3:06 D794/3:11
653/3
P0268
D794/3:05 D794/3:12
653/8
P0267
D794/3:05 D794/3:12
653/11
P0269
D794/3:05 D794/3:12
653/11
P0269
D794/3:05 D794/3:12
653/11
P1219
No limitation.
D794/3:05 D794/3:12
653/11
P121A
No limitation.
D794/3:05 D794/3:12
653/11
P121B
No limitation.
D794/3:05 D794/3:12
653/12
P0203
No limitation.
D794/3:05 D794/3:12
VDCT01.02GB
D:22
1 Engine Engine
Display
Supplier code
P0271
Description
Limitation
Action

D794/3:03 D794/3:14
Diagnostic menu
654/3
654/8
P0270
D794/3:03 D794/3:14
654/11
P0272
D794/3:03 D794/3:14
654/11
P0272
D794/3:03 D794/3:14
654/11
P121C
No limitation.
D794/3:03 D794/3:14
654/11
P121D
No limitation.
D794/3:03 D794/3:14
654/11
P121E
No limitation.
D794/3:03 D794/3:14
654/12
P0204
No limitation.
D794/3:03 D794/3:14
655/3
P0274
D794/3:01 D794/3:16
655/8
P0273
D794/3:01 D794/3:16
VDCT01.02GB
1 Engine Engine
D:23
Display
Supplier code
P0275
Description
Limitation
Action

D794/3:01 D794/3:16
Diagnostic menu
655/11
655/11
P0275
D794/3:01 D794/3:16
655/11
P121F
No limitation.
D794/3:01 D794/3:16
655/11
P1220
No limitation.
D794/3:01 D794/3:16
655/11
P1221
No limitation.
D794/3:01 D794/3:16
655/12
P0205
No limitation.
D794/3:01 D794/3:16
656/3
P0277
D794/3:02 D794/3:15
656/8
P0276
D794/3:02 D794/3:15
656/11
P0278
D794/3:02 D794/3:15
656/11
P0278
D794/3:02 D794/3:15
VDCT01.02GB
D:24
1 Engine Engine
Display
Supplier code
P1222
Description
Limitation
Action

D794/3:02 D794/3:15
Diagnostic menu
656/11
No limitation.
656/11
P1223
No limitation.
D794/3:02 D794/3:15
656/11
P1224
No limitation.
D794/3:02 D794/3:15
656/12
P0206
No limitation.
D794/3:02 D794/3:15
676/7
P0540
Relay, preheating (K312), signal error.
Preheating not working.
Check the cable harness between control unit and component. Check the component.
D794/1:55 K312/86 D794/1:59 K312/85 D794/1:37 D794/1:51 D794/1:37 D794/1:51 D794/1:37 D794/1:51 D794/1:55 K312/86 D794/1:59 K312/85 D794/1:55 K312/86 D794/1:59 K312/85 D794/1:55 K312/86 D794/1:59 K312/85
ENGINE, menu 5
677/3
P0617 P1638
Relay starter motor, short circuit to voltage or activated too long. Relay starter motor, short circuit to ground. Relay starter motor, open circuit. Relay preheating (K312), short circuit to ground.
No limitation.
Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness between control unit and component. Check the component.
677/4
P0616 P1639
No limitation.
677/5
P163A
No limitation.
729/3
P0541
No limitation.
ENGINE, menu 5
729/3
P0542
Relay preheating (K312), short circuit to voltage.
No limitation.
ENGINE, menu 5
729/3
P1020
Relay preheating (K312), high signal.
No limitation.
ENGINE, menu 5
VDCT01.02GB
1 Engine Engine
D:25
Display
Supplier code
P1021
Description
Limitation
Action

D794/1:55 K312/86 D794/1:59 K312/85 D794/1:55 K312/86 D794/1:59 K312/85 D794/1:55 K312/86 D794/1:59 K312/85 D794/1:34 D794/1:35
Diagnostic menu
729/4
Relay preheating (K312), active too short time.
No limitation.
ENGINE, menu 5
730/3
P1022
Relay preheating (K312), high signal.
No limitation.
ENGINE, menu 5
730/4
P1023
Relay preheating (K312), low signal.
No limitation.
ENGINE, menu 5
898/11 898/12
UD10E UD10F
CAN bus, communication error.
No limitation.
CAN/POWER, menu 3
970/3
P1617
Voltage error at shut-off, high battery voltage.
Check the cable harness at the control unit. Check the component.
D794/1:02
970/4
P1618
Voltage error at shut-off, low battery voltage.
D794/1:02
970/12
P1616
Voltage error at shut-off, monitoring switched off.
D794/1:02
985/2 985/12
P2519 P2519
AC compressor, incorrect CAN message.
No limitation.
D794/1:34 D794/1:35
CAN/POWER, menu 3
1041/7
P2530
Ignition key lock, incorrect signal. Switch remote start engine, fixed in activated position. Drive circuit cooling fan, overheated.
No limitation.
Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit.
D794/1:61
1041/8
P2530
No limitation.
D794/1:61
1071/2
P0483
No limitation.
D794/1:13 D794/1:58
VDCT01.02GB
D:26
1 Engine Engine
Display
Supplier code
P0692
Description
Limitation
Action

D794/1:13 D794/1:58 -
Diagnostic menu
1071/3
Drive circuit cooling fan, short circuit to voltage. Drive circuit cooling fan 2, short circuit to voltage. Drive circuit cooling fan, short circuit to ground. Drive circuit cooling fan 2, short circuit to ground. Drive circuit cooling fan, open circuit. Drive circuit brake valve, short circuit to voltage. Drive circuit brake valve, short circuit to ground. Drive circuit brake valve, open circuit. Drive circuit brake valve, short circuit to voltage. Drive circuit exhaust brake, overheated. Drive circuit exhaust brake, short circuit to voltage. Drive circuit exhaust brake, short circuit to ground. Drive circuit exhaust brake, open circuit. Voltage feed 1 sensor engine, high signal. Voltage feed 1 sensor engine, low signal. Voltage feed 2 sensor engine, high signal. Voltage feed 2 sensor engine, low signal.
No limitation.
Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit.
1071/3
P0694
No limitation.
1071/4
P0691
No limitation.
D794/1:13 D794/1:58 -
1071/4
P0693
No limitation.
1071/12
P0480
No limitation.
D794/1:13 D794/1:58 -
1072/3
P0080
No limitation.
1072/4
P0079
No limitation.
1072/255
P1633
No limitation.
1072/255
P1634
No limitation.
D794/3:08
1074/2
P0476
No limitation.
D794/3:08
1074/3
P0478
No limitation.
D794/3:08
1074/4
P0477
No limitation.
D794/3:08
1074/12
P0476
No limitation.
D794/3:08
1079/3
P0643
Reduced engine power. No limitation.
1079/4
P0642
1080/3
P0653
Reduced engine power. No limitation.
1080/4
P0652
VDCT01.02GB
1 Engine Engine
D:27
Display
Supplier code
P1638
Description
Limitation
Action

D794/1:38 D797F/K1:26
Diagnostic menu
1081/2
Drive circuit indicator light preheating, overheated.
No limitation.
ENGINE, menu 10
1081/3
P1635
Drive circuit indicator light preheating, short circuit to voltage.
No limitation.
D794/1:38 D797F/K1:26
ENGINE, menu 10
1081/4
P1636
Drive circuit indicator light preheating, short circuit to ground.
No limitation.
D794/1:38 D797F/K1:26
ENGINE, menu 10
1081/12
P1637
Drive circuit indicator light preheating, open circuit.
No limitation.
D794/1:38 D797F/K1:26
ENGINE, menu 10
1108/16
P1613
Engine speed too high.
No limitation.
Check the cable harness between control unit and the components. Check sensor camshaft rotation speed and sensor crankshaft. Check the fuel pressure.
D794/2:09 D794/2:23
ENGINE, menu 2
1192/2
P0046
Valve boost pressure control, overheating. Valve boost pressure control, short circuit to voltage. Valve boost pressure control, signal too high. Valve boost pressure control, short circuit to ground. Valve boost pressure control, signal too low. Valve boost pressure control, open circuit. Valve boost pressure control, incorrect signal.
No limitation.
Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit.
D794/2:01
1192/3
P0048
No limitation.
D794/2:01
1192/3
P1000
No limitation.
D794/2:01
1192/4
P0047
No limitation.
D794/2:01
1192/4
P1001
No limitation.
D794/2:01
1192/12
P0045
No limitation.
D794/2:01
1192/12
P1002
No limitation.
D794/2:01
VDCT01.02GB
D:28
1 Engine Engine
Display
Supplier code
P0650
Description
Limitation
Action

-
Diagnostic menu
1213/2
Drive circuit warning lamp engine fault, overheated. Drive circuit warning lamp engine fault, short circuit to voltage. Drive circuit warning lamp engine fault, short circuit to ground. Drive circuit warning lamp engine fault, open circuit. CAN bus (C), electrical problem.
No limitation.
Check the cable harness between control unit and component. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Use diagnostic menu to check communication. Check the cable harness between Control unit, cab (D790-1) and Control unit, engine (D794).
1213/3
P0650
No limitation.
1213/4
P0650
No limitation.
1213/12
P0650
No limitation.
1231/12 1235/12
UC038 UC047
No limitation.
D794/1:34 D794/1:35
CAN/POWER, menu 3
1322/3 1323/3 1324/3 1325/3 1326/3 1327/3 1328/3 1351/2
P0300 P0301 P0302 P0303 P0304 P0305 P0306 P0645
Misfiring on multiple cylinders. Misfiring cylinder 1. Misfiring cylinder 2. Misfiring cylinder 3. Misfiring cylinder 4. Misfiring cylinder 5. Misfiring cylinder 6. Drive circuit AC compressor, overheated. Drive circuit AC compressor, short circuit to voltage. Drive circuit AC compressor, short circuit to ground. Drive circuit AC compressor, open circuit. Main relay 2, electrical problem.
Reduced engine power. Reduced engine power. Reduced engine power. Reduced engine power. Reduced engine power. Reduced engine power. Reduced engine power. No limitation.
Contact Yuchai service. Contact Yuchai service. Contact Yuchai service. Contact Yuchai service. Contact Yuchai service. Contact Yuchai service. Contact Yuchai service. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit.
D794/2:11
1351/3
P0647
No limitation.
D794/2:11
1351/4
P0646
No limitation.
D794/2:11
1351/12
P0645
No limitation.
D794/2:11
1485/3
P0687
No limitation.
VDCT01.02GB
1 Engine Engine
D:29
Display
Supplier code
P0686
Description
Limitation
Action

-
Diagnostic menu
1485/4
Main relay 2, electrical problem. Sensor machine speed, speed too high. Sensor machine speed, speed too low. Sensor machine speed, speed message via CAN bus incorrect.
No limitation.
Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Use diagnostic menu to check communication. Check the cable harness between Control unit, cab (D790-1) and Control unit, engine (D794).
1624/3
P2158
Engine speed is limited. Engine speed is limited. Engine speed is limited.
D794/1:71
1624/4
P2160
D794/1:71
1624/12
P2157
D794/1:34 D794/1:35
CAN/POWER, menu 3
1624/255
P2159
Sensor machine speed, unreasonable speed. Sensor fan speed, short circuit to voltage. Sensor fan speed, short circuit to ground. Main relay, short circuit to voltage. Main relay, short circuit to ground. Drive circuit EGR valve, overheating. Drive circuit EGR valve, short circuit to voltage. Drive circuit EGR valve, short circuit to ground. Drive circuit EGR valve, open circuit. Voltage feed speed sensor, incorrect signal (ADC).
Engine speed is limited. No limitation.
Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness between control unit and sensor. Check the sensor.
D794/1:71
1639/3
P0526
D794/1:68 D794/1:69 D794/1:68 D794/1:69 -
1639/4
P0527
No limitation.
2634/3
P160E
No limitation.
2634/4
P160F
No limitation.
2791/2
P0403
No limitation.
2791/3
P0490
No limitation.
2791/4
P0489
No limitation.
2791/5
P0404
No limitation.
520192/2
P063B
The engine is only running at idle.
520192/3
P060B
Voltage feed speed sensor, signal too high (ADC).
VDCT01.02GB
D:30
1 Engine Engine
Display
Supplier code
P061B
Description
Limitation
Action

-
Diagnostic menu
520192/4
Voltage feed speed sensor, signal too low (ADC).
520192 /11
P062B
Voltage feed speed sensor, incorrect test impulse(ADC).
520193/3
P0103
Mass air flow sensor, air flow too high. Mass air flow sensor, air flow too low, Warning lamp speed limitation, overheated. Warning lamp speed limitation, short circuit to voltage. Warning lamp speed limitation, short circuit to ground. Warning lamp speed limitation, open circuit. EGR control, signal too high. EGR control, signal too low. Bypass valve cold start, short circuit to voltage. Bypass valve cold start, short circuit to ground. Bypass valve cold start, open circuit. Sensor coolant temperature, unreasonable signal.
No limitation.
Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness between control unit and sensor. Check the sensor.
520193/4
P0102
No limitation.
520194/2
P0649
No limitation.
520194/3
P0649
No limitation.
520194/4
P0649
No limitation.
520194/5
P0649
No limitation.
520195 /15 520196 /17 520197/3
P0402
No limitation.
P0401
No limitation.
P022C
No limitation.
520197/4
P022B
No limitation.
520197 /12 520198/2
P022A
No limitation.
P0116
No limitation.
D794/2:15
ENGINE, menu 7
520198/2
P0116
Sensor coolant temperature, unreasonable signal.
No limitation.
D794/2:15
ENGINE, menu 7
VDCT01.02GB
1 Engine Engine
D:31
Display
Supplier code
P0856
Description
Limitation
Action

-
Diagnostic menu
520199/2
DCS, unreasonable signal. Incorrect compression test. Sensor outdoor temperature (BET), signal too high. Sensor outdoor temperature (BET), signal too low. Sensor outdoor temperature (ClgZn), signal too high. Sensor outdoor temperature (ClgZn), signal too low. Sensor intake temperature, signal too high.
No limitation.
Check the cable harness at the control unit. contact Yuchai service. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness between control unit and sensor. Check the sensor.
520200 /20 520201/3
P161F P1505
520201/4
P1506
No limitation.
520202/3
P1507
No limitation.
520202/4
P1508
No limitation.
520203/3
P1509
No limitation.
D794/2:36
520203/4
P150A
Sensor intake temperature, signal too low.
No limitation.
D794/2:36
520204/2
P1635
Switch exhaust brake, unreasonable signal. EGR valve, short circuit to voltage or overheated. EGR valve, short circuit to ground. EGR valve, open circuit. Exhaust back pressure sensor, unreasonable signal. Sensor exhaust back pressure, signal too high. Sensor exhaust back pressure, signal too low. Relay heating coil fuel filter, short circuit to voltage. Relay heating coil fuel filter, short circuit to ground.
No limitation.
Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit.
D794/2:29
520205/3
P245D
No limitation.
520205/4
P245C
No limitation.
520205 /12 520206/2
P245A
No limitation.
P0470
No limitation.
520206/3
P0473
No limitation.
520206/4
P0472
No limitation.
520207/3
P1008
No limitation.
D794/2:04 D794/2:05 D794/2:04 D794/2:05
520207/4
P1009
No limitation.
VDCT01.02GB
D:32
1 Engine Engine
Display
Supplier code
P0409
Description
Limitation
Action

-
Diagnostic menu
520208/2
Sensor airflow EGR valve, unreasonable signal. Sensor airflow EGR valve, short circuit to voltage. Sensor airflow EGR valve, short circuit to ground. Sensor airflow EGR valve, open circuit. Sensor exhaust temperature, unreasonable signal. Sensor exhaust temperature, short circuit to voltage. Sensor exhaust temperature, short circuit to ground. Sensor exhaust temperature, open circuit. Communication error, display. Communication error, CAN bus.
No limitation.
Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Use diagnostic menu to check communication. Check the cable harness between Control unit, cab (D790-1) and Control unit, engine (D794).
520208/3
P0406
No limitation.
520208/4
P0405
No limitation.
520208 /12 520209/2
P0409
No limitation.
P040B
No limitation.
520209/3
P040D
No limitation.
520209/4
P040C
No limitation.
520209 /12 520210/3 or/255 520211 /12 520212/3 520213 /12 520214 /12 520215/3 520216/3 520217/3 520218/3 520218/4 520218 /12 520219/3 520219 /12 520220/3 520220 /12
P040A
No limitation.
UC158
No limitation.
P0000 UD100 UC103 UC113 UD101 UC156 UD103 UD10C UD10D UD104 UD110 UD111 UD112 UD113
No limitation.
D794/1:34 D794/1:35
CAN/POWER, menu 3
VDCT01.02GB
1 Engine Engine
D:33
Display
Supplier code
P0607 P0607 P0607 P160C P150B
Description
Limitation
Action

-
Diagnostic menu
520222 /14 520222 /14 520222 /14 520223 /20 520224/3
Internal error engine control unit.
Engine switched off: engine cannot be started. Engine running: engine misfires.
Contact Yuchai service.
Fuel injection, test mode. Sensor air humidity, signal too high. Sensor air humidity, signal too low. Injection error, software error. Injection error, uneven amount of fuel between the cylinders. Injection error, uneven output between the cylinders. Pressure fault on multiple injectors. Multi-function lever, unreasonable position. Multi-function lever, short circuit to voltage. Multi-function lever, short circuit to ground. Sensor engine speed, unreasonable signal
Contact Yuchai service. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the injectors. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness between control unit and sensor. Check the sensor.
520224/4
P150C
No limitation.
520225 /11 520225 /15 520225 /16 520226 /12 520227/2
P1302
No limitation.
P1301
No limitation.
P1300
No limitation.
P1225 P154C
The engine is switched off. No limitation.
D794/1:62
520227/3
P154A
No limitation.
D794/1:62
520227/4
23/04
No limitation.
D794/1:62
520228 /15
P1614
No limitation.
D794/2:23
ENGINE, menu 2
520229 /15
P2263
Intake pressure difference too high.
No limitation.
520230 /17
P2263
Intake pressure difference too low.
No limitation.
520231/2
P062A
Feed pump, overheated.
No limitation.
D794/23:09 D794/23:10
VDCT01.02GB
D:34
1 Engine Engine
Display
Supplier code
P0629
Description
Limitation
Action

D794/23:09 D794/23:10
Diagnostic menu
520231/3
Feed pump, short circuit to voltage.
No limitation.
520231/4
P0628
Feed pump, short circuit to ground.
No limitation.
D794/23:09 D794/23:10
520231 /12
P0627
Feed pump, open circuit.
No limitation.
D794/23:09 D794/23:10
520232/ 255 520233 /20 520234/2
P1615 P1621 P0488
Test mode.
No limitation.
Throttle, overheated.
No limitation.
Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Contact Yuchai service. Use diagnostic menu to check communication. Check the cable harness between Control unit, cab (D790-1) and Control unit, engine (D794).
D794/1:79 D794/1:80 D794/1:79 D794/1:80 D794/1:79 D794/1:80 D794/1:79 D794/1:80 -
520234/3
P2142
Throttle, short circuit to voltage. Throttle, short circuit to ground. Throttle, open circuit.
No limitation.
520234/4
P2141
The engine is running at idle. No limitation.
520234 /12 520235/3
P0487
P1636
Reference voltage 12 V, signal too high. Reference voltage 12 V, signal too high. Software error engine control unit (FMTC). Communication error, CAN bus.
No limitation.
520235/4
P1637
No limitation.
520236/2 520237/3 520238 /12
P1007 UD114 UD115
D794/1:34 D794/1:35
CAN/POWER, menu 3
520239/2 520239 /11
P161E P161D
No limitation.
VDCT01.02GB
1 Engine Engine
D:35
Display
Supplier code
UC104 UC157
Description
Limitation
Action

D794/1:34 D794/1:35
Diagnostic menu
523218 /12 523222 /12
Communication error, CAN bus.
No limitation.
CAN/POWER, menu 3
523350/3
P1203
Injector bank 1, short circuit between cables.
The engine is only running on three cylinders.
Check the cable harness between control unit and the components. Check the injectors.
D794/3:04 D794/3:13 D794/3:06 D794/3:11 D794/3:05 D794/3:12
523350/4
P1204
Injector bank 1, short circuit to ground.
D794/3:04 D794/3:13 D794/3:06 D794/3:11 D794/3:05 D794/3:12
523350 /11
P1205
Injector bank 1, installation-dependent error.
D794/3:04 D794/3:13 D794/3:06 D794/3:11 D794/3:05 D794/3:12
523350 /11
P1206
Injector bank 1, electrical problem.
D794/3:04 D794/3:13 D794/3:06 D794/3:11 D794/3:05 D794/3:12
523351 /11
P1207
D794/3:04 D794/3:13 D794/3:06 D794/3:11 D794/3:05 D794/3:12
523351 /11
P1208
D794/3:04 D794/3:13 D794/3:06 D794/3:11 D794/3:05 D794/3:12
VDCT01.02GB
D:36
1 Engine Engine
Display
Supplier code
P120A
Description
Limitation
Action

D794/3:04 D794/3:13 D794/3:06 D794/3:11 D794/3:05 D794/3:12
Diagnostic menu
523351 /11
523351 /12
P1209
Injector bank 1, open circuit.
D794/3:04 D794/3:13 D794/3:06 D794/3:11 D794/3:05 D794/3:12
523352/3
P120B
Injector bank 2, short circuit between cables.
D794/3:03 D794/3:14 D794/3:01 D794/3:16 D794/3:02 D794/3:15
523352/4
P120C
Injector bank 2, short circuit to ground.
D794/3:03 D794/3:14 D794/3:01 D794/3:16 D794/3:02 D794/3:15
523352 /11
P120D
D794/3:03 D794/3:14 D794/3:01 D794/3:16 D794/3:02 D794/3:15
523352 /11
P120E
Injector bank 2, electrical problem.
D794/3:03 D794/3:14 D794/3:01 D794/3:16 D794/3:02 D794/3:15 -
523353 /11
P120F
D794/3:03 D794/3:14 D794/3:01 D794/3:16 D794/3:02 D794/3:15
VDCT01.02GB
1 Engine Engine
D:37
Display
Supplier code
P1210
Description
Limitation
Action

D794/3:03 D794/3:14 D794/3:01 D794/3:16 D794/3:02 D794/3:15
Diagnostic menu
523353 /11
523353 /11
P1212
D794/3:03 D794/3:14 D794/3:01 D794/3:16 D794/3:02 D794/3:15
523352 /12
P1211
Injector bank 2, open circuit.
D794/3:03 D794/3:14 D794/3:01 D794/3:16 D794/3:02 D794/3:15 -
523354/2 523354/3 523354/4 523354 /12 523355/2 523355/3 523355/4 523355 /12 523420/2 523470/0 523470/7
P062B P062B P062B P062B P062B P062B P062B P062B P060C P100E P1010
The engine is switched off.
Valve fuel pressure control, leakage. Valve fuel pressure control, does not open. Valve fuel pressure control, fuel pressure too high. Communication error, CAN bus.
Reduced engine power. Reduced engine power. Reduced engine power. No limitation.
Check the component. Check the component.
D794/2:14 D794/2:14
523470 /11 523500 /12 523550/2
P100F
Check the component.
D794/2:14
UC001 P0607
D794/1:34 D794/1:35
CAN/POWER, menu 3
VDCT01.02GB
D:38
1 Engine Engine
Display
Supplier code
P0607 P0699
Description
Limitation
Action

-
Diagnostic menu
523600 /12 523601/3
Internal error engine control unit. Voltage feed 3 sensor, short circuit to voltage. Voltage feed 3 sensor, short circuit to ground.
No limitation. Reduced engine power. The engine takes longer to start than normal. The engine is running normally once it has started. No limitation.
Contact Yuchai service. Check the cable harness at the control unit. Check the cable harness at the control unit.
523601/4
P0698
523604 /12 523605 /11 523605 /12 523606 /11 523606 /12 523607 /11 523608 /11 523608 /12 523612/3 523612/4 523613/2
UD1102 UD1104 UD1105 UD1106 UD1107 UD1108 UD110A UD110B P1607 P1608 P1014
Communication error, CAN bus.
D794/1:34 D794/1:35
CAN/POWER, menu 3
Internal error engine control unit. Internal error engine control unit. Unreasonable fuel pressure.
No limitation.
D794/2:14
523613/3
P0088
Fuel pressure too high.
Check the fuel pressure. Check the fuel pump. Check the sensor.
D794/2:14
523613/4
P0087
Fuel pressure too low.
Check the fuel pressure. Check the fuel pump. Check the fuel filters. Check the sensor.
D794/2:14
523613/5
P1019
D794/2:14
VDCT01.02GB
1 Engine Engine
D:39
Display
Supplier code
P1018
Description
Limitation
Action

D794/2:14
Diagnostic menu
523613/7
Fuel pressure too low.
Check the fuel pressure. Check the fuel pump. Check the fuel filters Check the sensor.
523613 /15
P1012
D794/2:14
523613 /16 523613 /17
P1011 P1013
Fuel pressure too high. Fuel pressure too low.
Reduced engine power. Reduced engine power.
Check the component. Check the fuel pressure. Check the fuel pump. Check the fuel filters. Check the sensor.
D794/2:14 D794/2:14
523613 /18
P101A
D794/2:14
523615/2
P0252
Fuel metering valve, overheated power stage. Valve fuel metering, short circuit to voltage. Valve fuel metering, short circuit to ground. Valve fuel metering, open circuit. Fuel metering valve, status signal too low. Fuel metering valve, status signal too high. Communication error, CAN bus.
No limitation.
Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Check the cable harness at the control unit. Use diagnostic menu to check communication. Check the cable harness between Control unit, cab (D790-1) and Control unit, engine (D794).
523615/3
P0254
No limitation.
523615/4
P0253
No limitation.
523615/5
P0251
No limitation.
523615 /16 523615 /18 523617 /11
P025C
No limitation.
P025D
No limitation.
P060A
No limitation.
D794/1:34 D794/1:35
CAN/POWER, menu 3
VDCT01.02GB
D:40
1 Engine Engine
Error codes engine (engine alternative Cummins QSB6.7)

Table Error codes engine (engine alternative Cummins QSB6.7)
Description
Limitation
Action
Code
84 / 2
J1587
P084 / 2 Machine speed sensor circuit: Data erratic, intermittent or incorrect. The ECU 794 lost the machine speed signal. Engine speed limited to Maximum Engine Speed without VSS parameter value. Cruise control, Gear-Down Protection, and Road Speed Governor will not work. Engine speed limited to Maximum Engine Speed without VSS parameter value. Cruise control, Gear-Down Protection, and Road Speed Governor will not work. Heavy derating in power output of the engine. Only emergency operation power. Check the cable harness between control unit and component. Check the sensor.

D794
Diagnostic menu
ENGINE, menu 2
84 / 10
P084 / 10
Manipulation of machine speed sensor circuit has been detected: Abnormal change rate. Invalid or incorrect machine speed signal. The signal indicates an erratic connection or VSS manipulation.
Check the cable harness between control unit and component. Check the sensor.
D794
ENGINE, menu 2
91 / 0
P91 / 0
Accelerator pedal or lever position sensor 1: Data valid but higher than the normal working range, the most severe level. A frequency above 1500 Hz has been detected on the accelerator pedal's frequency input to ECU 794. Frequency in the accelerator pedal or lever position sensor circuit 1: Data valid but lower than the normal working range, the most severe level. A frequency under 100 Hz has been detected on the accelerator pedal's frequency input to ECU 794. System error for SAE J1939 multiplexing accelerator pedal or lever sensors: Network data error received. The machine's OEM control unit (VECU) detected an error on its accelerator pedal. Accelerator pedal position sensor.
ENGINE, menu 1
91 / 1
P91 / 1
Heavy derating in power output of the engine. Only emergency operation power.
ENGINE, menu 1
91 / 19
P91
Engine may only idle or engine will not accelerate to full speed.
Use diagnostic menu to find incorrect segment.
91 / 2
P31 / 2
ENGINE, menu 1
VDCT01.02GB
1 Engine Engine
D:41
Description
Limitation
Action
Code
91 / 3
J1587
P091 / 3 Accelerator pedal or lever position sensor circuit: Short.circuit high. High voltage detected in accelerator pedal or lever position circuit. Heavy derating in power output of the engine. Only emergency operation possible. Check the cable harness between control unit and component. Check the component. Heavy derating in power output of the engine. Only emergency operation possible. Check the cable harness between control unit and component. Check the component. Possibly difficult to start, low power, possibly smoke from the engine. The engine may not be possible to start. -

-
Diagnostic menu
ENGINE, menu 1
91 / 4
P091 / 4
Accelerator pedal or lever position sensor circuit: Voltage lower than normal or shorted to low source. Low voltage detected in accelerator pedal or lever position signal circuit. Fuel pump's delivery pressure: Data valid but below normal operational range - moderately severe level. The ECU 794 has detected the fuel pressure in the fuel rail is lower than the commanded performance. Injector Metering Rail 1 Pressure - Data Erratic, Intermittent, or Incorrect. The ECU 794 has detected that the fuel pressure signal is not changing. Fuel pump's delivery pressure: Data valid but higher than normal operational range moderately severe level. The ECU 794 has detected fuel pressure in the fuel rail that is higher than the commanded pressure. Sensor circuit for water in fuel indicator: Voltage higher than normal or short-circuited to a high source. High voltage detected on the water in the fuel circuit.
ENGINE, menu 1
94 / 1
P94 / 1
D794
94 / 2
P094 / 2
The ECU 794 will estimate fuel pressure, and power is reduced.
D794
94 / 18
P94 / 0
None or possible engine noise associated with higher injection pressures (especially at idle or light load). Engine power derate. None on performance. No water in fuel warning available.
D794
97 / 3
P097 / 3
D794
97 / 4
P097 / 4
Sensor circuit for water in fuel indicator: Voltage lower than normal or short-circuited to a low source. Low voltage detected on the water in the fuel circuit.
None on performance. No water in fuel warning available.
D794
97 / 15
P097 / 0
Water-in-fuel indicator Data valid but above normal operational range - least severe level. Water has been detected in the fuel filter.
Possible white smoke, loss of power, or hard starting
Drain water from the fuel.
VDCT01.02GB
D:42
1 Engine Engine
Description
Limitation
Action
Code
100 / 1
J1587
P100 / 1 Engine oil duct pressure: Data valid but lower than normal operational range, the most severe level. The oil pressure signal indicates that the oil pressure is lower than the critical limit for the engine's protection. Progressive power derate increasing in severity from time of alert. If the function Engine protection cut- off is activated, the engine switches off 30 seconds after the red STOP light starts flashing. None on performance. No engine protection for the oil pressure. Check the oil level in the engine; fill if necessary.

-
Diagnostic menu
ENGINE, menu 6
100 / 2
P100 / 2
Oil pressure switch sensor circuit Data erratic, intermittent or incorrect. An error in the engine oil pressure switch signal has been detected by ECU 794.
D794
ENGINE, menu 6
100 / 3
P100 / 3
Oil pressure sensor circuit: Voltage higher than normal or shorted to high source. High signal voltage detected in engine oil pressure circuit.
None on performance. No engine protection for the oil pressure.
D794
ENGINE, menu 6
100 / 4
P100 / 4
Oil pressure sensor circuit: Voltage lower than normal or shorted to low source. Low signal voltage detected in engine oil pressure circuit.
None on performance. No engine protection for the oil pressure.
D794
ENGINE, menu 6
100 / 18
P100 / 1
Engine oil duct pressure: Data valid but lower than normal operational range, moderately severe level. Engine oil pressure signal indicates that the engine oil pressure is lower than the limit for engine protection warning. Intake manifold pressure sensor circuit: Manifold Pressure Sensor Circuit Data Erratic, Intermittent or Incorrect. The ECU 794 has detected an intake manifold pressure signal that is too high or low for current engine operating conditions. Intake manifold pressure sensor circuit: Incorrect data. An error in the intake manifold pressure sensor signal has been detected by ECU 794.
None on performance.
Check the oil level in the engine; fill if necessary.
ENGINE, menu 6
102 / 2
P102 /2
Engine power derate.
D794
ENGINE, menu 6
102 / 2
P102 /2
Derate in power output of the engine.
D794
ENGINE, menu 6
VDCT01.02GB
1 Engine Engine
D:43
Description
Limitation
Action
Code
102 / 3
J1587
P102 / 3 Intake manifold pressure sensor circuit: Voltage higher than normal or shorted to high source. High signal voltage detected in the intake manifold pressure circuit. Intake manifold pressure sensor circuit: Voltage lower than normal or short-circuited to low source. Low signal voltage detected in the intake manifold pressure circuit. Derate in power output of the engine. Check the cable harness between control unit and component. Check the sensor. Derate in power output of the engine. Check the cable harness between control unit and component. Check the sensor. Possible-low-power estimated turbocharger speed will be used. Check the cable harness between control unit and component. Check the sensor.

D794
Diagnostic menu
ENGINE, menu 6
102 / 4
P102 / 4
D794
ENGINE, menu 6
103 / 10
P103 / 10
Turbocharger speed: Incorrect change rate detected. Turbocharger speed sensor detected an incorrect speed value.
D794
103 / 16
P103 / 0
Turbocharger number 1 speed high: Warning level. High turbocharger speed has been detected. Turbocharger number 1 speed low: Warning level. Low turbocharger speed has been detected by ECU 794. Temperate intake manifold 1: Data valid but higher than normal operational range, the most severe level. The intake manifold air temperature signal indicates that the air temperature in the intake manifold is higher than the critical limit for engine protection.
Engine power derate. The ECU 794 uses an estimated turbocharger speed. Engine power derate. The ECU 794 uses an estimated turbocharger speed. Progressive power derate increasing in severity from time of alert. If the function Engine protection cut- off is activated, the engine switches off 30 seconds after the red STOP light starts flashing.
D794
103 / 18
P103 / 1
D794
105 / 0
P105 / 0
Check the coolant level in the engine; fill if necessary. Check that the charge air cooler is clean, clean if necessary. Check that the fan belts are intact. Check the sensor.
ENGINE, menu 7
105 / 3
P105 / 3
Intake manifold air temperature sensor circuit: Voltage higher than normal or shorted to high source. High signal voltage detected in the intake manifold air temperature circuit.
Possible white smoke. Fan will stay ON if controlled by the ECU 794. No engine protection for intake manifold air temperature.
Check cable harness between control unit and component. Check the sensor.
D794
ENGINE, menu 7
VDCT01.02GB
D:44
1 Engine Engine
Description
Limitation
Action
Code
105 / 4
J1587
P105 / 4 Intake manifold air temperature sensor circuit: Voltage lower than normal or short-circuited to low source. Low signal voltage detected in the intake manifold air temperature circuit. Intake manifold temperature high: Data valid but higher than normal operational range, the least severe level. The intake manifold air temperature signal indicates that the air temperature in the intake manifold is higher than the warning limit for engine protection. Possible white smoke. Fan will stay ON if controlled by the ECU 794. No engine protection for intake manifold air temperature. Progressive power derate increasing in severity from time of alert. Check cable harness between control unit and component. Check the sensor. Check the coolant level in the engine; fill if necessary. Check that the charge air cooler is clean, clean if necessary. Check that the fan belts are intact. Check the sensor.

D794
Diagnostic menu
ENGINE, menu 7
105 / 15
P105 / 0
D794
ENGINE, menu 7
108 / 2
P108 / 2
Barometric pressure: Data erratic, intermittent or incorrect. The pressure sensor for the ambient air pressure reads an erratic value on power-up.
108 / 3
P108 / 3
Barometric pressure sensor circuit: Voltage higher than normal or shorted to high source. High signal voltage detected in barometric pressure sensor circuit.
D794
108 / 4
P108 / 4
Barometric pressure sensor circuit: Voltage lower than normal or shorted to low source. Low signal voltage detected in barometric pressure sensor circuit.
D794
110 / 0
P110 / 0
Engine coolant temperature: Data valid but higher than normal operational range, the most severe level. The engine coolant temperature signal indicates that the coolant temperature is higher than the critical limit for engine protection.
Progressive power derate increasing in severity from time of alert. If the function Engine protection cut- off is activated, the engine switches off 30 seconds after the red STOP light starts flashing.
Check the coolant level. Check that radiator is clean. Check if there is air in coolant system. Check the cap on the expansion tank. Check the sensor. Check the thermostat.
ENGINE, menu 7
VDCT01.02GB
1 Engine Engine
D:45
Description
Limitation
Action
Code
110 / 2
J1587
P110 / 2 Engine coolant temperature: Data erratic, intermittent or incorrect. The engine coolant temperature reading does not change when operating conditions change. The ECU 794 will estimate engine coolant temperature. Check cable harness between control unit and component. Check the sensor. Possible white smoke. Fan will stay ON if controlled by the ECU 794. No engine protection for the engine coolant temperature. Possible white smoke. Fan will stay ON if controlled by the ECU 794. No engine protection for the engine coolant temperature. Progressive power derate increasing in severity from time of alert. Check cable harness between control unit and component. Check the sensor. Check cable harness between control unit and component. Check the sensor. Check the coolant level. Check that radiator is clean. Check if there is air in coolant system. Check the cap on the expansion tank. Check the sensor. Check the thermostat.

D794
Diagnostic menu
ENGINE, menu 7
110 / 3
P110 / 3
Engine coolant temperature sensor circuit 1: Voltage higher than normal or shorted to high source. High signal voltage or open circuit detected in the engine coolant temperature circuit. Engine coolant temperature sensor circuit 1: Voltage lower than normal or shorted to low source. Low signal voltage detected in the engine coolant temperature circuit. Engine coolant temperature high: Data valid but higher than normal operational range, the least severe level. The engine coolant temperature signal indicates that the coolant temperature is higher than the warning limit for engine protection.
D794
ENGINE, menu 7
110 / 4
P110 / 4
D794
ENGINE, menu 7
110 / 15
P110 / 0
D794
ENGINE, menu 7
110 / 16
P110 / 0
Engine coolant temperature: Data valid but higher than normal operational range, moderately severe level. The engine coolant temperature signal indicates that the coolant temperature is higher than the warning limit for engine protection.
Progressive power derate increasing in severity from time of alert.
Check the coolant level. Check that radiator is clean. Check if there is air in coolant system. Check the cap on the expansion tank. Check the sensor. Check the thermostat.
D794
ENGINE, menu 7
VDCT01.02GB
D:46
1 Engine Engine
Description
Limitation
Action
Code
111 / 1
J1587
P111 / 1 Coolant level: Data valid but lower than normal operational range, the most severe level. Low coolant level detected. Progressive power derate increasing in severity from time of alert. If the function Motor cutoff is activated, the engine switches off in 30 seconds after the red STOP light starts flashing. None on performance. Check the coolant level; fill if necessary. Check the sensor.

-
Diagnostic menu
111 / 3
P111 / 3
Radiator coolant level sensor circuit: Voltage higher than normal or shorted to high source. High signal voltage detected in the engine coolant level circuit.
D794
111 / 4
P111 / 4
Radiator coolant level sensor circuit: Voltage lower than normal or shorted to low source. Low signal voltage detected in the engine coolant level circuit.
D794
157 / 0
P94 / 0
Injector Metering Rail Number 1 Pressure - Data Valid But Above Normal Operating Range - Most Severe Level. The ECU 794 has detected that fuel pressure in the rail fuel is higher than the commanded pressure. Injector Metering Rail 1 Pressure - Data Erratic, Intermittent, or Incorrect. the ECU 794 has detected that the fuel pressure signal is not changing. Injector measurement channel number 1, pressure sensor circuit: Voltage higher than normal or shorted to high source. High signal voltage detected in the fuel rail fuel pressure sensor circuit. Injector measurement channel number 1, pressure sensor circuit: Voltage lower than normal or short-circuited to low source. Low signal voltage detected in the fuel rail fuel pressure sensor circuit.
None or possible engine noise associated with higher injection pressures (especially at idle or light load). Engine power derate. The ECU 794 will estimate fuel pressure, and power is reduced.
D794
157 / 2
P157 / 2
D794
157 / 3
P157 / 3
Power and or speed derate.
D794
157 / 4
P157 / 4
Power and or speed derate.
D794
VDCT01.02GB
1 Engine Engine
D:47
Description
Limitation
Action
Code
157 / 16
J1587
P157 / 0 Injector measurement channel 1, pressure Data valid but higher than normal operational range - moderately severe level. The ECU 794 has detected that the fuel pressure is higher than the commanded pressure. Fuel pump's delivery pressure low: Data valid but lower than normal operational range moderately severe level. The ECU 794 has detected that the fuel pressure is lower than the commanded pressure. Charging system voltage low: Data valid but lower than normal operational range, the most severe level. Very low battery voltage detected by battery voltage monitoring. Charging system voltage high: Data valid but higher than normal operational range, moderately severe level. High battery voltage detected by battery voltage monitoring. Charging system voltage low: Data valid but lower than normal operational range, moderately severe level. Low battery voltage detected by battery voltage monitoring. Battery 1 Voltage - Data Valid but Above Normal Operational Range Moderately Severe Level. ECU 794 supply voltage is above the maximum system voltage level. Battery 1 Voltage - Data Valid but Below Normal Operational Range Moderately Severe Level. ECU 794 supply voltage is below the minimum system voltage level. Outdoor temperature sensor, circuit error: Abnormally high voltage or short-circuit to higher voltage. None or possible engine noise associated with higher injection pressures (especially at idle or light load). Engine power derate. Possibly difficult to start, low power or smoke from the engine. The engine may not be possible to start. -

D794
Diagnostic menu
157 / 18
P157 / 1
D794
167 / 1
P167 / 1
Warning lamp illuminated until very low battery voltage condition is corrected.
Check batteries and alternator.
D794
167 / 16
P167 / 0
Amber warning lamp illuminated until high battery voltage condition is corrected.
Check fuses. Check batteries and alternator.
D794
167 / 18
P167 / 1
Amber lamp will light until low battery voltage condition is corrected.
Check batteries and alternator.
D794
168 / 16
P168 / 0
Possible electrical damage to all electrical components.
D794
168 / 18
S168 / 1
Engine may stop running or be difficult to start.
D794
171 / 3
P171 / 3
D794
VDCT01.02GB
D:48
1 Engine Engine
Description
Limitation
Action
Code
171 / 4
J1587
P171 / 4 Outdoor temperature sensor, circuit error: Abnormally low voltage or short-circuit to lower voltage. Engine crankshaft speed/position: Data valid but higher than the normal working range: The most severe level. The engine speed signal indicates the engine speed over the engine protection limit. Engine crankshaft speed/position: Data erratic, intermittent or incorrect. Engine speed sensor on the crankshaft uneven synchronised. Fuel injection disabled until engine speed fails below the overspeed limit. -

D794
Diagnostic menu
190 / 0
P190 / 0
Ease off the throttle or select higher gear.
190 / 2
P190 / 2
The engine may misfire when steering switches from the primary to the backup speed sensor. The engine power derates while the engine is driven with the backup speed sensor. The engine runs unevenly. Can be difficult to start. The engine is driven by backup speed sensor. Engine power derated. None on performance. Data in the ECU 794 will not have accurate time and date information. None on performance.
D794
190 / 2
P190 / 2
Engine crankshaft speed/position: Data erratic, intermittent or incorrect. The signal from the crankshaft sensor missing.
Check cable harness between control unit and component. Check the sensor. -
D794
251 / 2
P251 / 2
Real-time clock power supply open circuit: Data erratic, intermittent or incorrect. The real time clock has no power.
441 / 3
P441 / 3
Auxiliary temperature sensor input signal 1: Voltage higher than normal or shorted to high source. High signal voltage or open circuit detected in the OEM auxiliary temperature circuit. Auxiliary temperature sensor circuit input signal 1: Voltage lower than normal or short-circuited to low source. Low voltage detected in the OEM auxiliary temperature circuit. Accelerator pedal or lever idle validation circuit: Data erratic, intermittent or incorrect. Voltage detected simultaneously on the validating switches for both idling and not idling.
D794
441 / 4
P441 / 4
D794
558 / 2
S230 / 2
Engine only running at idle.
Check cable harness between control unit and component. Check component.
D794
VDCT01.02GB
1 Engine Engine
D:49
Description
Limitation
Action
Code
558 / 4
J1587
S230 / 4 Accelerator pedal or lever idle validation circuit: Voltage lower than normal or short-circuited to low source. No voltage detected simultaneously on the validating switches for both idling and not idling. Accelerator pedal or lever idle validation circuit: Not calibrated. Voltage in the validation circuits for idling and not idling does not correspond with the accelerator pedal position. Validation of auxiliary transfer speed switch (PTO): Data erratic, intermittent or incorrect. The position of the transfer speed protection switch 1 does not correspond with the position of the validation switch for the transfer speed protection. Circuit for sensor supply voltage 4: Voltage higher than normal or shorted to high source. High voltage detected at +5 volt sensor supply circuit to the accelerator pedal position sensor. Circuit for sensor supply 3: 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. Circuit for sensor supply 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. Turbocharger compressor outlet temperature: Data higher than normal. High outlet temperature for the turbocharger compressor calculated by ECU 794. Engine only running at idle. Check cable harness between control unit and component. Check component. Engine only running at idle. Check cable harness between control unit and component. Check component. Intermediate speed control switch may not operate correctly. -

D794
Diagnostic menu
558 / 13
S230 / 13
D794
611 / 2
P089 / 2
D794
611 / 3
S232 / 3
Engine only running at idle.
D794
611 / 4
S232 / 4
Possible hard starting and rough running.
D794
611 / 4
S232 / 4
Engine will only die.
D794
611 / 15
S151 / 0
Fuel is limited in an attempt to decrease the calculated turbocharger compressor outlet temperature.
D794
VDCT01.02GB
D:50
1 Engine Engine
Description
Limitation
Action
Code
612 / 2
J1587
P190 / 2 The engine's magnetic crankshaft speed/position sensor has lost both signals: Data erratic, intermittent or incorrect. ECU 794 has detected that the signals from the primary and backup engine speed sensor are reversed. No power without the ignition switch turned off: Data erratic, intermittent or incorrect. The supply voltage to ECU 794 temporarily falls below 6.2 volt, or ECU 794 not allowed to shutdown correctly (battery voltage maintained for 30 seconds after the ignition has been turned off). Power supply missing with the ignition on: Data erratic, intermittent or incorrect. The supply voltage to ECU 794 temporarily falls below 6.2 volt, or ECU 794 not allowed to shutdown correctly (battery voltage maintained for 30 seconds after the ignition has been turned off). Injectors power supply: Bad Intelligent Device or Component. The ECU 794 measured injector boost voltage is low. Engine control unit: Critical internal error. Error internally in ECU 794 related to memory hardware failures or internal ECU 794 voltage supply circuits. Engine control unit, warning internal hardware error. Incorrect intelligent unit or component. Engine control unit data lost: Data erratic, intermittent or incorrect. Serious data loss from ECU 794. Fuelling to the injectors is disabled, and the engine can not be started. -

D794
Diagnostic menu
627 / 2
S251 / 2
Possibly no noticeable performance impact, or the engine stops or is hard to start. Incorrect information, release information and maintenance monitoring data may be incorrect. Possibly no noticeable performance impact, or the engine stops or is hard to start. Incorrect information, release information and maintenance monitoring data may be incorrect. Possible smoke, low power, engine misfire, and/or engine will not start. Engine may not start.
D794
627 / 2
S251 / 2
D794
627 / 2
S254 / 12
D794
629 / 12
S254 / 12
Check the control unit.
D794
629 / 12
S254 / 12
No performance effects or possible severe power derate. Possibly no noticeable performance impact, or the engine stops or is hard to start. Incorrect information, release information and maintenance monitoring data may be incorrect.
Check the control unit.
D794
630 / 2
S253 / 2
Reprogram the software in Control unit, engine (D794).
D794
VDCT01.02GB
1 Engine Engine
D:51
Description
Limitation
Action
Code
630 / 31
J1587
S240 / 11 Error occurs in the engine control unit calibration programme memory (RAM). Serious data loss from ECU 794. Possibly no noticeable performance impact, or the engine stops or is hard to start. Incorrect information, release information and maintenance monitoring data may be incorrect. Possible low power. -

D794
Diagnostic menu
633 / 31
S018 / 11
Fuelling Actuator Number 1 Circuit Error Conditions Exists. Fuel pump actuator circuit resistance too high or too low. Timeout error for SAE J1939 multiplexer-PNG: Abnormal update rate. Cummins ECU 794 did not receive a multiplexed message from an OEM-VECU by the time limit or not at all. SAE J1939 Multiplexing Configuration Error - Out of Calibration. The ECU 794 expected information from a multiplexed device but only received a portion of the necessary information. VGT actuator driver circuit - voltage above normal or shorted to high source. VGT actuator driver circuit - voltage below normal, or shorted to low source. Input signal from external speed request (synchronisation of multiple units): Data erratic, intermittent or incorrect. The accelerator pedal input signal to the primary or secondary motor for synchronisation of multiple devices is less than 3 percent or greater than 97 percent. Fan control circuit: Voltage higher than normal or shorted to high source. Open circuit or high voltage detected in the fan control circuit.
D794
639 / 9
S231 / 9
One or more multiplexed units not working correctly. One or more symptoms may occur. At least one multiplexed devices will not operate properly.
CAN/POWER, menu 2
639 / 13
S231 / 13
CAN/POWER, menu 2
641 / 3
S027 / 3
Possible low power. Power switched off to the turbocharger's actuator motor. Possible low power. Power switched off to the turbocharger's actuator motor. Primary or secondary engines may be shut down.
D794
641 / 4
S027 / 4
D794
644 / 2
S030 / 2
647 / 3
S033 / 3
The fan may stay on continuously or not run at all.
D794
VDCT01.02GB
D:52
1 Engine Engine
Description
Limitation
Action
Code
647 / 4
J1587
S033 / 4 Fan control circuit: Voltage lower than normal or shorted to low source. Low signal voltage detected in the fan control circuit when this is requested. The fan may stay on continuously or not run at all. Check cable harness between control unit and component. Check component. Engine can misfire or possibly run rough. Check cable harness between control unit and component. Check the injector. The engine is switched off. Check cable harness between control unit and component. Check the injector. Engine can misfire or possibly run rough. Check cable harness between control unit and component. Check the injector. The engine is switched off. Check cable harness between control unit and component. Check the injector. Engine can misfire or possibly run rough. Check cable harness between control unit and component. Check the injector. The engine is switched off. Check cable harness between control unit and component. Check the injector. Engine can misfire or possibly run rough. Check cable harness between control unit and component. Check the injector.

D794
Diagnostic menu
651 / 5
S001 / 5
Circuit injector magnetic coil drive cylinder 1: Current lower than normal or open circuit. High resistance or no current detected on injector no. 1, pin DRIVE or RETURN. Injector magnetic coil drive cylinder 1: Mechanical system not responding correctly or incorrectly adjusted. Accidental fuel supply detected in cylinder no. 1. Circuit injector magnetic coil drive cylinder 2: Current lower than normal or open circuit. High resistance or no current detected on injector no. 2, pin DRIVE or RETURN. Injector magnetic coil drive cylinder 2: Mechanical system not responding correctly or incorrectly adjusted. Accidental fuel supply detected in cylinder no. 2. Circuit injector magnetic coil drive cylinder 3: Current lower than normal or open circuit. High resistance or no current detected on injector no. 3, pin DRIVE or RETURN. Injector magnetic coil drive cylinder 3: Mechanical system not responding correctly or incorrectly adjusted. Accidental fuel supply detected in cylinder no. 3. Circuit injector magnetic coil drive cylinder 4: Current lower than normal or open circuit. High resistance or no current detected on injector no. 1, pin DRIVE or RETURN.
D794
651 / 7
S001 / 7
D794
652 / 5
S002 / 5
D794
652 / 7
S002 / 7
D794
653 / 5
S003 / 5
D794
653 / 7
S003 / 7
D794
654 / 5
S004 / 5
D794
VDCT01.02GB
1 Engine Engine
D:53
Description
Limitation
Action
Code
654 / 7
J1587
S004 / 7 Injector magnetic coil drive cylinder 4: Mechanical system not responding correctly or incorrectly adjusted. Accidental fuel supply detected in cylinder no. 4. Circuit injector magnetic coil drive cylinder 5: Current lower than normal or open circuit. High resistance or no current detected on injector no. 5, pin DRIVE or RETURN. Injector magnetic coil drive cylinder 5: Mechanical system not responding correctly or incorrectly adjusted. Accidental fuel supply detected in cylinder no. 5. Circuit injector magnetic coil drive cylinder 6: Current lower than normal or open circuit. High resistance or no current detected on injector no. 6, pin DRIVE or RETURN. Injector magnetic coil drive cylinder 6: Mechanical system not responding correctly or incorrectly adjusted. Accidental fuel supply detected in cylinder no. 6. Starter relay circuit: Voltage higher than normal or shorted to high source. Open circuit or high voltage detected in the start locking circuit. The engine is switched off. Check cable harness between control unit and component. Check the injector. Engine can misfire or possibly run rough. Check cable harness between control unit and component. Check the injector. The engine is switched off. Check cable harness between control unit and component. Check the injector. Engine can misfire or possibly run rough. Check cable harness between control unit and component. Check the injector. The engine is switched off. Check cable harness between control unit and component. Check the injector. Either the engine will not start or the engine will not have starter lockout protection. Check cable harness between control unit and component. Check the relay.

D794
Diagnostic menu
655 / 5
S005 / 5
D794
655 / 7
S005 / 7
D794
656 / 5
S006 / 5
D794
656 / 7
S006 / 7
D794
677 / 3
S39 / 3
D794
ENGINE, menu 5
677 / 4
S39 / 4
Starter relay circuit: Voltage lower than normal or shorted to low source. Low voltage detected in the start locking circuit.
The engine will not have starter lockout protection.
Check cable harness between control unit and component. Check the relay. -
D794
ENGINE, menu 5
697 / 3
S057 / 3
Auxiliary PWM drive no. 1: Voltage higher than normal or shorted to high source. High signal voltage detected in the analogue torque circuit.
Can not control transmission.
D794
VDCT01.02GB
D:54
1 Engine Engine
Description
Limitation
Action
Code
697 / 4
J1587
S057 / 4 Auxiliary PWM drive no. 1: Voltage lower than normal or shorted to low source. Low signal voltage detected in the analogue torque circuit. Auxiliary Equipment Sensor Input #3 (OEM Switch) Root Cause Not Known. Can not control transmission. -

D794
Diagnostic menu
703 / 11
S051 /11
Possible engine power derate.
Check cable harness between control unit and component. Check the component.
D794
723 / 2
S064 / 2
Engine backup crankshaft speed/position sensor no. 2: Data erratic, intermittent or incorrect Engine speed sensor on the crankshaft uneven synchronised.
Possible low power.
D794
723 / 2
S064 / 2
Engine Speed Sensor (Camshaft) Error - Data Erratic, Intermittent, or Incorrect. The ECU 794 has detected an error in the camshaft position sensor signal. Engine speed/position sensor camshaft and crankshaft, misaligned: Mechanical system not responding correctly or incorrectly adjusted. Mechanical misalignment between the crankshaft and camshaft speed sensors. Circuit for intake air heater no. 1: Voltage higher than normal or shorted to high source. High voltage detected at the intake air heater signal circuit.
Can be difficult to start. Engine power derate.
D794
723 / 7
S064 / 7
The engine runs at lower power. Abnormal smoke, difficult to start and erratic idling can occur.
D794
729 / 3
S070 / 3
The intake air heaters may be ON or OFF all the time.
D794
729 / 4
S070 / 4
Circuit for intake air heater no. 1: Voltage lower than normal or shorted to low source. Low voltage detected at the intake air heater signal circuit.
The intake air heaters may be ON or OFF all the time.
D794
974 / 3
P974 / 3
Circuit for remote accelerator pedal or lever position sensor 1: Voltage higher than normal or shorted to high source. High voltage detected at the remote accelerator pedal position circuit.
Remote accelerator pedal not working. Remote accelerator pedal position set to zero percent.
D794
VDCT01.02GB
1 Engine Engine
D:55
Description
Limitation
Action
Code
974 / 4
J1587
P974 / 4 Circuit for remote accelerator pedal or lever position sensor 1: Voltage lower than normal or short-circuited to low source. Low voltage detected in remote accelerator pedal position signal. Data error for SAE J1939 multiplexing remote accelerator pedal or lever: Network data error received. The machine's OEM control unit (VECU) detected an error on the remote accelerator pedal. Supply voltage circuit for accelerator pedal or lever position sensor: Voltage higher than normal or shorted to high source. High voltage detected in the voltage supply circuit for the accelerator pedal or lever position sensor. Supply voltage circuit for accelerator pedal or lever position sensor: Voltage lower than normal or shorted to low source. Low voltage detected in the voltage supply circuit to the accelerator pedal or lever position sensor. Supply voltage circuit for engine speed/position sensor (crankshaft): Voltage lower than normal or shorted to low source. Low voltage detected on ECU 794 voltage supply cable to the engine speed sensor. Engine brake actuator circuit no. 1: Voltage higher than normal or shorted to high source. Open circuit or high voltage detected on the signal circuit for the motor brake solenoid coil no. 1. Engine brake actuator circuit no. 1: Voltage lower than normal or shorted to low source. Low voltage detected in signal circuit for the motor brake solenoid coil no. 1. Remote accelerator pedal not working. Remote accelerator pedal position set to zero percent. Check cable harness between control unit and component. Check component. The engine does not react to the remote accelerator pedal. Perhaps the engine is only running at idle. The primary accelerator or the one in the cab can possibly be used. Engine only running at idle. Use diagnostic menu to find incorrect segment.

D794
Diagnostic menu
974 / 19
P29
CAN/POWER, menu 2
1043 / 3
S221 / 3
D794
1043 / 4
S221 / 4
Engine will only die.
D794
1043 / 4
S221 / 4
Possible hard starting and rough running.
D794
1072 / 3
S028 / 3
Engine brake on cylinders 1, 2, and 3 can not be activated or exhaust brake will not operate.
D794
1072 / 4
S028 / 4
Engine brake on cylinders 1, 2, and 3 can not be activated or exhaust brake will not operate.
D794
VDCT01.02GB
D:56
1 Engine Engine
Description
Limitation
Action
Code
1073 / 3
J1587
S029 / 3 Engine brake actuator circuit no. 2: Voltage higher than normal or shorted to high source. Open circuit or high voltage detected on the signal circuit for the motor brake solenoid coil no. 2. Engine brake actuator circuit no. 2: Voltage lower than normal or shorted to low source. Low voltage detected in signal circuit for the motor brake solenoid coil no. 2. Electrical lift pump for the engine fuel delivery circuit: Voltage higher than normal or shorted to high source. High signal voltage or open circuit detected in the fuel lift pump's signal circuit. Electrical lift pump for the engine fuel delivery circuit: Voltage lower than normal or short-circuited to low source. Low signal voltage detected in fuel lift pump circuit. Circuit for sensor supply voltage no. 1: Voltage higher than normal or shorted to high source. High voltage detected in the sensor supply circuit no. 1. Engine brake on cylinders 4, 5, and 6 can not be activated. Check cable harness between control unit and component. Check component. Engine brake on cylinders 4, 5, and 6 can not be activated. Check cable harness between control unit and component. Check component. Engine can be difficult to start. -

D794
Diagnostic menu
1073 / 4
S029 / 4
D794
1075 / 3
S126 / 3
D794
1075 / 4
S126 / 4
Engine can be difficult to start.
D794
1079 / 3
S212 / 3
D794
1079 / 4
S212 / 4
Circuit for sensor supply voltage no. 1: Voltage lower than normal or shorted to low source. Low voltage detected in the sensor supply circuit no. 1.
D794
1080 / 3
S232 / 3
Circuit for sensor supply no. 2: Voltage higher than normal or shorted to high source. High voltage detected in the sensor supply circuit no. 2.
D794
1080 / 4
S232 / 4
Circuit for sensor supply voltage no. 2: Voltage lower than normal or shorted to low source. Low voltage detected in the sensor supply circuit no. 2.
D794
VDCT01.02GB
1 Engine Engine
D:57
Description
Limitation
Action
Code
1137 / 2
J1587
S114 / 2 Synchronisation switch for multiple units: Data erratic, intermittent or incorrect. Synchronised ON/OFF switch for multiple units and supplementary synchronised ON/OFF switch for multiple units have different values in ECU 794. Intake temperature sensor circuit for compressor 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. Intake temperature sensor circuit for compressor 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. Circuit for the fuel high pressure solenoid valve: Voltage higher than normal or shorted to high source. Electronic fuel control actuator short-circuited high. Circuit for the fuel high pressure solenoid valve: Voltage lower than normal or shorted to low source. Electronic fuel control actuator short-circuited low. Fuel pump pressure attachment 1: Mechanical system not responding correctly or incorrectly adjusted. Pumping imbalance between the front and rear pump pistons have been detected. Fuel Pumping Element Number 1 (Front) Mechanical System Not Responding Properly or Out of Adjustment. It is time to change the lubricating oil and filter. Change the engine oil and filter. Multiple Unit Synchronisation feature is disabled. -

D794
Diagnostic menu
1172 / 3
/3
D794
1172 / 4
/4
D794
1347 / 3
S126 / 3
Engine runs badly and with derated power. Fuel rail pressure becomes higher than requested. The engine runs poorly when idling and has low power. Fuel pressure becomes higher than requested. Engine will not run or possible low power.
D794
1347 / 4
S126 / 4
D794
1347 / 7
S126 / 7
D794
1347 / 7
S126 / 7
Engine will not run or possible low power.
D794
1378 / 31
S153 / 11
None on performance; maintenance reminder only.
D794
VDCT01.02GB
D:58
1 Engine Engine
Description
Limitation
Action
Code
1388 / 3
J1587
P223 / 3 Circuit for auxiliary pressure sensor, input signal 1: Voltage higher than normal or shorted to high source. High signal voltage detected in the OEM pressure circuit. Circuit for auxiliary pressure sensor, input signal 1: Voltage lower than normal or shorted to low source. Low signal voltage detected in the OEM pressure circuit. Undetectable error code from the engine. Error codes above 2047 cannot be shown in the display. Possible error code: 2789. /0 Exhaust temperature: Data higher than normal. High exhaust temperature has been calculated by the electronic control system. None on performance. -

D794
Diagnostic menu
1388 / 4
P223 / 4
D794
2047 / xx
Contact the engine supplier for further information. -
D794
2789 / 15
Derate in power output of the engine in attempt to decrease the calculated exhaust gas temperature value.
D794
VDCT01.02GB
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
Display
520192 /31
Supplier code
00/31
Description
Limitation
Action

D793/59
Diagnostic menu
Digital input 0, active error.
No limitation or Shut down while error is active. For inactive error code, Limp home until ignition is switched off.
Check for more error codes and rectify them first. Check the cable harness to the control unit. Check for more error codes and rectify them first. Check the cable harness to the control unit. Check for more error codes and rectify them first. Check the cable harness to the control unit. Check for more error codes and rectify them first. Check the cable harness to the control unit. Check for more error codes and rectify them first. Check the cable harness to the control unit.
520193 /31
01/31
D793/58
520194 /31
02/31
D793/57
520195 /31
03/31
D793/56
520196 /31
04/31
Digital input 4, active error. The transmission control unit activates Shut down or Limp home depending on speed.
D793/55
VDCT01.02GB
D:60
Display
520197 /31
Supplier code
05/31
Description
Limitation
Action

D793/54
Diagnostic menu
Check for more error codes and rectify them first. Check the cable harness to the control unit. Check for more error codes and rectify them first. Check the cable harness to the control unit. Check for more error codes and rectify them first. Check the cable harness to the control unit. Check for more error codes and rectify them first. Check the cable harness to the control unit.
520198 /31
06/31
D793/53
520199 /31
07/31
D793/52
520208/3
16/03
Analogue input 0, short circuit to voltage.
No limitation.
D793/24 D793/25
520208/4
16/04
Analogue input 0, short circuit to ground.
No limitation.
Check for more error codes and rectify them first. Check the cable harness to the control unit.
D793/24 D793/25
520208 /16
16/16
Analogue input 0, the value is above highest normal value.
No limitation.
D793/24 D793/25
520208 /18
16/18
Analogue input 0, the value is below lowest normal value.
No limitation.
D793/24 D793/25
520208 /31
16/31
Analogue input 0, active error.
Check for more error codes and rectify them first. Check the cable harness to the control unit. Check the cable harness between control unit and sensor. Check the sensor.
D793/24 D793/25
520209/3
17/03
Sensor oil temperature transmission (B766), short circuit to voltage.
D793/26 B766/1 D793/27 B766/2
TRANSM, menu 10
VDCT01.02GB
D:61
Display
520209/4
Supplier code
17/04
Description
Limitation
Action

D793/26 B766/1 D793/27 B766/2 D793/26 B766/1 D793/27 B766/2 D793/26 B766/1 D793/27 B766/2 D793/26 B766/1 D793/27 B766/2 D793/26 B766/1 D793/27 B766/2
Diagnostic menu
Sensor oil temperature transmission (B766), short circuit to ground.
No limitation.
TRANSM, menu 10
520209 /18
17/18
Sensor oil pressure transmission (B766), value is below lowest calibrated value.
No limitation.
TRANSM, menu 10
520209 /16
17/16
Sensor oil pressure transmission (B766), value is above highest calibrated value.
No limitation.
TRANSM, menu 10
520209 /13
17/13
Sensor oil temperature transmission (B766), calibration incorrect.
No limitation.
TRANSM, menu 10
520209 /31
17/31
Sensor oil temperature transmission (B766), active error.
Check the cable harness between control unit and sensor. Check the sensor. Check the cable harness between control unit and sensor. Check the sensor.
TRANSM, menu 10
520210/3
18/03
Sensor oil pressure (D765), short circuit to voltage.
No limitation.
D793/28 B765/A D793/29 B765/B D793/28 B765/A D793/29 B765/B D793/28 B765/A D793/29 B765/B D793/28 B765/A D793/29 B765/B D793/28 B765/A D793/29 B765/B
TRANSM, menu 10
520210/4
18/04
Sensor oil pressure (D765), short circuit to ground.
No limitation.
TRANSM, menu 10
520210 /16
18/16
Sensor oil pressure (B765), value is above highest normal value.
No limitation.
TRANSM, menu 10
520210 /18
18/18
Sensor oil pressure (B765), value is below lowest normal value.
No limitation.
TRANSM, menu 10
520210 /13
18/13
Sensor oil pressure (B765), incorrectly calibrated.
No limitation.
TRANSM, menu 10
VDCT01.02GB
D:62
Display
520210 /31
Supplier code
18/31
Description
Limitation
Action

D793/28 B765/A D793/29 B765/B
Diagnostic menu
Sensor oil pressure (B765), active error.
Check the cable harness between control unit and sensor. Check the sensor. Check the cable harness to the control unit. Check the cable harness to the control unit. Check the cable harness to the control unit. Check the cable harness to the control unit. Check the cable harness to the control unit. Check the cable harness to the control unit.
TRANSM, menu 10
520211/3
19/03
Analogue input 3, short circuit to voltage. Analogue input 3, short circuit to ground. Analogue input 3, the value is above highest normal value. Analogue input 3, the value is below lowest normal value. Analogue input 3, incorrectly calibrated Analogue input 3, active error.
No limitation.
D793/13 D793/14 D793/13 D793/14 D793/13 D793/14 D793/13 D793/14 D793/13 D793/14 D793/13 D793/14
520211/4
19/04
No limitation.
520211 /16 520211 /18 520211 /13 520211 /31
19/16
No limitation.
19/18
No limitation.
19/13
No limitation.
19/31
520218/5
26/05
Speed input 0, short circuit to voltage.
Check the cable harness to the control unit.
D793/09 D793/10
520218/6
26/06
Speed input 0, short circuit to ground.
D793/09 D793/10
520218 /10
26/10
Speed input 0, value outside limit values.
D793/09 D793/10
520218 /31
26/31
Speed input 0, active error. The transmission control unit activates Shut down or Limp home depending on speed.
D793/09 D793/10
VDCT01.02GB
D:63
Display
520219/5
Supplier code
27/05
Description
Limitation
Action

D793/11 B751/2 D793/12 B751/1
Diagnostic menu
Sensor turbine speed (B751), short circuit to voltage.
Check the cable harness between control unit and sensor. Check the sensor. Check the cable harness between control unit and sensor. Check the sensor. Check the cable harness between control unit and sensor. Check the sensor. Check the cable harness between control unit and sensor. Check the sensor. Check the cable harness between control unit and solenoid valve. Check the solenoid valve. Check the cable harness between control unit and solenoid valve. Check the solenoid valve. Check the cable harness between control unit and solenoid valve. Check the solenoid valve. Check the cable harness between control unit and solenoid valve. Check the solenoid valve. Check the cable harness between control unit and solenoid valve. Check the solenoid valve.
520219/6
27/06
Sensor turbine speed (B751), short circuit to ground.
D793/11 B751/2 D793/12 B751/1
520219 /10
27/10
Sensor turbine speed (B751), value outside limit values.
D793/11 B751/2 D793/12 B751/1
520219 /31
27/31
Sensor turbine speed (B751), active error.
D793/11 B751/2 D793/12 B751/1
552022 4/3
32/03
Solenoid valve clutch forward (Y630), short circuit to voltage.
D793/33 Y630/1 D793/34 Y630/2
520224/4
32/04
Solenoid valve clutch forward (Y630), short circuit to ground.
D793/33 Y630/1 D793/34 Y630/2
520224/5
32/05
Solenoid valve clutch forward (Y630), open circuit or short circuit to battery.
No limitation or Shut down while error is active. For inactive error code, Limp home until ignition is switched off. No limitation or Shut down while error is active. For inactive error code, Limp home until ignition is switched off.
D793/33 Y630/1 D793/34 Y630/2
520224 /31
32/31
Solenoid valve clutch forward (Y630), active error.
D793/33 Y630/1 D793/34 Y630/2
520225/3
33/03
Solenoid valve clutch reverse (Y631), short circuit to voltage.
D793/31 Y631/1 D793/32 Y631/2
VDCT01.02GB
D:64
Display
520225/4
Supplier code
33/04
Description
Limitation
Action

D793/31 Y631/1 D793/32 Y631/2
Diagnostic menu
Solenoid valve clutch reverse (Y631), short circuit to ground.
Check the cable harness between control unit and solenoid valve. Check the solenoid valve. Check the cable harness between control unit and solenoid valve. Check the solenoid valve. Check the cable harness between control unit and solenoid valve. Check the solenoid valve. Check the cable harness between control unit and solenoid valve. Check the solenoid valve. Check the cable harness between control unit and solenoid valve. Check the solenoid valve. Check the cable harness between control unit and solenoid valve. Check the solenoid valve. Check the cable harness between control unit and solenoid valve. Check the solenoid valve. Check the cable harness between control unit and solenoid valve. Check the solenoid valve. Check the cable harness between control unit and solenoid valve. Check the solenoid valve.
520225/5
33/05
Solenoid valve clutch reverse (Y631), open circuit or short circuit to battery.
D793/31 Y631/1 D793/32 Y631/2
520225 /31
33/31
Solenoid valve clutch reverse (Y631), active error.
D793/31 Y631/1 D793/32 Y631/2
520226/3
34/03
Solenoid valve clutch gear 1 (Y6067-1), short circuit to voltage.
D793/48 Y60671/1 D793/49 Y60672/2 D793/48 Y60671/1 D793/49 Y60672/2 D793/48 Y60671/1 D793/49 Y60672/2 D793/48 Y60671/1 D793/49 Y60672/2 D793/18 Y6069/1 D793/19 Y6069/2
520226/4
34/04
Solenoid valve clutch gear 1 (Y6067-1), short circuit to ground.
520226/5
34/05
Solenoid valve clutch gear 1 (Y6067-1), open circuit or short circuit to battery.
520226 /31
34/31
Solenoid valve clutch gear 1 (Y6067-1), active error.
520227/3
35/03
Solenoid valve clutch gear 2 (Y6069), short circuit to voltage.
520227/5
35/05
Solenoid valve clutch gear 2 (Y6069), open circuit or short circuit to battery voltage.
D793/18 Y6069/1 D793/19 Y6069/2
VDCT01.02GB
D:65
Display
520227 /31
Supplier code
35/31
Description
Limitation
Action

D793/18 Y6069/1 D793/19 Y6069/2
Diagnostic menu
Solenoid valve clutch gear 2 (Y6069), active error.
Check the cable harness between control unit and solenoid valve. Check the solenoid valve. Check the cable harness to the control unit.
520229/3
37/03
Digital output 05, short circuit to voltage.
D793/17 D793/18
520229/4
37/04
Digital output 05, short circuit to ground.
D793/17 D793/18
520229/5
37/05
Digital output 05, open circuit or short circuit to battery.
D793/17 D793/18
520229 /31
37/31
Digital output 05, active error.
Check for more error codes and rectify them first. Check the cable harness to the control unit. Check the cable harness to the control unit.
D793/17 D793/18
520230/3
38/03
D793/35 D793/50
520230/4
38/04
D793/35 D793/50
520230/5
38/05
D793/35 D793/50
520230 /31
38/31
D793/35 D793/50
VDCT01.02GB
D:66
Display
520231/3
Supplier code
39/03
Description
Limitation
Action

D793/01 D793/02
Diagnostic menu
520231/4
39/04
D793/01 D793/02
520231/5
39/05
D793/01 D793/02
520231/6
39/06
D793/01 D793/02
520231 /31
39/31
Check for more error codes and rectify them first. Check the cable harness to the control unit. Check the cable harness to the control unit.
D793/01 D793/02
520232/3
40/03
D793/03 D793/04
520232/4
40/04
D793/03 D793/04
520232/5
40/05
D793/03 D793/04
520232/6
40/06
D793/03 D793/04
VDCT01.02GB
D:67
Display
520230 /31
Supplier code
40/31
Description
Limitation
Action

D793/03 D793/04
Diagnostic menu
Check for more error codes and rectify them first. Check the cable harness to the control unit. Use diagnostic menu to check communication. Check the cable harness between Control unit, cab (D790-1) and Control unit, transmission (D793). Use diagnostic menu to check communication. Check the cable harness between Control unit, cab (D790-1) and Control unit, transmission (D793). Check for more error codes and rectify them first. Check the cable harness to the control unit. Use diagnostic menu to check communication. Check the cable harness between Control unit, cab (D790-1) and Control unit, transmission (D793). Use diagnostic menu to check communication. Check the cable harness between Control unit, cab (D790-1) and Control unit, transmission (D793). Check for more error codes and rectify them first. Check the cable harness to the control unit.
520240/9
48/09
Incorrect declutch signal via the CAN bus.
Declutch of transmission with declutch pedal does not work.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520240 /19
48/19
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520240 /31
48/31
520241/9
49/09
Incorrect gear programme selection via the CAN bus.
Transmission control unit does not allow change of gear range, however, operation of machine is possible.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520241 /19
49/19
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520241 /31
49/31
VDCT01.02GB
D:68
Display
520242/9
Supplier code
50/09
Description
Limitation
Action

D793/22 D7901/K13:1 D7901/K13:1 D793/23
Diagnostic menu
Incorrect kickdown signal via the CAN bus.
Kickdown does not work.
Use diagnostic menu to check communication. Check the cable harness between Control unit, cab (D790-1) and Control unit, transmission (D793).
CAN/POWER, menu 3
520242 /19
50/19
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520242 /31
50/31
520243/9
51/09
Incorrect neutral position signal via the CAN bus.
The transmission is locked in neutral position.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520243 /19
51/19
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520243 /31
51/31
VDCT01.02GB
D:69
Display
520244/2
Supplier code
52/02
Description
Limitation
Action

D793/22 D7901/K13:1 D7901/K13:1 D793/23
Diagnostic menu
Incorrect idle signal from accelerator pedal via CAN bus.
No limitation.
CAN/POWER, menu 3
520244/9
52/09
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520244 /19
52/19
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520244 /31
52/31
No limitation.
520245/2
53/02
Incorrect full throttle signal from accelerator pedal via CAN bus.
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520245/9
53/09
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
VDCT01.02GB
D:70
Display
520245 /19
Supplier code
53/19
Description
Limitation
Action

D793/22 D7901/K13:1 D7901/K13:1 D793/23
Diagnostic menu
No limitation.
CAN/POWER, menu 3
520245 /31
53/31
No limitation.
520249/9
57/09
Incorrect parking brake signal via the CAN bus.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520249 /19
57/19
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520249 /31
57/31
520250/9
58/09
Incorrect load signal via the CAN bus.
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
VDCT01.02GB
D:71
Display
520250 /19
Supplier code
58/19
Description
Limitation
Action

D793/22 D7901/K13:1 D7901/K13:1 D793/23
Diagnostic menu
No limitation.
CAN/POWER, menu 3
520250 /31
58/31
No limitation.
520251/9
59/09
Incorrect signal for disengagement 4WD/2WD via the CAN bus.
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520251 /19
59/19
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520251 /31
59/31
No limitation.
520252/9
60/09
Incorrect high/low gear signal via the CAN bus.
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
VDCT01.02GB
D:72
Display
520252 /19
Supplier code
60/19
Description
Limitation
Action

D793/22 D7901/K13:1 D7901/K13:1 D793/23
Diagnostic menu
No limitation.
CAN/POWER, menu 3
250252 /31
60/31
No limitation.
520253/9
61/09
Incorrect extra neutral position signal via the CAN bus.
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520253 /19
61/19
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520253 /31
61/31
No limitation.
520254/1
62/01
Low oil pressure transmission.
Risk of slipping clutches.
Check the transmission oil level. Check the sensor.
520254/9
62/09
Incorrect oil pressure signal via the CAN bus.
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
VDCT01.02GB
D:73
Display
520254 /19
Supplier code
62/19
Description
Limitation
Action

D793/22 D7901/K13:1 D7901/K13:1 D793/23
Diagnostic menu
Incorrect oil pressure signal via the CAN bus.
No limitation.
CAN/POWER, menu 3
520254 /31
62/31
Oil pressure signal, active error.
No limitation.
520255/9
63/09
Incorrect brake signal via the CAN bus.
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520255 /19
63/19
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520255 /31
63/31
Brake signal, active error.
No limitation.
520256/9
64/09
Incorrect signal for operator-in-seat via the CAN bus.
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
VDCT01.02GB
D:74
Display
520256 /19
Supplier code
64/19
Description
Limitation
Action

D793/22 D7901/K13:1 D7901/K13:1 D793/23
Diagnostic menu
Incorrect signal for operator-in-seat via the CAN bus.
No limitation.
CAN/POWER, menu 3
520256 /31
64/31
Signal operator-inseat, active error.
No limitation.
520257/9
65/09
Incorrect signal for seat direction via the CAN bus.
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520257 /19
65/19
Incorrect signal for seat direction via the CAN bus.
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520257 /31
65/31
Signal for seat direction, active error.
No limitation.
520258/9
66/09
Incorrect signal for prevent shifting via the CAN bus.
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
VDCT01.02GB
D:75
Display
520258 /19
Supplier code
66/19
Description
Limitation
Action

D793/22 D7901/K13:1 D7901/K13:1 D793/23
Diagnostic menu
Incorrect signal for prevent shifting via the CAN bus.
No limitation.
CAN/POWER, menu 3
520258 /31
66/31
Signal prevent shifting, active error.
No limitation.
520260/0
68/00
High transmission oil temperature.
Control unit indicates the error to make operator aware of the warning's level.
Check the transmission oil cooler, clean if necessary. Check the thermostat in the transmission oil cooler. Use diagnostic menu to check communication. Check the cable harness between Control unit, cab (D790-1) and Control unit, transmission (D793).
520260/9
68/09
Incorrect transmission oil temperature via the CAN bus.
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520260 /19
68/19
Incorrect transmission oil temperature via the CAN bus.
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520260 /31
68/31
Transmission oil temperature, active error.
No limitation.
520261/9
69/09
Incorrect signal for lock-up function via the CAN bus.
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
VDCT01.02GB
D:76
Display
520261 /19
Supplier code
69/19
Description
Limitation
Action

D793/22 D7901/K13:1 D7901/K13:1 D793/23
Diagnostic menu
Incorrect signal for lock-up function via the CAN bus.
No limitation.
CAN/POWER, menu 3
520261 /31
68/31
Signal lock-up function active error.
No limitation.
520262/9
70/09
Incorrect signal for exhaust brake via the CAN bus.
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520262 /19
70/19
Incorrect signal for exhaust brake via the CAN bus.
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520262 /31
70/31
Exhaust brake signal, active error.
No limitation.
520263/9
71/09
Incorrect signal for retarder via the CAN bus.
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
VDCT01.02GB
D:77
Display
520263 /19
Supplier code
71/19
Description
Limitation
Action

D793/22 D7901/K13:1 D7901/K13:1 D793/23
Diagnostic menu
Incorrect signal for retarder via the CAN bus.
No limitation.
CAN/POWER, menu 3
520263 /31
71/31
Signal retarder, active error.
No limitation.
520264/9
72/09
Incorrect signal for raised idle via the CAN bus.
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520264 /19
72/19
Incorrect signal for raised idle via the CAN bus.
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520264 /31
72/31
Signal raised idle, active error.
No limitation.
520276/2
84/02
Incorrect gear position limitation. Incorrect gear position limitation via the CAN bus.
No limitation.
Check the cable harness to the control unit. Use diagnostic menu to check communication. Check the cable harness between Control unit, cab (D790-1) and Control unit, transmission (D793).
520276/9
84/09
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
VDCT01.02GB
D:78
Display
520276 /19
Supplier code
84/19
Description
Limitation
Action

D793/22 D7901/K13:1 D7901/K13:1 D793/23
Diagnostic menu
Incorrect gear position limitation via the CAN bus.
No limitation.
CAN/POWER, menu 3
520276 /31
84/31
Signal gear position limitation, active error.
No limitation.
520277/9
85/09
Incorrect signal for customer function 1 via the CAN bus.
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520277 /19
85/19
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520277 /31
85/31
Signal customer function 1, active error.
No limitation.
520278/9
86/09
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
VDCT01.02GB
D:79
Display
520278 /19
Supplier code
86/19
Description
Limitation
Action

D793/22 D7901/K13:1 D7901/K13:1 D793/23
Diagnostic menu
No limitation.
CAN/POWER, menu 3
520278 /31
86/31
No limitation.
520279/9
87/09
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520279 /19
87/19
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520279 /31
87/31
No limitation.
520280/9
88/09
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
VDCT01.02GB
D:80
Display
520280 /19
Supplier code
88/19
Description
Limitation
Action

D793/22 D7901/K13:1 D7901/K13:1 D793/23
Diagnostic menu
No limitation.
CAN/POWER, menu 3
520280 /31
88/31
No limitation.
520281/9
89/09
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520281 /19
89/19
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520281 /31
89/31
No limitation.
520282/9
90/09
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
VDCT01.02GB
D:81
Display
520282 /19
Supplier code
90/19
Description
Limitation
Action

D793/22 D7901/K13:1 D7901/K13:1 D793/23
Diagnostic menu
No limitation.
CAN/POWER, menu 3
520282 /31
90/31
No limitation.
520283/9
91/09
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520283 /19
91/19
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520283 /31
91/31
No limitation.
520284/9
92/09
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
VDCT01.02GB
D:82
Display
520284 /19
Supplier code
92/19
Description
Limitation
Action

D793/22 D7901/K13:1 D7901/K13:1 D793/23
Diagnostic menu
No limitation.
CAN/POWER, menu 3
520284 /31
92/31
No limitation.
520285/9
93/09
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520285 /19
93/19
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520285 /31
93/31
No limitation.
520286/9
94/09
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
VDCT01.02GB
D:83
Display
520286 /19
Supplier code
94/19
Description
Limitation
Action

D793/22 D7901/K13:1 D7901/K13:1 D793/23
Diagnostic menu
No limitation.
CAN/POWER, menu 3
520286 /31
94/31
No limitation.
520287/2
95/02
Incorrect signal from gear selector.
520287/9
95/09
Incorrect signal for gear selection via the CAN bus.
Use diagnostic menu to check communication. Check the cable harness between Control unit, cab (D790-1) and Control unit, transmission (D793). Use diagnostic menu to check communication. Check the cable harness between Control unit, cab (D790-1) and Control unit, transmission (D793). Check for more error codes and rectify them first. Check the cable harness to the control unit. Check for more error codes and rectify them first. Check the cable harness to the control unit.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520287 /19
95/19
Incorrect signal for gear selection via the CAN bus.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520287 /31
95/31
Signal gear selection, active error.
520288 /02
96/02
Incorrect signal from accelerator pedal.
No limitation.
VDCT01.02GB
D:84
Display
520288 /09
Supplier code
96/09
Description
Limitation
Action

D793/22 D7901/K13:1 D7901/K13:1 D793/23
Diagnostic menu
Incorrect accelerator pedal signal via the CAN bus.
No limitation.
CAN/POWER, menu 3
520288 /19
96/19
Incorrect accelerator pedal signal via the CAN bus.
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520288 /31
96/31
Signal accelerator pedal, active error.
No limitation.
520289/2
97/02
Incorrect signal from brake pedal.
No limitation.
520289/9
97/09
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520289 /19
97/19
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520289 /31
97/31
Signal brake pedal, active error.
No limitation.
VDCT01.02GB
D:85
Display
520290/0
Supplier code
98/00
Description
Limitation
Action

-
Diagnostic menu
Transmission oil temperature too high sump.
Transmission locked in neutral position (Shut down).
Check the transmission oil cooler, clean if necessary. Check the thermostat in the transmission oil cooler.
520290/2
98/02
Incorrect signal from sensor for transmission oil temperature sump.
520290 /16
98/16
High transmission oil temperature sump.
No limitation.
520290 /31
98/31
Signal transmission oil temperature sump, active error.
No limitation.
520291/0
99/00
Transmission oil temperature too high, radiator.
520291/2
99/02
Incorrect signal from sensor for transmission oil temperature radiator.
520291 /16
99/16
High transmission oil temperature radiator.
No limitation.
520291 /31
99/31
Signal transmission oil temperature cooler, active error.
No limitation.
520293/1
101/01
Oil pressure too low, transmission.
Risk of slipping clutches
Check the transmission oil level Check the sensor.
VDCT01.02GB
D:86
Display
520293/2
Supplier code
101/02
Description
Limitation
Action

-
Diagnostic menu
Incorrect signal oil pressure transmission.
Transmission in locked neutral position (Shut down).
520293 /31
101/31
Signal oil pressure transmission, active error.
No limitation.
520294/0
102/00
Clutch pressure, clutch forward, too high.
No limitation.
Check the transmission oil level Check the sensor. Check the hydraulics in the transmission.
520294/2
102/02
Incorrect signal clutch pressure, clutch forward.
No limitation.
520294 /16
102/16
High clutch pressure, clutch forward.
No limitation.
520294 /31
102/31
Signal clutch pressure, clutch forward, active error.
No limitation.
520295/0
103/00
Clutch pressure, clutch reverse, too high.
No limitation.
520294/2
103/02
Incorrect signal clutch pressure, clutch reverse.
No limitation.
520295 /16
103/16
High clutch pressure, clutch reverse.
No limitation.
VDCT01.02GB
D:87
Display
520295 /31
Supplier code
103/31
Description
Limitation
Action

-
Diagnostic menu
Signal clutch pressure, clutch reverse, active error.
No limitation.
520296/0
104/00
Clutch pressure, clutch forward high gear, too high.
No limitation.
520296/2
104/02
Incorrect signal clutch pressure, clutch forward, high gear.
No limitation.
520296 /16
104/16
High clutch pressure, clutch forward high gear.
No limitation.
520296 /31
104/31
Signal clutch pressure, clutch forward high gear, active error.
No limitation.
520297/0
105/00
Clutch pressure, clutch gear 1, too high.
No limitation.
520297/2
105/02
Incorrect signal clutch pressure, clutch gear 1.
No limitation.
520297 /16
105/16
High clutch pressure, clutch gear 1.
No limitation.
520297 /31
105/31
Signal clutch pressure, clutch gear 1, active error.
No limitation.
VDCT01.02GB
D:88
Display
520298/0
Supplier code
106/00
Description
Limitation
Action

-
Diagnostic menu
No limitation.
520298/2
106/02
No limitation.
520298 /16
106/16
No limitation.
520298 /31
106/31
No limitation.
520299/0
107/00
No limitation.
520299/2
107/02
No limitation.
520299 /16
107/16
No limitation.
520299 /31
107/31
No limitation.
520300/0
108/00
No limitation.
VDCT01.02GB
D:89
Display
520300/2
Supplier code
108/02
Description
Limitation
Action

-
Diagnostic menu
No limitation.
520300 /16
108/16
No limitation.
520300 /31
108/31
No limitation.
520314/0
122/02
Incorrect signal engine speed.
Check for more error codes and rectify them first. Check the cable harness to the control unit. Use diagnostic menu to check communication. Check the cable harness between Control unit, cab (D790-1) and Control unit, transmission (D793). Use diagnostic menu to check communication. Check the cable harness between Control unit, cab (D790-1) and Control unit, transmission (D793). Check for more error codes and rectify them first. Check the cable harness to the control unit. Check the cable harness between the sensor and control unit. Check the sensor.
520314/9
122/09
Incorrect signal for engine speed via the CAN bus.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520314 /19
122/19
Incorrect signal for engine speed via the CAN bus.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520314 /31
122/31
Signal engine speed, active error.
520315/2
123/02
Incorrect signal from Sensor, turbine speed.
D793/11 B751/2 D793/12 B751/1
VDCT01.02GB
D:90
Display
520315 /31
Supplier code
123/31
Description
Limitation
Action

D793/11 B751/2 D793/12 B751/1
Diagnostic menu
Signal turbine speed, active error.
No limitation.
520316/2
124/02
Incorrect signal rotation speed drum.
Check for more error codes and rectify them first. Check the cable harness to the control unit. Check for more error codes and rectify them first. Check the cable harness to the control unit.
520316 /31
124/31
Signal rotation speed drum, active error.
No limitation.
520317/2
125/02
Incorrect signal rotation speed output shaft.
Check for more error codes and rectify them first. Check the cable harness to the control unit. Check for more error codes and rectify them first. Check the cable harness to the control unit.
520317 /31
125/31
Signal rotation speed output shaft, active error.
No limitation.
520336/0
144/00
Control unit, transmission (D793), battery voltage too high.
Check the voltage feed. If equipment for assisted start is connected, disconnect it. Check the cable harness to the control unit. Check alternator, battery and cable harness between battery and alternator.
D793/45
CAN/POWER, menu 15
520336/1
144/01
Control unit, transmission (D793), battery voltage too low.
D793/45
CAN/POWER, menu 15
520336 /16
144/16
Control unit, transmission (D793), battery voltage high.
No limitation.
Check the voltage feed. If equipment for assisted start is connected, disconnect it.
D793/45
CAN/POWER, menu 15
VDCT01.02GB
D:91
Display
520336 /18
Supplier code
144/18
Description
Limitation
Action

D793/45
Diagnostic menu
Control unit, transmission (D793), battery voltage low.
No limitation.
Check the cable harness to the control unit. Check alternator, battery and cable harness between battery and alternator.
CAN/POWER, menu 15
520337/0
145/00
Control unit, transmission (D793), ignition voltage too high.
Check the voltage feed. If equipment for assisted start is connected, disconnect it. Check the cable harness to the control unit. Check alternator, battery and cable harness between battery and alternator.
D793/20 D793/60
CAN/POWER, menu 15
520337/1
145/01
Control unit, transmission (D793), ignition voltage too low.
D793/20 D793/60
CAN/POWER, menu 15
520337 /16
145/16
Control unit, transmission (D793), ignition voltage high.
No limitation.
Check the voltage feed. If equipment for assisted start is connected, disconnect it.
D793/20 D793/60
CAN/POWER, menu 15
520337 /18
145/18
Control unit, transmission (D793), ignition voltage low.
No limitation.
Check the cable harness to the control unit. Check alternator, battery and cable harness between battery and alternator.
D793/20 D793/60
CAN/POWER, menu 15
520346 /12
154/12
Control unit, transmission (D793), memory error. Control unit, transmission (D793), memory error. Control unit, transmission (D793), memory error. Control unit, transmission (D793), memory error. Incorrect configuration. Incorrect configuration.
Transmission locked in neutral position (Shut down). Transmission locked in neutral position (Shut down). Transmission locked in neutral position (Shut down). Transmission locked in neutral position (Shut down). No limitation. No limitation.
Switch off the ignition and the battery voltage, and check if the error remains. Switch off the ignition and the battery voltage, and check if the error remains. Switch off the ignition and the battery voltage, and check if the error remains. Switch off the ignition and the battery voltage, and check if the error remains. Reprogram the control unit. Reprogram the control unit.
520346 /31
154/31
520347 /31
155/31
520348 /31
156/31
520353 /31 520354 /31
161/31 162/31
VDCT01.02GB
D:92
Display
520355 /31 520356 /31 520368 /31
Supplier code
163/31 164/31 176/31
Description
Limitation
Action

-
Diagnostic menu
Incorrect configuration. Incorrect configuration. Output parking brake, active error.
No limitation. No limitation. No limitation.
Reprogram the control unit. Reprogram the control unit. Check for more error codes and rectify them first. Check the cable harness to the control unit.
520371 /31
179/31
Output disengagement 4WD/2WD, active error.
No limitation.
520372 /31
180/31
Output high/low gear, active error.
No limitation.
520373 /31
181/31
Output speed limitation, active error.
No limitation.
520374 /31
182/31
Output signal start interlock neutral position, active error.
No limitation.
520375 /31
183/31
Output signal warning lamp transmission error, active error.
No limitation.
520376 /31
184/31
Output signal lock-up, active error.
No limitation.
520377 /31
185/31
Output gear position, active error.
No limitation.
VDCT01.02GB
D:93
Display
520385/9
Supplier code
193/09
Description
Limitation
Action

D793/22 D7901/K13:1 D7901/K13:1 D793/23
Diagnostic menu
Control unit, cab (D790-1), communication error.
No limitation.
CAN/POWER, menu 3
520386/9
194/09
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520387/9
195/09
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520389/9
197/09
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520390/9
198/09
No limitation.
D793/22 D7901/K13:1 D7901/K13:1 D793/23
CAN/POWER, menu 3
520432 /XX 520433 /XX 520434 /XX
240/XX
Incorrect configuration. Incorrect configuration. Incorrect configuration.
No limitation.
Reprogram Control unit, transmission (D793). Reprogram Control unit, transmission (D793). Reprogram Control unit, transmission (D793).
241/XX
No limitation.
242/XX
No limitation.
VDCT01.02GB
D:94
Display
520435 /XX 520436 /XX 520437 /XX 520438 /XX 520439 /XX 520440 /XX 520441 /XX 520442 /XX 520443 /XX 520444 /XX
Supplier code
243/XX
Description
Limitation
Action

-
Diagnostic menu
Incorrect configuration. Incorrect configuration. Incorrect configuration. Incorrect configuration. Incorrect configuration. Incorrect configuration. Incorrect configuration. Incorrect configuration. Incorrect configuration. Incorrect configuration.
No limitation.
Reprogram Control unit, transmission (D793). Reprogram Control unit, transmission (D793). Reprogram Control unit, transmission (D793). Reprogram Control unit, transmission (D793). Reprogram Control unit, transmission (D793). Reprogram Control unit, transmission (D793). Reprogram Control unit, transmission (D793). Reprogram Control unit, transmission (D793). Reprogram Control unit, transmission (D793). Reprogram Control unit, transmission (D793).
244/XX
No limitation.
245/XX
No limitation.
246/XX
No limitation.
247/XX
No limitation.
248/XX
No limitation.
249/XX
No limitation.
250/XX
No limitation.
251/XX
No limitation.
253/XX
No limitation.
VDCT01.02GB
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.
Code
1
Description
Communication error with frame control unit (D797-1) Communication error with frame control unit (D797-2). Communication error with Control unit, attachment (D791-1). Communication error with Control unit KID (D795). Error in cable, CAN network, segment 1. Error in cable, CAN network, segment 2. Error in cable, CAN network, segment 3. Error in cable, CAN network, segment 4. Error in cable, CAN network, segment 5. Accelerator pedal 2 VBFS not calibrated.
Limitation
-
Action

D797-1
Diagnostic menu
CAN/POWER, menu 1-3 CAN/POWER, menu 1-3 CAN/POWER, menu 1-3 CAN/POWER, menu 1-3 CAN/POWER, menu 1-3 CAN/POWER, menu 1-3 CAN/POWER, menu 1-3 CAN/POWER, menu 2 and 3 CAN/POWER, menu 1-3 CALIBRATION: DRIVETRAIN, menu 5 and 6 CALIBRATION: DRIVETRAIN, menu 1 and 2
Group
11.6.2 Redundant CAN bus 11.6.2 Redundant CAN bus 11.6.2 Redundant CAN bus 11.6.2 Redundant CAN bus 11.6.2 Redundant CAN bus 11.6.2 Redundant CAN bus 11.6.2 Redundant CAN bus 11.6.2 Redundant CAN bus 11.6.2 Redundant CAN bus 1. Engine
2*
D797-2
D791-1
Use diagnostic menu to find incorrect segment. Use diagnostic menu to find incorrect segment.
D795
11
Varies depending on machine configuration. Varies depending on machine configuration. Varies depending on machine configuration. Varies depending on machine configuration. Varies depending on machine configuration. D790-1/K6:12 R690-2
12
13
14
15
19 *
Accelerator pedal for reversing does not work. Engine speed limited to idle. Accelerator pedal does not work. Engine speed limited to idle.
Calibrate the accelerator pedal. See section 8 Control system, group 8.5.2.3 Calibrate DRIVE-TRAIN. Calibrate the accelerator pedal. See section 8 Control system, group 8.5.2.3 Calibrate DRIVE-TRAIN.
20
Accelerator pedal not calibrated.
D790-1/K6:11 R690-1
1. Engine
VDCT01.02GB
D:96
Code
21
Description
Communication error with Control unit, transmission (D793).
Limitation
Gear selection not working.
Action

D790-1/K13:1 D793/M2 D790-1/K13:2 D793/L2
Diagnostic menu
CAN/POWER, menu 4
Group
22
Communication error with Control unit, engine (D794).
Engine does not respond to commands from the cab.
Use diagnostic menu to check communication. Check the cable harness between Control unit, cab (D790-1) and Control unit, engine (D794). Contact Cargotec.
Volvo: D7901/K13:1, K13:2 D794/2, 1 Cummins: D790-1/K13:1, K13:2 D794/46, 37 D790-1
CAN/POWER, menu 4
23
The set-up file cannot be read in Control unit, cab (D790-1). Power supply to cab fan below 18 V. Interference during software download. Buffer for error codes from Control unit, engine (D794), active error code when downloading.
No controls in the cab are working. Cab fan not working. Error code stored in Control unit, engine (D794).
11.5.3.1 Control unit, cab 9.4.3 Cabin fan 11.5.3.10 Engine control unit
24 25 26 27 28 29 30 31
Check fuse F58-5/3 Switch the ignition off and on. Repeat software download.
D790-1/K2:8 58-5/3:2 D794
ENGINE, menu 8
Incorrect power supply to Control unit, cab (D790-1). Voltage below 18 V or above 32 V.
Controls in cab not working.
Check fuse F58-5/1. Check cabling between the control unit and the component with diagnostic menu. Check the control unit.
D790-1/K1:2, K1:3, K1:4 F58-5/1:1, 1:2
CAN/POWER, menu 7
11.5.1.3 Ignition voltage (15)
32
Incorrect 5 V reference voltage to analogue cab controls. Voltage below 4.9 V or above 5.1 V.
Analogue controls in cab not working (miniwheel/steering lever and controls for air conditioning). Control breaker cannot be disengaged. All hydraulic functions are blocked. Parking brake cannot be released.
Check the wiring between the control unit and component with the diagnostic menu. Check component.
D790-1/K4:5, K 5:11, K5:13, K7:2, K 9:7
CAN/POWER, menu 7
11.5.3.1 Control unit, cab
33
No feedback signal for emergency stop switch voltage from Relay, emergency stop switch voltage (K3009-1). Incorrect signal from Switch, parking brake (S107), indicates released and applied at same time or nothing at all.
Check fuse F58-3/8. Check cabling between the control unit and the component with diagnostic menu.
D790-1/K11:13 K3009-1/87
CAN/POWER, menu 5
11.5.1.4 Emergency stop switch voltage (15E)
34
Check cabling between the control unit and the component with diagnostic menu. Check the switch.
D791-1/K8:5 S107/7 D791-1/K8:13 S107/1
HYD, menu 5
4.5 Parking brake
VDCT01.02GB
D:97
Code
35 36 37 38 39 40 41
Description
Interference during software download. Buffer for error codes from Control unit, transmission (D793), active error code when downloading. Transistor has been triggered due to short circuit or open circuit in circuit for rear wiper motor (M650-2). Transistor has been triggered due to short circuit or open circuit in circuit for rotating beacon (H428). Transistor has been triggered due to short circuit or open circuit in circuit for left reversing light (E405L). Transistor has been triggered due to short circuit or open circuit in circuit for right reversing light (E405R). Transistor has been triggered due to short circuit or open circuit in circuit for front wiper motor (M650-1). Transistor has been triggered due to short circuit or open circuit in circuit for fan motor (M657). Transistor has been triggered due to short circuit or open circuit in circuit for recirculation actuating motor (M612). Transistor has been triggered due to short circuit or open circuit in circuit for water valve (Y673).
Limitation
Error code stored in Control unit, transmission (D793).
Action
Switch the ignition off and on. Repeat software download.

D793
Diagnostic menu
TRANSM, menu 13
Group
11.5.3.9 Transmission control unit
Wiper rear not working.
Check cabling between the control unit and the component with diagnostic menu. Check the motor.
D790-1/K2:4 M650-2/53
CAB, menu 3
9.5.7 Wiper motor rear
42
Revolving beacon not working.
Check cabling between the control unit and the component with diagnostic menu. Check the component.
D790-1/K2:5 H428
LIGHTS, menu 6
43
Left cab reversing light not working.
Check bulb. Check cabling between the control unit and the component with diagnostic menu. Check bulb. Check cabling between the control unit and the component with diagnostic menu. Check cabling between the control unit and the component with diagnostic menu. Check the component.
D790-1/K2:6 E405L
LIGHTS, menu 8
44
Right cab reversing light not working.
D790-1/K2:7 E405R
LIGHTS, menu 8
45
Wiper front not working.
D790-1/K2:1 M650-1/53
CAB, menu 2
9.5.5 Wiper motor front
46
Cab fan not working.
D790-1/K2:2 M657/2
CLIMATE, menu 6
9.4.3 Cabin fan
47
Recirculation damper to ventilation not working.
D790-1/K2:3 M612/3
CLIMATE, menu 6
9.4.2 Fresh air filter and recirculation damper
48
Heat in cab cannot be adjusted.
D790-1/K4:1 Y673/5
CLIMATE, menu 7
9.4.5 Water valve
VDCT01.02GB
D:98
Code
49
Description
Transistor has been triggered due to short circuit or open circuit in circuit for water valve (Y673). Transistor has been triggered due to short circuit or open circuit in circuit for actuating motor (Y672). Transistor has been triggered due to short circuit or open circuit in circuit for actuating motor (Y672). Transistor has been triggered due to short circuit or open circuit in circuit for bypass of external top lift attachment. Transistor has been triggered due to short circuit or open circuit in circuit for roof and rear washer motor (M651-2). Transistor has been triggered due to short circuit or open circuit in circuit for flashing hazard light switch (S109). Transistor has been triggered due to short circuit or open circuit in circuit for background lighting in switches and instruments. Transistor has been triggered due to short circuit or open circuit in circuit for relay for 20' working lights. Transistor has been triggered due to short circuit or open circuit in circuit for indicator light for levelling lock in joystick (S815).
Limitation
Heat in cab cannot be adjusted.
Action

D790-1/K4:2 Y673/6
Diagnostic menu
CLIMATE, menu 7
Group
9.4.5 Water valve
50
Air distribution in cab cannot be adjusted.
D790-1/K4:3 Y672/5
CLIMATE, menu 8
51
Air distribution in cab cannot be adjusted.
D790-1/K4:4 Y672/6
CLIMATE, menu 8
52 *
Bypass of external top lift attachment not working.
Check component. Check the wiring.
D790-1/K5:3
53
Windscreen washer rear and roof not working.
D790-1/K5:4 M651-2
CAB, menu 1
54
Flashing hazard lights not working.
D790-1/K5:5 S109/
LIGHTS, menu 7
55
Reduced or no background lighting in instruments and controls.
Check bulbs for background lighting, replace if necessary. Check the cable harness for background lighting.
D7901/K6:1, K 8:15, K 9:2, all inputs of type A Digital in
LIGHTS, menu 14
56
Work lights 20' not working.
D790-1/ K7:8 R3017-2/86
LIGHTS, menu 12
57
Indicator light for levelling lock in joystick not working.
D790-1/ K7:9 S815/7
7.1.1 Control levers/Joystick
VDCT01.02GB
D:99
Code
58 *
Description
Transistor has been triggered due to short circuit or open circuit in circuit for relay for twistlock on external top lift attachment (K3005). Transistor has been triggered due to short circuit or open circuit in circuit for relay for spreading on external top lift attachment (K3006). Transistor has been triggered due to short circuit or open circuit in circuit for relay for heating element in driver's seat (K383). Transistor has been triggered due to short circuit or open circuit in circuit for relay for 40' working lights (K3017-1). Transistor has been triggered due to short circuit or open circuit in circuit for relay for ignition voltage (K315-1). The transistor has been triggered due to short circuit or open circuit in circuit for Relay, emergency stop switch voltage (K3009-1). The transistor has been triggered due to short circuit or open circuit in circuit for Relay, emergency stop switch voltage (K3009-2). Transistor has been triggered due to short circuit or open circuit in circuit for windscreen washer motor (M651-1, M651-2).
Limitation
Twistlock on external top lift attachment does not work.
Action

D790-1/ K7:10 K3005/86
Diagnostic menu
EXTATTACH, menu 6
Group
7.9.2 Twistlocks
59 *
Spreading on external top lift attachment does not work.
D790-1/ K7:11 K3006/86
EXTATTACH, menu 6
7.10.5.1 Spreading
60
Seat heating does not work.
D790-1/ K10:7 K383/86
CAB, menu 8
9.3.3 Heating coil
61
Work lights 40' not working.
D790-1/ K10:8 K3017-1/86
LIGHTS, menu 12
63
No ignition voltage to the machine's Control units.
D790-1/K10:10 K315-1/86
CAN/POWER, menu 5
64
No emergency stop switch voltage to the machine's Control units.
D790-1/K10:11 K3009-1/86
CAN/POWER, menu 6
11.5.1.4 Emergency stop switch voltage
65
No emergency stop switch voltage to the machine's Control units.
D790-1/K10:12 K3009-2/86
CAN/POWER, menu 6
66
Windshield washer not working.
D790-1/K10:13 M651-1, M651-2
CAB, menu 1
VDCT01.02GB
D:100
Code
67
Description
Transistor has been triggered due to short circuit or open circuit in circuit for roof wiper motor (M650-3). Transistor has been triggered due to short circuit or open circuit in circuit for circulation pump, pause heater (M667). Transistor has been triggered due to short circuit or open circuit in circuit for relay for drivetrain ignition voltage (K315-2). Transistor has been triggered due to short circuit or open circuit in circuit for cab interior lighting (E434-1). Relay ignition voltage (K315-1) has jammed in position on.
Limitation
Wiper roof not working.
Action

D790-1/K10:14 M650-3
Diagnostic menu
CAB, menu 4
Group
9.5.6 Wiper motor roof
68 *
Pause heater not working.
D790-1/K10:15 M667
9.4 Heating, ventilation and air conditioning
69
No voltage feed to engine and transmission.
D790-1/K10:16 K315-2/86
71
Interior lighting in cab not working.
Check bulb. Check cabling between the control unit and the component with diagnostic menu. Check cabling between the control unit and the component with diagnostic menu. Check the component. Check the drive belt for the compressor for air conditioning. Check that compressor for air conditioning is activated. Check cabling between the control unit and the component with diagnostic menu.
D790-1/K11:6 E434-1
LIGHTS, menu 9
9.6.11 Interior lighting cab
75
The cab control unit (D790-1) still has a power supply and is thereby active. Air conditioning not working.
CAN/POWER, menu 5
11.5.1.3 Ignition voltage
80
No signal from Pressure switch, air conditioning (S246), despite the AC compressor being activated.
D797-1/K1:40 S246
CLIMATE, menu 3
9.4.10 Pressure switch
81
Incorrect signal from Damper motor (Y672). Signal voltage below 0.2 V or above 4.8 V. Incorrect signal from accelerator pedal (B690-1). Signal voltage below 0.2 V or above 4.8 V. Incorrect signal from extra accelerator pedal (B690-2). Signal voltage below 0.2 V or above 4.8 V.
Air distribution cannot be adjusted.
D790-1/K4:7 Y672/9
CLIMATE, menu 4
9.4.6 Fresh air and recirculation damper
85
Accelerator pedal for driving forward does not work. Engine speed limited to idle. Accelerator pedal for reversing does not work. Engine speed limited to idle.
Check cabling between the control unit and the component with diagnostic menu. Check the component. Check the wiring between the control unit and component with the diagnostic menu. Check component.
D790-1/K6:11 B690-1/2
ENGINE, menu 1
1 Engine
86 *
D790-1/K6:12 B690-2/2
VBFS, menu 4
1 Engine
VDCT01.02GB
D:101
Code
87
Description
Error signal from Control lever lifting/lowering (R8071). Signal voltage below 0.2 V or above 4.8 V. Error signal from Control lever tilt (R8072). Signal voltage below 0.2 V or above 4.8 V. Error signal from Control lever side shift (R8073). Signal voltage below 0.2 V or above 4.8 V. Error signal from Control lever spreading (R8074). Signal voltage below 0.2 V or above 4.8 V. Error signal from Control lever extra function (R8075-1). Signal voltage below 0.2 V or above 4.8 V. Incorrect signal from Steering lever (R825-1) or Mini-wheel (R825-1). Signal voltage below 0.2 V or above 4.8 V. Incorrect signal from Mini-wheel (R825-2). Signal voltage below 0.2 V or above 4.8 V. Incorrect signal from Water valve, cab heating (Y673). Signal voltage below 0.2 V or above 4.8 V. Error signal from Control lever extra function (R8075-2). Signal voltage below 0.2 V or above 4.8 V.
Limitation
Lift and lower not working.
Action
Check cabling between the control unit and the component with diagnostic menu. Check the lever.

D790-1/K7:3 R8071/3
Diagnostic menu
ELSERV, menu 1 (P1)
Group
7.1.1 Control lever
88
Tilt not working.
D790-1/K7:4 R8072/3
ELSERV, menu 1 (P2)
7.1.1 Control lever
89
Side shift not working.
D790-1/K7:5 R8073/3
ELSERV, menu 1 (P3)
7.1.1 Control lever
90 *
Spreading not working.
D790-1/K7:6 R8074/3
ELSERV, menu 2 (P4)
7.1.1 Control lever
91 *
Extra load handling function not working.
Check the wiring between the control unit and component with the diagnostic menu. Check component.
D790-1/K7:7 R8075-1/3
ELSERV, menu 2 (P5)
7.1.1 Control lever
92 *
Joystick control or mini-wheel not working.
D790-1/K9:8 R825-1/H1
EL-STEERING, menu 1
5.1.2 Miniwheel 5.1.3 Joystick
93 *
Joystick control or mini-wheel not working.
D790-1/K9:9 R825-2/H2
EL-STEERING, menu 1
5.1.2 Mini steering wheel
94
Cab heat cannot be adjusted.
D790-1/K10:4 Y673/9
CLIMATE, menu 4
9.4.5 Water valve
95 *
Extra load handling function not working.
D790-1/K9:9 R8075-2/3
ELSERV, menu 2 (P7)
7.1.1 Control lever
VDCT01.02GB
D:102
Code
96
Description
Incorrect signal from Sensor, cab temperature (B775-1). Sensor indicates temperature below -43 C or above 105 C. Incorrect signal from Sensor, outer temperature (B774). Temperature signal above 105 C. Incorrect signal from Sensor, outlet fan temperature (B775-2). Sensor indicates temperature below -43 C or above 105 C. Incorrect signal from Sensor, refrigerant temperature (B775-3). Sensor indicates temperature below -43 C or above 105 C. Redundant voltage feed left to frame control unit (D797-1) does not reach destination. Redundant voltage feed right to frame control unit (D797-1) does not reach destination. Incorrect power supply to Control unit, frame (D797-1). Voltage below 18 V or above 32 V. Incorrect emergency stop switch voltage to frame control unit (D797-1).
Limitation
Air conditioning not working.
Action
Check cabling between the control unit and the component with diagnostic menu. Check the sensor.

D790-1/K4:8 B775-1/2
Diagnostic menu
CLIMATE, menu 1
Group
9.4.17 Sensor cab temperature
97
D790-1/K4:9 B774/2
CLIMATE, menu 2
9.4.18 Sensor, ambient temperature
98
D790-1/K4:10 B775-2/2
CLIMATE, menu 2
9.4.16 Sensor, temperature outlet fan
99
D790-1/K4:11 B775-3/2
CLIMATE, menu 2
9.4.12 Sensor temperature refrigerant
101
Check cabling between the control unit and the component with diagnostic menu. Check the control unit.
D797-1/K2:7
CAN/POWER, menu 10
11.5.1.2 Redundant voltage feed of control units
102
D797-1/K2:8
CAN/POWER, menu 10
11.5.1.2 Redundant voltage feed of control units
103
No electric power feed to components.
Check fuse F58-2/1, replace if necessary. Check cabling between the control unit and the component with diagnostic menu. Check fuse F58-2:1 and replace if necessary. Check the wiring between the control unit and component with the diagnostic menu. Check component.
D797-1/K2:1, K2:9, K2:10 F58-2/1:1, 1:2
CAN/POWER, menu 10
104
Functions normally supplied emergency stop switch voltage have no feed. All hydraulic functions are blocked.
D797-1/K2:11 F58-2/1:1
CAN/POWER, menu 10
VDCT01.02GB
D:103
Code
105
Description
Incorrect 5 V reference voltage to pressure sensor. Voltage below 4.9 V or above 5.1 V. Transistor has been triggered due to short circuit or open circuit in circuit for hydraulic oil cooling fan (M668). Transistor has been triggered due to short circuit or open circuit in circuit for mast work lights (E404R-1, E404L-1). Transistor has been triggered due to short circuit or open circuit in circuit for high beam (E402R-1, E402L-1). Transistor has been triggered due to short circuit or open circuit in circuit for low beam (E400L, E400R). Transistor has been triggered due to short circuit or open circuit in circuit for running lights (H416-1, H416-2, H417-1, H417-2). Transistor has been triggered due to short circuit or open circuit in circuit for brake oil cooling fan (M674). Transistor has been triggered due to short circuit or open circuit in circuit for solenoid valve, lift mast (Y6005) and solenoid valve, lower mast (Y6004). Transistor has been triggered due to short circuit or open circuit in circuit for solenoid valve, tilt in (Y6011) and solenoid valve, tilt out (Y6010)
Limitation
Incorrect function, lift and tilt sensor.
Action

D797-1/K1:8 B768-1/1, B768-2/1
Diagnostic menu
CAN/POWER, menu 11
Group
8.2.1 Overload protection
106
Cooling fan hydraulic oil not working.
D797-1/K1:14 M668/1
HYD, menu 1
10.6.3 Cooling fan
107
Mast work lights not working.
Check bulb. Check the bulb holder. Check cabling between the control unit and the component with diagnostic menu.
D797-1/K1:1 E404L-1, E404R-1
LIGHTS, menu 10
9.6.9 Working lights mast
108
High beam not working.
D797-1/K1:15 E402L-1, E402R-1
LIGHTS, menu 3
9.6.1 Headlights
109
Low beams not working.
D797-1/K1:28 E400L, E400R
LIGHTS, menu 3
9.6.1 Headlights
111
Running lights not working.
D797-1/K1:2 H416-1, H416-2, H417-1, H417-2
LIGHTS, menu 2
9.6.2 Running lights
112
Cooling fan brake oil not working.
D797-1/K1:3 M674/1
HYD, menu 2
4.8.9 Cooling fan
113
Lift and lower not working.
Check cabling between the control unit and the component with diagnostic menu. Check the solenoid valves.
D797-1/K1:4 Y6004/1, Y6005/1
ELSERV, menu 3 and 4
114
Tilt not working.
Check cabling between the control unit and the component with diagnostic menu. Check the solenoid valve.
D797-1/K1:5 Y6010/1, Y6011/1
ELSERV, menu 5 and 6
VDCT01.02GB
D:104
Code
115
Description
Transistor has been triggered due to short circuit or open circuit in circuit for left direction indicator (H422, H426). Transistor has been triggered due to short circuit or open circuit in circuit for right direction indicator (H423, H427). Transistor has been triggered due to short circuit or open circuit in circuit for start relay (K315) for starter motor. Transistor has been triggered due to short circuit or open circuit in circuit for tail light (H412L, H412R). Transistor has been triggered due to short circuit or open circuit in circuit for left brake light (H411L). Transistor has been triggered due to short circuit or open circuit in circuit for right brake light (H411R). The transistor has been triggered due to short circuit or open circuit in circuit for Back-up warning device (H965). Transistor has been triggered due to short circuit or open circuit in circuit for electromagnetic clutch of AC compressor (M645). NOTE! Error code 122 and 123 apply to the same user.
Limitation
Left direction indicator not working.
Action

D797-1/K1:30 H422/1, H426/1
Diagnostic menu
LIGHTS, menu 4
Group
116
Right direction indicator not working.
D797-1/K1:31 H423/1, H427/1
LIGHTS, menu 4
117
Starter motor not working.
D797-1/K1:32 K315/85
ENGINE, menu 5
1.11 Start and stop
118
Tail lights not working.
D797-1/K1:33 H412L/1, H412R/1
LIGHTS, menu 2
9.6.3 Tail lights
119
Brake light left not working.
D797-1/K1:7 H411L/1
LIGHTS, menu 8
9.6.4 Brake light
120
Brake light right not working.
D797-1/K1:9 H411R/1
LIGHTS, menu 8
9.6.4 Brake light
121
Back-up alarm not working.
D797-1/K1:10 H965/1
LIGHTS, menu 8
9.7.5 Back-up alarm
122 123
D797-1/K1:25 M645/1 D797-1/K1:29 M645/1
CLIMATE, menu 6
9.4.7 Compressor
VDCT01.02GB
D:105
Code
124
Description
Transistor has been triggered due to short circuit or open circuit in circuit for solenoid valve, hydraulic pump disengagement (Y6062). Transistor has been triggered due to short circuit or open circuit in circuit for solenoid valve regeneration, lift, right (Y6051). Transistor has been triggered due to short circuit or open circuit in circuit for solenoid valve regeneration, lift, left (Y6052). Vehicle Data file missing.
Limitation
Pressurising of attachment control valve does not work. No attachment functions working. Regeneration not working.
Action

D797-1/K1:39 Y6062/1
Diagnostic menu
HYD, menu 6
Group
125 *
Check cabling between the control unit and the component with diagnostic menu. Check component.
D797-1/K1:11 Y6051/1
ELSERV, menu 15
7.2.6 Valve block lift cylinder
126 *
Regeneration not working.
Check cabling between the control unit and the component with diagnostic menu. Check component. -
D797-1/K1:12 Y6052/1
ELSERV, menu 15
7.2.6 Valve block lift cylinder
132
Some functions in machine not working. Scales, regeneration and slack chain logic, not working. Overload system not working. Error code 150 activated.
133 *
Faulty signal from hydraulic pressure sensor for lift cylinder (B768-1).
Check the sensor. Check cabling between the control unit and the component with diagnostic menu.
D797-1/K1:21 B768-1/3
HYD, menu 3 OLS, menu 1
7.2.8 Sensor hydraulic pressure lift cylinder
134 *
Faulty signal from hydraulic pressure sensor for tilt cylinder (B768-2).
Overload system not working. Error code 150 activated.
Check the sensor. Check cabling between the control unit and the component with diagnostic menu.
D797-1/K1:22 B768-2/3
HYD, menu 3 OLS, menu 1
7.7.8 Hydraulic pressure sensor, tilt cylinder
135 *
No feedback signal from brake oil cooling fan (M674).
Check that cooling fan is working. Check cabling between the control unit and the component with diagnostic menu.
D797-1/K2:6 M674/2
HYD, menu 2
4.8.9 Cooling fan
137
Error signal from Solenoid valve lift mast (Y6005). Return current does not correspond with control current.
Lift mast not working.
D797-1/K1:16 Y6005/2
ELSERV, menu 3
VDCT01.02GB
D:106
Code
138
Description
Error signal from Solenoid valve lower mast (Y6004). Return current does not correspond with control current. Incorrect signal from Solenoid valve, tilt in (Y6011). Return current does not correspond with control current. Incorrect signal from Solenoid valve, tilt out (Y6010). Return current does not correspond with control current. Transistor has been triggered due to short circuit or open circuit in circuit for parking brake solenoid valve (Y642). Transistor has been triggered due to short circuit or open circuit in circuit for solenoid valve, hydraulic pump disengagement (Y6012/6062). Transistor has been triggered due to short circuit or open circuit in circuit for solenoid valve, lock twistlocks/spreading out (Y6039/6018). Transistor has been triggered due to short circuit or open circuit in circuit for solenoid valve, open twistlocks/spreading in (Y6040/6019). High brake oil temperature.
Limitation
Lower mast not working.
Action

D797-1/K1:17 Y6004/2
Diagnostic menu
ELSERV, menu 4
Group
139
Tilt in not working.
D797-1/K1:18 Y6011/2
ELSERV, menu 5
140
Tilt out not working.
D797-1/K1:19 Y6010/2
ELSERV, menu 6
141
Parking brake cannot be released.
D797-1/K1:34 Y642/1
HYD, menu 5
4.5.3 Solenoid valve parking brake
142
Pressurising of attachment control valve does not work. No attachment functions working. Spreading and twistlocks on top lift attachment not working.
D797-1/K1:35 Y6012/6062/1
HYD, menu 6
143 *
D797-1/K1:36 Y6039/6018/1
EXTATTACH, menu 5
7.10.5 Separate top lift attachment
144 *
Spreading and twistlocks on top lift attachment not working.
D797-1/K1:37 Y6040/6019/1
EXTATTACH, menu 5
7.10.5 Separate top lift attachment
145 *
Reduced braking capacity. If the temperature continues to rise, speed is limited to 5 km/h.
Check that cooling fan is working. Check that the radiator is not clogged. Check the brake oil level. Check the sensor.
D797-1/K2:6 B772/1
HYD, menu 2
4.8.10 Sensor brake oil temperature
VDCT01.02GB
D:107
Code
146 *
Description
Incorrect signal from Sensor, brake oil temperature (Y772). Signal voltage below 0.2 V or above 4.8 V. High temperature hydraulic oil.
Limitation
Speed limited to 5 km/h.
Action
Check the sensor. Check cabling between the control unit and the component with diagnostic menu. Check that cooling fan is working. Check that the radiator is not clogged. Check the sensor.

D797-1/K2:6 B772/1
Diagnostic menu
HYD, menu 2
Group
4.8.10 Sensor brake oil temperature
147
Reduced braking capacity. If the temperature continues to rise, speed is limited to 5 km/h. Incorrect temperature display.
D797-1/K2:13 B776/1
HYD, menu 1
148
Incorrect signal from Sensor, hydraulic oil temperature (B776). Incorrect signal from fuel level sensor (B757). Resistance above 180. Defective overload protection. This error code cannot be removed with Reset.
Check the sensor. Check cabling between the control unit and the component with diagnostic menu. Check the sensor. Check cabling between the control unit and the component with diagnostic menu. Check if there are error codes for sensors in the overload system.
D797-1/K2:13 B776/1
HYD, menu 1
149
Incorrect display of fuel volume (empty or full).
D797-1/K2:15 B757/1
CAB, menu 7
1.2.2 Sensor fuel level
150 *
Overload system not working. All lift functions run at reduced speed. Right front brake light not working.
OLS, menu 17
8.2.1 Overload protection
193
Transistor has been triggered due to short circuit or open circuit in circuit for right front brake light (H410R). Transistor has been triggered due to short circuit or open circuit in circuit for left front brake light (H410L). Redundant voltage feed left to attachment control unit (D791-1) does not reach destination. Redundant voltage feed right to frame control unit (D791-1) does not reach destination.
D797-1/K1:36 H410R/1
VBFS, menu 8
9.6.4 Brake light
194
Left front brake light not working.
D797-1/K1:37 H410L/1
VBFS, menu 8
9.6.4 Brake light
251
D791-1/K2:7
CAN/POWER, menu 15
11.5.1.2 Redundant voltage feed of Control units
252
D791-1/K2:8
CAN/POWER, menu 15
11.5.1.2 Redundant voltage feed of Control units
VDCT01.02GB
D:108
Code
253
Description
Incorrect power supply to Control unit, attachment (D791-1). Voltage below 18 V or above 32 V.
Limitation
Functions normally supplied emergency stop switch voltage have no feed. No attachment functions working. Functions normally supplied emergency stop switch voltage have no feed. No attachment functions working. -
Action
Check fuse F58-3/1, replace if necessary. Check cabling between the control unit and the component with diagnostic menu.

D791-1/K2:1, K2:9, K2:10 F58-3/1:1
Diagnostic menu
CAN/POWER, menu 15
Group
254
Incorrect emergency stop switch voltage to Control unit, attachment (D791-1).
Check fuse F58-3/1, replace if necessary. Check cabling between the control unit and the component with diagnostic menu.
D791-1/K2:11 F58-3/1:1
CAN/POWER, menu 15
255
Incorrect 5 V reference voltage to pressure sensor. Voltage below 4.9 V or above 5.1 V. Transistor has been triggered due to short circuit or open circuit in circuit for central unit for central lubrication (M693-2). Transistor has been triggered due to short circuit or open circuit in circuit for attachment work lights, left (E404L-3). Transistor has been triggered due to short circuit or open circuit in circuit for attachment work lights, right (E404R-3). Transistor has been triggered due to short circuit or open circuit in circuit for warning signal, automatic spreading (H9003). Transistor has been triggered due to short circuit or open circuit in circuit for control valve for levelling clockwise (Y637-1, Y637-2).
D791-1/K1:8
CAN/POWER, menu 16
11.5.1 Power supply
256
Central lubrication attachment not working.
D791-1/K1:14 M693-2/1
OPT, menu 2
9.14.1 Pump unit
257
Work light attachment left not working.
D791-1/K1:1 E404L, E404UL, E404LL-3/1
LIGHTS, menu 13
9.6.12 Work light attachment
258
Work light attachment right not working.
Check bulb. Check the bulb holder. Check cabling between the control unit and the component with diagnostic menu. Check the buzzer. Check cabling between the control unit and the component with diagnostic menu.
D791-1/K1:15 E404R, E404UR, E404LR-3/1
LIGHTS, menu 13
9.6.12 Work light attachment
259
Warning signal for automatic spreading not working.
D791-1/K1:28 H9003/1
ATTACH, menu 21
7.5.7 Buzzer, automatic spread 20"-40"
260 *
Levelling of attachment not working.
D791-1/K1:42 Y637-1/1, Y637-2/1
ATTACH, menu 15
VDCT01.02GB
D:109
Code
261
Description
Transistor has been triggered due to short circuit or open circuit in circuit for solenoid valve, spreading left in (Y6019L). Transistor has been triggered due to short circuit or open circuit in circuit for solenoid valve, spreading left out (Y6018L). Transistor has been triggered due to short circuit or open circuit in circuit for solenoid valve, spreading right in (Y6019R). Transistor has been triggered due to short circuit or open circuit in circuit for solenoid valve, spreading right out (Y6018R). Transistor has been triggered due to short circuit or open circuit in circuit for levelling, left (Y6036). Transistor has been triggered due to short circuit or open circuit in circuit for solenoid valve, levelling right (Y6035). Transistor has been triggered due to short circuit or open circuit in circuit for solenoid valve, side shift left (Y6020). Transistor has been triggered due to short circuit or open circuit in circuit for solenoid valve, side shift right (Y6021). Transistor has been triggered due to short circuit or open circuit in circuit for solenoid valve for locked twistlocks (Y6040).
Limitation
Spreading left in of attachment not working.
Action

D791-1/K1:16 Y6019L/2
Diagnostic menu
ATTACH, menu 18
Group
7.5.2 Control valve attachment
262
Spreading left out of attachment not functioning.
D791-1/K1:16 Y6018L/2
ATTACH, menu 17
263
Spreading right in of attachment not working.
D791-1/K1:17 Y6019R/2
ATTACH, menu 20
264
Spreading right out of attachment not functioning.
D791-1/K1:17 Y6018R/2
ATTACH, menu 19
265 *
Levelling left of attachment not working.
D791-1/K1:19 Y6036/2
ATTACH, menu 13
266 *
Levelling right of attachment not working.
D791-1/K1:19 Y6036/2
ATTACH, menu 14
267
Side shift left of attachment not working.
D791-1/K1:18 Y6020/2
ATTACH, menu 11
268
Side shift right of attachment not working.
D791-1/K1:18 Y6021/2
ATTACH, menu 12
269
Twistlock not working.
D791-1/K1:7 Y6040/1
ATTACH, menu 9
7.9.1.2 Control valve attachment
VDCT01.02GB
D:110
Code
270
Description
Transistor has been triggered due to short circuit or open circuit in circuit for solenoid valve for open twistlocks(Y6039). The transistor has been triggered due to short circuit or open circuit in circuit for Voltage feed, position sensor attachment.
Limitation
Action

D791-1/K1:9 Y6039/1
Diagnostic menu
ATTACH, menu 9
Group
271
Twistlocks and spreading not working.
D791-1/K1:10 B769L/A, B769R/A, B777L/A, B777R/A, B7203L/A, B7203R/A, B7204L/A, B7204R/A, B7205LL/A, B7205RL/A D791-1/K1:25 H562/1
CAN/POWER, menu 16
272
The transistor has been triggered due to short circuit or open circuit in the circuit for Indicator light, open twistlocks (H562). The transistor has been triggered due to short circuit or open circuit in the circuit for Indicator light, locked twistlocks (H563). The transistor has been triggered due to short circuit or open circuit in circuit for Indicator light, alignment (H564). Error signal from the Solenoid valve spreading left in (Y6019L) and Solenoid valve spreading left out(Y6018L). Return current does not correspond with control current. Error signal from the Solenoid valve spreading right in (Y6019R) and Solenoid valve spreading right out (Y6018R). Return current does not correspond with control current.
Indicator light, open twistlock/lock tongue not working.
Check bulb. Check the bulb holder. Check cabling between the control unit and the component with diagnostic menu. Check bulb. Check the bulb holder. Check cabling between the control unit and the component with diagnostic menu. Check bulb. Check the bulb holder. Check cabling between the control unit and the component with diagnostic menu. Check cabling between the control unit and the component with diagnostic menu. Check the solenoid valve.
ATTACH, menu 10
7.9.1 Twistlocks
273
Indicator light, locked twistlock/lock tongues not working.
D791-1/K1:29 H563/1
ATTACH, menu 10
7.9.1 Twistlocks
274
Indicator light, attachment alignment not working.
D791-1/K1:39 H564/1
ATTACH, menu 10
7.9.1 Twistlocks
287
Spreading left not working.
D791-1/K1:16 Y6019L/2, Y6019R/2
ATTACH, menu 17 and 18
288
Spreading right not working.
D791-1/K1:17 Y6019R/2, Y6018R/2
VDCT01.02GB
D:111
Code
289
Description
Error signal from Solenoid valve for side shift left (Y6020) and Solenoid valve for side shift right (Y6021). Return current does not correspond with control current. Error signal from Solenoid valve levelling right (Y6036) and Solenoid valve levelling left (Y6035). Return current does not correspond with control current. Transistor has been triggered due to short circuit or open circuit in circuit for indicator light, upper alignment (H564UL). Transistor has been triggered due to short circuit or open circuit in circuit for solenoid valve, spreading in (Y6019). Sensor twistlock left side indicates both locked and open twistlock at the same time.
Limitation
Side shift of attachment not working.
Action

D791-1/K1:18 Y6020/2, Y6021/2
Diagnostic menu
Group
290 *
Levelling of attachment not working.
D791-1/K1:19 Y6035/2, Y6036/2
291 *
Indicator light for upper alignment not working.
Check bulb. Check the bulb holder. Check cabling between the control unit and the component with diagnostic menu. Check cabling between the control unit and the component with diagnostic menu. Check the solenoid valve.
D791-1/K1:34 H564UL/1
ATTACH, menu 23
292
Spreading in of attachment not working.
D791-1/K1:35 Y6019/1
ATTACH, menu 14
298
Check that Sensors, twistlock, are clean and correctly adjusted. Check cabling between the control unit and the component with diagnostic menu.
D791-1/K2:13
ATTACH, menu 8
7.9.1.7 Sensor twistlocks
299
Sensor twistlock right side indicates both locked and open twistlock at the same time.
Check that Sensors, twistlock, are clean and correctly adjusted. Check cabling between the control unit and the component with diagnostic menu.
D791-1/K2:15
ATTACH, menu 8
7.9.1.7 Sensor twistlocks
300
Sensor, alignment, indicates unreasonable distance.
Check that Sensors, alignment, are clean and correctly adjusted. Check that the contact pin runs smoothly. Check cabling between the control unit and the component with diagnostic menu.
ATTACH, menu 7
7.9.1.6 Sensor alignment
VDCT01.02GB
D:112
Code
451
Description
Redundant voltage feed left to Control unit KID (D795) does not reach destination. Redundant voltage feed right to Control unit KID (D795) does not reach destination. No messages received on CAN buffer 1. No messages received on CAN buffer 2.
Limitation
-
Action
Check cabling between the control unit and the component with diagnostic menu. Check cabling between the control unit and the component with diagnostic menu. Use diagnostic menu to check the CAN bus.

D795/K1:7
Diagnostic menu
CAN/POWER, menu 9
Group
11.5.1.2 Redundant voltage feed of control units 11.5.1.2 Redundant voltage feed of control units 11.6.2 Redundant CAN bus 11.6.2 Redundant CAN bus
452
D795/K1:8
CAN/POWER, menu 9
460
Incorrect values in operating menus. Error codes from other Control units cannot be shown. -
D795/K1:10, K1:11, K1:12, K1:13 D795/K1:5, K1:6
CAN/POWER, menu 1, 2, 17 CAN/POWER, menu 1, 2, 17
461
Use diagnostic menu to check the CAN bus.
500
Time for service.
Check that servicing has been performed. 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.
VDCT01.02GB
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
VDCT01.02GB
E:2
VDCT01.02GB
E Schematics Schematics
E:3
E Schematics
Common hydraulics
Hydraulic diagrams, compilation
Designation
Hydraulic diagrams, page E:4
Drawing number
A54948.0100
VDCT01.02GB
E:4
13 17 16 14
13
VDCT01.02GB
12
1 15 11 a b c d e f g h
18
20
a 19
8 b 10 e
E Schematics Common hydraulics
Hydraulic diagrams
32 21 24 29 28 25 27 31 30 26 25 23 24
34
22
22 23
36
35
33
015048 [A58447-0200 ver . 03]
E Schematics Common hydraulics
E:5
1. 2. 3. 4. 5. 6. 7. 8.
Wheel brakes Drive axle block Brake cylinder Parking brake caliper Make-contact (closing switch) declutch (S220) Make-contact (closing switch) brake light (S216) Brake valve Valve block brake system a b Accumulator drain valve Solenoid valve parking brake (Y642)
17. Spreading cylinder right spreader beam 18. Main valve a b c d e f Solenoid valve hydraulic pressure attachment (Y6012/6062) Relief valve, attachment Servo valve, lift (Y6005) Servo valve, lower (Y6004) Servo valve, tilt in (Y6011) Servo valve, tilt out (Y6010)
19. Lift, tilt and attachment control valve 20. Valve block accumulator charging and priority valve 21. Accumulator lift cylinder 22. Load control valve 23. Lift cylinder 24. Overcentre valve 25. Tilt cylinder 26. Hydraulic oil tank 27. Breather filter 28. Hydraulic oil pump, load handling 29. Hydraulic oil pump, brake and steering 30. Hydraulic oil filter, load handling 31. Hydraulic oil filter, cooling circuit 32. Steering valve 33. Steering cylinder 34. Oil cooler 35. Thermal bypass valve 36. Fine filter
9.
Switch (NC) low brake pressure (S204)
10. Switch (NO), parking brake (S200) 11. Accumulator brake system 12. Side shift cylinder 13. Lock cylinder, twistlock 14. Overcentre valve 15. Control valve, attachment a b c d e f g h Servo valve, side shift left (Y6020) Servo valve, side shift right (Y6021) Servo valve, open twistlock (Y6039) Servo valve, lock twistlock (Y6040) Servo valve spreading out left (Y6018L) Servo valve spreading in left (Y6019L) Servo valve spreading out right (Y6018R) Servo valve spreading in right (Y6019R)
16. Spreading cylinder left spreader beam
VDCT01.02GB
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
-X M 6 7 4 m
-X M 6 7 4 f
Connectors
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).
-X 3 7 -2 0 1
013017
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 -S 2 2 0 -2
Components
Components are described with component number (S220-2) and a short descriptive text. Components (sensors, switches, etc.) are shown in standby mode i.e. de-energised mode or not mechanical standby mode. S indicates the type of component, see Component designations, page 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.
P 1
1 D E C L U C H IN G 3 ,0 M P a 2
1
013018
VDCT01.02GB
E:7
Cable marking
)
# #
9 ,
Cable marking
All cables are either white (ground signal) or grey (other wiring) and labelled with numbers. Cable numbering is interpreted as follows:
)
# "
9 +
)
# !
9 *
0525: the number on a cable can usually be traced to a pin in a connector, in this example, connector X052 pin 5. W212: cables that start with W and serial number cannot be traced directly to a connector. A01012: cables that start with A are in the electronic box in the cab. W212D: cables that end with a capital letter are jointed in the wiring from a main cable with the same number. Each joint will have its own letter.
) $
# %
9 -
9 ) !'
References
0
00816
References
An arrow symbol means that the circuit continues on another page in the circuit diagram at the specified coordinates. Sometimes there are also references for components that can then be part of a component whose other parts are on a different diagram. In some cases there is also a help text where the cable connects. Example: /11.5_1.D3 means page 11.5_1 coordinate D3.
1
013020
/4 .0 _ 1 .B 1 /9 .1 0 _ 1 .A 2
5
00816
Connection to control unit
Connection to control unit

-X 4 1 1 21
K 1 :2 1 A n a lo g In 0 -5 V /0 .0 _ 4 .D 5
+BO O M -D 7 9 1 -1
013021
M E A S U R E P O IN T S C A L E
Connections to control units are described as a table with two fields; the upper one shows the type of connection, the lower one has a reference to the compilation of the control unit's connections. Together with this there are descriptive texts that specify control unit and signal. For more information about the different connection types on the 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.
VDCT01.02GB
E:8
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
B D E F G H K M P R S X Y
Description
Converter from non-electric to electric signals or vice versa. Example: inductive sensor. Binary element, delay unit, memory. Example: control unit. White light. Example: work lighting. Protective device. Example: fuse. Alternator, power supply device. Example: battery. Signal device. Example: horn, brake lights. Relay, contactor. Example: power relay ignition key lock. Motor. Example: electric motor. Measuring instrument, testing equipment. Example: hour meter. Resistor. Example: potentiometer. Electric switch for control circuit, selector. Example: switch. Outlet/socket, connecting device. Example: connection terminal. 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
0.0-1 0.0-2 0.0-3 0.0-4 0.1-1 1.0-1 1.0-2E1 1.0-2E2 2.0-1 4.0-1 4.8-1 7.0-1 7.0-2 7.0-4 7.0-5 7.2-1 7.2-6 7.7-1
Designation
Cross-reference list Cross-reference list Cross-reference list Cross-reference list Truth table opt. Circuit, drivetrain, engine Circuit, Cummins QSB6.7 engine Circuit, Cummins QSB6.7 engine Circuit, drivetrain gearbox Circuit, brake system Circuit, brake oil cooling Circuit, electric servo levers Circuit, electric servo joystick Circuit, accessory attachment Circuit, accessory attachment Circuit, lift/lower electric servo Circuit, mast valves Circuit, tilt electric servo
VDCT01.02GB
E:9
Sheet
7.7-2 7.9-1 8.2-1 9.0-1 9.1-1 9.1-2 9.3-1 9.3-2 9.4-1 9.4-2 9.4-3 9.5-1 9.6-1 9.6-2 9.6-3 9.6-4 9.6-5 9.6-6 9.6-7 9.6-8 9.6-9 9.6-10 9.6-11 9.6-12 9.6-13 9.6-14 9.7-1 9.7-2 9.7-3 9.7-4 9.8-1 9.8-2 9.9-1 9.9-2 9.10-1 9.141 10.4-1 10.6-1 11.5-1 11.5-2 11.5-3 11.5-4
Designation
Circuit, tilt indication Circuit, twistlock Circuit, bypassing Circuit, std. opt. Circuit, optional equipment Circuit, hour counter Circuit, seat heating Circuit, air suspension seat Circuit, climate system Circuit, climate system Circuit, condenser chassis Circuit, wipers Circuit, work lights 20'-40' Circuit, work lights, carriage Circuit, work lights, mast Circuit lighting Circuit lighting Circuit lighting Circuit, direction indicators & hazard Circuit, interior lighting Circuit, work lights, option Circuit, work lights, option Circuit, entry lighting Circuit, aux. lights, attachment Circuit, work lights, option, hood lamp Circuit, work lights, option carriage Circuit, alarm, audible signals Circuit, back-up alarm Circuit, compressor horn Circuit for horn, servo panel Circuit, radio Circuit, printer Circuit, rearview mirror heating Circuit, camera Circuit, cab tilt/sliding cab Circuit, central lubrication Circuit, hydr. pump disengagement Circuit, hydraulic oil cooling Circuit, current Circuit, current Circuit, current Circuit, current
VDCT01.02GB
E:10
Sheet
11.5-5 11.5-6 11.5-7 11.5-8 11.5-9 11.5-10 11.5-11 11.6-1
Designation
Circuit, current Circuit, emergency stop switch current Circuit 24/12V Circuit 24V socket Circuit, option, ground power Circuit, option, ground Circuit, option, ground Circuit CAN bus ground
Circuit diagram Yuchai YC6A240-30 and Dana HR32000, drawing number A59539.0100.
Sheet
1.0_1A1 1.0_1A2 2.0_1A1 2.0_1A2
Designation
Circuit Yuchai YC6A240-30 Circuit Yuchai YC6A240-30 Circuit Dana HR32335 Circuit Dana HR32335
Circuit diagram for side lift attachment, drawing number A50400.0100.
Sheet
0.0_1 7.4_1 7.5_1 7.5_2 7.5_3 7.8_1 7.9_1 7.9_2 7.9_3A 7.9_3B 7.9_4 7.9_5A 7.9_5B 9.6_1 9.14_1 11.5_1 11.5_2 11.6_1
Designation
Cross-reference list Circuit, side shift Circuit, spreading Circuit, spreading buzzer Circuit, spreading sensors Circuit, levelling Circuit, open/lock Circuit, open/lock sensors Circuit, indicator lights Circuit, indicator lights Circuit, alignment sensors Circuit, alignment sensors Circuit, alignment sensors Circuit, work lights, carriage/attachment Circuit, central lubrication Circuit, current Circuit, current Circuit, CAN bus
VDCT01.02GB
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E Schema Komponentfrteckning / E Schematics List of Components
NUMBER A 32 A 685 A 779 A 782 A 783 A 784 A 785 A 786 A 799 A 806 A 810 A 827 A 900 A 905 A 907 A 908 A 909 A 911 A 912 A 940 A 950 A 955 A 960 A B B B B B B B B B B B B B 961 649 690 697 751 752 753 754 755 756 757 758 759 760
SVENSKA Kretskort elcentral Reglerenhet termostat AC Reglersystem terladdning (EC) Logik interface 2 drivmotorer Logik interface gaspdrag Logik interface bromsregl Logik interface styrsystem Servofrstrkare styrsystem Logik allm (option) Aggregat klimatanlggning Kondensor AC, flkt Vxellda Radio/bandspelare Kommunikationsradio Monitor Kamera Skrivare Dataterminal Alkols Logik batterivakt Logik transistortndning Logik vervarvningsskydd (LPG) Logik rev-sprr/aut-vxl Motor/kupevrmare Termostat klimatannlggning Fartreglage (EC) Elbroms Givare varvtal turbin Givare varvtal inre vxellda Varvtalsgivare motor Givare lufttryck Givare hydraulfilter indikering Temperatur kylvtska motor Brnslenivgivare Varvtalsgivare v-lda Nivindikator kylvtska Givare rev-sprr/aut-vxl trans
761 Givare rev-sprr/aut-vxl motor
ENGLISH Printed circuit board, Junction box Control unit, termostat AC Control system, recharging (EC) Logic (interface) two main motors (EC) Logic (interface) throttle Logic (interface) brake control Logic (interface) control system Servo amplifier steering system Logic, general (option) Aggregate, air conditioner Condensor AC, fan Gearbox Radio/tape recorder Communication radio Monitor Camera Printer Dataterminal Interlock device Logic switch , battery watch Logic transistor ignition Logic overspeed protection (LPG) Logic unit, reversing interlock/automatic gear changing Engine- and cab heater Thermostat, air condition Speed control (EC) Electric brake Transmitter, speed turbin Transmitter, speed internal gear chain Transmitter, engine revolution Transmitter, air pressure Transmitter, hydraulics filter indication Transmitter, engine coolant temperature Transmitter, fuel level Transmitter, gear box revolution Transmitter, coolant level Transmitter, reversing interlock / automatic gear change system (on gearbox output shaft) Transmitter, reversing interlock / automatic gear changing system (engine speed) Transmitter, brake flushing circuit Transmitter, hydraulic fluid level Transmitter, gear box servo pressure Transmitter, oil pressure gear box Transmitter, oil temperature gear box Transmitter, oil pressure engine Transmitter, hydraulic pressure Transmitter, end position Transmitter, steering wheel angle Transmitter, angle Transmitter, temperature brake fluid
VDCT01.02SE/GB
B B B B B B B B B B B
762 763 764 765 766 767 768 769 770 771 772
Givare temp,spolkrets bromsar Givare niv hydraulolja Givare servotryck vxellda Givare oljetryck v-lda Givare oljetemp. v-lda Givare oljetryck motor Givare oljetryck hydraulik Givare ndlge Givare rattutslag Givare vinkel Givare temp bromsolja
Verkstadmanual / Workshop Manual DCT 80-90
NUMBER B 773 B 774 B 775 B 776 B 777 B 778 B 789 B 902 B 7224 B 7225 B 7226 B 7227 B 7228 B 7229 B 7230 B 7231 B 7232 B 7233 B 7234 B 7235 B 7236 C 821 D 740 D 742 D 743 D 744 D 780 D 781 D 790 D 791 D 792 D 793 D 794 D 796 D 797 D 798 D 2000 D E E E E E E E E E E E E E E 9001 400 400 401 401 402 403 404 405 406 406 408 408
SVENSKA Givare nrvaro Givare utomhustemp Givare temp klimatanlggning Givare temp hydraulolja Givare lge Givare drivbrytning Givare allmn Hgtalare Givare, mtlge vg Givare, rotationsstopp Givare, tryck lyftcylinder Givare, tryck klmma Givare lyfthjd analog Givare tiltvinkel analog Givare ultraljud last position Givare, Over Height, Ben uppe Givare,IR Last position Givare lambda sond Givare vatten i brnsle Givare temp avgaser Givare tryck avgaser KONDENSATOR FleetManager kontrollenhet FleetManager kortlsare FleetManager accelerations givare Galvaniskt isolerad CAN brygga Reglersystem drivmotor Reglersystem pumpmotor Elektronisk kontrollenhet ECU, hytt Elektronisk kontrollenhet aggregat Elektronisk kontrollenhet styrning Elektronisk kontrollenhet vxellda Elektronisk kontrollenhet motor Elektronisk kontrollenhet, lasthantering Elektronisk kontrollenhet, ram Elektronisk kontrollenhet, stolvndning Elektronisk kontrollenhet, proportionalventil kerstrms fjrrkontroll G-lampa v fram G-lampa h fram G-lampa v bak G-lampa h bak G-lampa fjrrljus G-lampa lastljus G-lampa arbetsljus G-lampa backljus G-lampa cont belysning vnster G-lampa cont belysning hger G-lampa park ljus v fram G-lampa park ljus h fram
ENGLISH Transmitter, presence Transmitter, ambient temperature Transmitter, temperature air condition Transmitter, hydraulic temperature Transmitter, position Transmitter, drive break Transmitter, common Loud speaker Sensor, measurepoint scale Sensor, rotation stop Sensor, pressure lift cylinder Sensor, pressure clamp Sensor lift height analogue Sensor tilt angle analogue Sensor, ultrasonic load position Sensor, Over Height, Leg upper position Givare,IR Load position Sensor lambda sond Transmitter water in fuel Sensor exhaust temperature Sensor exhaust pressure CAPACITOR FleetManager control unit FleetManager card device FleetManager acceleration sensor Galvanic insulated CAN bridge Control system traction motor Control system pump motor Electronic Control Unit ECU, cab Electronic Control Unit, attachment Electronic Control Unit, steering system Electronic Control Unit, gearbox Electronic Control Unit, engine Electronic Control Unit, Loadhandling Electronic Control Unit, frame Electronic Control Unit, seat rotation Electronic control unit, propotional valve kerstrms Remote Control Light bulb, roading light left hand front Light bulb, roading light right hand rear Light bulb, roading light left hand front Light bulb, roading light right hand rear Light bulb, distance light Light bulb, mast light Light bulb, working light Light bulb, rear light Container light left-hand Container light right-hand Light bulb, parking light, left-hand forward Light bulb, parking light, right-hand forward Light bulb, cigarett lighter illumination Light bulb, instrument illumination
VDCT01.02SE/GB
429 G-lampa cigarettndare belysning 431 G-lampa instrument belysning
NUMBER E 432 E 433 E 434 E 435 E 436 E 437 E 438 E 439 E 440 E 456 E 456 E 458 E 458 E E E E E E E E E E E E E E E E E E E E E F F F F F F F G G G
SVENSKA G-lampa handsfack belysning G-lampa instegs belysning G-lampa innerbelysning G-lampa lsbelysning G-lampa identifikationsljus G-lampa identifikationsljus/takskylt G-lampa motorrumsbelysning Nummerskyltsbelysning G-lampa vrmereglage belysning G-lampa backljus blackout IR vnster G-lampa backljus blackout IR hger G-lampa fram blackout vnster G-lampa fram blackout hger
ENGLISH Light bulb, glove pocket light Light bulb, step-in lighting Light bulb, interior lighting Light bulb, reading lighting Light bulb, identification light Light bulb, identification light/roof sign Light bulb, engine compartment light Light license plate Light bulb, heating control light Light bulb, rear light blackout IR left-hand Light bulb, rear light blackout IR right-hand Light bulb, roading light blackout left-hand Light bulb, roading light blackout right-hand Light bulb, roading light blackout IR lefthand Light bulb, roading light blackout IR righthand Light bulb, working light cab blackout IR left Light bulb, working light cab blackout IR right Light bulb, working light boom20' b.out IR left Light bulb, working light boom20' b.out IR right Light bulb, working light boom40' b.out IR left Light bulb, working light boom40' b.out IR right Light bulb,Container light IR left-hand Light bulb,Container light IR right-hand Heater compartment/engine diesel Electrical heated observation mirror Electrical heated seat Cigarett lighter Electrical heating cab Electrical heater air dryer Ignition plug Air Dryer, Compressor Logic indication of wear, brush electrical motor Search light Electrical heated window Fuse holder, 1-pole Fuse holder, 2-pole Fuse holder, 6-pole Fuse holder, 8-pole Fuse holder, 12-pole Battery connector, 2-pole Battery connector, 4-pole Battery Alternator extra Alternator without loading regulator
VDCT01.02SE/GB
459 G-lampa fram blackout IR vnster 459 G-lampa fram blackout IR hger 460 G-lampa arb.belysning hytt blackout IR v 460 G-lampa arb.belysning hytt blackout IR h 461 G-lampa arb.bel. bom 20' blackout IR v 461 G-lampa arb.bel. bom 20' blackout IR h 462 G-lampa arb.bel. bom 40' blackout IR v 462 G-lampa arb.bel. bom 40' blackout IR h 464 464 669 802 803 804 805 808 835 888 962 4370 8092 51 52 56 58 59 62 64 30 658 659 G-lampa cont belysning IR vnster G-lampa cont belysning IR hger Vrmare kupe/ motor diesel Eluppvrmd backspegel Eluppvrmd stol Cigarettndare Elvrme hytt Eluppvrmd lufttorkare Tndstift Lufttork, kompressor Logik slitageind kol elmotor Skljus Eluppvrmd ruta Skringshllare 1-polig Skringshllare 2-polig Skringshllare 6-polig Skringshllare 8-polig Skringshllare 12-polig Batterihandske 2-polig Batterihandske 4-polig Batteri Generator (extra) Generator utan laddregulator
NUMBER G 660 G 662 H 410 H 410 H 411 H 411 H 412 H 412 H 413 H H H H H H H H H H H H H H H H H H H H H H H H H H H H H H
SVENSKA Generator med laddregulator Laddregulator G-lampa broms ljus v fram G-lampa broms ljus h fram G-lampa broms ljus v bak G-lampa broms ljus h bak G-lampa bak ljus v bak G-lampa bak ljus h bak G-lampa bak ljus v fram (VBFS)
413 G-lampa bak ljus h fram (VBFS) 416 G-lampa sidomarkering v fram 416 G-lampa sidomarkering v bak 417 G-lampa sidomarkering h fram 417 G-lampa sidomarkering h bak 420 G-lampa positionsljus vnster 421 G-lampa positionsljus hger 422 G-lampa krvisare v fram 423 G-lampa krvisare h fram 426 G-lampa krvisare v bak 427 G-lampa krvisare h bak 428 445 446 451 452 453 G-lampa roterande varningsljus G-lampa krvisare v (extra) G-lampa krvisare h (extra) G-lampa dimbakljus vnster G-lampa dimbakljus hger G-lampa bromsljus/krvisare vnster
ENGLISH Alternator with loading regulator Loading regulator Light bulb, brake light, left-hand forward Light bulb, brake light, right-hand forward Light bulb, brake light, left-hand rear Light bulb, brake light, right-hand rear Light bulb, rear light, left-hand rear Light bulb, rear light right-hand rear Light bulb, rear light, left-hand forward (VBFS) Light bulb, rear light,right-hand forward (VBFS) Light bulb, side position light, left-hand forward Light bulb, side position light, left-hand rear Light bulb, side position light, right -hand forward Light bulb, side position light, right-hand rear Light bulb, position light, left-hand Light bulb, position light, right-hand Light bulb, direction indicator left-hand forward Light bulb, direction indicator right-hand forwrd Light bulb, direction indicator left-hand rear Light bulb, direction indicator right-hand rear Light bulb, flashing beacon lamp Light bulb, extra direction indicator left Light bulb, extra direction indicator right Light bulb, fog light rear left Light bulb, fog light rear right Light bulb, brake light/dir. indicator left-hand Light bulb, brake light/dir. indicator righthand Light bulb, brake light blackout left-hand Light bulb, brake light blackout right-hand Light bulb, position light blackout left-hand Light bulb, position light blackout right-hand Light bulb, rear light left-hand rear, blackout Light bulb, rear light right-hand rear, blackout Light-bulb, red extender exended Light bulb, orange vertical hold on Light bulb, green clamp pressure OK Light bulb,Red Overload Indicating lamp, direction indicator Indicating lamp, direction indicator extra
VDCT01.02SE/GB
453 G-lampa bromsljus/krvisare hger 454 454 457 457 G-lampa bromsljus blackout vnster G-lampa bromsljus blackout hger G-lampa positionsljus blackout vnster G-lampa positionsljus blackout hger
463 G-lampa bak ljus vnster bak, blackout 463 G-lampa bak ljus hger bak, blackout 465 466 467 468 500 501 G-lampa rd saxagregat ute G-lampa orange vertikalhlning p G-lampa grn klmtryck OK G-Lampa Rd Maxlast Kont lampa krvisare Kont lampa krvisare (extra)
NUMBER H 503 H 504 H 505 H 506 H 507 H 508 H 509 H 510 H 512 H 514 H 519 H 524 H 525 H 528 H 530 H 531 H 532 H 533 H 547 H 549 H 550 H 551 H 552 H 554 H H H H H H H H H H H H H H H H H H H H H H H H H H
SVENSKA Varn lampa oljetryck motor Kont lampa helljus Varn lampa laddning Varn lampa laddning (extra) Varn lampa frdbroms Varn lampa parkerings broms Varn lampa niv kylvatten Kont lampa diff sprr Varn lampa temp momentfrst Kont lampa vervxel Kont lampa halvljus Kont lampa luftfilter Kont lampa UNIKAT Kont lampa frvrmning Kont lampa framhjuls styrning Kont lampa 4-hjuls styrning Kont lampa crab styrning Kont lampa hyd.pump Varn lampa centralvarning Varn lampa oljetryck v-lda Varn lampa hyttlsning Varn lampa temp v-lda Varn lampa bromstryck Varn lampa temp spolkrets bromsar
555 Varn lampa temp kylvatten mot 556 560 561 562 563 564 565 569 569 570 571 572 573 574 575 576 577 578 579 580 581 582 583 584 599 Varn lampa lsning vndskiva Varn lampa temp drivmotor el Varn lampa temp pumpmotor el Varn lampa ppen twistlock Varn lampa lst twistlock Varn lampa anliggning Varn lampa temp motor el Kont lampa elvrme Kont lampa elvrme Varn lampa verkoppling skerhetssystem Kont lampa brnsleniv Varningslampa lyfthjd Kontroll lampa motor information Kontroll lampa stdben nere Kontroll lampa stdben ur arb.lge Kontroll lampa anliggning frmre ben Kontroll lampa anliggning bakre ben Kontroll lampa klmlge frmre ben Kontroll lampa klmlge bakre ben Kontroll lampa frmre ben uppe Kontroll lampa frmre ben nere Varningslampa verlast Kontroll lampa anliggning ett ben Kontroll lampa anliggning alla ben Kont lampa option
ENGLISH Warning lamp, oil pressure engine Indicating lamp, main beam Warning lamp, loading Warning lamp, loading extra Warning lamp, brake Warning lamp, parking brake Warning lamp, coolant level Indicating lamp, diff. interlock Warning lamp, temperature converter Indicating lamp, overdrive clutch Indicating lamp, dipped lights Indicating lamp, air filter Indicating lamp, UNIKAT Indicating lamp, preheating Indicating lamp, forward wheel steering Indicating lamp, 4-wheel steering Indicating lamp, crab steering Indicating lamp, emergency hyd. pump Warning lamp, central warning Warning lamp, oil pressure gear box Warning lamp, cab lock Warning lamp, temperature gear box Warning lamp, brake pressure Warning lamp, temp. cooling system brakes Warning lamp, temperature coolant engine Warning lamp, interlocking of turntable Warning lamp, temperature, drive motor Warning lamp, temperature, pump motor Warning lamp, unlocked twist lock Warning lamp, locked twist lock Warning lamp, alignement Warning lamp ,temperature motor Indicating lamp, electric heater Indicating lamp, electric heater Warning lamp, by-pass safety system Indicating lamp, fuel level Warning lamp lifting height Indicator lamp engine information Indicator lamp support jacks down Indicator lamp support jacks out of working pos Indicator lamp, alignment front legs Indicator lamp, alignment rear legs Indicator lamp, clamp position front legs Indicator lamp, clamp position rear legs Indicator lamp, front legs upper position Indicator lamp, front legs lower position Warning lamp overload Indicator lamp, alignment one leg Indicator lamp, alignment all legs Indicating lamp, option
VDCT01.02SE/GB
NUMBER H 850 H 853 H 965 H 5000 H 5001 H 9003 K 300 K 301 K 302 K 303 K 304 K 305 K 306 K 307 K 308 K 309 K 310 K 311 K 312 K 313 K 314 K 315 K 316 K 317 K 318 K 319 K 320 K 321 K 322 K 323 K 324 K 325 K 326 K 327 K 328 K 329 K 330 K 331 K 332 K 333 K 334 K 335 K K K K K K K K K K
SVENSKA Signalhorn Summer Backvarnare Kont lampa tryck lyfttng Varn lampa, Over Height ben uppe Varningssignal aut. rrelse Rel hel/halvljus Rel dimljus Rel fjrrljus Rel lastljus Rel arbetsljus Rel backljus Rel helljus Rel halvljus Rel bromsljus Rel parkeringsbroms Rel krvisare v Rel krvisare h Rel startelement Rel vndbar frarstol Rel parkeringsbroms Rel tndningsls Rel torkare Rel strlkastartorkare Rel AT-regulator Rel varningsblinkers Rel elektrisk stopp Rel intervalltorkare Rel kylvtskeniv Rel blinkers Rel rangesprr Rel blinkande bromsljus (back) Rel blinkande bromsljus (runt) Rel vxel neutral Rel vxelskifte Rel vxel hg/lg Rel startsprr Rel drivning fram Rel drivning bak Tidrel frvrmning Rel frikoppling/drivbrytning Rel vxelventil 1:a (diesel, gas)
336 Rel vxelventil 2:a (diesel, gas) 337 338 339 340 341 342 343 344 345 Rel drivriktning motor Rel kylflkt drivmotor Rel kylflkt elskp Tidrel frdrjt tillslag Tidrel frdrjt frnslag Rel drivning 2/4 hjul Rel dimbakljus Rel momentfrstrkare Rel lsning vndskiva
ENGLISH Horn Buzzer Reversing alarm Indicating lamp, pressure lift tong Warn. Lamp, Over Height leg upper pos Warning alarm aut. movement Relay, main/dipped beam Relay, fog light Relay, distance light Relay, mast light Relay, working light Relay, reversing light Relay, main beam Relay, dipped beam Relay, brake light Relay, parking light Relay, direction indicator left Relay, direction indicator right Relay,element preheater Relay, rotating drivers seat (VBFS) Relay, parking brake Relay, ignition key Relay, wiper Relay, roading lights wiper Relay, AT-regulator Relay, hazard blinkers Relay, electical stop Relay, intermittent wiper Relay, coolant level Relay, blinkers Relay, range interlock Relay, flashing brake lights (reversing) Relay, flashing hazard brake lights Relay, gear neutral Relay, gear shift Relay, high/low gear Relay, start interlock Relay, forward driving Relay, reversing driving Time relay, automatically preheating Relay, free wheel/drive disconnection Relay, gear change valve 1-gear (diesel,LPG) Relay, gear change valve 2-gear (diesel,LPG) Relay, motor drive direction Relay, cooling fan drive motor Relay, cooling fan electrical box Time relay, start delay Time relay, stop delay Relay, switching 2/4 WD Relay, fog light rear Relay, torque amplifier Relay, interlocking of turntable
VDCT01.02SE/GB
NUMBER SVENSKA K 346 Rel frikoppling stollsning K 347 Rel stolvndning/ljussignal K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K 348 349 350 351 352 353 354 355 356 357 358 359 360 361 362 363 364 365 366 367 368 369 370 371 372 373 375 376 377 378 379 380 381 382 383 384 385 386 387 388 389 399 3001 3002 3003 3004 3005 3006 3007 Rel flktmotor vrmare Rel fartreglage Rel pumpkontaktor/pumpkontroll Rel hyttlyft upp Rel hyttlyft ner Rel skerhetsslinga Rel styrsystem Rel sensorstyrning Skiftrel lngskrning/tvrskrning Rel roterande varningsljus Rel komressor luft Rel Hydrauloljekylare Rel startsolenoid Rel kompressor AC Rel vattenventil AC Rel kondensor AC Rel stolsbrytare Rel fnsterhiss upp Rel fnsterhiss ner Rel styrning Rel lgt bromstryck Rel centralsmrjning Rel centralsmrjning, aggregat Rel lyfthjd Rel blinkande varn.ljus, hjdbegrnsn. Rel bakljus Huvudkontaktor reglersystem Kontaktor fram reglersystem Kontaktor bak reglersystem Kontaktor by-pass reglersystem/Fltfrsvagning Kontaktor pumpmotor Kontaktor Kontaktor terladdning Rel, frbikoppling skerhetssystem Rel, Stolsvrme Rel vattenseparator Rel brnslepump insprutning Rel, hg motortemperatur. Rel alternativ gaspedal Rel, Extra frdriktningsvljare Rel, Pausvrme Rel option Rel rotation Rel tilt Rel sidofring Rel lngdinstllning Rel twist lock Rel spridning Rel lyft/snk
ENGLISH Relay, releasing of seat interlocking Relay, multifunction, seat rotation/light signal Relay, fan heating Relay, speed control Relay, pump contactor/pump control Relay, cab hoist up Relay, cab hoist down Relay, safety loop Relay, signal control system Relay, sensor control Shift relay, length/sideways driving Relay, hazard beacon Relay, compressor air Relay hydraulic oil cooler Relay, starting solenoid Relay, compressor air conditione Relay, water valve air conditioner Relay, condenser air conditione Relay seat switch Relay, electrical screen elevator up Relay, electrical screen elevator down Relay, steerin Relay, low brake pressure Relay, central lubrication Relay, central lubrication, attatchment Relay, liftheight Relay, flashing beacon, lifting height limiter Relay light Main contactor, operating control Contactor, forward operating control Contactor, reversing operating control Contactor, by-pass operating control/ Field weakening Contactor, pump motor Contactor Contactor, recharging Relay, by-pass safety system Relay, heated seat Relay, waterseparator Relay, fuel injection pump Relay, high motor temperature Relay alternative throttle pedal Relay, Extra direction selector Relay, Paus heat Relay, option Relay, rotation Relay, tilt Relay, side shifting Relay, length adjustment Relay, twist lock Relay, spreading Relay, lifting/lowering
VDCT01.02SE/GB
NUMBER K 3008 K 3009 K 3010 K 3011 K 3012 K 3013 K 3014 K 3015 K K K K K K K K K K K K K K K K K K K K K K K K K K L M M M M M M M M M M M
SVENSKA Rel hydraulfunktion extra Rel manverbrytare hydr Rel bromsljus vxl std/blackout Rel backljus vxl std/blackout Rel arb.bel hytt vxl std/blackout Rel arb.bel. bom 20' vxl std/blackout Rel arb.bel. bom 40' vxl std/blackout Rel vxl bromsljus/blinkers v
3015 Rel vxl bromsljus/blinkers h 3016 3017 3018 3305 3306 3307 3308 3310 Rel signalhorn Rel containerbelysning Rel containerbelysning IR Rel VBFS, backljus Rel VBFS, helljus Rel VBFS, halvljus Rel VBFS, bromsljus Rel VBFS, krvisare v
ENGLISH Relay, extra hydraulic function Relay, operating switch Relay, brake light shift std/blackout Relay, reversing light shift std/blackout Relay, working light cab, shift std/blackout Relay,working light boom20' shift std/b.out Relay,working light boom40' shift std/b.out Relay, shift brake light/direction indicator left Relay, shift brake light/direction indicator right relay, horn Relay, Container light Relay, Container light IR Relay, rotating drivers seat, reversing light Relay, rotating drivers seat, main beam Relay, rotating drivers seat, dipped beam Relay, rotating drivers seat, brake light Relay, rotating drivers seat, direction indicator left Relay, rotating drivers seat, direction indicator right Relay, seat belt Relay, rotating drivers seat, forward driving Relay, rotating drivers seat, reversing driving Relay, rotating drivers seat, speed control Relay, rotating drivers seat, mast light Relay,reversealarm Relay, rotating drivers seat, rear light Relay, hydraulic pressure Relay, blocking of cab tilt Relay, alignment Relay, Hook Relay, charge signal (D+) Relay 12V for radio memory Relay, cooling fan oil Relay heated window Relay, Holdcircuit Ignition coil Pump unit, cab hoist Regulating motor, throttle Regulating motor, re-circulation
3311 Rel VBFS, krvisare h 3330 Rel, skerhetsblte 3331 Rel VBFS, drivning fram 3332 Rel VBFS, drivning bak 3349 Rel VBFS, fartreglage 3404 3405 3412 3768 3769 3770 3771 3772 3773 3774 3776 93774 830 608 609 612 650 650 650 650 651 652 653 654 Rel VBFS, mastljus Rel,backalarm Rel bak ljus Rel oljetryck hydraulik Rel, blockering av hyttilt Rel anliggning Rel Krok Rel laddsignal (D+) Rel 12V fr minne radio Rel kylflkt olja Rel vrmare ruta Rel hllkrets Tndspole Pumpaggregat hyttlyft Stllmotor gaspdrag Stllmotor recirkulation Torkarmotor fram Torkarmotor fram Torkarmotor fram Torkarmotor fram Vindrutespolarmotor Strlkastarmotor Strlkastarspolarmotor Startmotor
Washer motor Light motor Light washer motor Starter motor

VDCT01.02SE/GB
NUMBER M 655 M 656 M 657 M 661 M 663 M 664 M 666 M 667 M 668 M 670 M 671 M 672 M 674 M 675 M 677 M 693 M 694 M 695 M 696 M 698 M 9000 P 700 P 701 P 702 P 703 P 704 P 705 P 706 P 707 P 708 P 709 P 710 P 711 P 712 P 714 P 715 P 795 Q 144 R 807 R 820 R 825 R 828 R 8071 R 8072 R 8073 R 8074 R 8075 R 8076 R 8077 R 8078 R 8079 R 8080 R 8081 R 8082
SVENSKA Kylflkt drivmotor (EC) Kylflkt elskp (EC) Flktmotor vrme Fnsterhissmotor Doseringspump klimatanlggning Cirk pump klimatanlggning Flktmotor cirkulation Cirkulationspump vrmesystem Kylflkt hydraulolja Kompressor Doseringspump diesel Spjll motor, ECC Kylflkt bromsolja Motor, Stolsvndning Motor Lsning stolsvridning Pump centralsmrjning Styrmotor Drivmotor (EC) Pumpaggregate ndstyrning Pumpmotor (EC) Motor hj/snkbar stolspelare Hastighetsmtare Mtare oljetemp v-lda Klocka Varvtalsmtare Tryckluftsmtare Mtare oljetryck v-lda Termometer temp kylvtska motor Brnslemtare Timrknare Kapacitetsmtare batteri Tidur motor/kupevrmare Rknare, impuls Mtare oljetryck motor Mtare, temp. Hydraulolja Extra instrument allm Display Batterifrnskiljare Potentiometer Motstnd Reglage spakstyrning Shuntmotstnd Potentiometer lyft/snk Potentiometer tilt Potentiometer sidofring Potentiometer spridning Potentiometer extra Potentiometer mast in/ut Potentiometer hger framhjul Potentiometer vnster framhjul Potentiometer hger bakhjul Potentiometer vnster bakhjul Potentiometer tiltvinkel Potentiometer flkthastighet, ECC
ENGLISH Cooling fan, main motor (EC) Cooling fan, electrical box (EC) Heating fan Screenelevator motor Dosage pump, air condition Circulating pump, air condition Circulation fan Circulation pump heating system Cooling fan, hydraulic oil Compressor Dosage pump diesel Draught valve motor, ECC Cooling fan, brake fluid Motor, Seat rotation Motor Locking revolving seat Pump, central lubrication Steering motor Drive motor (EC) Pump, emergency steering Pump motor (EC) Motor rise/lower seat column Speedometer Gear box oil temperature gauge Clock Engine rev meter Air pressure gauge Gear box oil pressure gauge Temperature gauge, engine coolant Fuel gauge Hour meter Capacity gauge, battery Timer, engine- and cab heater Counter, impulse Motor oil pressure gauge Hydraulic fluidtemperature, guage Extra instrument, general Display Battery disconnecting switch Potentiometer Resistor Controls, (steering with control levers). Shunt-resitor Potentiometer lift/lower Potentiometer tilt Potentiometer side shifting Potentiometer spreading Potentiometer extra Potentiometer reach in/out Potentiometer right front wheel Potentiometer left front wheel Potentiometer right rear wheel Potentiometer left rear wheel Potentiometer tilt angle Potentiometer fan speed, ECC
VDCT01.02SE/GB
10
NUMBER R 8083 R 8084 R 8085 R 8086 R 8087 R 8088 R 8089 S 100 S 101 S 102 S 103 S 104 S 105 S 106 S 107 S 108 S 109 S 110 S 111 S 112 S 113 S 114 S 115 S 116 S 117 S 118 S 119 S 120 S 121 S 122 S 123 S 124 S 125 S 126 S 127 S 128 S 129 S 130 S 131 S 132 S 135 S 136 S 137 S 138 S 139 S 141 S 142 S 143 S 145 S 147 S 149 S 150 S 152 S 156
SVENSKA Potentiometer temperatur, ECC Potentiometer spjll, ECC Potentiometer rotation Potentiometer sax Potentiometer klmma Potentiometer skevning Potentiometer kroklsning Strmstllare ljus Strmstllare omk hel/halvljus Strmstllare dimljus Strmstllare fjrrljus Strmstllare lastljus Strmstllare arbetsljus Strmstllare containerljus Strmstllare park broms Strmstllare centr smrjning Strmstllare varningsljus Strmstllare rot varningsljus Strmstllare fnsterhiss Strmstllare kylanlggning (AC) Strmstllare styrning alt Strmstllare lsbelysning Strmstllare instr belysning Strmstllare innerbelysning Strmstllare vrme Strmstllare flktm vrme Strmstllare vindrutetorkare Strmstllare spolare Strmstllare blackout Strmstllare nd hydraulpump Strmstllare backspegel Strmstllare kallstart Strmstllare avgasbroms Strmstllare diff sprr/broms Strmstllare vrmesystem diesel Strmstllare kraftuttag sida Strmstllare kraftuttag bak Strmstllare hg/lgvxel Strmstllare frdvljare fram Strmstllare frdvljare bak Strmstllare vxelvljare Strmstllare framhjuls styrning Strmstllare 4-hjuls styrning Strmstllare crab styrning Strmstllare defroster Strmstllare Stegbelysning Strmstllare fot Strmstllare sitsvrme Strmstllare AT-regulator Strmstllare krvisare Strmstllare signalhorn Strmstllare startls/ellas Strmstllare intervalltorkare Strmstllare kupevrmare
ENGLISH Potentiometer temperature, ECC Potentiometer draught valve, ECC Potentiometer rotation Potentiometer extender Potentiometer clamp Potentiometer levelling Potentiometer flaps Switch, light Switch, main/dipped beam Switch, fog light Switch, distance light Switch, mast lights Switch, working lights Switch, container light Switch, parking brake Switch, central lubricator Switch, hazard lights Switch, rotating hazard beacon Switch, window regulator Switch, air conditioner (AC) Switch, alternative steering Switch, reading light Switch, instrument illumination Switch, interior lighting Switch, heating Switch, heater fan Switch, wiper Switch, washer Switch, blackout Switch, emergency hydraulic pump Switch, observation mirror Switch, cold start Switch, exhaust brake Switch, diff. Block Switch, heating system diesel Switch, power take off side Switch, power take off rear Switch, high/low gear Switch, gear selector forward Switch, gear selector rear Switch, gear shift Switch, forward wheel steering Switch, 4-wheel steering Switch, crab steering Switch, defroster Switch, Steplight Switch, foot Switch, seat heater Switch, AT-regulator Switch, direction indicators Switch, horn Switch, main key switch Switch, intermittent wiper Switch, cab heating
VDCT01.02SE/GB
11
NUMBER S 157 S 158 S 159 S 160 S 161
SVENSKA Strmstllare stoltilt Strmstllare dimbakljus Strmstllare extra fram/back vljare Strmstllare komb fram/back Strmstllare komb signal, ljus hel/halv spol,torkare m intervall krvisare
162 Strmstllare komb signal ljus hel/halv, spol, torkare m 2 int, fram/bacK 163 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 190 191 192 195 196 197 198 199 200 Strmstllare start p 2-an Strmstllare stolvrme Strmstllare lsning vndskiva Strmstllare luftfjdring Strmstllare lsn stol Strmstllare stolsvndning Strmstllare frngare (LPG) Strmstllare v-skiva upp/ner Strmstllare v-skiva fr/back Strmstllare v-skiva skevning Strmstllare,utskjut Strmstllare hyttlyft upp Strmstllare hyttlyft ner Strmstllare hyttskjutning Strmstllare nollstllning Strmstllare Aut/man vxling Strmstllare fyrhjulsdrift Strmstllare klimatanlggning Strmstllare recirkulation Strmstllare vattenavskiljare Strmstllare joy-stick X Strmstllare joy-stick X+Y Strmstllare lngs/tvrskrning Strmstllare flytlge skevning Strmstllare option Brytkontakt lampa park broms
ENGLISH Switch, seat tilt Switch, rear fog light Switch, extra direction selector Switch, combi-forward/reverse Switch, combi-horn, light main/dipped beam, washer, wiper (intermittent), direction indicator Switch, combi horn, light main/dipped beam, washer, wiper w 2int., forward/revers Switch, start 2nd gear Switch, seat heater Switch, interlocking of turntable Switch, pneumatic springing Switch, interlocking of seat Switch, reversible seat Switch, evaporator (LPG) Switch, fifth wheel up/down Switch, fifth wheel forward/reverse Switch, fifth wheel, levelling Switch, projecting Switch, cab hoist up Switch, cab hoist down Switch, cab movement Switch, reset Switch Aut/man gearshifting Switch, 4-WD Switch, air conditioner Switch, re-circulation Switch, joy-stick X Switch, joy-stick X+Y Switch, length/sideways driwing Switch, equalizing fifth wheel Switch, option Contact, breaking,warning lamp,parking brake Contact, breaking, warning lamp, brake Contact, breaking, warning lamp, oil pressure engine Contact, breaking, pressure accumulatortank Contact, breaking, interior lighting Contact, breaking, glove Contact, making, diff. interlock Contact, making, warning lamp temperature brake Contact, making, over drive Contact, making, temperature engine Contact, making, brake lights Contact, making, reversing light Contact, making, AT-control Contact, making, indicating light air filter Contact, breaking, drive cut off
VDCT01.02SE/GB
S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S
201 Brytkontakt lampa frdbroms 202 Brytkontakt lampa oljetryck motor 204 Brytkontakt tryck ackumulator 205 206 207 208 214 215 216 217 218 219 220 Brytkontakt innerbelysning Brytkontakt handskfack belysning Slutkontakt diff sprr Slutkontakt lampa temperatur spolkrets bromsar Slutkontakt vervxel Slutkontakt temp motor Slutkontakt bromsljus Slutkontakt backljus Slutkontakt AT-regulator Slutkontakt lampa luftfilter Brytkontakt drivning
12
NUMBER SVENSKA S 221 Slutkontakt temp vxellda S 222 Slutkontakt lampa temp moment frstrkare S 223 Slpkontakt signal S 224 Slutkontakt insprutningspump S 225 Brytkontakt skerhetsblte S 228 Slutkontakt hyttlsning S 229 Slutkontakt stolslsning S 230 Brytkontakt stol S 231 Slutkontakt fotkontroll stolvndning S 232 Brytkontakt lampa luftanslutning slp S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S 233 235 236 239 240 241 Slutkontakt lampa lsning vndskiva Slutkontakt sidoskjutning stol Slutkontakt vattenniv Brytkontakt termisk Slutkontakt termisk Brytkontakt lampa luftmatning slp
242 Slutkontakt lampa oljetryck v-lda 243 Brytkontakt tryck kylmedia AC 244 Slutkontakt hydraulik aktiverad 245 Slutkontakt hydraultryck styrning 246 250 251 260 261 262 263 264 265 266 267 268 269 270 271 299 720 800 815 840 1001 1002 1003 1004 1005 Slutkontakt tryck kylmedia Manverbrytare Slutkontakt vndbar frarstol Slutkontakt lyft steg 1 Slutkontakt lyft steg 2 Slutkontakt tilt Slutkontakt gaffelspridning Slutkontakt sidofring Slutkontakt stativ in/ut Brytkontakt hyttdrr Slutkontakt bromstryck Slutkontakt kompressor Slutkontakt sax inne Slutkontakt verlastskydd Slutkontakt, filter vxellda Slut/brytkontakt option Givare vndbar frarstol
ENGLISH Contact, making, temperature gear box Contact, making, warning lamp temperature torque amplifier. Contact, brush, horn Contact, making, injection pump Contact, breaking, seat belt Contact, making, cab locking Contact, making, seat locking Contact, breaking, seat Contact, making, seat rotation, foot switch Contact, breaking, warning lamp air connection Contact, warning, interlocking of turntable Contact, making, side shifting of seat Contact, water level Contact, breaking, thermic Contact, making, thermic Contact, breaking, warning lamp air supply to trailer Contact, making, warning lamp, oil pressure gear box Contact, breaking, coolant pressure (air condition) Contact, making, hydraulics Contact, making, hydraulic pressure control Contact, pressure refrigerant Operating Switch Contact, making, VBFS Contact, making, hoist step 1 Contact, making, hoist step 2 Contact, making, tilting Contact, making, fork positioning Contact, making, sideshift Contact, making, lifting mast in-out Contact, breaking cab door Contact, making, brake pressure Contact, making, Compressor Contact, making extender in Contact, making, overload protection Contact, making, filter gearbox Contact, making/braking option Transmitter, revolving drivers seat (VBFS) Start element Control lever Distributor Switch, TW Switch, unlocking of TW Switch, locking of TW Switch, stop at 30 -35 Switch, overriding of the safety system Switch, front legs down
VDCT01.02SE/GB
Startelement Manverspak Strmfrdelare Strmstllare, TW Strmstllare, lossa TW Strmstllare, lsa TW Strmstllare, stopp vid 30'-35' Strmstllare, frbikoppling av skerhetssystem 1006 Strmstllare, fllning frmre ben
13
NUMBER S 1007 S 1008 S 1009 S 1010 S 1011 S 1012 S 1013 S 1014 S 1015 S 1017 S 1018 S 1019 S 1020 S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S 1021 1022 1023 1024 1025 1026 1027 1028 1029 1030 1031 1032 1033 1034 1035 1036 1037 1038 1039 1040 1041 1042 1043 1044 1045 1046 1047 1048 1049 1440 7200 7201 7202 7202 7203 7203 7204 7204 7205
SVENSKA Strmstllare, fllning bakre ben Strmstllare, klmma/lossa ben Strmstllare, Motor information Srmstllare, tilt av hytt Strmstllare IR ljus Strmstllare utskjut 20-40 Strmstllare stdben Strmstllare frbikoppling rotationstopp Strmstllare frbikoppling hjdbeg/tp-beg Strmstllare diagnostik ka/minska Strmstllare diagnostik on/off Strmstllare rastvrme Strmstllare automatisk slpp/klm funktion Strmstllare sax Strmstllare vertikalhllning Strmstllare lsning vre arm Strmstllare Korta Armen av/p Strmstllare pappersfunktioner av/p Strmstllare omkoppling pappers/klmmagregat Strmstllare lyfthjdsfrval Strmstllare lyfthjdsfrval ka Strmstllare lyfthjdsfrval minska Strmstllare lraringng givare ultraljud Strmstllare, Over Height Upp/Ned Brytare backljus Flytta korta armen Strmstllare frbikoppling startsprr Strmstllare Val av klmtryck Strmstllare Korta Armen av/p Strmstllare lsning skevning Strmstllare vre armpar/Sidofring Strmstllare Inching Switch stopp motor Strmstllare motorrumsbelysning Strmstllare hjdjustering stol Strmstllare lngdjustering stol Strmstllare Tankvljare Strmstllare Avstngning backalarm Strmstllare eluppvrmd ruta Henrik testar en brytare! Strmstllare fjrrstyrning Strmstllare styrning spegel Huvudstrmbrytare Givare, axeltryck hger Givare, axeltryck vnster Givare, anliggning vnster fram Givare, anliggning hger fram Givare, anliggning vnster bak Givare, anliggning hger bak Givare, ppen vnster twistlock Givare, ppen hger twistlock Givare, lst vnster twistlock
ENGLISH Switch, rear legs down Switch, clamping/-releasing legs Switch, Engine information Switch, tilt of cab Switch IR light Switch, Extension 20-40 Switch, Support jacks Switch, over ride rotation stop Switch, over ride height limit/tp-limit Switch, diagnostics increase/decrease Switch, diagnostics on/off Switch, paus heat Switch automatic release/clamp funktion Switch extender Switch, vertical position Switch, lock upper arm Switch, Short Arm on/off Switch, paper funktions on/off Switch, switch papper/bale clamp Switch, lift height selection Switch, lift height selection increase Switch, lift height selection decrease Switch, teaching ultrasonic sensor Switch, Over Height Up/Down Switch reverse light. Move short arm Switch Override Start interlock Switch, Clamp pressure selection Switch , Short Arm on/off Switch, lock levelling Switch Upper arms/Sideshift Switch, Inching Switch, Stop engine Switch, light engine compartment Switch, Seat height level Switch, Seat for/aft adjustment Switch, Tankselector Switch, Rev. Alarm on/off Switch electrical heated shield Switch remote control Switch mirror control Sensor, axle pressure right Sensor, axle pressure left Sensor, alignment left front Sensor, alignment right front Sensor, alignment left rear Sensor, alignment right rear Sensor, unlocked twistlock left Sensor, unlocked twistlock right Sensor, locked twistlock left
VDCT01.02SE/GB
14
NUMBER S 7205 S 7206 S 7207 S 7208 S 7209 S 7210 S 7211 S 7212 S 7213 S 7214 S 7215 S 7216 S 7217 S 7218 S 7219 S 7220 S 7221 S 7222 S 7223 U 741 U 823 U 824 U 901 U 910 U 941 V 665 V 8090 W 903 W 906 W 8093 X 37 X 39 X 72 X 77 X 78 Y 600 Y 601 Y 602 Y 603 Y 604 Y 605 Y 606 Y 607 Y 610 Y 611 Y 613 Y 614 Y 615 Y 616 Y 617 Y 618 Y 620 Y 621 Y 622
SVENSKA Givare, lst hger twistlock Givare, gaffel aggregat Givare, 2WD/4WD Givare, hytt i krlge Givare, oljefilter indikering Givare, hytt i transportlge Givare, lyfthjd Givare, krlge Givare, Anliggning frmre ben Givare, Anliggning bakre ben Givare, klm frmre ben Givare, klm bakre ben Givare, frmnre kn Givare, bakre kn Givare, frmre ben Givare, bakre ben Givare, styraxel Givare, stdben uppe Givare, stdben nere FleetManager batterifilter Signalomvandlare hger Signalomvandlare vnster Spnningsomvandlare Spnningsomvandlare 80V/24V Laddningsutjmnare Diod Laser, pappersaggretgat Antenn radio Antenn kommunikationsradio Genomfring, kablage Terminal stomanslutning Terminal minusanslutning Stickuttag 2-polig Stickuttag 7-polig Stickuttag extra 7-polig M-ventil avgasbroms M-ventil diff sprr M-ventil broms M-ventil vrme M-ventil kraftuttag sida M-ventil kraftuttag bak M-ventil 2/4 hjulsdrift M-ventil hg/lg vxel M-ventil hydraulsystem allm M-ventil fldesbegrnsning M-ventil momentfrstrkare M-ventil rangesprr M-ventil hjulvridning M-ventil kallstart M-ventil AT-regulator by-pass M-ventil vatten klimatanlggning M-ventil vndskiva upp M-ventil vndskiva ner M-ventil vndskiva fram
ENGLISH Sensor, locked twistlock right Sensor, fork attachment Sensor, 2WD/4WD Sensor, Cab in drive position Sensor, Oil filter indication Sensor, Cab in transportation position Sensor, lifting height Sensor, driving position Sensor, Alignment front legs Sensor, Alignment rear legs Sensor, Clamp front legs Sensor, Clamp rear legs Sensor, front knee Sensor, rear knee Sensor, front legs Sensor, rear legs Sensor, steering axle Sensor, brace up Sensor, brace down FleetManager battery filter Signal amplifier, right Signal amplifier, left Voltage converter Voltage converter 80 V / 24 V Even charger Diode Lase, Pulp an Paper Aerial, radio Aerial, communication radio Lead-through, harness Earthing terminal on chassis Terminal, negative terminal Outlet, 2-pole Outlet, 7-pole Outlet, extra, 7-pole Solenoid valve, exhaust brake Solenoid valve, diff. interlock Solenoid valve, brake Solenoid valve, heater Solenoid valve, power take off, side Solenoid valve, power take off, rear Solenoid valve, 2/4WD Solenoid valve, high/low gear Solenoid valve, hydraulics, general Solenoid valve, flow restriction Solenoid valve, torque amplifier Solenoid valve, ranging interlock Solenoid valve, wheel turning Solenoid valve, cold start aid Solenoid valve, AT-regulator by-pass Solenoid valve, water air conditioner Solenoid valve, fifth wheel up Solenoid valve, fifth wheel down Solenoid valve, fifth wheel forward
VDCT01.02SE/GB
15
NUMBER Y 623 Y 624 Y 625 Y 626 Y 627 Y 628 Y 630 Y 631 Y 632 Y 633 Y 634 Y 635 Y 636 Y 637 Y 638 Y 639 Y 640 Y 641 Y 642 Y 643 Y 644 Y 645 Y 646 Y 647 Y 648 Y 673 Y 676 Y 699 Y 826 Y 6001 Y 6002 Y 6003 Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y 6004 6005 6006 6007 6008 6009 6010 6011 6012 6013 6014 6015 6016 6017 6018 6019 6020 6021 6022
SVENSKA M-ventil vndskiva bak M-ventil skevning h M-ventil skevning v M-ventil AT-regulator M-ventil vakuum M-ventil brnsleblandning M-ventil v-lda fram M-ventil v-lda back M-ventil v-lda spole 1 M-ventil v-lda spole 2 M-ventil v-lda spole 3 M-ventil klmtryck M-ventil styrning M-ventil flytlge skevning M-ventil stopp insprut pump M-ventil lsning orbitrol ls M-ventil gasol M-ventil frngare (LPG) M-ventil park broms M-ventil lsning stol (VBFS) M-ventil lsning vndskiva Magnetkoppling komp AC M-ventil stolsvndning M-ventil stolstilt M-ventil luftfjdring Vatten ventil motor, ECC M-ventil Broms stolsvndning M-ventil option Ventil spakstyrning M-ventil blockering hger M-ventil blockering vnster M-ventil inkoppling av hydraulik till topplyft M-ventil snk M-ventil lyft M-ventil bom ut M-ventil bom in M-ventil vridning medsols M-ventil vridning motsols M-ventil tilt ut M-ventil tilt in M-ventil tilt M-ventil fllning frmre ben M-ventil fllning bakre ben M-ventil klmma/lossa ben M-ventil Hyttskjutning fram M-ventil Hyttskjutning bak M-ventil spridning ut M-ventil spridning in M-ventil sidofring vnster M-ventil sidofring hger M-ventil extra hydraulfunktion ut
ENGLISH Solenoid valve, fifth wheel rear Solenoid valve, levelling right hand Solenoid valve, levelling left hand Solenoid valve, AT-regulator Solenoid valve vacuum Solenoid valve fuelmixture Solenoid valve, gear box, forward gear Solenoid valve, gear box, rear gear Solenoid valve, gear box, 1 gear Solenoid valve, gear box, 2 gear Solenoid valve, gear box, 3 gear Solenoid valve, clamping pressure Solenoid valve, steering Solenoid valve, equalizing fifth wheel Solenoid valve, stop injection pump Solenoid valve, locking LS orbitrol Solenoid valve, LPG Solenoid valve, evaporator (LPG) Solenoid valve, parking brake Solenoid valve, seat locking (VBFS) Solenoid valve, fifth wheel locking Magnetic clutch, compressor AC Solenoid valve, seat rotation Solenoid valve, seat tilt Solenoid valve, pneumatic springing Water valve motor, ECC Solenoid valve Brake seat turning Solenoid valve, option Valve, (steering with control levers). Solenoid valve, blocking right Solenoid valve, blocking left Solenoid valve, activation of toplift hydraulics Solenoid valve, lower Solenoid valve, lift Solenoid valve, boom out Solenoid valve, boom in Solenoid valve, rotation clockwise Solenoid valve, rotation counter-clockwise Solenoid valve, tilt out Solenoid valve, tilt in Solenoid valve, tilt Solenoid valve, lowering front legs Solenoid valve, lowering rear legs Solenoid valve, clamping/releasing legs Solenoid valve, cab movement forward Solenoid valve, cab movement reverse Solenoid valve, spreading out Solenoid valve, spreading in Solenoid valve, side shift left Solenoid valve, side shift right Solenoid valve, extra hydraulic function out Solenoid valve, extra hydraulic function in
VDCT01.02SE/GB
6023 M-ventil extra hydraulfunktion in
16
NUMBER Y 6024 Y 6025 Y 6026 Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y
SVENSKA M-ventil stativ ut M-ventil stativ in M-ventil hger framhjul styrning vnster
6027 M-ventil hger framhjul styrning hger 6028 M-ventil vnster framhjul styrning vnster 6029 M-ventil vnster framhjul styrning hger 6030 M-ventil hger bakhjul styrning vnster 6031 M-ventil hger bakhjul styrning hger 6032 M-ventil vnster bakhjul styrning vnster 6033 M-ventil vnster bakhjul styrning hger 6034 6035 6036 6037 6038 6039 6040 6041 6042 6043 6044 6045 6046 6047 6048 6049 6050 6051 6052 6053 6054 6055 6056 6057 6058 6059 6060 6061 6062 6063 6064 6065 6066 6067 M-ventil skevning M-ventil skevning hger M-ventil skevning vnster M-ventil kylflkt M-ventil frikoppling koppling M-ventil ppna twistlock M-ventil lsa twistlock M-ventil nd, twistlock M-ventil mellan bom Magnetventil, fllning torn (RTCH) M-ventil blockering twistlock M-ventil blockering lyft M-ventil utskjut M-ventil, hyttilt upp M-ventil, hyttilt ner M-ventil, kylkrets broms M-ventil blockering utskjut M-ventil, regenerering hger M-ventil, regenerering vnster M-ventil, krlge M-ventil, klmma ihop M-ventil, klmma isr M-ventil, frmre kn ut M-ventil, frmre kn in M-ventil, bakre kn ut M-ventil, bakre kn in M-ventil, frmre ben upp M-ventil, bakre ben upp M-ventil, urkoppling hydraulpump M-ventil, stdben upp M-ventil, stdben ner M-ventil, frikoppling vridbroms M-ventil, v-lda, drivning M-ventil, v-lda, oljetryck till 1:a/3:e vxeln
ENGLISH Solenoid valve, mast out Solenoid valve, mast in Solenoid valve, right front wheel, steering left Solenoid valve, right front wheel, steering right Solenoid valve, left front wheel, steering left Solenoid valve, left front wheel, steering right Solenoid valve, right rear wheel, steering left Solenoid valve, right rear wheel, steering right Solenoid valve, left rear wheel, steering left Solenoid valve, left rear wheel, steering right Solenoid valve, levelling Solenoid valve, levelling right Solenoid valve, levelling left Solenoid valve, Cooling fan Solenoid valve, lockup clutch Solenoid valve, unlocked twist lock Solenoid valve, locked twist lock Solenoid valve, emergency, twistlock Solenoid valve, middle boom Solenoid valve, boom lowering (RTCH) Solenoid valve, blocking twistlock Solenoid valve, blocking lift Solenoid valve, projecting Solenoid valve, cab tilt up Solenoid valve, cab tilt down Solenoid valve, cooling cicuit brake Solenoid valve, blocking projecting Solenoid valve, regeneration right Solenoid valve, regeneration left Solenoid valve, driving position Solenoid valve, clambing in Solenoid valve, clambing out Solenoid valve, front knee out Solenoid valve, front knee in Solenoid valve, rear knee out Solenoid valve, rear knee in Solenoid valve, front legs up Solenoid valve, rear legs up Solenoid valve interruption hydraulic pump Solenoid valve, brace up Solenoid valve, brace down Solenoid valve, lockup rotation brake Solenoid valve, gearbox, drive Solenoid valve, gearbox,oilpressure to 1st/3rd gear Solenoid valve externder/rotation
VDCT01.02SE/GB
6068 M-ventil sax/rotation
17
NUMBER SVENSKA Y 6069 M-ventil, v-lda, oljetryck till 2:a/4:e vxeln Y Y Y Y Y Y Y Y Y Y Y Y Y Z 6070 6071 6072 6073 6074 6075 6076 6077 6078 6079 6080 6081 6082 822 M-ventil Over Height upp M-ventil Over Height ner M-ventil klmtryck Propertional ventil, Opti speed M-ventil, v-lda, vxelvljare fr 2:a/4:e vxeln M-ventil, v-lda, vxelvljare fr 1:a/3:e vxeln M-ventil blockering snk M-ventil Inching M-ventil,Avstngning vre klmarm M-Ventil, Sidofring/vre armar M-ventil, aktivering hyttkrning M-ventil, ackumulatorladdning M-ventil tryckbegrnsning Signalfilter
ENGLISH Solenoid valve, gearbox,oilpressure to 2nd/4th gear Solenoid valve, Over Height up Solenoid valve, Over Height down Solenoid valve clamp pressure Proportional valve, Opti speed Solenoid valve, gearbox, gearswitch for 2nd/4th gear Solenoid valve, gearbox, gearswitch for 1st/3rd gear Solenoid valve, blocking lower Solenoid valve, Inching Solenoid valve, upper arm off Solenoid valve, Sideshift/Upper arms Solenoid valve, activate sliding cab Solenoid valve, accumulator charge Solenoid valve, pressure restriction Signal filter
VDCT01.02SE/GB
18
VDCT01.02SE/GB
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
VDCT01.02GB
F:2
VDCT01.02GB
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
Power acc. to ISO 3046 (net power) Torque ISO 3046 Max. rotation speed Number of cylinders Alternator, output System voltage, voltage-capacity
Yuchai YC6A240-30 164 kW at 2200 rpm 800 Nm at 1500 rpm 2200 rpm 6 cylinders 2640 W
Cummins QSB6.7 164 kW at 2200 rpm 949 Nm at 1500 rpm 2200 rpm 6 cylinders 2240 W
24 V (2x12 V / 135 Ah) Dana HR32000 3 3
2. Transmission
No. of gears, forward - reverse
3. Power transmission
Drive axle, type Kessler D81 Kessler D91
4. Brakes
Service brake system actuated wheel Parking brake system actuated wheel Wet Disc Brake - drive 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 Tyre type, front and rear 1.0 MPa Inflated. Spare and replacement tyres must be from a manufacturer approved by Cargotec.
9. Cab
Equivalent sound pressure level in cab according to EN12053 with measurement uncertainty R=2.5 dB. Measurement value with standard engine. Whole-body vibrations according to EN13059 with measurement uncertainty k=0.3 x measured value. Yuchai YC6A240-30 LpAZ 67 dB(A)
Spirit Delta Cummins QSB6.7 LpAZ 65 dB(A)
0.4 - 0.7 m/s2
VDCT01.02GB
F:4
9.6 Frame, body, cab and accessories, lighting system Lamp

Check lamps Interior lighting Tail lights Brake light Direction indicators Position lamps Headlights (high and low beams) Back-up lights Work lights Work lights, Xenon Revolving beacon Output (W) 1.2 10 5 21 21 5 75/70 70 70 35 70 Socket W2x4.6d S8.5 BA15s BA15s BA15s W2.1x9.5d P43t-38 (H4) PK22s (H3) PK22s (H3) D1S Xenon tubes. Cartridge and ballast replaced complete. PK22s (H3)
Volumes
Any deviation from this table must be approved in writing by Cargotec.
1.2 Engine, fuel system

Fuel tank, volume Fuel quality
Yuchai YC6A240-30 380 l
Cummins QSB6.7
Diesel according to: EN590, ASTM D 975 No 1-D, ASTM D 975 No 2-D.
1.7 Engine, cooling system

Coolant volume Coolant, filling point 32 l Volvo Penta Coolant VCS, ready-mixed. 29 l ES Compleat, Premix
See Oils and lubricants, recommendation, page F:8.
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. 1.8 Engine, lubrication system
Oil type, quality Oil volume, incl. filter See Oils and lubricants, recommendation, page F:8. 24 l HR32000 See Oils and lubricants, recommendation, page F:8. 32 l 20 l
2.6 Transmission, lubrication system

Oil type Oil volume
VDCT01.02GB
F:5
3.3 Power transmission, drive axle

Oil grade Oil volume, differential Oil volume, hub reduction
Kessler D81
Kessler D91
See Oils and lubricants, recommendation, page F:8. 42 l 2x4 l 54 l 2x4 l
7 Load handling
Oil grade See Oils and lubricants, recommendation, page F:8.

Refrigerant, air conditioning Refrigerant volume Lubricant, air conditioning Washer fluid, volume R134a See air conditioning plate ZEXEL PAG oil ZXL100 5 l
Oil grade Hydraulic oil tank, volume Hydraulic oil system, volume See Oils and lubricants, recommendation, page F:8. 320 l 450 l
VDCT01.02GB
F:6
Specification for lifting capacity and dimensions
A2 100 100
H4 H5
B S H3
R1
H6 H8 H10 100
R2
100 L3 L L2 A1
DCT80
E5 E6 E7 E8
DCT90
E5 E6 E7 E8
Lifting capacity
Classed [kg x 103] Centre of gravity distance (L4 [mm]) Number of containers, 8'6 container Number of containers, 9'6 container 5 5 6 5 8 1220 7 6 8 7 5 5 6 5 9 1220 7 6 8 7
Dimensions
Truck length (L [mm]) Truck width (B [mm]) Height, base machine Spirit Delta (H6 [mm]) Seat height (H8 [mm]) Spacing drive axle - attachment front section (L2 [mm]) Wheelbase (L3 [mm]) Track (front - rear) (S [mm]) Slewing radius, outer (R1 [mm]) Slewing radius, inner (R2 [mm]) 6900 4050 3940 2800 1185 4550 3270 2250 6750 1150 6900 4100 4000 2860 1185 4550 3270 2200 7000 1500
VDCT01.02GB
014020
F:7
DCT80
E5 Ground clearance, min. [mm] Minimum aisle width for 90 stacking, 20' container (A1 [mm]) Minimum aisle width for 90 stacking, 40' container (A2 [mm]) E6 250 10600 14200 E7 E8
DCT90
E5 E6 300 10850 14350 E7 E8
Standard Duplex mast

Lifting height (H4 [mm]) Mast height, min. (H3 [mm]) Mast height, max. (H5 [mm]) Mast tilting, forward - backward ( - [mm]) 15220 8540 15040 16220 9040 16040 18720 10290 18540 21220 11540 21040 15280 8600 15100 16280 9100 16100 18780 10350 18600 21280 11600 21100
3 3
3 3
Attachment
Height under twistlock (H10 [mm]) Height under lifting hooks (H10 [mm]) Side shift (V1 [mm]) 2220 600 2280 600
Weight
Service weight [kg x 103] Axle pressure front, (without load) [kg x 103] Axle pressure front, (with classified load) [kg x 103] Axle weight rear, (without load) [kg] Axle weight rear, (with classed load) [kg] 35.5 22.7 34.9 36.1 23.3 35.5 37.6 24.8 37.0 39.1 26.3 38.5 36.4 22.9 36.7 37.0 23.5 37.3 38.5 25.0 38.8 40.0 26.5 40.3
12800 8600
13500 8700
VDCT01.02GB
F:8
Oils and lubricants, recommendation

The service intervals specified by Cargotec in the maintenance manual only apply if oils are selected in accordance with the table below. The table indicates recommended viscosity for different oil types, and grades, depending on the outdoor temperature. Any deviation from this table must be approved in writing by Cargotec, and may mean changed service intervals. Oil type, quality C F 1.8 Engine, lubrication system Yuchai YC6A240-30 API CH-4 or ACEA E5 SAE 15W-40 (motor oil) SAE 15W-30 (motor oil) SAE 10W-30 (motor oil) SAE 5W-30 (motor oil) -20 -4 -10 +14 0 +32 +10 +50 +20 +68 +30 +86 +40 +104
Cummins QSB6.7 API CH-4 or ACEA E5 2.6 Transmission, lubrication system GM Allison C-4 John Deere J20 C, D Caterpillar TO-4 MIL-PRF-2104G
SAE 15W-40 (motor oil) SAE 5W-30 (motor oil)
SAE 50 SAE 40 SAE 30 SAE 20 SAE 10W SAE 0W-20
NOTE
Engine oil or GL-5 oil must not be used. 3.3 Power transmission, drive axle API GL-5
SAE 80W-140 SAE 75W-90
10 Common hydraulics 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 Europenne d'Automobiles API = American Petroleum Institute
VDCT01.02GB
F:9
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
VDCT01.02GB
F:10
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.
Condition
1 2 3
Screw
untreated bright galvanised hot-galvanised
Nut
untreated untreated or bright galvanised untreated 8.8 1 2 3
Lubrication
oil dry or oil dry or oil 10.9 1 12.9 1
Quality Condition Fine M-thread

M81 M101.25 M121.25 M161.5 M181.5 27 Nm 54 Nm 96 Nm 230 Nm 330 Nm
24 Nm 48 Nm 85 Nm 205 Nm 294 Nm
30 Nm 61 Nm 108 Nm 260 Nm 373 Nm
39 Nm 78 Nm 135 Nm 323 Nm 466 Nm
46 Nm 91 Nm 162 Nm 388 Nm 559 Nm
M-thread
M4 M5 M6 M8 M10 M12 M16 M20 M24 M30 3.2 Nm 6.4 Nm 11 Nm 26 Nm 52 Nm 91 Nm 220 Nm 430 Nm 750 Nm 1480 Nm 2.9 Nm 5.7 Nm 9.8 Nm 24 Nm 47 Nm 81 Nm 198 Nm 386 Nm 668 Nm 1317 Nm 3.6 Nm 7.2 Nm 12.5 Nm 30 Nm 59 Nm 103 Nm 250 Nm 490 Nm 848 Nm 1672 Nm 4.6 Nm 9.1 Nm 16 Nm 38 Nm 74 Nm 128 Nm 313 Nm 620 Nm 1050 Nm 2080 Nm 5.5 Nm 11 Nm 19 Nm 45 Nm 89 Nm 154 Nm 375 Nm 732 Nm 1270 Nm 2500 Nm
UNC-thread
1/4 5/16 3/8 7/16 1/2 9/16 5/8 12.5 Nm 25 Nm 44 Nm 70 Nm 107 Nm 153 Nm 210 Nm 11.1 Nm 22.3 Nm 39 Nm 62 Nm 95 Nm 136 Nm 187 Nm 14.1 Nm 28.3 Nm 50 Nm 79 Nm 121 Nm 173 Nm 237 Nm 17.6 Nm 35 Nm 62 Nm 100 Nm 151 Nm 216 Nm 298 Nm 20 Nm 42 Nm 73 Nm 118 Nm 178 Nm 255 Nm 353 Nm
VDCT01.02GB
F:11
Quality
3/4 7/8 1 1 1/8 1 1/4 1 3/8 1 1/2 370 Nm 594 Nm 889 Nm 1260 Nm 1760 Nm 2320 Nm 3060 Nm
8.8 390 Nm 528 Nm 791 Nm 1120 Nm 1565 Nm 2065 Nm 2720 Nm 418 Nm 671 Nm 1005 Nm 1424 Nm 1990 Nm 2620 Nm 3455 Nm
10.9 524 Nm 839 Nm 1260 Nm 1780 Nm 2490 Nm 3280 Nm 4320 Nm
12.9 619 Nm 990 Nm 1480 Nm 2100 Nm 2940 Nm 3870 Nm 5100 Nm
Tightening torque, connections for air conditioning

O-ring couplings cooling hoses
Hose diameter mm 6 10 10 12 16 19 Pressure switch inch 1/4" 3/8" 3/8" 1/2" 5/8" 3/4" Thread inch 7/16" 5/8" 11/16" 3/4" 7/8" 1 1/16" 3/8" 7/16" The above values should be considered guidelines and may vary depending on installation. Tightening torque Nm 7-13 Nm 14-20 Nm 14-20 Nm 14-26 Nm 27-41 Nm 34-46 Nm 7-13 Nm
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Tightening torque, ORFS connections

Pipe and hose fitting Pipe diameter mm
6 8 10 12 14 15 16 18 20 22 25 28 30 32 35 38
Tightening torque Nm
23-25 33-38 51-57
inch
1/4 5/16 3/8 1/2 5/8 3/4 7/8 1" 1"1/4 1"1/2
80-90
120-130
150-170
180-200
200-240
Wrench size mm
17 22 24 36 41
Tightening torque Nm
23-25 33-38 51-57 120-130 150-170
inch
11/16 13/16 15/16 1 3/8 1 5/8
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Material fitting UNF-UN

Thread (inch) 7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1"1/16-12 1"3/16-12 1"5/16-12 1"5/8-12 1"7/8-12 Tightening torque (Nm) 21 27 40 78 110 180 230 285 320 400
Metric-ISO
Thread (mm) 10x1 12x1.5 14x1.5 16x1.5 18x1.5 20x1.5 22x1.5 26x1.5 27x2 33x2 42x2 48x2 Tightening torque (Nm) 20 35 45 55 68 80 98 170 180 310 330 400
BSSP
Thread (inch) 1/8-28 1/4-19 3/8-19 1/2-14 3/4-14 1"-11 1"1/4-11 1"1/2-11 Tightening torque (Nm) 20 35 70 100 190 300 330 400
Unit explanations
Unit
Newton metre Kgf/m Kilo pascal Mega pascal Kilowatt Kilojoule British thermal unit Calorie Inch Feet Yard Mile Centimetre Metre Kilometre
Abbreviation
Nm kpm kPa MPa kW kJ Btu ca in ft yd mile cm m km
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Conversion SI-units
SI-unit Torque Nm Nm Nm Pressure (Pa = N/m2) kPa kPa kPa bar kp/cm N/mm MPa Power (W = J/s) kW kW kW W Energy (J = Nm) kJ J Speed and acceleration m/s2 m/s km/h Horsepower/torque Bhp x 5252 rpm= TQ (lbft) Temperature C = (F 32)/1.8 Flow factor l/min (dm3 /min) x 0.264 = US gal/min x 3.785 = litre/min F = (C x 1.8) + 32 TQ x rpm 5252 = bhp x 3.28 x 3.28 x 0.62 = ft/s2 = ft/s = mph x 0.305 x 0.305 x 1.61 = m/s2 = m/s = km/h x 0.948 x 0.239 = Btu = calorie x 1.055 x 4.19 = kJ = J x 1.36 x 1.34 x 0.948 x 0.74 = hp (cv) = bhp = Btu/s = ftlb/s x 0.736 x 0.746 x 1.055 x 1.36 = kW = kW = kW = W
2 2
Recalculation factor
Non-SI
Recalculation factor
SI
x 10.2 x 0.74 x 0.102
= kgcm = lbfft = kgm
x 0.8664 x 1.36 x 7.22
= lbin = Nm = lbft
x 4.0 x 0.30 x 0.145 x 14.5 x 14.22 x 145.04 x 145
= in.H2O = in.Hg = psi = psi = psi = psi = psi
x 0.249 x 3.38 x 6.89 x 0.069 x 0.070 x 0.069 x 0.00689
= kPa = kPa = kPa = bar = kp/cm2 = bar = MPa
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Conversion table length

Unit cm m km in ft yd mile cm 1 100 100000 2.54 30.48 91.44 160930 m 0.01 1 1000 0.0254 0.3048 0.9144 1609.3 km 0.00001 0.001 1 0.000025 0.000304 0.000914 1.6093 in 0.3937 39.37 39370.7 1 12 36 63360 ft 0.03281 3.2808 3280.8 0.08333 1 3 5280 yd 0.01094 1.0936 1093.6 0.02777 0.3333 1 1760 mile 0.000006 0.00062 0.62137 0.000015 0.000189 0.000568 1
1 mm = 0.1 cm 1 mm = 0.001 m
Conversion table area

Unit cm2 m2 km2 a ft2 yd2 in2 cm2 1 10000 0.01 6.4516 m2 0.0001 1 1000000 100 0.092903 0.83613 0.000645 km2 0.000001 1 0.0001 a 0.000001 0.01 10000 1 0.000929 0.008361 ft2 0.001076 10.764 1076400 1076.4 1 9 0.006943 yd2 0.000012 1.1958 1195800 119.58 0.1111 1 0.000771 in2 0.155000 1550.000 144.000 1296.00 1
1 ha = 100 a 1 mile2 = 259 ha = 2.59 km2
Conversion table volume

Unit cm3 = ml m3 dm3 (l) in3 ft3 yd3 cm3 = cc 1 1000000 1000 16.387 28316.8 764529.8 m3 0.000001 1 0.001 0.000016 0.028317 0.76453 l 0.001 1000 1 0.01638 28.317 764.53 in3 0.061024 61024 61.024 1 1728 46656 ft3 0.000035 35.315 0.035315 0.000578 1 27 yd3 0.000001 1.30796 0.001308 0.000021 0.03704 1
1 gal (US) = 3785.41 cm3 = 231 in3 = 0.83267 gal (UK)
Conversion table weight

Unit g kg t oz lb g 1 1000 1000000 28.3495 453.592 kg 0.001 1 1000 0.02835 0.45359 t 0.000001 0.001 1 0.000028 0.000454 oz 0.03527 35.273 35273 1 16 lb 0.0022 2.20459 2204.59 0.0625 1
1 tonne (metric) = 1.1023 ton (US) = 0.9842 ton (UK)
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Conversion table pressure

Unit kp/cm2 bar Pa = N/m2 kPa lbf/in2 lbf/ft2 kp/cm2 1 1.01972 0.00001 0.01020 0.07032 0.00047 bar 0.98067 1 0.001 0.01 0.0689 0.00047 Pa = N/m2 98066.5 100000 1 1000 6894.76 47.88028 kPa 98.0665 100 0.001 1 6.89476 0.04788 lbf/in2 14.2233 14.5037 0.00015 0.14504 1 0.00694 lbf/ft2 2048.16 2088.6 0.02086 20.886 144 1
kg/cm2 = 735.56 Dry (mmHg) = 0.96784 atm
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G Terminology and index
Contents G Terminology and index

Terminology and index .....................................................................................G:3 Terminology..................................................................................................... G:3 Index ............................................................................................................... G:5
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G Terminology and index Terminology and index
G:3
G Terminology and index

Terminology
Explanations
Term
Accumulator Attachment Anti-corrosion agent Working hydraulics Wheelbase Bar Battery disconnector Daily inspection Decitonne Display Operating time Drive axle Drive-train ECC EHC Electrolyte level Expansion tank Fixed displacement Hanging load FMI Main fuse Hydraulic oil Hydraulic oil pump Hydraulic system Indicator Refrigerant Low-emission engine LC Lift capacity Lifting point Trolley Solenoid valve Control valve Machine model
Description
Reservoir that stores (accumulates) pressure for, i.e. hydraulic functions. Part of the machine that grips the load when lifting. Prevents oxidation, in simple terms, rustproofing. All load handling functions, that is, lift and lower, tilt, side shift, spreading (extension) and levelling. Distance between drive axle and steering axle. Unit to express pressure. Cuts off power supply from battery. Actions that should be performed daily to ensure the machine's functionality. Tenth of a tonne, measure of machine's lift capacity. "Window" showing digital information, i.e. on steering wheel panel in the cab. Number of hours machine has been in operation, shown on hour meter in cab. Driving axle that receives the torque from the drive-train. Parts in machine involved in power transmission; engine, torque converter, transmission, propeller shaft, and drive axle with differential and hub reduction. Electric Climate Control. Air conditioning system with thermostat-controlled cooling, dehumidification and heating. Electric Heat Control. Heating system with thermostat-controlled heating. Fluid level in battery cells. Tank for coolant. Non-adjustable volume (capacity) in a pump. Lifted load. Fault Message Identifier. Located by battery. Breaks the current to all systems in the whole machine. Oil for hydraulic system. See specifications in operator's manual. Pump in hydraulic system. System that uses oil pressure to transfer power to different functions. Manual "sensor", for example, shows that a filter is clogged and needs to be changed. Fluid/gas in air conditioning. Must only be handled by authorised trained personnel. Engine with low emissions of hazardous substances. Manufactured in accordance with regulations. Load centre. Indicates machine's maximum lift capacity. Attaching point for lift device when lifting an object. Lifts the load, located on the mast. An electro-magnetically controlled valve. See also proportional valve. Valves that can be used to control something, for example, to release pressure and thus lower a boom or a fork. Machine type. Specified, for example: DCT 80-90. See also type designation.
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G Terminology and index Terminology
Term
Environmental waste Torque converter Hub reduction Pilot oil pressure Planetary gear Product alternative Proportional valve
Description
Used oils, filters, etc., must be handled according to governing national laws and regulations. Hydraulic, variable clutch. Type of final drive (often next to drive wheel) that reduces rpm and increases torque from the drive-train. A low control pressure to, for example, a valve. Type of transmission with the gears in constant mesh. One of several alternatives is selected for a machine, e.g. engine alternative. 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. Structural members in the frame. Circulate over and over again. Unique machine designation. On the machine plate. How machine should be safely positioned before service may be started. A small movement by the user results in a large angle, i.e. servo steering. A low control pressure to control a higher pressure, for example, to a valve. Attachment. See attachment Parallel sideways movement of attachment. Attachment is tilted, for example if load stands on uneven ground. Enclosed type of cab. Suspect Parameter Number. Widening of attachment. Carrier of trolley, attachment and load. The air filter collects the coarsest particles in a dust reservoir, which is emptied automatically during operation. Wheel axle with steering. Acoustic alarm to catch the operator's attention. Extra equipment for machine. Load is leaned forward or backward. Oil for transmission and torque converter. See specifications in operator's manual. Actions before transporting machine. 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. Indicates machine type and capacity. See also machine model. Periodic maintenance actions so that machine functions safely and for a long service life. Brake discs in oil bath. Moveable part in valve. Determines oil's path.
Frame member Recirculation Serial number Service position Servo Servo pressure Side lift Side shift Levelling Spirit Delta SPN Spreading (positioning) Mast Dust reservoir Steering axle Buzzer Option Tilting Transmission oil Securing machine for transport Twistlocks Type designation Maintenance Wet brakes Valve slide
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G Terminology and index Index
G:5
Index
A
About the documentation . About the Workshop Manual Accelerator . . . . . . . Accumulator . . . . . . . Accumulator charging valve Accumulator drain valve . . Accumulator lift . . . . . . Air cleaning system . . . . Air distributor . . . . . . . Air intake and exhaust outlet Air suspension . . . . . . Alternator . . . . . . . . Arm rest . . . . . . . . . ATTACH . . . . . . . . . ATTACH, menu 1 . . . . . ATTACH, menu 10 . . . . ATTACH, menu 11 . . . . ATTACH, menu 12 . . . . ATTACH, menu 13 . . . . ATTACH, menu 14 . . . . ATTACH, menu 15 . . . . ATTACH, menu 16 . . . . ATTACH, menu 17 . . . . ATTACH, menu 18 . . . . ATTACH, menu 19 . . . . ATTACH, menu 2 . . . . . ATTACH, menu 20 . . . . ATTACH, menu 21 . . . . ATTACH, menu 3 . . . . . ATTACH, menu 4 . . . . . ATTACH, menu 5 . . . . . ATTACH, menu 6 . . . . . ATTACH, menu 7 . . . . . ATTACH, menu 8 . . . . . ATTACH, menu 9 . . . . . ATTACHMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A:12 . . . A:3 . . . 1:20 4:10, 10:5 . . . 4:7 . . . 10:3 . . . 7:30 . . . 1:23 . . . 9:50 . . . 1:23 . . . 9:17 . . . 11:6 . . . 9:18 . . . 8:76 . . . 8:76 . . . 8:81 . . . 8:82 . . . 8:83 . . . 8:84 . . . 8:84 . . . 8:84 . . . 8:84 . . . 8:85 . . . 8:86 . . . 8:87 . . . 8:76 . . . 8:88 . . . 8:89 . . . 8:77 . . . 8:77 . . . 8:78 . . . 8:78 . . . 8:79 . . . 8:79 . . . 8:80 . . 8:104
B
Back rest cushion . . . . . . . . . . . . . Back-up alarm . . . . . . . . . . . . . . Back-up lights . . . . . . . . . . . . . . Batteries. . . . . . . . . . . . . . . . . Battery disconnector . . . . . . . . . . . Body structure . . . . . . . . . . . . . . Brake cylinder . . . . . . . . . . . . . . Brake lights . . . . . . . . . . . . . . . Brake oil filter . . . . . . . . . . . . . . Brake pedal . . . . . . . . . . . . . . . Brake valve . . . . . . . . . . . . . . . Brakes . . . . . . . . . . . . . . . . . Break contact (opening switch) brake pressure Break contact (opening switch) parking brake Breather filter hydraulic oil tank . . . . . . . Bumper . . . . . . . . . . . . . . . . . Buzzer, automatic spread 20'-40' . . . . . . Bypass . . . . . . . . . . . . . . . . . Bypass valve, cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9:15 9:71 9:64 11:4 11:3 9:85 4:26 9:63 4:6 4:3 4:14 4:3 4:19 4:36 10:24 . 9:16 . 7:56 . 8:7 10:23
C
CAB . . . . . . . . . . . . . . . . . . . . . . . 8:37 Cab frame . . . . . . . . . . . . . . . . . . . . . 9:80 Cab interior . . . . . . . . . . . . . . . . . . . . 9:81
Cab structure and suspension . . . . . . . . . . . . 9:80 Cab substructure . . . . . . . . . . . . . . . . . . 9:80 CAB, menu 1. . . . . . . . . . . . . . . . . . . . 8:37 CAB, menu 2. . . . . . . . . . . . . . . . . . . . 8:38 CAB, menu 3. . . . . . . . . . . . . . . . . . . . 8:39 CAB, menu 4. . . . . . . . . . . . . . . . . . . . 8:40 CAB, menu 5. . . . . . . . . . . . . . . . . . . . 8:41 CAB, menu 6. . . . . . . . . . . . . . . . . . . . 8:42 CAB, menu 7. . . . . . . . . . . . . . . . . . . . 8:43 CAB, menu 8. . . . . . . . . . . . . . . . . . . . 8:44 Cabin fan . . . . . . . . . . . . . . . . . . . . . 9:32 Cable harness . . . . . . . . . . . . . . . . . . 11:25 Calibrate DRIVE-TRAIN . . . . . . . . . . . . . . 8:114 Calibration . . . . . . . . . . . . . . . . . . . . 8:112 CAN bus . . . . . . . . . . . . . . . . . . . . 11:34 CAN bus drive-train . . . . . . . . . . . . . . . . 11:38 CAN/POWER . . . . . . . . . . . . . . . . . . . 8:11 CAN/POWER, menu 1 . . . . . . . . . . . . . . . 8:11 CAN/POWER, menu 10 . . . . . . . . . . . . . . . 8:20 CAN/POWER, menu 11 . . . . . . . . . . . . . . . 8:21 CAN/POWER, menu 12 . . . . . . . . . . . . . . . 8:21 CAN/POWER, menu 13 . . . . . . . . . . . . . . . 8:22 CAN/POWER, menu 14 . . . . . . . . . . . . . . . 8:22 CAN/POWER, menu 15 . . . . . . . . . . . . . . . 8:22 CAN/POWER, menu 16 . . . . . . . . . . . . . . . 8:23 CAN/POWER, menu 17 . . . . . . . . . . . . . . . 8:24 CAN/POWER, menu 2 . . . . . . . . . . . . . . . 8:12 CAN/POWER, menu 3 . . . . . . . . . . . . . . . 8:13 CAN/POWER, menu 4 . . . . . . . . . . . . . . . 8:13 CAN/POWER, menu 5 . . . . . . . . . . . . . . . 8:14 CAN/POWER, menu 6 . . . . . . . . . . . . . . . 8:15 CAN/POWER, menu 7 . . . . . . . . . . . . . . . 8:17 CAN/POWER, menu 8 . . . . . . . . . . . . . . . 8:18 CAN/POWER, menu 9 . . . . . . . . . . . . . . . 8:20 Central lubrication . . . . . . . . . . . . . . . . . 9:87 Chassis . . . . . . . . . . . . . . . . . . . . . . 9:84 CLIMATE . . . . . . . . . . . . . . . . . . . . . 8:45 CLIMATE, menu 1 . . . . . . . . . . . . . . . . . 8:45 CLIMATE, menu 2 . . . . . . . . . . . . . . . . . 8:45 CLIMATE, menu 3 . . . . . . . . . . . . . . . . . 8:46 CLIMATE, menu 4 . . . . . . . . . . . . . . . . . 8:47 CLIMATE, menu 5 . . . . . . . . . . . . . . . . . 8:47 CLIMATE, menu 6 . . . . . . . . . . . . . . . . . 8:48 CLIMATE, menu 7 . . . . . . . . . . . . . . . . . 8:49 CLIMATE, menu 8 . . . . . . . . . . . . . . . . . 8:50 Common electrics . . . . . . . . . . . . . . . 11:3, E:6 Common hydraulics . . . . . . . . . . . . . . 10:3, E:3 Communication. . . . . . . . . . . . . . . . . . 11:34 Communication between PC and machine . . . . . . 11:39 Complete machine . . . . . . . . . . . . . . . . . 0:3 Compressor . . . . . . . . . . . . . . . . . . . . 9:39 Compressor air-suspension seat . . . . . . . . . . . 9:17 Condenser . . . . . . . . . . . . . . . . . . . . . 9:43 Container counter. . . . . . . . . . . . . . . . . . 7:75 Control breaker . . . . . . . . . . . . . . . . 9:10, 11:3 Control levers . . . . . . . . . . . . . . . . . . . 7:4 Control system . . . . . . . . . . . . . . . . 8:3, D:95 Control system, engine . . . . . . . . . . . . . . . 1:30 Control system, transmission . . . . . . . . . . . . . 2:18 Control unit KID . . . . . . . . . . . . . . . . . 11:24 Control unit KIT. . . . . . . . . . . . . . . . . . 11:23 Control unit, attachment . . . . . . . . . . . . . . 11:19 Control unit, cab . . . . . . . . . . . . . . . . . 11:17 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 Coolant . . . . . . . . . . . . . . . . . . . . . . 1:26 Cooler hydraulic oil . . . . . . . . . . . . . . . . 10:20 Cooling fan . . . . . . . . . . . . . . . . 1:26, 10:21 Cooling system . . . . . . . . . . . . . . . . 1:25, 2:17
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Counterweights. . . . . . . . . . . . . . . . . . . 9:86
D
Defroster nozzles . . . Diagnostics . . . . . Direction indicators . . Disc pack . . . . . . Distribution block . . . Distribution of electricity Doors . . . . . . . . Drive axle . . . . . . Drive axle block . . . DRIVE-TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9:51 8:9 9:64 4:26 9:90 11:7 9:80 3:4 4:18 8:108
Foreword . . . . . . . . . . . . Frame control unit . . . . . . . . Frame, body, cab and accessories . FREELIFT . . . . . . . . . . . . Fresh air filter . . . . . . . . . . Fresh air filter or recirculation damper Fuel system . . . . . . . . . . . Fuel tank . . . . . . . . . . . . Fuses . . . . . . . . . . . . . .
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A:3 11:18 . 9:3 . 8:90 . 9:28 . 9:29 . 1:21 . 1:21 . 11:3
G
Gear pump with fixed displacement . Gear selector and multi-function lever General safety information . . . . . Glass/windows/mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10:6 . 2:9, 9:8 . . . B:3 . . . 9:73
E
EL-STEERING . . . . . . . . . . Electric protection. . . . . . . . . ELECTRIC SERVO . . . . . . . . Electronic box . . . . . . . . . . Electronic box frame . . . . . . . Electronic box, cab . . . . . . . . ELSERV. . . . . . . . . . . . . ELSERV, menu 1 . . . . . . . . . ELSERV, menu 10 . . . . . . . . ELSERV, menu 11 . . . . . . . . ELSERV, menu 12 . . . . . . . . ELSERV, menu 13 . . . . . . . . ELSERV, menu 14 . . . . . . . . ELSERV, menu 15 . . . . . . . . ELSERV, menu 2 . . . . . . . . . ELSERV, menu 3 . . . . . . . . . ELSERV, menu 4 . . . . . . . . . ELSERV, menu 5 . . . . . . . . . ELSERV, menu 6 . . . . . . . . . ELSERV, menu 7 . . . . . . . . . ELSERV, menu 8 . . . . . . . . . ELSERV, menu 9 . . . . . . . . . Emergency stop switch voltage (15E) Engine . . . . . . . . . . . . . ENGINE . . . . . . . . . . . . . Engine control unit . . . . . . . . ENGINE, menu 1 . . . . . . . . . ENGINE, menu 10 . . . . . . . . ENGINE, menu 2 . . . . . . . . . ENGINE, menu 3 . . . . . . . . . ENGINE, menu 4 . . . . . . . . . ENGINE, menu 5 . . . . . . . . . ENGINE, menu 6 . . . . . . . . . ENGINE, menu 7 . . . . . . . . . ENGINE, menu 8 . . . . . . . . . ENGINE, menu 9 . . . . . . . . . Entertainment and communication . Environment . . . . . . . . . . . Error code menu . . . . . . . . . Error codes . . . . . . . . . . . Exhaust system . . . . . . . . . Expansion valve . . . . . . . . . EXT-ATTACH . . . . . . . . . . EXTRA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8:90 . . . 11:3 . . . 8:98 . . 11:14 . . 11:15 . . 11:14 . . . 8:69 . . . 8:69 . . . 8:74 . . . 8:74 . . . 8:74 . . . 8:75 . . . 8:75 . . . 8:75 . . . 8:69 . . . 8:70 . . . 8:71 . . . 8:72 . . . 8:73 . . . 8:73 . . . 8:74 . . . 8:74 . . 11:11 . 1:3, D:9 . . . 8:55 1:30, 11:21 . . . 8:55 . . . 8:60 . . . 8:55 . . . 8:56 . . . 8:57 . . . 8:57 . . . 8:58 . . . 8:59 . . . 8:59 . . . 8:60 . . . 9:72 . . B:20 . . . 8:4 . . . D:3 . . . 1:23 . . . 9:46 . . . 8:90 . . . 8:89
H
Headlights . . . . . . . . . . . . . . . . . . . . . 9:63 Heat exchanger heat . . . . . . . . . . . . . . . . 9:35 Heat exchanger, cooling . . . . . . . . . . . . . . . 9:49 Heating coil . . . . . . . . . . . . . . . . . . . . 9:16 Heating, ventilation and air conditioning . . . . . . . . 9:21 Hood engine compartment . . . . . . . . . . . . . . 9:85 Horn . . . . . . . . . . . . . . . . . . . . . . . 9:70 Hoses, pipes and valves . . . . . . . . . . . . . . 10:13 HYD . . . . . . . . . . . . . . . . . . . . . . . 8:51 HYD, menu 1 . . . . . . . . . . . . . . . . . . . 8:51 HYD, menu 2 . . . . . . . . . . . . . . . . . . . 8:51 HYD, menu 3 . . . . . . . . . . . . . . . . . . . 8:52 HYD, menu 4 . . . . . . . . . . . . . . . . . . . 8:52 HYD, menu 5 . . . . . . . . . . . . . . . . . . . 8:53 HYD, menu 6 . . . . . . . . . . . . . . . . . . . 8:54 HYD, menu 7 . . . . . . . . . . . . . . . . . . . 8:54 HYD, menu 8 . . . . . . . . . . . . . . . . . . . 8:54 Hydraulic cylinders . . . . . . . . . . . . . . . . 10:29 Hydraulic oil . . . . . . . . . . . . . . . . . . . 10:26 Hydraulic oil filter . . 4:30, 7:30, 7:40, 7:57, 7:62, 7:74, 10:24 Hydraulic oil pump . . . . . . . . . . . . 4:6, 4:30, 5:3, 7:10, 7:32, 7:47, 7:59, 7:66 Hydraulic oil tank . . . . . . . . . . . . . . . . . . 10:5
I
I/O . . . . . . . . . . . . Ignition . . . . . . . . . . Ignition voltage (15) . . . . . Initiation . . . . . . . . . . Instrument and control panels Insulation . . . . . . . . . Intercooler . . . . . . . . . Interior fittings, plastic . . . . Interior fittings, textile . . . . Interior lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8:94 1:20 11:9 8:95 9:81 9:82 1:24 9:82 9:82 9:66
L
Levelling. . . . . . . . . . . . . Lift and lower. . . . . . . . . . . Lift cylinder . . . . . . . . . . . Lift, tilt and attachment control valve. Lighting system. . . . . . . . . . LIGHTS . . . . . . . . . . . . . LIGHTS, menu 1 . . . . . . . . . LIGHTS, menu 10 . . . . . . . . LIGHTS, menu 11. . . . . . . . . LIGHTS, menu 12 . . . . . . . . LIGHTS, menu 13 . . . . . . . . LIGHTS, menu 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7:63 . . . . . 7:8 . . . . . 7:15 7:40, 7:56, 7:74 . . . . . 9:59 . . . . . 8:25 . . . . . 8:25 . . . . . 8:32 . . . . . 8:33 . . . . . 8:33 . . . . . 8:34 . . . . . 8:36
F
Feedback . . . . . . Fine filter hydraulic oil . Fire extinguisher . . . Flashing hazard lights . Flex plates . . . . . . Floor covering . . . . Footsteps and hand rail
VDCT01.02GB
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LIGHTS, menu 15 . LIGHTS, menu 2 . . LIGHTS, menu 3 . . LIGHTS, menu 4 . . LIGHTS, menu 5 . . LIGHTS, menu 6 . . LIGHTS, menu 7 . . LIGHTS, menu 8 . . LIGHTS, menu 9 . . Lines . . . . . . . Link arm . . . . . . Load carrier . . . . Load handling . . . Load retention valve Lock cylinder . . . . Lock mechanism . . Lubrication system .
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8:36 8:25 8:26 8:27 8:28 8:29 8:29 8:30 8:31 9:90 5:11 7:64 7:3 7:61 7:68 7:69 2:13
R
Radiator and expansion tank . . . . . Reading instructions . . . . . . . . Reading-lamp . . . . . . . . . . . Rear view mirror . . . . . . . . . . Rear window . . . . . . . . . . . . Redundant CAN bus . . . . . . . . Redundant voltage feed of control units Relief valve, attachment . . . . . . . Revolving beacon. . . . . . . . . . Rim . . . . . . . . . . . . . . . . RMI . . . . . . . . . . . . . . . . Roof window . . . . . . . . . . . . Running lights . . . . . . . . . . . . . . . . . . . . . . . . . 1:25 . . . . . . . A:4 . . . . . . . 9:83 . . . . . . . 9:79 . . . . . . . 9:79 . . . . . . 11:36 . . . . . . . 11:7 7:39, 7:56, 7:74, 10:3 . . . . . 9:64, 9:71 . . . . . . . . 6:16 . . . . . . . . 8:94 . . . . . . . . 9:79 . . . . . . . . 9:63
S
Safety . . . . . . . . . . . . . Safety and emergency equipment. Safety instructions . . . . . . . Safety valves. . . . . . . . . . Schematics . . . . . . . . . . Seat . . . . . . . . . . . . . Seat belt. . . . . . . . . . . . Seat buzzer . . . . . . . . . . Seat cushion . . . . . . . . . . Sensor cab temperature . . . . . Sensor fuel level . . . . . . . . Sensor hydraulic oil temperature . Sensor twistlocks . . . . . . . . Sensor, alignment . . . . . . . Sensor, ambient temperature . . . Sensor, engine temperature . . . Sensor, operator-in-seat . . . . . Sensor, temperature outlet fan . . Sensor, temperature refrigerant . . Service indicator . . . . . . . . Setup . . . . . . . . . . . . . Side shift . . . . . . . . . . . Side shift cylinder . . . . . . . . Side window . . . . . . . . . . Signalling system . . . . . . . . SLIDING-CAB . . . . . . . . . Solenoid valve parking brake . . . Speed limitation . . . . . . . . Spreader beam . . . . . . . . . Spreading (positioning) . . . . . Spreading cylinder . . . . . . . Start battery . . . . . . . . . . Start/stop . . . . . . . . . . . Starter motor . . . . . . . . . . Steering . . . . . . . . . . . . STEERING . . . . . . . . . . Steering axle cradle . . . . . . . Steering cylinder . . . . . . . . Steering valve . . . . . . . . . Stopping device . . . . . . . . Suspension . . . . . . . . . . Switch, automatic spreading . . . Switch, direction indicators . . . . Switch, lock twistlock . . . . . . Switch, spreading 20\q-40\q . . . Switch, stop at 30\q . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B:3 . . 9:10 . . B:4 . . 10:3 . . E:3 . . 9:11 . . 9:10 . . 9:10 . . 9:14 . . 9:53 . . 1:22 . 10:21 . . 7:72 . . 7:71 . . 9:54 . . 9:38 . . 9:19 . . 9:52 . . 9:48 . . 8:8 . . 8:95 . . 7:31 . . 7:37 . . 9:76 . . 9:68 . 8:112 . . 4:31 . . 8:7 . . 7:49 . . 7:41 . . 7:49 . . 11:4 . . 1:31 . . 1:31 . . 5:3 . 8:108 5:11, 6:4 . . 5:9 . . 5:7 . . 1:31 . . 6:3 . . 7:7 . . 9:9 . . 7:5 . . 7:6 . . 7:6
M
Main beam, side lift attachment . . . . . . Main valve . . . . . . . . . . . . . . . Make-contact (closing switch) brake lights . Make-contact (closing switch) water in fuel . Mast . . . . . . . . . . . . . . . . . Mast position sensor . . . . . . . . . . Mechanical seat adjustment . . . . . . . Moisture filter . . . . . . . . . . . . . Monitoring . . . . . . . . . . . . . . . MOVE-CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7:51 . 10:14 . . 4:21 . . 1:22 7:16, 7:62 . . . 7:25 . . . 9:18 . . . 9:45 . . . 8:7 . . . 8:90
N
NO (normally open) switch, disengagement . . . . . . 2:18 Nut, washer and clamp . . . . . . . . . . . . . . . 6:17
O
Oil cooler . . . OLS . . . . . OPT . . . . . Other . . . . . Other functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2:15, 2:17 . . 8:89 . . 8:90 . 10:29 . . 7:75
P
Paint/coatings . . . . . . . . . . . . . . . . . . . Parking brake caliper . . . . . . . . . . . . . . . . Parking brake disc . . . . . . . . . . . . . . . . . Parking brake pads . . . . . . . . . . . . . . . . . Parking brake system . . . . . . . . . . . . . . . . Parking brake unit . . . . . . . . . . . . . . . . . Passenger seat. . . . . . . . . . . . . . . . . . . Pipes and hoses . . 4:26, 4:36, 5:12, 7:30, 7:39, 7:56, 7:62, 7:74, 10:410:5, 10:1210:13, 10:27 Position sensor, spreading . . . . . . . . . . . . . . Power assisted system . . . . . . . . . . . . . . . Power transmission . . . . . . . . . . . . . . . . . Power-assisted brake system . . . . . . . . . . . . Pressure limiting valve . . . . . . . . . . . . . . . Pressure reducer . . . . . . . . . . . . . . . . . . Pressure switch . . . . . . . . . . . . . . . . . . Preventive maintenance . . . . . . . . . . . . . . . Priority valve . . . . . . . . . . . . . . . . . . . . Propeller shaft . . . . . . . . . . . . . . . . . . . Pump unit . . . . . . . . . . . . . . . . . . . . . Pumps . . . . . . . . . . . . . . . . . . . . . . 9:91 4:34 4:35 4:34 4:29 4:32 9:18 7:56 5:3 3:3 4:5 10:4 7:11 9:45 C:1 5:4 3:3 9:89 10:6
T
Tail lights . . . . . . . . . . . . . . . . . . . . . 9:63 Tanks and accumulators . . . . . . . . . . . . . . . 10:5 Technical data . . . . . . . . . . . . . . . . . . . F:3
VDCT01.02GB
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Temperature control, cleaning and hydraulic oil Terminal console . . . . . . . . . . . . . Terminology . . . . . . . . . . . . . . . Terminology and index . . . . . . . . . . Tilt . . . . . . . . . . . . . . . . . . . Tilt cylinder . . . . . . . . . . . . . . . Torque converter/Clutch system . . . . . . TRANSM . . . . . . . . . . . . . . . . TRANSM, menu 1 . . . . . . . . . . . . TRANSM, menu 10 . . . . . . . . . . . . TRANSM, menu 11 . . . . . . . . . . . . TRANSM, menu 12 . . . . . . . . . . . . TRANSM, menu 13 . . . . . . . . . . . . TRANSM, menu 14 . . . . . . . . . . . . TRANSM, menu 2 . . . . . . . . . . . . TRANSM, menu 3 . . . . . . . . . . . . TRANSM, menu 4 . . . . . . . . . . . . TRANSM, menu 5 . . . . . . . . . . . . TRANSM, menu 6 . . . . . . . . . . . . TRANSM, menu 7 . . . . . . . . . . . . TRANSM, menu 8 . . . . . . . . . . . . TRANSM, menu 9 . . . . . . . . . . . . Transmission. . . . . . . . . . . . . . . Transmission cable harness . . . . . . . . Transmission control unit . . . . . . . . . Trolley. . . . . . . . . . . . . . . . . . Twistlock overcentre valve . . . . . . . . . Twistlocks . . . . . . . . . . . . . . . . Tyres . . . . . . . . . . . . . . . . . . Tyres and rims . . . . . . . . . . . . . .
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V
Valve block brake system VBFS . . . . . . . . . Voltage converter . . . . Voltage feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4:27, 4:36 . . . . 8:89 . . . 11:13 . . . . 11:7
W
Warning parking brake . . Washer motor and reservoir Water valve . . . . . . . Wheel brakes . . . . . . Wheel hub . . . . . . . . Wheel spindle . . . . . . Windscreen . . . . . . . Wings . . . . . . . . . . Wiper front . . . . . . . . Wiper motor front . . . . . Wiper motor rear . . . . . Wiper motor roof . . . . . Wiper rear . . . . . . . . Wiper roof . . . . . . . . Wiper/washer system . . . Work lights, front wing . . . Working lights, attachment . Working lights, cab . . . . Working lights, mast. . . . Writing desk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9:71 . . 9:55 . . 9:38 . . 4:24 5:12, 6:8 5:12, 6:6 . . 9:74 . . 9:85 . . 9:55 . . 9:56 . . 9:58 . . 9:57 . . 9:55 . . 9:55 . . 9:55 . . 9:67 . . 9:67 . . 9:66 . . 9:64 . . 9:83
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last page
Cargotec improves the efficiency of cargo flows by offering solutions for the loading and unloading of goods on land and at sea wherever cargo is on the move. Cargotecs main daughter brands for cargo handling Hiab, Kalmar and MacGregor are global market leaders in their fields. Cargotecs global network offers extensive services that ensure the continuous, reliable and sustainable performance of equipment.
Cargotec Sweden AB Torggatan 3 SE-340 10, Lidhult, Sweden tel. +46 372 260 00 fax +46 372 263 90 www.cargotec.com

DCT80 Workshop Manual

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DCT80 Workshop Manual

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Empty Container Handler 8-9 tonnes

Publ. no VDCT01.02GB Workshop Manual in original

A Foreword B Safety C Preventive maintenance 0 Complete machine 1 Engine

Workshop Manual DCT 80-90

Workshop Manual DCT 80-90

About machine version

Workshop Manual DCT 80-90

A Foreword Reading instructions

Read operator's manual

Read the operator's manual

Read the Maintenance manual

Read the Maintenance manual

Workshop Manual DCT 80-90

A Foreword Reading instructions

The workshop manual's contents

Workshop Manual DCT 80-90

A Foreword Reading instructions

Function group structure

Workshop Manual DCT 80-90

A Foreword Reading instructions

References between different information types

Function descriptions (Technical description)

Hydraulic diagrams (Section E)

Component descriptions (Technical description, normally in Workshop manual)

Error codes (Section D)

Diagnostics (Technical description, group 8.4)

Workshop Manual DCT 80-90

A Foreword Reading instructions

Product alternatives and optional equipment

Symbol for optional equipment

Workshop Manual DCT 80-90

A Foreword Reading instructions

Workshop Manual DCT 80-90

A Foreword Reading instructions

A c k u m u la to r, b e s k riv n in g , s id a 4 :1 4 B ro m s v e n til, b e s k riv n in g , s id a 4 :1 8

10. Electrical wiring

Workshop Manual DCT 80-90

A Foreword Reading instructions

Symbol explanation function descriptions

Symbol explanation function descriptions

Workshop Manual DCT 80-90

A Foreword About the documentation

About the documentation

Workshop Manual DCT 80-90

Date: .................................... - .................. - .................. Manual information

Suggestions, views, remarks, etc.

Workshop Manual DCT 80-90

Workshop Manual DCT 80-90

Workshop Manual DCT 80-90

Workshop Manual DCT 80-90

A near accident is a warning!

Workshop Manual DCT 80-90

B Safety Safety instructions

Machine with trolley and attachment in totally lowered position

Workshop Manual DCT 80-90

B Safety Safety instructions

Hydraulic and brake systems, depressurising

Workshop Manual DCT 80-90

B Safety Safety instructions

Depressurise the attachment. Open relief valve top lift.

The figure above shows open valve.

Workshop Manual DCT 80-90

B Safety Safety instructions