Академический Документы
Профессиональный Документы
Культура Документы
B Safety
C Preventive maintenance
0 Complete machine
1 Engine
Workshop manual
2 Transmission
3 Driveline/axle
4 Brakes
5 Steering
6 Suspension
7 Load handling
8 Control system
10 Common hydraulics
11 Common electrics
12 Common pneumatics
D Error codes
E Schematics
F Technical data
A Foreword
Foreword......................................................................................................... 3
About the Workshop Manual ...................................................................... 3
General ............................................................................................................. 3
Workshop manual contents ............................................................................... 3
References between different information types ............................................... 4
Function group breakdown ................................................................................ 5
Conditions ......................................................................................................... 5
Storage .............................................................................................................. 5
About the machine version ................................................................................ 5
Copyright ........................................................................................................... 5
Reading instructions ................................................................................... 6
Warning information .......................................................................................... 6
Important information ........................................................................................ 6
Read the operator's manual/maintenance manual ............................................ 6
Optional equipment ........................................................................................... 6
Function descriptions ........................................................................................ 7
About the documentation ......................................................................... 10
Documentation sections .................................................................................. 10
Ordering of documentation .............................................................................. 10
Feedback .................................................................................................. 11
Form for copying ............................................................................................. 11
Foreword
mm mm mm mm mm mm
A Foreword General information about the workshop manual's purpose, contents and reading in-
structions as well as survey for feedback of views and any inaccuracies.
0 Complete machine
1 Engine
2 Transmission
3 Driveline/axle
Technical description, comprehensive function descriptions and a description of the
4 Brakes function of components included in the machine, divided into function groups.
5 Steering The components used for each function are described under each subfunction. Con-
sequently, common components are described in several places, but in general un-
6 Suspension der the first function to use the component.
7 Load handling Together with the general description is a detailed description of what is unique
about the specific subfunction. The next subfunction to use the same component
8 Control system
only has a description what is unique for the new function.
9 Frame, body, cab and acces-
Work instructions for corrective maintenance (replacement of components).
sories
10 Common hydraulics
11 Common electrics
12 Common pneumatics
D Error codes Error code information and instructions for reading error code information.
F Technical data Technical data, conversion tables, information for conversion of units.
G Terminology and index General terminology and abbreviations, explanation of terms and abbreviations that
can appear in the sections, index for headings in the sections.
Breakdown into function groups is common for all machines from Ka-
lmar Industries, down to two-digit heading level (e.g., 4.3 Power-as-
sisted brake system). Machine-unique adaptations of function groups
are done at the third and fourth group levels (e.g., 4.3.9 Wheel brake
resp. 4.3.9.1 Disc assembly).
This results in certain headings (function groups) being omitted in the
documentation for certain machines since the machine lacks that par-
ticular function. This means that there may be gaps in the function
groups' numbering (e.g., the three-digit heading level 4.8.7 Oil cooler
may be included for certain machines, but may be missing for other
machines).
References between sections within the same manual are indicated
using section and group number, e.g., "see section 4 Brakes, group
4.3.9 Wheel brake ". A reference within the same section is indicated
with page number, e.g., "see Sensor fuel level, description page 24 ".
Conditions
page
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Storage
page
–
NOTE
The workshop manual should be accessible to service personnel.
Copyright
page
–
Kalmar Industries AB
Duplication of the content in this manual, in whole or in part, is strictly
prohibited without written permission from Kalmar Industries AB.
Duplication by any means such as copying, printing, etc., is prohibited.
Reading instructions
Warning information
page
–
DANGER
Situation that may result in serious personal injury,
possible death, if the instruction is not followed.
WARNING
Situation that may result in serious personal injury if
the instruction is not followed.
CAUTION
Situation that may result in damage to the product if
the instruction is not followed.
Important information
page
–
NOTE
Information that is important without being safety related.
manual
The symbol to the left is used in certain cases on the machine and re-
fers to important information in the operator’s/maintenance manual.
000262
Optional equipment
page
–
The symbol to the left is used in the manual to indicate that a function
000264
Function descriptions
page
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10
8
3
7 4
6
010689
Operator's manual
The Operator's manual is supplied with the machine in the cab.
Documentation kit
Maintenance manual and spare parts catalogue with machine card are
supplied with the machine as a separate documentation kit.
Supplementary documentation
Supplementary documentation can be ordered for the machine.
• Workshop manual.
• Supplier documentation for engine, transmission and drive axle.
Ordering of documentation
page
–
Feedback
Form for copying
page
–
From:
Company / Sender: ..........................................................................................................................................
Telephone: ..........................................................................................................................................................
E-mail: .................................................................................................................................................................
Manual
informa- Name / Publication number: .............................................................................................................................
tion
Sugges-
tions, .............................................................................................................................................................................
views, re-
marks,
etc. .............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
.............................................................................................................................................................................
B Safety
Safety .............................................................................................................. 3
General safety information ......................................................................... 3
Safety concerns everyone! ................................................................................ 3
A near accident is a warning! ............................................................................ 3
Safety instructions ...................................................................................... 4
General ............................................................................................................. 4
Service position ................................................................................................. 4
Hydraulic and brake systems, depressurizing ................................................... 5
Oils .................................................................................................................... 6
Fuel system ....................................................................................................... 7
Clothing, etc. ..................................................................................................... 8
Several mechanics on the same machine ......................................................... 8
Working under machine .................................................................................... 9
Lifting heavy components ................................................................................. 9
Vibrations ........................................................................................................ 10
Noise ............................................................................................................... 10
Solvents .......................................................................................................... 11
Fire and explosion risks ................................................................................... 11
Fluid or gas under pressure ............................................................................ 12
Coolant ............................................................................................................ 13
Refrigerant ...................................................................................................... 14
Air pollution ..................................................................................................... 14
Tensioned springs ........................................................................................... 15
Electric motors ................................................................................................. 15
Rotating components and tools ....................................................................... 16
Tyre and rim system ........................................................................................ 17
Lifting equipment ............................................................................................. 17
Environment ............................................................................................. 18
General ........................................................................................................... 18
Safety
mm mm mm mm mm mm
The safety information concerns everyone who works with the ma-
chine! 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 risk of damage to machine or ma-
chine 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 for the job
• wear the correct clothes
• use common sense and work carefully. Do not take any risks!
Kalmar Industries has in this publication documented and warned for
situations and risks that may occur in connection with using as well as
service/repairs of the machine during normal circumstances.
That’s why it’s important that all who work with the machine or repair/
service the machine read and follow the information in the mainte-
nance manual and operator’s manual.
Safety instructions
General
page
–
Read, consider and follow the safety instructions below before starting
to work in the machine:
• Service position page 4
• Hydraulic and brake systems, depressurizing page 5
• Oils page 6
• Fuel system page 7
• Clothing, etc. page 8
• Several mechanics on the same machine page 8
• Working under machine page 9
• Lifting heavy components page 9
• Vibrations page 10
• Noise page 10
• Solvents page 11
• Fire and explosion risks page 11
• Fluid or gas under pressure page 12
• Coolant page 13
• Refrigerant page 14
• Air pollution page 14
• Tensioned springs page 15
• Electric motors page 15
• Rotating components and tools page 16
• Tyre and rim system page 17
• Lifting equipment page 17
Service position
page
–
General
Service position is used for service, maintenance and other situations
when the machine needs to be secured.
Service position means:
• Machine parked, that is, parking brake applied.
• Lifting carriage and attachment in totally lowered position.
• Engine off.
• Main electric power off (with battery disconnect switch).
009797
009798
NOTE
Keep the drain valve open as long as work is in progress.
When closing the drain valve, check that it is fully closed and
tighten the lock ring.
005648
Oils
page
–
The following safety instructions shall be followed for work when hand-
ling oils.
WARNING
Warm and pressurized oil.
IMPORTANT
Always clean the area around components and con-
nections before they are loosened. Dirt in oil systems
causes increased wear, resulting in subsequent ma-
terial damages.
Fuel system
page
–
The following safety instructions shall be followed for work when hand-
ling fuel.
DANGER
Pay attention to the risk of fire when working on the
fuel system.
WARNING
Use protective gloves and protective goggles. If a
component is to be disconnected, hold a rag over the
connection as protection and to collect fuel. The en-
gine’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 injuries.
CAUTION
Always clean the area around components and con-
nections before they are loosened. Dirt in the fuel may
cause malfunctions and engine stop in undesirable
situations as well as increase wear, resulting in sub-
sequent material damages.
IMPORTANT
Always take action to avoid spills. In places where
drain containers cannot be used, use a pump or hose
for safe handling.
Clothing, etc.
page
–
WARNING
Be extra careful if several mechanics work on the
same vehicle, so that unintentional movements do
not injury another person. Communicate so that eve-
ryone knows where all are and what they are doing.
Risks
Work with wheels or axle suspension, mountings, etc. may result in
components on the other side moving and causing damage/injury.
Movements performed from the operator's station, e.g., movement of
lifting equipment, may cause severe personal injuries.
Safety precautions
• Make sure that the machine's lifting equipment is completely low-
ered or secured in another way.
• Move battery disconnector to position zero, remove the key.
• Be aware of the risks when several persons work around the ve-
hicle.
• Make your co-workers aware of what you’re working with.
• Do not work with drive wheels on the machine's both sides at the
same time.
Risks
Mechanical or hydraulic tools and lifting devices can fall over or acci-
dentally be lowered due to malfunctions or incorrect use.
Safety precautions
Use axle stands and supports that stand securely.
Lifting tools should be inspected and type approved for use.
WARNING
Careless handling of heavy components can lead to
serious personal injury and material damage.
Risks
Unsuitable lift slings, straps, etc. may break or slip.
The centre of gravity (balance point) of the component can change
during the course of the work, and the component may then make un-
expected movements which may cause severe personal injuries and
material damage.
A component lifted with lifting equipment can start to turn if the equilib-
rium is upset.
Safety precautions
Lifting with lifting device. Use lifting tools or other tools, especially
when there are such adapted for certain work. See 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 good protection against minor crushing in-
juries and cuts to fingers.
• Always use protective shoes.
Vibrations
page
–
In case of long-term use of vibrating tools, for example, impact nut run-
ners or grinders, injuries may be sustained as vibrations can be trans-
mitted from tools to hands. Especially when fingers are cold.
Safety precautions
Use heavy gloves to protect against cold and somewhat against vibra-
tions.
Switch between work duties to give the body time to rest.
Vary work position and grip so that the body is not stressed in only one
position by the vibrations.
Noise
page
–
Noise louder than 85 dB (A) that lasts for longer than 8 hours is con-
sidered harmful to hearing. (Limit values may vary between different
countries.) High tones (high frequencies) are more damaging than low
tones at the same sound level. Impact noise can also be hazardous,
e.g. hammer blows.
Risks
At noise levels higher than the limits hearing damage can occur. In
more severe cases, hearing damage can become permanent.
Safety precautions
Use hearing protection. Make sure that it is tested and protects against
the noise level in question.
Limit noise with noise-absorbing dividers, for example, noise-absorb-
ing materials in roof and on walls.
Solvents
page
–
Fluids that (as opposed to water) dissolve grease, paint, lacquer, wax,
oil, adhesive, rubber, etc. are called organic solvents. Examples:
White (petroleum) spirits, gasoline, thinner, alcohols, diesel, xylene,
trichloroethylene, toluene. Many solvents are flammable and consti-
tute a fire hazard.
Risks
Products containing solvents produce vapours that can cause dizzi-
ness, headaches and nausea.They may also irritate mucous mem-
branes in the throat and respiratory tracts.
If the solvent comes into direct contact with the skin, this may cause
drying and cracking.Risk for skin allergies increases. Solvents may
also cause injury if they penetrate through the skin and are absorbed
by the blood.
If the body is continuously exposed to solvents, the nervous system
may be damaged. Symptoms include sleep disorders, depressions,
nervousness, poor memory or general tiredness and fatigue. Continu-
ous inhalation of gasoline and diesel fumes is suspected to cause can-
cer.
Safety precautions
Avoid inhaling solvent 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 solvent container without tight-sealing lid.
Use solvents with low content of aromatic substances. This reduces
the risk of injuries.
Avoid skin contact.
Use protective gloves.
Make sure that work clothes are solvent-resistant.
Risks
Examples of cause of ignition is welding, cutting, smoking, sparks
when working with grinders, contact between hot machine parts and
flammable materials, heat development in rag drenched with oil or
paint (linseed oil) and oxygen. Oxygen cylinders, lines and valves shall
be kept free from oil and grease.
Fumes from, e.g., gasoline are heavier than air and may "run" down
into a sloping plane, or down in a grease pit, where welding flames,
grinding sparks or cigarette embers may cause an explosion. Evapo-
rated gasoline explodes very forcefully.
Special cases
Diesel fuel oil with added gasoline has a lower ignition point. Risk of
explosion already at room temperature. The explosion risk for warmed
diesel fuel oil is higher than for gasoline.
When changing oil in the engine, hydraulic system and transmission,
keep in mind that the oil may be hot and can cause burn injuries.
Welding on or near machine. If diesel and or other oils have leaked out
and been absorbed by rags, absorbent agents, paper or other porous
material, hot welding sparks can cause ignition and explosive fires.
When a battery is charged, the battery fluid is divided into oxygen and
hydrogen gas. This mixture is very explosive. The risk of explosion is
especially high when using a booster battery or quick-charger, as this
increases the risk of sparks.
Today’s machines contain a lot of electronic equipment. When weld-
ing, the control units must be disconnected and the electric power
must be turned off with the battery disconnect switch. Powerful weld-
ing currents may otherwise short-circuit the electronics, destroy ex-
pensive equipment or cause an explosion or fire.
Never weld on painted surfaces (remove paint, by blasting at least 10
cm around the welding or cutting point). Use gloves, breathing protec-
tion and protective goggles. In addition, welding work may not be done
near plastic or rubber materials without first protecting them from the
heat. Paints, plastics, and rubber develop a number of substances that
may be hazardous to health when heated. Be careful with machines
that have been exposed to intense heat or fire.
Safety precautions
Store hazardous substance in 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.
High-pressure lines can be damaged during work, and fluid or gas can
stream out.
There may be high pressure in a line even if the pump has stopped.
Therefore, gas or fluid can leak out when the connection to the hose
is loosened.
A gas cylinder subjected to careless handling can explode, for exam-
ple, if it falls onto a hard surface. Gas can stream out through dam-
aged valves.
Risks
There are injury risks in connection with work on:
• Hydraulic systems (e.g., working hydraulics and brake system).
• Fuel system.
• Tyre changes.
• Air conditioning.
Safety precautions
• Use safety glasses and protective gloves.
• Never work on a pressurized system.
• Never adjust a pressure limiting valve to a higher pressure than
recommended by the manufacturer.
• A hydraulic hose that swells, for example, at a connection, is
about to rupture. Replace it as soon as possible! Check connec-
tions thoroughly.
• Use fluid when checking for leaks.
• Never blow clothes clean with compressed air.
• Discarded pressure accumulators must first be punctured before
they are deposited as waste (to avoid risk of explosion). Carefully
drill a hole with 3 mm diameter after depressurizing.
• Never use your hands directly to detect a leak. A fine high-pres-
sure stream from a hydraulic hose can easily penetrate a hand
and causes very severe injuries.
Coolant
page
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Risks
The cooling system operates at high pressure when the engine is
warm. Hot coolant can jet out and cause scalding in case of a leak or
when the expansion tank cap (filler cap) is opened.
Ingesting ethylene glycol and anti-corrosion compound is dangerous
and hazardous to health.
Safety precautions
• Use protective gloves and safety glasses if there is a risk of
splashing or spraying.
• Open the filler cap first, to release the excess pressure. Open
carefully.Hot steam and coolant can stream out.
• If possible, avoid working on the cooling system when the coolant
is hot.
Refrigerant
page
–
Risks
The air conditioning operates at high pressure. Escaping refrigerant
can cause frostbite.
Refrigerant that is heated (e.g., when repairing leaking climate/AC
system), generates gases that are very dangerous to inhale.
Safety precautions
• Use special instructions and equipment for refrigerant according
to the manual when working on the air conditioning system. Spe-
cial certification and authorization is often required of the person
who may do the work. (Note national legislation and local regula-
tions!)
• Use protective gloves and safety glasses if there’s a risk of leaks.
• Make sure that heat-producing sources or objects are not close by
(cigarette glow, welding flame).
Air pollution
page
–
Air pollution is the impurities in the air around us and which are regard-
ed as hazardous to health. Certain pollution is more prominent in cer-
tain environments.
The following health-hazardous air pollution is especially prominent in
workshops:
• Carbon monoxide (fumes) is present in exhaust fumes. Odour-
less and therefore especially dangerous.
• Nitrogen oxides (nitrous gases) are present in exhaust fumes.
• Welding smoke especially hazardous to health when welding on
oily surfaces, galvanized or lacquered materials.
• Oil mist for example, when applying anti-corrosion agent.
• Grinding dust and gases 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
Sulfuric acid mist is corrosive and injures the respiratory tracts. (Gen-
erated when heating certain plastics and paints.)
Isocyanates can be released in the form of steam, dust (or may be
present in aerosols) when cutting, grinding or welding. Can irritate mu-
cous membranes producing symptoms similar to asthma and impair-
ing lung function. Even brief exposure to high concentrations can give
problems with persistent high sensitivity.
Safety precautions
• Make sure of adequate ventilation with fresh air when welding,
battery charging and other work when hazardous gases are gen-
erated.
• Use suitable protective gloves and breathing protection when
there is a risk of oil mist. Make sure that the protection is oil-proof.
• Apply oil-resistant protective lotion to unprotected skin.
• Make sure that an eye-wash station is in the immediate vicinity
when working with corrosive substances.
• Avoid unnecessary operation of the machine inside the workshop.
Connect an air extractor to the exhaust pipe so that the exhaust
fumes are removed from the workshop.
Tensioned springs
page
–
Risks
If a tensioned spring releases, it is shot out by the spring force and can
also take adjoining parts with it.
Small springs can cause eye injuries.
Parking brake springs are tensioned with high force and can cause
very severe accidents if they are accidentally released in an uncon-
trolled manner.
Gas springs and gas-charged shock absorbers are tensioned with
high force and can cause very severe accidents if they are accidentally
released in an uncontrolled manner.
Safety precautions
• Use safety glasses.
• Lock rings should be of a suitable type and in good condition.
• Follow the instructions in this and other manual when performing
maintenance and changing parts and components.
• Always use recommended tools.
Electric motors
page
–
Safety precautions
Always turn off the battery disconnector when working on electric mo-
tors.
Always block the machine’s wheels and make sure that the parking
brake is activated and that the gear selector is in neutral position be-
fore starting any work on the machine.
Risks
Rotating components, for example, fans or shafts, can cause severe
injuries if touched.
Drills, lathes, grinders or other machines with rotating parts can cause
severe accidents if clothes or hair get caught and are wound up in the
machine.
Safety precautions
• Do not use gloves when working with a drill.
• Remove loose, hanging clothing, scarf or tie.
• Never use clothing with wide sleeves or trouser legs.
• Make sure that clothing is intact and in good condition.
• Long hair should be gathered up in a hair-net or similar.
• Remove large or loose hanging jewellery from hands, arms and
neck.
DANGER
Tyres should be regarded as pressurized containers.
They constitute fatal danger if handled incorrectly.
Risks
Dismantling wheels: Tyres, rims or lock rings can be thrown.
Inflating of wheels: Tyres, rims or lock rings may be ejected.
Safety precautions
• Deflate the tyre before starting to work on the wheel.
• Check that tyres, rims and lock rings aren’t damaged. Never re-
pair damaged rims or lock rings.
• Wheels shall be inflated on the machine or in a protective device,
designed and dimensioned so that it can handle or dissipate a
shock wave from a tyre explosion as well as catch the ejected
parts.
• Use protective screen and safety glasses.
Lifting equipment
page
–
When working on the machine in general, and with the machine’s lift-
ing equipment in particular, the greatest caution must be exercised
with respect to securing the mast, carriage and attachment.
Always make a habit of lowering the carriage to its lowest position be-
fore working on the machine.
Risks
Risk of crushing if the machine’s lifting equipment is not lowered or se-
cured.
Risk of crushing is extra high when depressurising the hydraulic sys-
tem; see Hydraulic and brake systems, depressurizing page 5.
Safety precautions
• Do not start work until the carriage is completely lowered. If by na-
ture the work requires a raised carriage, this must be secured.
Environment
General
page
–
Recycling
Well-thought out recycling of the machine is the cornerstone of ending
its life cycle and being able to reuse materials in new products. Ac-
cording to calculations by Kalmar Industries, the machine can be recy-
cled to more than 90% by weight.
Declarations
The machine does not contain asbestos.
The machine contains lead in batteries and electric cabling. Some
models have counterweights of cast lead.
If the machine is equipped with air conditioning, then refrigerant of the
type R134a is used, in an amount between 1-3 kg.
C Preventive maintenance
C Preventive maintenance
mm mm mm mm mm mm
Preventive maintenance
page
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0 Complete machine
Complete machine
mm mm mm mm mm mm
lowering, tilt, side shift, spreading, levelling and load securing. Lifting/
lowering is a function for raising and lowering the lifting carriage. Side
1. Counterweight
shift is moving the side lifting attachment laterally along the lifting car-
2. Steering axle
riage. Spreading is adjusting the width between Twistlock or lifting
3. Cab
hooks of the side lifting attachment. Tilt is angling the load in the lon-
4. Tank
gitudinal direction of the truck with the help of the mast. Levelling is an-
5. Drive axle
gling the side lifting attachment in the lateral direction of the truck.
6. Tilt cylinder
Load securing is locking the load onto the side lifting attachment.
7. Fork carriage
8. Mast The control system is functions for warning the operator of dangerous
9. Side lifting attachment situations and machine faults. The control system has diagnostic re-
sources that simplify troubleshooting.
The frame bears the machine. The frame houses the engine, trans-
mission, drive axle and steering axle. The sides of the frame house the
fuel and hydraulic oil tanks. The cab can be tilted as an option.
The hydraulic system is fed by four hydraulic oil pumps, which are
mounted together to form two pump banks, which in turn are mounted
on the gearbox’ power-take off. Three variable pumps feed load han-
dling, steering and other hydraulic functions. A fixed pump feeds the
brake system’s the brake and cooling circuits across an accumulator
charging valve. The hydraulic oil tank sits on the right side of the ma-
chine. The hydraulic oil filter is a return filter housed inside the hydrau-
lic oil tank.
instructions
When troubleshooting, it is important that the work is structured and
logical. The point of the troubleshooting described in the maintenance
manual is to exclude components as error source so that the real error
source can be pin-pointed. A suggested structured work method is de-
scribed below.
When troubleshooting, it is important to understand how the machine
functions. Certain malfunctions can be pin-pointed directly using func-
tion descriptions. Sections 0–12 contain descriptions of the various
functions of the machine.
Troubleshooting procedure
1 Check that there is battery voltage available.
• Battery disconnect switch, must be in position 1.
• Battery voltage, should be 22–30 V.
• Fuses, check that they are intact.
2 Check that all oil and fluid levels are normal.
• Fuel
• Engine oil
• Transmission oil
• Hydraulic oil
• Coolant
• Washer fluid
3 Check if there are error codes.
4 If there are error codes, use the error code lists as a guide. See
Troubleshooting with error code, example page 5.
In the error code lists there are recommended actions for every
error code. Error code lists are found in section D Error codes.
5 If there is no error code or the problem persists, use the function
description for the function in question in section 0–12.
The function description contains information on which compo-
nents are involved in the function and how these components
work together. In some cases, there is information on what con-
ditions are required in order for it to be possible to activate the
function. Measurement points are marked with flags (C as in
checkpoint for measuring outlet, D for diagnostic menu).
code, example
1 Choose suitable section 0–12 to find the function and sub-func-
tion that have caused the symptom.
2 Read the function description for the function in question to get
an overall understanding of which components are affected and
how these interact.
3 Use the function description and check the signals for the func-
tion in question to find where in the function chain that signal or
reaction is incorrect.
4 The fault is probably between the two units where the signal is
failing. Start by checking the component that should send the
signal.
5 If the component that is to send the signal seems to be correct,
check transmission of the signal (electric wiring or hydraulic
hoses).
For electric cabling, see Troubleshooting cable harness page 7.
For hydraulic hoses, see Troubleshooting hydraulic hoses page
8.
6 If the leads or hoses between the components seem in order,
then check the component that receives the signal.
example
Error codes are strong indicators of malfunctions detected by the con-
trol system. Many error codes are connected to electrical malfunctions
but there are also error codes that interpret associations between one
or several signals that indicate a non-electrical malfunction. It’s impor-
tant to not draw conclusions too fast based on an error code.
1 Read out error codes from the display, e.g., error code 34.
2 Use the error code lists and search information about the error
code, see "Example of error code information in error code list"
below.
Error code lists are found in section D Error codes.
For detailed instruction on reading out error code, see section D
Error codes.
3 Follow the instructions in the field “Action”.
4 Use diagnostic menus and circuit diagrams to determine if the in-
put signal to the control unit is correct; see section 8 Control sys-
tem, group 8.4 Diagnostics as well as section E Schematics.
5 Use the function group to find more information if needed.
In section 0–12 there is function description, the function's includ-
ed components and their position as well as, in certain cases,
work instructions for how components are checked, cleaned or
adjusted.
NOTE
The main electric power shall be turned off with the battery
disconnector!
9 Disconnect the cable from the component in question.
10 Turn on the main electric power with the battery disconnect
switch.
11 Turn the ignition key to the operating position.
12 Check that voltage reaches the component.
Connec-
tions and Diagnos- Function
Code Description Limitation Action
component tic menu group
s
34 Signal error from Parking brake Check cabling be- D790-1/ HYD, menu 4.1.2 Parking
parking brake cannot be tween the control K8:5 - S107, 5 brake control
switch, indicates re- released. unit and the compo- K8:13 - S107
leased and applied nent with diagnostic
at same time or menu.
nothing at all. Check component.
NOTE
Perform troubleshooting for all cables in the same way to avoid
damage to control units, components or measuring equipment.
NOTE
Some components cannot be checked without power supply
to the component. In such an event, proceed to point 5.
a. Measure resistance between connections for the component
in the connector at the control unit or component.
b. The resistance must correspond with the component. Other-
wise there may be an open circuit or short circuit in cable har-
ness and/or component.
5 Check if there is short circuit to frame:
a. Unplug the connector at both the control unit and the compo-
nent in question.
b. Measure the resistance of one lead at a time. Measure be-
tween the lead and a frame-connected part of the machine.
c. The multimeter should show endless resistance.
WARNING
Oil under high pressure!
Personal injury!
1 Engine
1 Engine ............................................................................................................. 3
1.1 Controls and instruments ......................................................................... 23
1.1.1 Ignition switch ...................................................................................... 23
1.1.2 Accelerator pedal ................................................................................. 24
1.2 Fuel system .............................................................................................. 25
1.2.1 Fuel tank .............................................................................................. 25
1.2.2 Sensor, fuel level ................................................................................. 25
1.6 Air intake and exhaust outlet .................................................................... 26
1.6.1 Air cleaning system .............................................................................. 26
1.6.3 Exhaust system ................................................................................... 26
1.6.4 Intercooler ............................................................................................ 27
1.7 Cooling system ......................................................................................... 28
1.7.4 Radiator and expansion tank ............................................................... 29
1.7.5 Cooling fan ........................................................................................... 30
1.7.7 Coolant ................................................................................................ 31
1.7.8 NO (normally open) switch, coolant level ............................................ 37
1.7.10 Engine heater ...................................................................................... 37
1.9 Control system engine .............................................................................. 38
1.9.1 Control unit, engine .............................................................................. 38
1.11 Start/stop .................................................................................................. 39
1.11.1 Starter motor ........................................................................................ 39
1.11.2 Stopping device ................................................................................... 39
1 Engine
mm mm mm mm mm mm
Engine, general
page
–
Engine alternative
The machine is equipped with the following engine alternative:
• Volvo TAD760VE (step III as per directive 97/68/EU)
• Cummins QSB6.7 (step III as per directive 97/68/EU)
In case there are differences between different engine alternatives,
this is written in brackets after headings or under figures to clarify that
which is shown.
˚C
. bar
0 rpm
P I kph
II
III
D5
<˚
1,5
10
D10
D1
D14 D11
3,12,14,23 11,22 2,6
D794 D790-1 D790-2
D7
D793 D797-1 D795
D19 20 17 15,18,21
D16
D12
19 D4 H2O
SENSORS D8
4 13 16
9
7 009685
8 M
2 Cab control unit KIT (D790-2) sends Checked by control sys- See section 11 Common electrics, group
ignition on via the CAN bus. If the tem, error shown with er- 11.5.3.11 Control unit KIT (D790-2)
key is turned to the preheating posi- ror code.
tion, then preheating is also sent on
the CAN bus.
4 The preheating coils (E800-1) warm - D4: Diagnostic menu, see section 8 Control sys-
each cylinder with a glow plug. tem, group 8.4.6.5 ENGINE, menu 5
6 Control unit KIT (D790-2) transmits a - See section 11 Common electrics, group
start signal on the CAN bus. 11.5.3.11 Control unit KIT (D790-2)
7 The starter motor (M654) is control- U = 24 V Starter motor, description (Volvo engine) page
led by the engine control unit (D794) 39
through starter relays and receives D7: Diagnostic menu, see section 8 Control sys-
signals from the cab control unit tem, group 8.4.6.5 ENGINE, menu 5
(D790-1) via the CAN bus.
8 The starter motor (M654) cranks the - Starter motor, description (Volvo engine) page
engine. 39
D8: Diagnostic menu, see section 8 Control sys-
tem, group 8.4.6.5 ENGINE, menu 5
9 The engine’s sensors send signals - Se Engine control unit, general page 38
to the engine control unit (D794),
which regulates the injectors so that
the engine starts.
11 The cab control unit (D790-1) trans- Checked by control sys- See section 11 Common electrics, group
mits a message with the rpm request tem, error shown with er- 11.5.3.1 Cab control unit (D790-1)
on the CAN bus ror code. D11: Diagnostic menu, see section 8 Control
system, group 8.4.6.1 ENGINE, menu 1
12 The engine control unit (D794) in- - Se Engine control unit, general page 38
creases engine speed. D12: Diagnostic menu, see section 8 Control
system, group 8.4.6.1 ENGINE, menu 1
13 The NO switch for coolant level U = 24 V NO (normally open) switch, coolant level page
(B759) sends a voltage signal to the 37
engine unit (D794) if the coolant lev-
el in the expansion tank is low.
15 The KID control unit (D795) shows - See section 11 Common electrics, group
engine data via display figures. 11.5.3.12 KID control unit (D795)
16 The fuel level sensor (B757) sends R = 0–70 ohm Sensor, fuel level, description page 25
the frame control unit (D797-1) a D16: Diagnostic menu, see section 8 Control
voltage signal proportional to the fuel system, group 8.4.3.7 CAB, menu 7
level in the tank.
17 The frame control unit (D797-1) Checked by control sys- See section 11 Common electrics, group
transmits fuel level on the CAN bus. tem, error shown with er- 11.5.3.2 Frame control unit (D797-1)
ror code.
18 The KID control unit (D795) shows - See section 11 Common electrics, group
fuel level in the operating menu for 11.5.3.12 KID control unit (D795)
engine and transmission.
20 The transmission control unit (D793) Checked by control sys- See section 11 Common electrics, group
transmits speed on the CAN bus. tem, error shown with er- 11.5.3.9 KIT control unit (D793)
ror code.
21 The KID control unit (D795) shows - See section 11 Common electrics, group
the machine’s speed. 11.5.3.12 KID control unit (D795)
22 If output shaft rpm is so high that it Checked by control sys- See section 11 Common electrics, group
reaches the limit for the machine’s tem, error shown with er- 11.5.3.1 Cab control unit (D790-1)
speed limitation, the cab control unit ror code.
(D790-1) transmits a reduce engine
rpm request on the CAN bus.
23 Control unit engine (D794) restricts - Se Engine control unit, general page 38
engine rpm.
4
3 8
2
1 9
10
11
12
13
14
15
16
17
18
010197
19
3
2
010198
1
Engine, replacement
page
–
DANGER
The engine is very heavy.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Machine in service position, see section B Safety.
2 Attach hoisting equipment to the engine.
3 Disconnect required hoses and cables before separating engine
and transmission.
NOTE
Drain and collect liquids before detaching hoses.
4 Remove the radiator.
5 Use a jack to secure the gearbox.
7 Remove the nuts for the flex plate through the hole under the cov-
er washer.
NOTE
Turn the engine for each nut to be removed from the flex plate.
8 Take up the slack in the hoisting equipment.
NOTE
Do not lift the engine.
NOTE
Beware of balance before the engine is lifted.
NOTE
If the flex plates are damaged during engine replacement, they
must be replaced.
12 Lift the engine away.
Assembly
13 Apply lubricating grease to the converter connection - both on the
engine and the gearbox.
008301
14 Insert two studs into the flywheel housing as a guide when the en-
gine is installed.
15 Transfer the engine brackets to the new engine; tighten to
169 Nm (oiled screw).
007775
16 Centre a stud on the flywheel so that it aligns with the hole in the
flywheel housing.
007772
17 Lift the engine into place. Make sure that the studs on the fly-
wheel come into correct alignment and do not damage the flex
plate.
18 Install the screws which fix the gearbox and engine, but do not
tighten the screws fully. Leave about a millimetre between the en-
gine and gearbox to facilitate installation of the nuts for the flex
plate/flywheel.
007776 19 Fit the nuts that fix the flex plates at the flywheel in two steps. First
fit the nuts without tightening. Then rotate the flywheel one more
revolution and tighten the nuts to 40 Nm (oiled screw).
NOTE
Turn the engine for each nut to be installed to the flex plate.
20 Tighten the screws which fix the gearbox and engine. Tighten the
gearbox to the gearbox mountings. Refit the cover plate and pro-
peller shaft.
007973
˚C
. bar
0 rpm
P I kph
II
III
D5
<˚
1,5
10
D10
D1
D14 D11
3,12,14,23 11,22 2,6
D794 D790-1 D790-2
D7
D793 D797-1 D795
D19 20 17 15,18,21
D16
D12
19 D4 H2O
SENSORS D8
4 13 16
9
009622
8 M 7
2 Cab control unit KIT (D790-2) sends Checked by control sys- See section 11 Common electrics, group
ignition on via the CAN bus. If the tem, error shown with er- 11.5.3.11 Control unit KIT (D790-2)
key is turned to the preheating posi- ror code.
tion, then preheating is also sent on
the CAN bus.
4 The preheating coil (E800) heats the - D4: Diagnostic menu, see section 8 Control sys-
primary air to the engine. tem, group 8.4.6.5 ENGINE, menu 5
6 Control unit KIT (D790-2) transmits a - See section 11 Common electrics, group
start signal on the CAN bus. 11.5.3.11 Control unit KIT (D790-2)
7 The starter motor (M654) is control- U = 24 V Starter motor, description (Cummins engine)
led by the engine control unit (D794) page 39
through starter relays and receives D7: Diagnostic menu, see section 8 Control sys-
signals from the cab control unit tem, group 8.4.6.5 ENGINE, menu 5
KCU (D790-1) via the CAN bus.
8 The starter motor (M654) cranks the - Starter motor, description (Cummins engine)
engine. page 39
D8: Diagnostic menu, see section 8 Control sys-
tem, group 8.4.6.5 ENGINE, menu 5
9 The engine’s sensors send signals - Se Engine control unit, general page 38
to the engine control unit (D794),
which regulates the injectors so that
the engine starts.
11 The cab control unit (D790-1) sends Checked by control sys- See section 11 Common electrics, group
the engine control unit (D794) an tem, error shown with er- 11.5.3.1 Cab control unit (D790-1)
rpm request via the CAN bus. ror code. D11: Diagnostic menu, see section 8 Control
system, group 8.4.6.1 ENGINE, menu 1
12 The engine control unit (D794) in- - Se Engine control unit, general page 38
creases engine speed. D12: Diagnostic menu, see section 8 Control
system, group 8.4.6.1 ENGINE, menu 1
13 The NO switch for coolant level U = 24 V NO (normally open) switch, coolant level page
(B759) sends a voltage signal to the 37
engine unit (D794) if the coolant lev-
el in the expansion tank is low.
15 The KID control unit (D795) shows - See section 11 Common electrics, group
engine data via display figures. 11.5.3.11 KID control unit (D795)
16 The fuel level sensor (B757) sends R = 0–70 ohm Sensor, fuel level, description page 25
the frame control unit (D797-1) a A warning message ap- D16: Diagnostic menu, see section 8 Control
voltage signal proportional to the fuel pears on the display if the system, group 8.4.3.7 CAB, menu 7
level in the tank. amount of fuel in the tank
is less than 15% for more
than 40 seconds.
17 The frame control unit (D797-1) Checked by control sys- See section 11 Common electrics, group
transmits fuel level on the CAN bus. tem, error shown with er- 11.5.3.2 Frame control unit (D797-1)
ror code.
18 The KID control unit (D795) shows - See section 11 Common electrics, group
fuel level in the operating menu for 11.5.3.12 KID control unit (D795)
engine and transmission.
20 The transmission control unit (D793) Checked by control sys- See section 11 Common electrics, group
transmits speed on the CAN bus. tem, error shown with er- 11.5.3.9 KIT control unit (D793)
ror code.
21 The KID control unit (D795) shows - See section 11 Common electrics, group
the machine’s speed. 11.5.3.12 KID control unit (D795)
22 If output shaft rpm is so high that it Checked by control sys- See section 11 Common electrics, group
reaches the limit for the machine’s tem, error shown with er- 11.5.3.1 Cab control unit (D790-1)
speed limitation, the cab control unit ror code.
(D790-1) transmits a reduce engine
rpm request on the CAN bus.
23 Control unit engine (D794) restricts - Se Engine control unit, general page 38
engine rpm.
Component locations
page
–
(Cummins engine)
6 7
8
9
10
11
3 12
13
14
2
15
009440
1 16
7
6
8
10
5
11
4
12
13
14
15
007396
16
Engine, replacement
page
–
(Cummins engine)
DANGER
The engine is very heavy.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Machine in service position, see section B Safety.
2 Attach hoisting equipment to the engine.
3 Disconnect required hoses and cables before separating engine
and transmission.
NOTE
Drain and collect liquids before detaching hoses.
009088
6 Remove the screws holding the cover plate to the flywheel on the
left side of the engine.
008314
7 Remove the screws in the flex plate through the hole under the
cover plug.
NOTE
Rotate the engine for each bolt in the flex plate that has to be re-
moved.
8 Take up the slack in the hoisting equipment.
NOTE
008315
Do not lift the engine.
NOTE
008275
NOTE
If the flex plates are damaged during engine replacement, they
must be replaced.
13 Lift the engine away.
Assembly
14 Transfer the engine brackets to the new engine; tighten to
330 Nm (oiled screw).
15 Apply lubricating grease to the converter connection - both on the
engine and the gearbox.
008301
16 Insert a stud into one of the nuts on the flexible plate as a guide
when the engine is installed.
007769
20 Fit the screws that fix the flex plates at the flywheel in two steps.
First fit the screws without tightening. Then rotate the flywheel
one more revolution and tighten the screws to 35 Nm (oiled
screw).
NOTE
Turn the engine for each screw to be installed in the flex plate.
NOTE
008315
The engine must be loosened from the engine mounts and sep-
arated from the transmission to remove a dropped bolt. Secure
the bolt in the socket when installing.
21 Fit the screws that fasten the gearbox and engine and tighten
them to 52 Nm (oiled screw).
008275
007796
P No function.
0 Stop position. Everything is off; key can be removed.
I Operating position.
Voltage to all electrical functions. Engine and transmission con-
trol units are now active.
The signal can be checked from the diagnostic menu, see section
8 Control system, group 8.4.6.4 CAN/POWER, menu 4.
II Preheating position (function applies to Volvo engines only).
When the switch is in the preheating position, the engine’s intake
air is manually heated to a suitable temperature with glow plugs
in each cylinder on Volvo engines (Cummins engines are heated
automatically with a heating coil). The preheating lamp is on dur-
ing the preheating process.
0
The signal can be checked from the diagnostic menu, see section
P I 8 Control system, group 8.4.6.4 ENGINE, menu 4.
III Start position.
Engagement of starter motor for engine start.
II
NOTE
The machine is equipped with an electric restart interlock,
000317
III
which prevents engagement of the starter motor when the
engine is rotating.
Conditions for starter motor engagement are that transmis-
sion is in neutral position and the engine is not already run-
ning.
The signal can be checked from the diagnostic menu, see section
8 Control system, group 8.4.6.4 ENGINE, menu 4.
1. Accelerator pedal
2. Brake pedal
The fuel tank is located on the machine’s left side and has a sensor for
fuel level. The fuel volume in the tank is shown in an operating menu
on the display in the cab. The fuel pre-filter with water trap and fuel fil-
ter is located on the engine. The water trap is equipped with electric
indication, an event menu is shown in the display when the water trap
has to be drained of water.
For component locations, see the section 1 Engine.
WARNING
Fuel under high pressure.
The fuel tank is located on the left-hand side of the machine behind the
brake fluid reservoir.
The signal can be checked from the diagnostic menu, see section 8
Control system, group 8.4.3.7 CAB, menu 7.
3
2
1
009863
The air cleaning system consists of an air cleaner with filter, filter indi-
cator, pipes and hoses. There are two filter in the air cleaner that clean
the air and a dust reservoir that collects larger particles. The dust res-
2 ervoir can be emptied without opening the air cleaner.
3
Combustion in the engine requires air. Free unobstructed flow for
fresh air and exhausts is essential for effective engine operation.
When the air filter cleans the air for engine, particles collect in the filter
material. With time, so many particles collect that the filter does not let
1
through enough air for effective combustion, then the filter has to be
replaced. The filter indication measures the vacuum pressure on the
engine side of the filter. When the filter is clogged, the vacuum pres-
008040
sure increases and the indicator indicates that it’s time to replace filter.
WARNING
2 3
Hot exhaust system!
1.6.4 Intercooler
Intercooler, description
page
–
5
3
6
1
010120
Radiator core
1. Transmission oil cooler
2. Fuel cooler
3. Radiator engine
4. Intercooler
5. Expansion tank
6. Attachment condenser (to AC)
The engine is water-cooled and has passages through which the cool-
ant from the radiator flows round a closed system.
Main parts of the cooling system:
• Coolant pump, located in the engine.
• Expansion tank, located in the engine compartment.
• Thermostat, located in the engine
• Cooling fan, located in front of the radiator
• Water cooler, part of radiator assembly (middle).
• Engine oil cooler, located in the engine
• Transmission oil cooler, part of radiator assembly (lower).
• Intercooler, part of radiator assembly (upper).
• Fuel cooler, located behind the radiator
How the engine cooling system works:
1. Coolant is circulated through the cylinder head, engine block and
oil cooler by the coolant pump.
2. The thermostat directs the heated coolant back to the coolant
pump or through the radiator.
3. When the coolant is colder than the thermostat opening tempera-
ture it is pumped back to the engine.
When the coolant is warmer than the thermostat opening temper-
ature it is pumped through the radiator and then back to the cool-
ant pump.
4. The expansion tank allows the coolant to expand without escap-
ing from the engine.
Radiator for the engine is located in the cooler unit which is placed be-
4 hind the engine.
The purpose of the cooler assembly is to cool:
• Engine coolant.
5
• Gearbox oil (cooled in the lower part of the radiator assembly),
3
see also section 2 Transmission, group 2.6.3 Oil cooler.
6
• Charge air (cooled in the upper part of the radiator assembly), see
also Intercooler, description page 27.
2 Also refer to Cooling system, description page 28.
For more information, see supplier documentation, engine.
1
010120
Radiator core
1. Transmission oil cooler
2. Fuel cooler
3. Radiator engine
4. Intercooler
5. Expansion tank
6. Attachment condenser (to AC)
1
007314
1. Drift
3 Remove the belt from the coolant pump first.
4 Install the new belt.
Let back the belt tensioner and check that the belt is positioned
correctly in the grooves, and that it is tensioned correctly.
1
007969
1. Coolant pump
NOTE
The belt tensioner tensions in the same direction as the
spring is bent over the belt tensioner arm. To reduce tension
in the belt, rotate the belt tensioner to tighten the spring.
CAUTION
008013
Do not use too much force in or against the tension-
ing direction after the belt tensioner has been ten-
sioned to its positive stop. This could break the belt
tensioner.
3. Lift up the belt tensioner and fit the drive belt. If it is difficult to fit
(the belt seems too short), first position the belt on the grooved
pulley. Then continue holding up the belt tensioner and wriggle
the belt over the water pump pulley.
Undo the belt tensioner and check that the belt is correctly posi-
tioned in the groove and is correctly tensioned.
1.7.7 Coolant
Changing coolant and cleaning the cooling system
page
–
(Volvo engine)
Cooling performance is reduced due to deposits in the radiator and
cooling channels. Always clean the cooling system in connection with
coolant change.
IMPORTANT
Cleaning may not be performed if there is a risk of
freezing in the cooling system since the cleaning so-
lution does not have anti-freeze properties.
NOTE
Read the safety instructions before starting work with the cooling
system, see section B Safety.
NOTE
Before draining, stop the engine and remove the filler cap.
Draining
1 Remove the filler cap from the cooling system’s expansion tank.
2 Open all drain points. Drain the coolant from the radiator and en-
gine block with the drain hose. The drain nipples are located un-
der the radiator and on the engine block’s right side.
3 Check that all coolant drains.
NOTE
There may be deposits inside the tap or the plug. These
must be cleaned away, otherwise there is a risk that coolant
may remain and cause freezing damage.
Check if the installation has additional valves or plugs at the cool-
007394
ant lines’ lowest points. Let drain valves or plugs be open and
make sure that the heat control is at max. heat when cleaning.
Drain point, engine.
4 Insert a hose in the filler hole in the expansion tank and flush with
clean water, until the draining water is clear.
5 If impurities remain after flushing for a long time, it’s possible to
clean with coolant. Otherwise, continue with step 10.
NOTE
To prevent dissolved material from clogging the system
again, drain the system quickly, within 10 minutes, without
the machine’s engine being off for a long time. Remove the
filler cap from the expansion tank and also the lower coolant
hose to increase drain speed.
8 Flush the system immediately and very thoroughly with clean
warm water to prevent impurities from settling again on the inner
surfaces. Flush until the draining water is completely clean. Make
sure that the heat control is at max. heat when cleaning.
9 If impurities should remain after flushing for a long time, then
cleaning can be performed with a radiator cleaning agent and an
aftertreatment with a neutralizing agent.
NOTE
Only use cleaning agents approved by the engine manufac-
turer. Carefully follow the instructions on the package.
Filler orifice
10 When the cooling system is completely free from impurities, close
the drain valves.
NOTE
Only use recommended coolant.
IMPORTANT
It is very important that the correct concentration and
volume of coolant is filled in the system. Mix in a sep-
arate clean container for filling the cooling system, be
sure that the fluids mix.
11 Fill coolant so that the level ends up between MIN and MAX
markings. See Coolant, mixing page 36. The engine must not
be started until the system is bled and completely filled.
12 Start the engine when the engine is completely bled free from air
and filled with coolant. Open any breather valves for a time after
start, so that any trapped air can escape.
Open all heat controls on the heater so that it is bled free from air.
13 Stop the engine after approx. one hour and check the coolant lev-
el, top up if needed.
(Cummins engine)
Because cooling performance is reduced by deposits in the radiator
and cooling channels, clean the cooling system when changing cool-
ant.
IMPORTANT
Cleaning may not be performed if there is a risk of
freezing in the cooling system since the cleaning so-
lution does not have anti-freeze properties.
NOTE
Read the safety instructions for coolant before starting work, see
section B Safety.
NOTE
Before draining, stop the engine and remove the filler cap.
1 Remove the filler cap from the cooling system’s expansion tank.
2 Open all drain points. Drain the coolant from the radiator and en-
gine block. There is a drain nipple under the radiator and a drain
plug under the coolant inlet on the engine block.
3 Check that all coolant drains.
NOTE
There may be deposits inside the tap or the plug. These
must be cleaned away, otherwise there is a risk that coolant
may remain and cause freezing damage.
Check if the installation has additional valves or plugs at the low-
008020
est points of the coolant lines. Leave drain valves or plugs open
and make sure that the heat control is at max. heat when clean-
ing.
4 Check the condition of the hoses and clamps and check the radi-
ator for leaks. Replace and clean as necessary.
CAUTION
The system must be filled well to prevent air pocket
formation. During filling, air must be vented out from
the cooling channels. Wait 2 to 3 minutes to vent the
system and then fill it.
5 Cleaning:
NOTE
Do not fit the pressure cap. The engine must be run without
pressure cap during this process.
6 Fill the system with a radiator cleaning agent approved by the en-
gine manufacturer.
NOTE
008021
Only use cleaning agents approved by the engine manufac-
turer. Carefully follow the instructions on the package.
7 Start and run the engine for 5 minutes with coolant temperature
over 80 °C.
Switch off the engine and drain the cooling system.
8 Fill the cooling system with clean water.
NOTE
Make sure that the system is properly bled during filling.
NOTE
Do not fit the cap.
008022
9 Start and run the engine for 5 minutes with coolant temperature
over 80 °C.
Switch off the engine and drain the cooling system.
NOTE
If the water that drains out is still dirty, the system must be
flushed until the water is clean.
10 When the cooling system is completely free from impurities, close
the drain valves and plugs.
NOTE
Only use recommended coolant.
NOTE
Never use pure water as a coolant. This could cause corrosion
damage to the cooling system.
IMPORTANT
It is very important that the correct concentration and
volume of coolant is filled in the system. Mix in a sep-
arate clean container prior to filling the cooling sys-
tem. Be sure that the fluids mix well.
11 Filling:
Fill coolant so that the level ends up between MIN and MAX
markings. The engine must not be started until the system is
bled and completely filled.
12 Fit the pressure cap and start the engine once the cooling system
has been completely bled and filled.
Open all heat controls on the heater so that it is bled free from air.
13 Stop the engine after approx. one hour and check the coolant lev-
el, top up if needed.
Coolant, mixing
page
–
NOTE
Read the safety instructions for coolant before starting work, see
section B Safety.
IMPORTANT
Ethylene glycol shall not be mixed with other types of
glycol.
Mix
40% glycol
60% water
This mixture protects against internal corrosion, cavitation and freez-
ing down to -28 °C (At 60% glycol mixture, the freezing point is lowered
to -54 °C.) Never mix more than 60% concentrated glycol in the cool-
ant as this reduces cooling effect with risk of overheating and reduces
frost protection.
IMPORTANT
Mix the coolant with clean water.
007395
IMPORTANT
It is very important that the correct concentration and
volume of coolant is filled in the system. Mix in a sen-
parate clean container prior to filling the cooling sys-
tem. Be sure that the fluids mix well.
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 glycol. Otherwise there is
a risk that the air conditioning system will freeze dur-
ing usage.
NOTE
It is important that the coolant is mixed correctly all year to ensure
adequate corrosion protection. The corrosion-protective proper-
ties decline with time, that is why the coolant has to be changed
according to given intervals.
1.11 Start/stop
1.11.1 Starter motor
Starter motor, description (Volvo engine)
page
–
The starter motor cranks the engine until fuel combustion begins and
the engine starts.
The starter motor is supplied with voltage directly from the start batter-
ies. A relay on the starter motor (solenoid) is activated by the engine
control unit (D794).
The signal can be checked from the diagnostic menu, see section 8
Control system, group 8.4.6.5 ENGINE, menu 5.
For more information, see supplier documentation, engine.
The starter motor cranks the engine until fuel combustion begins and
the engine starts.
The starter motor is supplied with voltage directly from the start batter-
ies. A relay on the starter motor (solenoid) is activated by the frame
control unit (D797-1).
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.6.5 ENGINE, menu 5.
For more information, see supplier documentation, engine.
NOTE
The battery disconnect switch must not be used for emergency
stop!
For more information, see supplier documentation, engine.
2 Transmission
2 Transmission.................................................................................................. 3
2.1 Controls and instruments ......................................................................... 18
2.1.1 Gear selector and multi-function lever ................................................. 18
2.2 Torque converter/Clutch system .............................................................. 19
2.2.1 Flex plates ........................................................................................... 19
2.6 Lubrication system ................................................................................... 21
2.6.3 Oil cooler .............................................................................................. 24
2.6.4 Oil filter ................................................................................................. 26
2.7 Cooling system ......................................................................................... 27
2.7.3 Oil cooler .............................................................................................. 27
2.8 Transmission control system .................................................................... 28
2.8.1 Control unit transmission ..................................................................... 28
2.8.2 Normally closed (NC) switch, disengagement ..................................... 28
2.8.3 Transmission cable harness ................................................................ 29
2 Transmission
mm mm mm mm mm mm
Transmission, general
page
–
F
D27 R
22 <˚ 1
27 Pa D1
5
D5
21 6,23,28 2, 7
D794 D790-1 D790-2
4 17
11
3
009864
2 The KIT control unit (D790-2) trans- Checked by control sys- See section 11 Common electrics , group
mits the selected direction of travel tem, error shown with er- 11.5.3.11 Control unit KIT (D790-2)
(forward or reverse) on the CAN bus. ror code.
6 The cab control unit (D790-1) trans- Checked by control sys- See section 11 Common electrics , group
mits the desired throttle application tem, error shown with er- 11.5.3.1 Cab control unit (D790-1)
on the CAN bus. ror code.
7 The KIT control unit (D790-2) trans- Checked by control sys- See section 11 Common electrics , group
mits the selected shifting program on tem, error shown with er- 11.5.3.11 Control unit KIT (D790-2)
the CAN bus. ror code.
8 The oil pressure sensors sends a Checked by Control unit D8: Diagnostic menu, see section 8 Control
voltage signal to the transmission transmission, error system , group 8.4.7.10 TRANSM, menu 10
control unit (D793) if oil pressure is shown with error code.
too low.
9 The engine speed and oil tempera- Checked by Control unit D9: Diagnostic menu, See Section 8 Control
ture sensor (B758/766) sends the transmission, error system , group 8.4.7.6 TRANSM, menu 6 and
transmission control unit (D793) a shown with error code. 8.4.7.10 TRANSM, menu 10
pulse signal with frequency propor-
tional to engine speed and a voltage
signal proportional to the transmis-
sion oil temperature.
10 The transmission control unit (D793) Checked by Control unit Transmission control unit, general page 28
supplies voltage to valve block trans- transmission, error
mission control to obtain desired shown with error code.
function.
12 The turbine speed sensor (B751) Checked by Control unit D12: Diagnostic menu, see section 8 Control
sends the transmission control unit transmission, error system , group 8.4.7.6 TRANSM, menu 6
(D793) a pulse signal with frequency shown with error code.
proportional to turbine speed.
13 The drum sensor (B752) sends the Checked by Control unit D13: Diagnostic menu, see section 8 Control
transmission control unit (D793) a transmission, error system , group 8.4.7.6 TRANSM, menu 6
pulse signal with frequency propor- shown with error code.
tional to drum speed.
14 The output shaft speed sensor Checked by Control unit D14: Diagnostic menu, see section 8 Control
(B758) sends the transmission con- transmission, error system , group 8.4.7.6 TRANSM, menu 6
trol unit (D793) a pulse signal with shown with error code.
frequency proportional to output
shaft speed.
16 The transmission control unit (D793) Checked by Control unit Transmission control unit, general page 28
controls gear shifting according to transmission, error
selected shifting program. shown with error code.
17 The oil cooler cools the transmission - Oil cooler, description page 27
oil. A thermostat senses the oil’s
temperature and directs the oil back
to the transmission if the oil is cold.
18 The transmission control unit (D793) Checked by control sys- Transmission control unit, general page 28
transmits temperature and speed tem, error shown with er-
data on the CAN bus. ror code.
19 The KID control unit (D795) shows Checked by control sys- See section 11 Common electrics , group
transmission information in operat- tem, error shown with er- 11.5.3.12 KID control unit (D795)
ing menus. ror code.
20 If the signal from the output shaft - D20: Diagnostic menu, see section 8 Control
speed sensor (B758) indicates that system , group 8.4.7.6 TRANSM, menu 6
machine speed exceeds the speed
limitation, the transmission control
unit (D793) transmits a engine
speed reduction request on the CAN
bus.
21 The engine control unit (D794) re- - See section 11 Common electrics , group
duces engine speed. 11.5.3.10 Engine control unit (D794)
22 If the clutch pedal (S220-1) is U = 24 V Section 9 Frame, body, cab and accessories ,
pressed down, it sends a voltage group 9.1 Controls and instruments
signal to the cab control unit (D790- D22: Diagnostic menu, see section 8 Control
1). system , group 8.4.7.1 TRANSM, menu 1
23 The cab control unit (D790-1) trans- Checked by control sys- See section 11 Common electrics , group
mits disengage drive on CAN bus. tem, error shown with er- 11.5.3.1 Cab control unit (D790-1)
ror code.
24 Normally closed (NC) switch, disen- Brake pressure above Normally closed (NC) switch, disengagement,
gagement (S220-2) sends the frame 0.2 MPa: description page 28
control unit (D797-1) a voltage signal Conn 1, U = 24 V D24: Diagnostic menu, see section 8 Control
if brake pressure is high enough to system , group 8.4.7.1 TRANSM, menu 1
Conn 2, U = 24 V
allow drive disengagement.
Brake pressure below
0.2 MPa:
Conn 1, U = 24 V
Conn 2, U = 0 V
26 The transmission control unit (D793) Checked by Control unit Transmission control unit, general page 28
supplies voltage to valve block trans- transmission, error
mission control so that drive is disen- shown with error code.
gaged.
27 If the operator leaves the driver’s U = 24 V Section 9 Frame, body, cab and accessories,
seat, the operator-in-seat sensor group 9.3.14 Operator-in-seat sensor
(S230) sends a voltage signal to the D27: Diagnostic menu, see section 8 Control
cab control unit (D790-1). system , group 8.4.7.1 TRANSM, menu 4
28 The cab control unit (D790-1) trans- Checked by control sys- See section 11 Common electrics , group
mits go to neutral on the CAN bus. tem, error shown with er- 11.5.3.1 Cab control unit (D790-1)
ror code.
29 The transmission control unit (D793) Checked by Control unit Transmission control unit, general page 28
supplies voltage to valve block trans- transmission, error
mission control so that the drive is shown with error code.
put in neutral three seconds after the
operator leaves the driver’s seat.
description
7 9 11 13 15
RSP
25 5
Fwd 2 Rev 1/3
6
8
26 10 12 14 16
18
VFS 1/3
3 4
17
28
27
19
2
008240
29 20 21 22 23 24
2. The transmission’s oil pump 1 feeds the 92.1 l/min at 2420 rpm -
transmission with control pressure for con-
trol of the transmission.
4. The bypass valve in the filter bracket leads Opening pressure: 390 -
the oil past the filter if the resistance through kPa
the filter becomes too high.
7. Solenoid valve neutral position (RSP) - Diagnostic menu, see section 8 Control
(Y6066) controls Valve spool neutral posi- system , group 8.4.7.7 TRANSM, menu
tion. 7
9. Solenoid valve drive forward (Y630) con- 0-1000 mA Diagnostic menu, see section 8 Control
trols Pressure booster drive forward. system , group 8.4.7.8 TRANSM, menu
8 and 8.4.7.9 TRANSM, menu 9
13. Solenoid valve drive reverse controls Pres- 0-1000 mA Diagnostic menu, see section 8 Control
sure booster drive reverse. system , group 8.4.7.8 TRANSM, menu
8 and 8.4.7.9 TRANSM, menu 9
15. Solenoid valve 1/3 (Y6067) controls Pres- 0-1000 mA Diagnostic menu, see section 8 Control
sure booster gear 1/3. system , group 8.4.7.8 TRANSM, menu
8 and 8.4.7.9 TRANSM, menu 9
18. Solenoid valve VFS 1/3 (Y6075) controls 0-1000 mA Diagnostic menu, see section 8 Control
servo pressure to Valve spool gear selec- system , group 8.4.7.7 TRANSM, menu
tion 1/3. 7
25. The safety valve leads the oil back to the Opening pressure: 850 -
sump if the pressure to the torque converter kPa
becomes too high.
28. The bypass valve torque converter leads Opening pressure: 400 -
the oil past the torque converter if the pres- kPa
sure becomes too high.
3 4
6
2 7
14 13 12
15
8
16
9
17
10
004269
19 18 11
3 4 5
2
11
10 9b 9a 8
008057
1. Accelerator pedal (B690) 7. Declutch pedal (S220-1)
2. Multi-function lever (S162) 8. Transmission control unit (D793)
3. Control unit KIT (D790-2) 9a. Control unit, Volvo engine (D794)
4. Control unit KID (D795) 9b. Control unit, Cummins engine (D794)
5. Control unit cab (D790-1) 10. Frame control unit (D797-1)
6. Sensor operator in seat (S230) 11. Switch (NC), disengagement (S220-2)
Gearbox, replacement
page
–
DANGER
The gearbox is very heavy.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Machine in service position, see section B Safety.
2 Remove the propeller shaft from the transmission.
3 Detach relevant hoses and cables before separating the engine
and gearbox.
NOTE
Drain and collect liquids before detaching hoses.
5 Remove the nuts for the flex plate through the hole under the cov-
er washer.
NOTE
Turn the engine for each nut to be removed from the flex plate.
6 Attach the transmission to an overhead crane.
7 Support the engine from underneath with a jack
NOTE
Secure the engine so that it does not tip over when the gearbox
is removed.
8 Remove the screws holding the gearbox to the gearbox mount-
ing.
NOTE
Check the balance of the gearbox before lifting it.
NOTE
If the flex plates are damaged during gearbox replacement, they
must be replaced.
11 Remove the gearbox.
007780
Assembly
12 Apply lubricating grease to the converter connection - both on the
engine and the gearbox.
008301
13 Insert two studs into the flywheel housing as a guide when the
gearbox is installed.
14 Transfer the gearbox mountings to the new gearbox; tighten to
330 Nm (oiled screw).
007775
15 Centre a stud on the flywheel so that it aligns with the hole in the
flywheel housing.
007772
16 Lift the gearbox into place. Make sure that the studs on the fly-
wheel come into correct alignment and do not damage the flex
plate.
17 Install the screws which fix the gearbox and engine, but do not
tighten the screws fully. Leave about a millimetre between the en-
gine and gearbox to facilitate installation of the nuts for the flex
plate/flywheel.
007776
18 Fit the nuts that fix the flex plates at the flywheel in two steps. First
fit the nuts without tightening. Then rotate the flywheel one more
revolution and tighten the nuts to 46-50 Nm (oiled screw).
NOTE
Turn the engine for each nut to be installed to the flex plate.
The signal can be checked from the diagnostic menu, see section 8
R
Control system , group 8.4.7.2 TRANSM, menu 2.
4 Replace the flex plate. Tighten the screws fixing the flex plate to
the transmission to 40 Nm (oiled screws).
5 Reinstall the gearbox; see Gearbox, replacement page 13.
6 Before the machine is put into operation, the transmission must
be calibrated; see Transmission, calibration page 28.
007773
NOTE
Read the safety instructions for oil before working, see section B
Safety.
NOTE
The transmission must not be over filled!
1 Operate and warm up the transmission oil.
2 Machine in service position, see section B Safety.
3 Remove the drain plug for transmission oil and let the oil drain
into the receptacle.
NOTE
Make sure that the sealing washer stays with the drain plug.
4 If the oil filter must be changed, see Transmission oil filter, chang-
ing page 26.
5 When the transmission oil has drained, fit the drain plug.
Make sure that the washer for the oil plug is included.
008054
a 11 Allow the engine to idle. Check the transmission oil level (see
Transmission oil level check page 23) and top up to the max. oil
level mark.
000356
NOTE
Read the safety instructions for oil before working, see section B
Safety.
The transmission’s oil filler pipe and dipstick (position B) are located
under the service hatch in front of the cab.
1 Check the oil level with the engine at idle, transmission in neutral
position and at operating temperature (approx. 60-65 °C). The
dipstick has two markings, MAX and MIN. The oil level should be
at MAX.
A
Wipe off the dipstick before checking.
B
NOTE
The oil dipstick is long. Wear gloves.
2 Fill transmission oil (position B) if needed (for volume and grade,
see section F Technical data).
3 The oil should be filled when the transmission is at operating tem-
perature. Top up – wait a moment – check the dipstick.
NOTE
008054
The transmission oil is cooled in the lower section of the cooler unit.
4 A temperature-controlled bypass valve, which only acts on the trans-
mission 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
5 working temperature. This means that the oil reaches normal working
3 temperature more quickly.
6 For more detailed information, see supplier documentation, transmis-
sion.
1
010120
Radiator core
1. Transmission oil cooler
2. Fuel cooler
3. Radiator engine
4. Intercooler
5. Expansion tank
6. Attachment condenser (to AC)
NOTE
Read the safety instructions for oil before working, see section B
Safety.
IMPORTANT
007447
6 Fill with transmission oil; see Transmission oil, changing page 21.
7 Start the engine and check for leaks.
8 Check the transmission oil level; see Transmission oil level check
page 23.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
NOTE
It is not necessary to drain the gearbox oil before changing the
filter.
1 Machine in service position, see section B Safety.
2 Remove the oil filter with the filter tool.
3 Lubricate the O-ring on the new oil filter with transmission oil.
4 Install the new filter on the gearbox.
Tighten to contact and then another two-thirds of a turn.
5 Turn on the main electric power and start the engine. Run the en-
gine at idling speed.
NOTE
If the transmission oil is to be changed - change the trans-
004331
description
The NC switch for disengagement detects if the wheel brakes are
pressurised. The NC switch is located on the distribution block for the
brake system, above the drive axle’s differential.
The sensor can be checked from the diagnostic menu, see section 8
Control system , group 8.4.7.1 TRANSM, menu 1.
1
10
2
1
3
3
4
5
5
9 6
8 7
009865
3 Driveline/Axle
3 Driveline/axle .................................................................................................. 3
3.2 Propeller shaft ............................................................................................ 3
3.3 Drive axle ................................................................................................... 4
3 Driveline/axle
mm mm mm mm mm mm
DANGER
Drive axle and machine are very heavy.
1 Remove the mast, see section 7 Load handling , group 7.2 Lifting/
lowering.
2 Park the machine with blocks behind the steering wheels.
3 Depressurize the hydraulic systems, See section B Safety.
4 Turn the start key to position 0 and turn off the main electric pow-
er.
NOTE
Plug all unions at once to protect the hydraulic system from
contamination.
1
004501
2
1. Hydraulic hoses
2. Cables
7 Remove the casing (position 3) on the parking brake.
3
004505
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. Reinstall the casing on the parking
6 brake (position 3).
9 Disconnect the hydraulic hose (position 6) from the parking
brake.
5
NOTE
4 Plug all unions at once to protect the hydraulic system from
contamination.
004506
4. Lock nut
5. Release screw
6. Hydraulic hose parking brake
10 Disconnect the propeller shaft from the drive axle. Secure the
propeller shaft, otherwise there is a risk that it will be pulled apart.
CAUTION
The drive axle may start to roll.
Crushing injury!
Make sure that the drive axle does not roll away when
not under control.
Lifting machine
14 Remove the bolts that secure the drive axle in the frame.
15 Lift away the drive axle.
CAUTION
The drive axle may start to roll.
Crushing injury!
Make sure that the drive axle does not roll away when
not under control.
NOTE
Plug all unions at once to protect the hydraulic system from
contamination.
17 Transfer the couplings from the old axle to the new axle.
19 Undo the distribution block bracket and move it to the new axle.
20 Connect the hydraulic hoses from the distribution block to the
drive wheels.
21 Clean the contact surfaces on the drive axle and frame. Also
clean the bolts’ contact surface on the drive axle’s underside.
22 Remove the nuts for attaching the drive axle, blow clean and re-
install the nuts.
23 Lift the drive axle into place under the frame.
CAUTION
The drive axle may start to roll.
Crushing injury!
Make sure that the drive axle does not roll away when
not under control.
25 Fit the new screws that fix the drive axle in the frame. Tighten to
1530 Nm (oiled screw).
26 Install the drive wheels on the new axle.
27 Rustproof the bolts with suitable paint.
4 Brakes
4 Brakes ............................................................................................................. 3
4.1 Controls and instruments ........................................................................... 3
4.1.1 Brake pedal ............................................................................................ 3
4.3 Power-assisted brake system .................................................................... 6
4.3.1 Hydraulic oil pump ................................................................................. 9
4.3.2 Oil filter ................................................................................................. 11
4.3.3 Accumulator charging valve ................................................................. 12
4.3.4 Accumulator ......................................................................................... 15
4.3.5 Brake valve .......................................................................................... 19
4.3.6 Drive axle block ................................................................................... 23
4.3.7 Brake pressure NC (normally closed) switch ....................................... 24
4.3.8 NO (normally open) switch, brake lights .............................................. 25
4.3.9 Wheel brake ......................................................................................... 27
4.3.10 Pipes and hoses .................................................................................. 29
4.5 Parking brake system ............................................................................... 30
4.5.1 Hydraulic oil pump ............................................................................... 33
4.5.2 Oil filter ................................................................................................. 33
4.5.3 M-valve parking brake ......................................................................... 33
4.5.4 Parking brake unit ................................................................................ 34
4.5.5 Parking brake NC switch ..................................................................... 37
4.5.6 Pipes and hoses .................................................................................. 37
4.8 Temperature control, cleaning and hydraulic oil ....................................... 38
4.8.1 Hydraulic oil tank ................................................................................. 38
4.8.3 Hydraulic oil pump ............................................................................... 39
4.8.4 Accumulator charging valve ................................................................. 39
4.8.5 Drive axle block ................................................................................... 39
4.8.6 Wheel brake ......................................................................................... 39
4.8.8 Thermal bypass valve .......................................................................... 39
4.8.9 Cooling fan ........................................................................................... 39
4.8.10 Sensor hydraulic oil temperature ......................................................... 39
4.8.11 Breather filter hydraulic oil tank ........................................................... 39
4.8.12 Oil filter ................................................................................................. 39
4.8.13 Pipes and hoses .................................................................................. 39
4.8.14 Hydraulic oil ......................................................................................... 40
4 Brakes
mm mm mm mm mm mm
1 Clean the floor round the brake pedal and check that nothing is
obstructing the movement of the brake pedal.
2 Check that the brake pedal springs back adequately and that the
clearance between brake pedal and brake valve is 1–1.5 mm. If
needed, adjust the brake pedal’s stop bolt to correct clearance.
3 Check that the pedal moves easily.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Turn off the engine and the main electrical power.
2 Depressurize the hydraulic systems, See section B Safety.
3 Detach the brake valve from the brake pedal.
Secure the brake valve on the cab’s underside and remove the
brake valve attaching bolt.
4 Remove the panel around the steering wheel shaft.
NOTE
There is a variant available with adjustable steering wheel
shaft.
NOTE
Check that the accumulator drain valve is fully closed and tighten
the lock ring.
15 Grease and adjust the brake pedal, see Brake pedal, checking
and adjusting page 3.
description
5
B
13 P
T
D790-2
D11
D797-1
10, 12 8 C
Pa
11
C 9 D9
D8
4 Pa
3
C ACC
7
B
P
6
2
008059
B
Pos Explanation Signal description Reference
1 The hydraulic oil pump pumps oil See pressure plate on left Hydraulic oil pump, description page 9
from the oil tank. frame beam.
2 The hydraulic oil filter cleans the - Hydraulic oil filter, description page 39
oil.
3 The accumulator charging valve di- Charge: P = 20.5 ±0.5 MPa Accumulator charging valve, description page
rects oil to charging of accumula- Cooling: P < 0.1 MPa 12
tors or through the brake system's
cooling circuit.
4 The accumulators store oil pres- See pressure plate on left Accumulator, description page 15
sure. frame beam.
6 The brake cylinders compress the See pressure plate on left Wheel brake, description page 27
discs in the brake unit. frame beam.
7 The wheel brakes brake the ma- - Wheel brake, description page 27
chine.
8 The brake light NO switch (S216) Brake pressure above Switch normally open (NO), brake lights, de-
closes the circuit when the brake 0.2 MPa: scription page 25
cylinders are pressurised. Conn 1, U = 24 V D8: Diagnostic menu, see section 8 Control
Conn 2, U = 24 V system , group 8.4.5.4 HYD, menu 4
9 NC switch, brake pressure (S204) Brake pressure above Brake pressure NC switch, description page
opens the circuit if the pressure in 11.5 MPa: 24
the accumulators is low. Conn 1, U = 24 V D9: Diagnostic menu, see section 8 Control
Conn 2, U = 24 V system , group 8.4.5.4 HYD, menu 4
10 The frame control unit (D797-1) Controlled by control system, Section 11 Common electrics , group 11.5.3.2
transmits the brake light request on error shown with error code. Frame control unit (D797-1)
the CAN bus.
11 The brake light lamps (H411L and U = 24 V Section 9 Frame, body, cab and accessories ,
H411R) are activated by the frame group 9.6.4 Brake lights
control unit (D797-1). D11: Diagnostic menu, see section 8 Control
system , group 8.4.2.8 LIGHTS, menu 8
12 The frame control unit (D797-1) Controlled by control system, Section 11 Common electrics , group 11.5.3.2
transmits a warning about low error shown with error code. Frame control unit (D797-1)
brake pressure on the CAN bus.
13 Control unit KIT (D790-2) activates Controlled by control system, Section 11 Common electrics , group
Warning light brake pressure. error shown with error code. 11.5.3.11 KIT control unit (D790-2)
positions
4
1 2
5 6
3 8
9
12
008061
11 10
The brake system has a gear pump with fixed displacement. The hy-
1
2 draulic oil pump sits in the rear of the right main pump. The pump gen-
erates hydraulic power, which is stored in the accumulators for brake
force to the power-assisted brake and parking brake. It also generates
the oil flow used for cleaning and cooling. The switchover between
power generation and flow is regulated by the accumulator charging
valve; see Accumulator charging valve, description page 12.
For a description of how a gear pump works, see section 10 Common
hydraulics , group 10.4.1 Gear pump with fixed displacement .
3
4
009967
NOTE
Read the safety instructions for oil before working, see section B
Safety.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
During charging the pressure should increase to 20.5 ±1.0 MPa
before the accumulator charging valve switches to cooling. When
the accumulator charging valve switches to cooling, the pressure
drops.
008049
7 Check the pressure during cooling.
Close the accumulator charging valve During cooling the pressure should be max. 0.10–0.15 MPa at
max. engine rpm.
8 Stop the engine
9 Depressurize the hydraulic systems, See section B Safety.
10 Remove the pressure gauge and fit the protective cap on the
measuring outlet.
11 Close the drain valve on the accumulator charging valve.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
16 Check that the pressure rises slowly to 20.5 ±1.0 MPa.
17 Brake repeatedly and check at which pressure the accumulator
charging valve switches to charging.
The valve must switch to cooling at 15.5 ±0.5 MPa.
008049
18 Depressurize the hydraulic systems, See section B Safety.
19 Remove the pressure gauge and fit the protective cap on the
Close the accumulator charging valve
measuring outlet.
20 Close the drain valve on the accumulator charging valve.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
The hydraulic oil pump for the brake system, cooling and filtering and
the pump for load handling are replaced as a unit. See the section 10
Common hydraulics, group 10.4.1 Gear pump with fixed displace-
ment.
The accumulator charging valve distributes oil from the hydraulic oil
3 4 5 6
pump between pressure storage and cooling of the wheel brakes. The
accumulator charging valve is located on the left of the frame in the
area beside the gearbox.
The accumulator charging valve stores pressure by guiding the oil to
the accumulators. The wheel brakes are cooled by oil being guided to
the drive axle cooling circuit and then on to the brake system cooler.
The accumulator charging valve prioritises charging of the accumula-
tors above cooling. A restriction of the charging means that a small
quantity of oil also flows to cooling during accumulator charging. At
idling speed the flow from the pump is so small that all oil flows to pres-
sure storage.
The drain valve (position 11) is used to relieve the pressure in the ac-
cumulators to the tank. The valve opens a connection between the ac-
cumulators and the wheel brake’s cooling circuit. The oil is drained
through the wheel brake to the tank.
2 1 13 12 11 10 9 8 7 There is a measuring outlet for measuring accumulator pressure (po-
sition 5) and pump pressure (position 4) on the accumulator charging
valve. The pressures are individual to each machine and are on the
pressure plate on the left-hand frame beam, see section 10 Common
hydraulics. On the accumulator charging valve, there is also a sole-
noid valve, parking brake (position 6), switch (NC) brake pressure (po-
sition 9) and switch (NC) parking brake (position 7).
• Solenoid valve parking brake, description page 33
• Switch normally open (NO), brake lights, description page 25
009867
1. Safety valve
2. Connection from pump (P)
3. Connection, wheel brake (T)
4. Measuring outlet, pump pressure (P)
5. Measuring outlet, accumulator pressure (M)
6. Solenoid valve parking brake (Y642)
7. NC switch, parking brake (GHB) (S260)
8. Connection, accumulators (ACC)
9. NC switch, brake pressure (LB) (S204)
10. Connection, parking brake calliper (HB)
11. Drain valve
12. Main valve charging
13. Pressure limiting valve
NOTE
Read the safety instructions for oil before working, see section B
Safety.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Machine in service position, see section B Safety.
2 Depressurize the hydraulic systems, See section B Safety.
3 Mark up hydraulic hoses and electric cables.
4 Detach the wiring from the accumulator charging valve.
5 Detach and plug all hydraulic hoses from the accumulator charg-
ing valve.
Remove the parking brake valve for easier access.
NOTE
Plug all connections immediately to protect the brake sys-
tem from impurities.
6 Remove the accumulator charging valve.
7 Transfer the connection adapters and sensors to the new accu-
mulator charging valve.
8 Fit the new valve.
9 Connect the hoses to the accumulator charging valve in accord-
008244
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
13 Turn on the main electric power and start the engine.
Check that the hydraulic connections are sealed tightly.
14 Check the charging and changing function, see Accumulator
charging, checking and adjustment page 13.
009868
4.3.4 Accumulator
Accumulator, description
page
–
ing brake systems and for supplying the servo hydraulics’ reducing
valve (see section 4 Brakes and section 7 Load handling).
Brake system accumulators
NOTE
If the accumulator delivers low oil pressure, the pumps may be
damaged and the hydraulic functions may cease to work.
Accumulator, checking
page
–
NOTE
Read the safety instructions for oil before working, see section B
Safety.
NOTE
A special tool for checking the accumulators can be ordered from
Kalmar Industries. The procedure without use of the special tool
is described below.
009870
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
10 Check that the plug seals properly.
11 Stop the engine
004810
NOTE
Check that the seals are intact and are fitted correctly.
18 Turn on the main electric power and start the engine.
19 Close the drain valve on the accumulator charging valve so that
the accumulators are charged.
NOTE
Check that the accumulator drain valve is fully closed and tighten
the lock ring.
20 Check that the accumulators’ connections are sealed tightly.
21 When the accumulators are fully charged, shut off the engine and
turn the start key to position I.
22 Check that at least 8 brake applications (pedal depressions) can
be performed before the pressure drops to 10 MPa.
At 11.5 MPa the warning lamp for low brake pressure must come
on.
Accumulator, replacement
page
–
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Machine in service position, see section B Safety.
2 Turn off the engine and the main electrical power.
3 Depressurize the hydraulic systems, See section B Safety.
4 Detach the accumulator’s clamp and remove the bolt.
3
2 5 Detach the accumulator from the distribution block.
1
NOTE
Hold the block firmly so that the other accumulator does not
work loose.
6 Bend the clamp away and remove the accumulator.
009871
NOTE
Check that the seal is intact and is fitted correctly.
8 Secure the accumulator’s clamp and tighten the bolt.
9 Close the drain valve on the accumulator charging valve.
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 15 steps 18-19.
009868
The brake valve, which is located on the underside of the cab under-
3
neath the brake pedal, controls the hydraulic pressure to the brakes.
2 A lever transfers pedal force to the valve.
1
The brake valve is a mechanically activated proportional valve. This
means that the resistance in the brake valve increases in proportion to
brake pressure. This provides optimum pedal responsiveness and in-
creased safety as the operator senses if no brake pressure is being
built up (no resistance in the pedal).
009872
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Operate and warm up the machine so that the hydraulic oil reach-
es operating temperature, at least 50 °C.
2 Machine in service position, see section B Safety.
3 Depressurize the hydraulic systems, See section B Safety.
4 Connect a pressure gauge (0-25 MPa) to the measuring outlet for
brake pressure on the distribution block on the front axle.
5 Close the drain valve on the accumulator charging valve.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
6 Start the machine and run it at idling speed until the accumulators
are charged and the accumulator charging valve changes to
cooling.
7 Press down the pedal completely and read off the pressure.
Compare to the pressure plate on the left frame member.
8 Stop the engine
9 Depress the pedal fully and keep it pressed down, check the
pressure.
The brake pressure must correspond with the value specified on
the pressure plate and must not decrease from this value for 15
seconds.
10 Release the pedal, the brake pressure must decrease to 0 MPa
immediately. Otherwise the brake valve is not sealed and can
cause the brakes to remain applied and then overheat during op-
eration.
Replace the brake valve if it is not sealed.
11 Depressurize the hydraulic systems, See section B Safety.
12 Remove the pressure gauge and fit the protective cap on the
measuring outlet.
13 Close the drain valve on the accumulator charging valve.
NOTE
009873
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Machine in service position, see section B Safety.
2 Depressurize the hydraulic systems, See section B Safety.
3 Mark up and detach the hydraulic hoses from the brake valve.
B
T NOTE
P Plug the connections immediately to protect the brake sys-
tem from impurities.
009875 4 Secure the brake valve under the cab.
NOTE
Remember the spacer ring.
T
NOTE
P
Check that the O-rings are intact and are fitted correctly.
10 Grease and adjust the brake pedal, see Brake pedal, checking
and adjusting page 3.
004795
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. Run the en-
gine at idling speed.
13 Test the brakes a couple of times.
14 Check that the brake valve's connections are sealed tightly.
15 Bleed the wheel brakes' brake cylinders, see Wheel brakes,
bleeding page 28.
009868
The drive axle block distributes oil flow and brake pressure to the right
1
10 and left-hand wheel brakes. The drive axle block is located on a brack-
2 et above the drive axle differential.
1
3 The drive axle block has a measuring outlet for brake pressure and for
3 measuring back pressure in the disc brake’s cooling circuit.
4
The drive axle block has a bypass valve which guides oil directly from
5
5 the cooling circuit intake to the cooling circuit return if the resistance in
9 the axle becomes too great. This protects the wheel brake seals, e.g.
6
when the oil is cold.
8 7 There are two contacts in the drive axle block: brake light NO switch
(216), see Switch normally open (NO), brake lights, description page
25 and disengagement NO switch, see section 2 Transmission,group
2.8.2 Normally closed (NC) switch, disengagement.
009876
The brake pressure NC switch (S204) detects the pressure in the ac-
cumulators. The NC switch is located on the accumulator charging
valve on the lifting beam in front of the gearbox in the engine
compartment.
When the pressure in the feed circuit is high enough to ensure braking
of the machine, the sensor closes an electric circuit. This is used to
warn for pressure-drop in the brake system. The sensor’s opening
pressure is chosen so that there is pressure for at least 8 brake appli-
cations without additional feed from the pump after the light has gone
off.
The brake pressure NC switch (S204) is supplied power by the frame
control module (D797-1). When the pressure increases above the cut-
off pressure, the voltage signal to frame control unit (D797-1) is cut off.
The signal can be checked from the diagnostic menu, see tab 8 Con-
trol system , group 8.4.5.4 HYD, menu 4.
009877
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Operate and warm up the machine until the oil reaches operating
temperature, at least 50 °C.
2 Machine in service position, see section B Safety.
3 Depressurize the hydraulic systems, See section B Safety.
4 Connect a pressure gauge (0-25 MPa) to the measuring outlet for
accumulator pressure on the accumulator charging valve.
5 Close the drain valve on the accumulator charging valve.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
6 Start the engine and fully charge the accumulators (the accumu-
lator charging valve changes to cooling).
7 Stop the engine and turn the starter key to position I.
8 Brake several times, stop when the warning lamp for low brake
pressure comes on.
9 Read off the accumulator pressure. The pressure should be ap-
prox. 11.5 MPa.
004810
NOTE
The setting is very sensitive, turn max. 1/4 turn at a time.
11 Repeat steps 6-10 until the warning lamp comes on at 11.5 MPa.
12 Seal the adjusting screw with locking fluid.
13 Depressurize the hydraulic systems, See section B Safety.
14 Remove the pressure gauge and fit the protective cap on the
measuring outlet.
15 Close the drain valve on the accumulator charging valve.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
The brake light NO switch controls brake light activation when the ma-
chine brakes. The switch is located on the drive axle block which sits
on a bracket above the drive axle differential.
The brake light NO switch (S216) is supplied power by and sends a
voltage signal to the frame control unit (D797-1). When the pressure
increases above the closing pressure, a voltage signal is sent to the
frame control unit (D797-1).
The signal can be checked from the diagnostic menu, see tab 8 Con-
trol system , group 8.4.5.4 HYD, menu 4.
009878
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Operate and warm up the machine until the hydraulic oil reaches
operating temperature, at least 50 °C.
2 Stop the engine and turn the starter key to position I.
3 Brake and check that the brake light comes on.
4 Depressurize the hydraulic systems, See section B Safety.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
7 Start the engine.
DECLUTCH PRESSURE X 9 Press down the brake pedal slowly until the brake light is activat-
ed or the status of the input signal changes. Keep the pedal in this
position and check the pressure on the pressure gauge.
The status can be changed and the brake light should come on
when the pressure is approx. 0.2 MPa.
10 Stop the engine
11 Depressurize the hydraulic systems, See section B Safety.
12 Remove the pressure gauge and fit the protective cap on the
measuring outlet.
13 Close the drain valve on the accumulator charging valve.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
The wheel brakes brake the machine during operation and are located
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 effective cooling. Maintenance requirements are minimised since oil
circulates in the brake system and prevents corrosion.
009879
The wheel brakes have two main sections - disc assembly and brake
1 2
cylinder. The disc assembly performs the braking. The brake cylinder
presses the discs in the disc assembly together during braking.
000016
NOTE
Read the safety instructions for oil before working, see section B
Safety.
IMPORTANT
Both brake cylinders must be bled after work where
the brake system is opened or after work on the wheel
brake.
NOTE
The hydraulic hose between the brake pedal and brake is
approx. 7 metres long. Therefore, allow at least two litres of
oil to pass through the air bleeder nipple when bleeding to
ensure that no air pockets remain in the system.
Bleed nipple, brake cylinder, on top of the drive axle at 5 Close the bleed nipple.
the wheel hub's inner short side (left-hand side). 6 Move the spanner and hose and repeat steps 1–4 on the other
side.
7 Check the oil level in the brake system, fill as necessary.
The disc assembly consists of several thin metal discs fixed alternately
to the wheel brake housing and to the hub reduction housing. The
discs are mounted on splines, which allows them to move laterally.
Oil circulates between the discs cooling them, thus the name wet disc
brake. The oil is the same as in other parts of the brake system.
Braking is effected by the brake cylinder pressing together the discs.
This creates friction between the discs that are fixed to the axle and
those fixed to the hub reduction.
000008
Disc assembly
Brake cylinder
D5
5
6 12
D790-1 D790-2
D797-1
7 11
C D8 D10
4
8
Pa 10 9
C ACC
3
H
P
T
2
008060
B
Pos Explanation Signal description Reference
1 The hydraulic oil pump pumps oil from P = 21 ±1 MPa Hydraulic oil tank, description page 38
the hydraulic oil tank. Hydraulic oil pump, description page 9
2 The hydraulic oil filter cleans dirt from the - Hydraulic oil filter, description page 39
oil.
3 The accumulator charging valve directs Charge: P = 20.5 Accumulator charging valve, description
oil to charging of accumulators or through ±0.5 MPa page 12
the brake system's cooling circuit. Cooling: P < 0.1 MPa
4 The accumulators store oil pressure. See pressure plate on left Accumulator, description page 15
frame beam.
5 Switch parking brake (S107) activates Switch activated: Section 9 Frame, body, cab and accesso-
parking brake. Conn 1, U = 24 V ries , group 9.1 Controls and instruments
The switch uses two signals - one for ap- Conn. 7, U = 0 V D5: Diagnostic menu, see section 8 Con-
plied and one for released parking brake. trol system , group 8.4.5.5 HYD, menu 5
Switch in resting position:
Both signals must be correct to enable re-
lease of the parking brake. Conn. 1, U = 0 V
Conn. 7, U = 24 V
6 The cab control unit (D790-1) transmits Controlled by control sys- Section 11 Common electrics , group
Activate parking brake on the CAN bus. tem, error shown with er- 11.5.3.1 Cab control unit (D790-1)
ror code.
7 The frame control unit (D797-1) activates U = 24 V Solenoid valve parking brake, description
the parking brake solenoid valve (Y642). page 33
D7: Diagnostic menu, see section 8 Con-
trol system , group 8.4.5.5 HYD, menu 5
8 Solenoid valve parking brake (Y642) af- Pump pressure Solenoid valve parking brake, description
fects the valve spool which drains pres- page 33
sure in the parking brake calliper to tank.
9 The brake caliper is drained of pressure 0 MPa Parking brake unit, description page 34
and the spring applies the parking brake.
10 The parking brake NC switch (S200) Applied parking brake: Parking brake NC switch, description page
closes the circuit when the pressure Conn 1, U = 24 V 37
increases. D10: Diagnostic menu, see section 8 Con-
Conn. 2, U = 0 V
trol system , group 8.4.5.5 HYD, menu 5
Released parking brake:
Conn 1, U = 24 V
Conn 2, U = 24 V
11 The frame control unit (D797-1) transmits Controlled by control sys- Section 11 Common electrics , group
Parking brake applied on the CAN bus. tem, error shown with er- 11.5.3.2 Frame control unit (D797-1)
ror code.
12 The KIT control unit (D790-2) activates Controlled by control sys- Section 9 Frame, body, cab and accesso-
the parking brake indicator light (508). tem, error shown with er- ries , group 9.1 Controls and instruments
ror code.
1 4
2 5 6
12
008062
11 10 9 8
The parking brake solenoid valve (Y642) activates the parking brake.
The solenoid valve sits on the accumulator charging valve, which is lo-
cated on the lifting beam in front of the gearbox in the engine compart-
ment; see Accumulator charging valve, description page 12.
The solenoid valve opens a connection between the accumulators and
the parking brake calliper at activation. This means that the parking
brake calliper is pressurised and the parking brake is disengaged.
When the voltage feed to the solenoid valve is cut off, the connection
between the accumulators and parking brake calliper is terminated. In-
stead, a connection between the parking brake calliper and tank is
opened and the parking brake applied. This means that the parking
brake is applied if the machine loses electrical power or if the brake
system becomes depressurised.
The solenoid valve is supplied with voltage by the frame control unit
009880
(D797-1) at activation.
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.5.5 HYD, menu 5.
DANGER
The machine may start to roll. Risk of crushing.
1 Start the engine and run the engine at idling speed until the warn-
ing lamp for brake pressure goes out and the accumulator charg-
ing valve changes to cooling.
2 Turn off the engine and turn the start key to position I.
3 Release the parking brake with switch parking brake and check
that the parking brake’s brake caliper releases. The brake caliper
should be able to move.
4 Activate the parking brake with the parking brake switch and
check that the parking brake’s brake caliper is applied.
The parking brake unit keeps the machine stationary when parked.
3 1 2
The parking brake unit is located on the drive axle input shaft between
the propeller shaft and drive axle.
The parking brake acts on the propeller shaft via a disc mounted on
the drive axle input shaft and a brake 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 ac-
tivated before the pressure drops so low that the parking brake is
applied. If the parking brake is applied while the machine is on the
move, the brake disc and brake pads must be checked and re-
placed if necessary.
009881
DANGER
The machine may start to roll.
Risk of crushing.
1 Start the engine and run up hydraulic pressure until the accumu-
lators are fully charged and the accumulator charging valve
switches to cooling.
2 Turn off the engine and turn the start key to position I.
3 Release the parking brake.
4 Check that the parking brake caliper can move on the bracket.
5 Check that the brake disc is free from oil and dirt.
6 Remove the cover from the brake calliper and check for oil inside
the cover. Oil inside the cover indicates internal leakage.
NOTE
To avoid turning the adjustment screw as well it must be
held still when tightening the lock nut.
11 Refit the cover to the caliper.
12 Test the operation of the parking brake.
The brake calliper has a spring section and a hydraulic section. The
1 2 3 4 5
spring section applies the brake while the hydraulic section is used to
release the brake. This means that the parking brake is applied if the
brake system loses pressure. This, in turn, means that the machine is
braked if a serious fault arises.
000020
1. Brake pads
2. Release cylinder
3. Application spring
4. Release screw
5. Adjusting washer
The brake pads consist of a metal plate with friction material (lining).
DANGER
The machine may start to roll.
Risk of crushing.
6 Pull the attaching bolt out so that the brake pads can be angled
out and removed.
NOTE
The bolt does not need to be removed.
7 Remove the parking brake pads.
8 Clean the brake disc with methylated spirit.
9 Install new parking brake pads.
10 Press the attaching bolt back.
11 Fit the nut and a new split pin.
12 Adjust the parking brake, see Parking brake unit, checking and
adjusting page 34.
The brake disc is mounted on the drive axle input shaft. The drive ax-
le’s gear ratio amplifies the braking force.
NOTE
Gears cannot be engaged when the parking brake is applied.
function description
C C
4
P T
2 5
3
002611
Pos Explanation Signal description Reference
1 The hydraulic oil pump pumps oil from See pressure plate on left Hydraulic oil pump, description page 9
the hydraulic oil tank. frame beam. Section 10 Common hydraulics , group
10.3.1 Tank
2 The hydraulic oil filter cleans the oil. - Hydraulic oil filter, description page 39
3 The accumulator charging valve directs Charge: P = 20.5 ±0.5 MPa Accumulator charging valve, description
oil to charging of accumulators or Cooling: P < 0.1 MPa page 12
through the brake system's cooling
circuit.
4 The oil cools the wheel brake. - Wheel brake, description page 27
5 The bypass valve in the distribution - Drive axle block, description page 23
block leads oil past the drive axle if the
back pressure through the wheel brake
is too high.
component positions
Hydraulic oil pump, hydraulic oil filter, accumulator charg-
ing valve, drive axle block, wheel brakes
See Power-assisted brake system, component positions page 8.
5 Steering
5 Steering........................................................................................................... 3
5.2 Power assisted system ............................................................................... 3
5.2.1 Hydraulic oil pump ................................................................................. 5
5.2.2 Priority valve .......................................................................................... 6
5.2.3 Steering valve ........................................................................................ 8
5.2.4 Steering cylinder .................................................................................. 10
5.2.5 Steering axle cradle ............................................................................. 12
5.2.6 Link arm ............................................................................................... 12
5.2.7 Wheel spindle ...................................................................................... 12
5.2.8 Wheel hub ............................................................................................ 12
5.2.9 Shuttle valve ........................................................................................ 13
5.2.13 Pipes and hoses .................................................................................. 13
5 Steering
mm mm mm mm mm mm
description
2
PP P
C
CF LS
T
5
P
LS T L R
3
1
6
008053
Pos Explanation Signal description Reference
1 The hydraulic oil pump pumps oil to the See pressure plate on left Section 10 Common hydraulics , group
priority valve. frame beam. 10.4.2 Axial piston pump with variable
displacement
2 The priority valve prioritises pressure Checked by control sys- Priority valve, description page 6
supply to the steering valve over the tem, error shown with er-
working hydraulics. The priority valve ror code.
also transmits a control signal to the hy-
draulic oil pump.
3 Shuttle valve control selects the strong- Checked by control sys- Section 10 Common hydraulics, group
est load signal to the hydraulic oil pump tem, error shown with er- 10.5.3 Shuttle valve
if hydraulic functions are activated at the ror code.
same time as the steering wheel is
turned.
4 The steering wheel is turned and acts on - Section 9 Frame, body, cab and accesso-
the steering valve's input shaft. ries, group 9.1 Controls and instruments
6 The steering cylinder turns the wheels. - Steering cylinder, description page 10
positions
4
5
6
1 009972
Hydraulic components
1. Hydraulic oil pump for steering and load handling 4. Connection terminal, return oil
2. Shuttle valve 5. Steering valve
3. Priority valve 6. Steering axle with steering cylinder
Steering is supplied oil by the hydraulic oil pump for steering and load
handling; see section 10 Common hydraulics , group 10.4 Pumps.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Operate and warm up the machine so that the hydraulic oil reach-
es operating temperature, 50 °C.
2 Machine in service position, see section B Safety.
3 Connect the pressure gauge to the measuring outlet on the hy-
draulic oil pump for steering and load handling.
4 Start the engine and increase engine speed to approx. 1200 rpm.
009885
1 2 The priority valve separates the oil flow from the hydraulic oil pump for
steering and load handling so that there is always oil to the steering
valve. The residual flow goes to the working hydraulics or the servo
circuit.
The priority valve is load sensing and pilot pressure compensating.
Load sensing means that the valve adapts the control signal to the
steering valve’s consumption. Pilot pressure compensating means
that the priority valve compensates for the pressure drop between the
3 priority valve and steering valve via a separate line.
6 4
5 The priority valve has a built-in pressure limiter on the load signal. The
pressure limiter maximizes the load signal’s pressure.
009884
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Machine in service position, see section B Safety.
2 Depressurise the hydraulic system, see section B Safety.
3 Turn the start key to position 0 and turn off the main electric
power.
1 2 4 Mark up and detach the hydraulic hoses from the priority valve.
NOTE
Plug all connections immediately to protect the brake sys-
tem from impurities.
5 Remove the priority valve attaching bolts.
6 Disconnect the priority valve from control valve lift and lower.
NOTE
Transfer one connection at a time so that the marking is not
mixed up.
9 Connect the new priority valve to control valve lift and lower.
CAUTION
009884
The steering valve is a closed centre, non-reaction valve with load sig-
nal connection to the priority valve.
The load signal generates load-dependent control of oil flow from the
1 priority valve to the steering valve. Closed centre means that the steer-
ing valve is closed in its neutral position. This is necessary so that sig-
nal pressure can be connected to the steering valve.
2
5 The steering valve consists of a gear pump and a distribution valve.
When the steering wheel is turned, oil flows from the main pump over
4 3
the gear pump to the distribution valve, which guides oil to the steering
cylinder. The gear pump ensures that the oil flow fed to the cylinder is
proportional to the steering wheel angle.
There are double shock and anti-cavitation valves in the steering
valve. The shock valves protect the hydraulics against pressure spikes
which can arise from impacts on the steering wheels. The anti-cavita-
tion valves (non-return valves) protect against vacuum on the piston’s
rear side, which can lead to cavitation.
009887
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Stop the engine and turn the starter key to position I.
2 Depressurize the hydraulic systems, See section B Safety.
3 Turn the start key to position 0 and turn off the main electric
power.
1. Water valve
2. Steering valve
NOTE
Plug all connections immediately to protect the brake sys-
tem from impurities.
6 Remove the steering valve.
7 Transfer the connection adapters to the new steering valve.
NOTE
Transfer one at a time so that the marking is not mixed up.
8 Connect the hydraulic hoses to the steering valve in accordance
with the marking.
NOTE
Check that the O-rings are intact and are fitted correctly.
9 Connect the new steering valve to the brake pedal.
Place the steering valve and check that the steering wheel shaft’s
splines enter straight in the steering valve’s slot. Install the at-
taching bolts.
10 Turn on the main electric power and start the engine.
11 Check that the connections on the steering valve are sealed.
12 Steer very carefully a few times right - left, to bleed the steering
valve and steering cylinder.
The steering cylinder acts on the wheels via the link arms. The steer-
1 2 3 ing cylinder is a double-acting hydraulic cylinder.
4
009888
1. Steering cylinder
2. Shaft
3. Lock bolt
4. Attaching bolt (locked with locking fluid)
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Park the machine with the wheels fully turned so that the steering
cylinder can be lifted out to one side.
2 Machine in service position, see section B Safety.
3 Depressurise the brake and hydraulic systems, see section B
Safety.
NOTE
Plug all connections immediately to protect the brake sys-
tem from impurities.
NOTE
The steering cylinder is heavy, use lifting equipment.
8 Support the new steering cylinder so that the holes in the attach-
ing bolts are lined up directly opposite the holes in the steering
axle.
9 Lubricate and fit the steering cylinder attaching bolts. Tighten
them crosswise in steps until 680 Nm is reached.
10 Transfer parts to the new steering cylinder.
NOTE
Check that the O-rings are intact and fitted correctly.
009889
NOTE
Check that the O-rings are intact and fitted correctly.
13 Close the drain valve on the accumulator charging valve. See
section B Safety.
14 Start the engine and check for leaks.
The link arm transfers the lateral movement of the steering cylinder to
turning the wheel spindles.
The setting of the steering wheels cannot be adjusted. If the link arms
are deformed in a way that changes the setting of the steering wheels,
they must be replaced.
The link arms must be turned to the right direction, otherwise they can
1 be damaged by the rims with large wheel angles.
008854
1. Link arm
6 Suspension
6 Suspension..................................................................................................... 3
6.2 Suspension ................................................................................................. 3
6.2.1 Steering axle cradle ............................................................................... 4
6.2.2 Wheel spindle ........................................................................................ 6
6.2.3 Wheel hub .............................................................................................. 8
6.3 Tyre and rim system ................................................................................. 13
6.3.1 Tyres .................................................................................................... 15
6.3.2 Rims ..................................................................................................... 16
6.3.3 Nut, washer and clamp ........................................................................ 17
6 Suspension
mm mm mm mm mm mm
6.2 Suspension
Bushing steering axle mounting, changing
page
–
DANGER
Steering axle and machine are very heavy.
NOTE
Do not lift so much that the wheels are off the ground.
5 Remove the shafts holding the steering axle.
6 Lift the machine so that the frame is off the steering axle.
7 Support the machine under the frame.
8 Move the steering axle so that the mountings can be accessed.
NOTE
If needed, disconnect the cabling for the sensors on the
steering axle.
009890
010121
Steering axle
1. Wheel hub
2. Wheel spindle
3. Link arm
4. Steering axle cradle
5. Steering cylinder
6. King pin/bearing
DANGER
Steering axle and machine are very heavy.
NOTE
Plug all unions at once to protect the hydraulic system from
contamination.
9 Remove the shafts holding the steering axle.
10 Lift the machine up so that the frame is lifted away from the axle.
11 Lift out the steering axle.
CAUTION
The steering axle may start to roll.
Crushing injury!
Make sure that the steering axle does not start uncon-
trolled movement.
NOTE
Check that the O-rings are intact and that they are fitted
correctly.
18 Remove the lifting equipment from the machine.
The wheel spindle is the link between steering axle and wheel hubs
which means that the wheels can be turned.
3
2
4
5
1 6
8 7
9
009780
11 10
1. Wheel spindle
2. Seal ring
3. Bearing (upper)
4. Guard ring
5. Seal ring
6. Bearing (lower)
7. Circlip
8. Shim
9. Bearing cage
10. Bolt
11. Grease nipple
7 Remove the six screws holding the bearing cage to the wheel
spindle.
14 From underneath, tap in the outer bearing race of the upper bear-
ing into the steering axle cradle. Use a pipe of a suitable diameter
so as not to damage the bearing race.
15 Refit the three screws on the top of the steering axle cradle.
16 Fit upper bearing’s inner bearing race, seal ring, guard ring and
seal ring as well as the lower bearing’s inner bearing race and cir-
clip on the wheel spindle.
17 Fit the wheel spindle.
18 Tap the lower bearing’s outer bearing race into the bearing cage.
Use a pipe of a suitable diameter so as not to damage the bearing
race.
19 Fit the bearing cage. Use a shim to get it in the right position.
Tighten the screws.
20 Check that the wheel spindle rotates smoothly and that there is
no play in the spindle bearing arrangement. Correct with shims as
necessary.
NOTE
The correct number of shims have been used when it takes at
least 200 Nm to move the bearing arrangement to move laterally.
If it takes more than 400 Nm for the bearing arrangement to
move, it is too hard and the number of shims must be corrected.
21 Lubricate the wheel spindle bearings via the grease nipples.
22 Fit the wheel hub and wheel bearing; see Wheel bearing, re-
placement page 8.
23 Connect the link arm to the wheel spindle.
24 Fit the wheel.
25 Remove the support and lower the steering wheel.
26 Test-run the machine and test the steering. Check also that the
machine feels stable when driving straight ahead.
The wheel hub holds the wheel in place and allows the wheel to rotate.
3 2
1
4
5
6
7
8
9
10 11
008595
1. Wheel hub
2. Wheel bolt
3. Wheel nut
4. Hub cap
5. Spacer
6. Nut
7. Washer
8. Bearing
9. Bolt
10. Bearing
11. Seal ring
1 Lift the machine under the steering axle by the wheel in question.
Support securely under the steering axle.
2 Remove the steering wheel in question.
7 Bend up the lock washer’s tabs, remove the lock nut and the lock
washer.
8 Tension the lifting equipment so that the hub is unloaded.
9 Remove the hub nut.
NOTE
Fit the outer bearings with the larger diameter outward.
16 Fit a new seal on the inside with the seal lip turned out.
Press in a new seal in the hub. Use a suitable round plate, the
seal does not tolerate impacts from a hammer.
NOTE
Turn the seal correctly.
17 Install the inner bearing’s inner race and rollers on the wheel
spindle. Pack the bearing with universal grease "EP2".
18 Fill the empty space in the hub with universal grease "EP2".
DANGER
Always block the wheels on the side of the axle that is
not going to be worked on before positioning the jack.
Always secure the jack to prevent it from sliding out
of position.
CAUTION
When removing wheels, the wheel nuts should be left
in place after loosening. If the wheel nuts are removed
immediately, the wheel may release from the hub.
6.3.1 Tyres
Tyres, description
page
–
The tyres are the point of contact between the machine and the
ground. These 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 exchange tyres shall be of a make approved by Kalmar
Industries.
009892
Front wheels
009893
Rear wheels
Tyre replacement
page
–
DANGER
Changing tyres is complicated and dangerous work.
FATAL DANGER!
The rims must be checked when tyres are changed. See Maintenance
manual DCF 90-100.
6.3.2 Rims
Rim, description
page
–
The rim is split to make it possible to fit a tyre, the rim consists of the
1 2 3 4
following parts.
• Rims
• Rim bead seat
• Rim flange
• Lock ring
5
009899
1. Rims
2. Lock ring
3. Rim flange
4. Rim bead seat taper
5. Wheel nut
6. Wheel bolt
5
009899
1. Rims
2. Lock ring
3. Rim flange
4. Rim bead seat taper
5. Wheel nut
6. Wheel bolt
7 Load handling
7 Load handling................................................................................................. 3
7.1 Controls and instruments ........................................................................... 5
7.1.1 Control levers ......................................................................................... 5
7.1.2 Switch, lock twistlock/lock tongue .......................................................... 7
7.1.3 Switch, spreading 20'-40' ....................................................................... 7
7.1.4 Switch, stop at 30' .................................................................................. 8
7.1.13 Switch, automatic spreading .................................................................. 8
7.2 Lifting/lowering ........................................................................................... 9
7.2.1 Hydraulic oil pump ............................................................................... 12
7.2.2 Servo filter ............................................................................................ 12
7.2.3 Pressure reducer ................................................................................. 13
7.2.4 Accumulator servo circuit ..................................................................... 14
7.2.5 Control valve, lift and tilt ....................................................................... 15
7.2.6 Shuttle valve ........................................................................................ 17
7.2.7 Lift cylinder ........................................................................................... 17
7.2.8 Sensor hydraulic pressure lift cylinder ................................................. 17
7.2.9 Mast ..................................................................................................... 19
7.2.10 Mast position sensor ............................................................................ 28
7.2.11 Lifting carriage ..................................................................................... 29
7.2.12 Valve block quick-lift ............................................................................ 33
7.2.13 Pipes and hoses .................................................................................. 33
7.4 Side shift ................................................................................................... 34
7.4.1 Hydraulic oil pump ............................................................................... 36
7.4.2 Control valve attachment ..................................................................... 36
7.4.3 Side shift cylinder ................................................................................. 40
7.4.4 Shuttle valve ........................................................................................ 40
7.4.5 Lifting carriage ..................................................................................... 41
7.4.6 Valve block, main pump relief .............................................................. 42
7.4.7 Attachment relief valve ........................................................................ 42
7.4.8 Pipes and hoses .................................................................................. 42
7.5 Spreading ................................................................................................. 43
7.5.1 Hydraulic oil pump ............................................................................... 50
7.5.2 Control valve attachment ..................................................................... 50
7.5.3 Spreading cylinder ............................................................................... 51
7.5.4 Spreader beam .................................................................................... 52
7.5.5 Main beam, side lifting attachment ...................................................... 53
7.5.6 Position sensor positioning .................................................................. 58
7.5.7 Buzzer, automatic spread 20'-40' ........................................................ 58
7.5.8 Pipes and hoses .................................................................................. 59
7.7 Tilt ............................................................................................................. 60
7.7.1 Hydraulic oil pump ............................................................................... 62
7.7.2 Accumulator ......................................................................................... 62
7.7.3 Pressure reducer ................................................................................. 62
7.7.4 Servo filter ............................................................................................ 62
7 Load handling
mm mm mm mm mm mm
Position sensor
page
–
3
1
4
009906
The illustration depicts a machine with a twistlock attachment
1. Sensor, hydraulic pressure in the lift cylinder (B768-L1), see Sen-
sor hydraulic pressure lift cylinder, description page 17.
2. Mast position sensor (B7211-2), see Position sensor, adjusting
page 4.
3. Sensor alignment
(Twistlock B7203L and B7203R), see Alignment sensor, checking
and adjusting page 77,
(Lifting hook B7203LL, B7203LU-2, B7203RL and B7203RU-2),
see Alignment sensor, checking and adjusting page 90.
4. Sensor, locked twistlocks/lock tongues (B7205LL and B7205RL),
see Twistlocks sensor, checking and adjusting page 79 or Lock
tongue sensor, checking and adjusting page 92.
5. Detection sensor, upper container (ultrasound) for attachment
with lifting hook (B7203LU and B7203RU), see Detection sensor,
upper container, checking page 91.
6. Damping sensor (B769L, B769R, B777L and B777R), see Posi-
tion sensor, adjusting page 4.
C-C
3 Check that the distance between the sensor and the indicator is
5±1 mm
5 ±1 mm.
4 Adjust if necessary.
009632
5±1 mm
d. Levelling (R8075-1-P5) .
RIGHT side up - push lever forwards.
LEFT side up - pull lever backwards.
e. Emergency stop switch
f. Opening of locked twistlocks/lock tongues, attachment (S1002)
Pull the switch sideways.
f
008110
The control lever (S815) is used to control the mast and attachment.
2 3
1 The lever sends voltage signals to the cab control unit (D790-1).
4 The control lever has four potentiometer-controlled functions and six
on/off functions.
5
Lifting/lowering
6
Lifting and lowering are controlled by moving the control lever forward
7 (lower - position 10) or rearward (lift - position 12). See Lift and lower,
function description page 9.
8
The signal can be checked from the diagnostic menu, see section 8
12 9 Control system , group 8.4.8.1 ELSERV, menu 1.
Spreading
009711
Tilt
Tilt is controlled by moving the lever to the right (tilt out - position 10)
or the left (tilt in - position 12). See Tilt, function description page 60.
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.8.1 ELSERV, menu 1.
action.
Twistlocks are opened with the switch on the control lever, see Control
levers for electric servo, description page 5.
The switch is supplied power by and sends a voltage signal to the cab
control unit (D790-1).
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.9.3 ATTACH, menu 5.
Switch (green) for spreading 20’ to 40’ (S1012). The spreader remains
in the position it held when the switch was released. The switch has a
return spring.
This function is used to adapt the attachment to the width of the
containers.
009910
The switch (green) for spreading stop for the attachment at 30’
(S1004) activates the 30-foot stop. When the switch is depressed, the
35 function changes from spreading from 20’–40’ to stop at 30’.
30-
The switch is supplied power by and sends a voltage signal to the cab
control unit (D790-1).
009909
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.9.2 ATTACH, menu 3.
Switch (green) for automatic spreading between 20’ and 40’ (S1004).
When the switch is depressed, spreading automatically goes to the
next position (20, 30 or 40 feet) if spreading is activated with the con-
trol lever.
This switch is used to activate automatic spreading.
009908
WARNING
Risk of pinching and product damage!
7.2 Lifting/lowering
Lift and lower, function description
page
–
Twistlocks/lock Locked or unlocked, not inter- Twistlocks, description page 69 or Lifting hook, description page
tongues mediate position 80
Alignment Mast down: no contact Sensor alignment, description page 77 or Alignment and detec-
tion sensor, description page 90
Bypassed or lift height lower Section 8 Control system, group 8.2.4 Height limitation
Height limitation
than height limitation
2,4 5
D790-1 D794
D1
D21 D15
D797-1
3,16,22
˚<
21
1b 1a
D16 6 6
D3
7
LS
15
17 P
A2
13 B2
14 P PS
8,20,23
12
C
P EF
9
LS
11
19 C C
009367
18 10
1b The control lever (S815-P1) sends the US815-P1 = 0.5-4.5 V Control lever, description page 6
cab control unit (D790-1) a voltage sig- Lower: US815-P1 = <2.5 V D1: Diagnostic menu, see section 8
nal proportional to lever movement. Control system , group 8.4.8.1
Lift: US815-P1 = >2.5 V
ELSERV, menu 1
0.5 V is the fastest lowering
speed and 4.5 V is the fastest lift
speed. Lower voltages than 0.5
V and higher voltages than 4.5 V
are used to detect malfunctions
in cabling and controls.
2 The cab control unit (D790-1) sends the Checked by control system, error Section 11 Common electrics,
frame control unit (D797-1) a lift/lower shown with error code. group 11.5.3.1 Cab control unit
request via the CAN bus. (D790-1)
3 The frame control unit (D797-1) sends I = 380–650 mA Section 11 Common electrics,
current proportional to the lever move- group 11.5.3.2 Frame control unit
ment to the lift mast solenoid valve (D797-1)
(Y6005) or the lower mast solenoid D3: Diagnostic menu, see section 8
valve (Y6004). Control system , group 8.4.8.3
ELSERV, menu 3 and 8.4.8.4
ELSERV, menu 4
4 The cab control unit (D790-1) transmits Checked by control system, error Section 11 Common electrics,
are request for increased engine speed shown with error code. group 11.5.3.1 Cab control unit
on the CAN bus. (D790-1)
5 The engine control unit (D794) increas- Checked by control system, error Section 11 Common electrics,
es engine speed. shown with error code. group 11.5.3.10 Engine control unit
(D794)
6 The lift solenoid valve (Y6005) or the - Control valve, lift and tilt, description
lower solenoid valve (Y6004) pressuris- page 15
es the control valve’s lift spool with servo
pressure.
7 The control valve’s lift spool changes - Control valve, lift and tilt, description
position and pressurises the lift cylinders page 15
and sends a load signal to the hydraulic
oil pumps.
8 The lift cylinders are pressurised and the - Lift cylinder, description page 17
mast is lifted or lowered.
10 The steering hydraulic oil pump and load See pressure plate on left frame Section 10 Common hydraulics,
handling pump oil from the hydraulic oil beam. group 10.4.2 Axial piston pump with
tank to the priority valve and pressure variable displacement
reducer.
11 The priority valve leads feed pressure to - Section 5 Steering, group 5.2.2 Pri-
Control valve lift and lower. ority valve
12 The pressure reducer reduces the oil See pressure plate on left frame Pressure reducer, description page
pressure from the steering hydraulic beam. 13
pump and load handling to servo pres-
sure for the control valve.
13 The accumulator stores servo pressure. See pressure plate on left frame Accumulator servo circuit, descrip-
The non-return valve in the pressure re- beam. tion page 14
ducer makes it possible to store the
pressure when the engine is shut off.
14 The servo filter cleans the servo oil be- - Servo filter, description page 12
fore Control valve lift and lower.
18 The quick-lift hydraulic oil pump pumps See pressure plate on left frame Section 10 Common hydraulics,
oil from the hydraulic oil tank to lifting/ beam. group 10.4.2 Axial piston pump with
lowering control valve. variable displacement
The servo filter prevents the control valve’s servo circuits from contam-
inants. The servo filter sits on the hydraulic plate in front of the trans-
mission, to the right of the servo pressure accumulator.
The servo filter is a low-pressure filter with detachable filter insert. The
oil is cleaned when it passes through the filter insert’s filter material.
The filter insert is pressed against the upper section of the filter hous-
ing by a spring. Rubber gaskets seal between the insert and filter
housing. If the back pressure through the filter is too great the insert is
pressed down so that the oil passes by the insert. This occurs if the oil
009161
The pressure reducer reduces the pressure from the hydraulic oil
1
pump which supplies the servo circuit for control valve servo pressure.
2 The pressure reducer is located on the hydraulic plate in front of the
3 transmission, mounted together with the servo pressure accumulator.
Servo pressure is stored in an accumulator for quicker start-up and for
emergency reduction of load. An integrated non-return valve prevents
pressure leakage from the accumulator when the machine is not in
use.
7
6
5
4 009911
NOTE
Read the instructions for oil before working, see section B Safety.
1 Operate and warm up the machine so that the hydraulic oil is at
operating temperature, at least 50 °C. As an alternative, operate
until the cooling fan is activated.
2 Machine in service position, see section B Safety.
3 Depressurize the hydraulic systems, See section B Safety.
4 Connect a pressure gauge (0–25 MPa) to the test outlet on the
pressure reducer.
009912
5 Start the engine and check the servo pressure. Compare with the
pressure plate.
M Pa Turn the steering wheel or activate a load handling function to ac-
tivate the hydraulic oil pumps. The servo pressure is higher than
the standby pressure of the hydraulic oil pumps.
6 If the pressure does not match the value specified on the pres-
sure plate, adjust the servo pressure adjusting screw until the
right pressure is obtained; see Pressure reducer, description
page 13. Slacken the lock nut and turn the adjusting screw.
NOTE
If the servo pressure is too high, a load handling function
009913 must be activated so that servo pressure is used from the
accumulator for a reduction on the adjusting screw to be
seen on the pressure gauge. Sometimes the engine has to
be shut off between the checks.
Clockwise: reduce pressure.
Counter-clockwise: increase pressure.
7 Depressurize the hydraulic systems, See section B Safety.
8 Remove the pressure gauge and fit the protective cap on the
measuring outlet.
The accumulator stores pressurised oil and ensures that there is servo
pressure for activating control valve functions. The accumulator sits on
the hydraulic plate in front of the transmission, on top of the pressure
reducer.
The accumulator is a diaphragm type and is divided into two spaces
by a diaphragm. One side of the diaphragm is pressurised with nitro-
gen gas. The other side is pressurised by hydraulic oil which compacts
the nitrogen gas.
Furthest up on the accumulator is a test outlet for checking gas pres-
sure and filling gas.
009914
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Depressurize the hydraulic systems, See section B Safety.
2 Machine in service position, see section B Safety.
3 Detach the accumulator from its mounting.
4 Replace the accumulator.
5 Fit in the reverse order.
6 Check the oil level and fill with hydraulic oil as necessary.
4 7
3
8
2
5
1 6
14 11
13 12 10
009915
1 Solenoid valve, lift (Y6005) 8 Connection, rod side, right lift cylinder (B1)
2 Solenoid valve, lower (Y6004) 9 Connection, piston side, tilt cylinder (A1)
3 Connection, piston side, left lift cylinder (A2) 10 Connection, rod side, tilt cylinder (B1)
4 Connection rod side left lift cylinder (B2) 11 Connection return to tank (T)
5 Connection, feed from hydraulic oil pump (P) 12 Connection, piston side, tilt cylinder (A1)
6 Connection, feed from priority valve (P) 13 Solenoid valve, tilt out (Y6010)
7 Connection piston side right lift cylinder (A1) 14 Solenoid valve, tilt in (Y6011)
The control valve controls speed and direction of lift and tilt. The con-
trol valve is located on the hydraulic plate in front of the transmission.
The valve has two sections - one for the lift function and one for the tilt
function. The sections have many similarities, but are described sep-
arately under the respective function. For tilt, see Control valve, lift and
tilt, description page 62. Electric control valves control the flow from
the valve.
The control valve is proportionally controlled by solenoid valves. This
means that both volume and direction of the flow from the valve can
be adjusted and that the valve can also send a control signal to the
variable pumps.
Electrically controlled pressure reducing valves (solenoid valves) con-
vert electrical current into a low hydraulic pressure that is proportional
to the current, known as the servo pressure. The servo pressure acts
on the spring-centred control spool in the control valve for the function
in question and thereby controls the main flow.
The speed of the function is controlled by means of the flow being reg-
ulated in proportion to the lever movement.
Lift spool
The lift spool controls direction and flow of oil to the lift cylinder.
The lift cylinders lift and lower the inner mast, which runs inside the
outer mast. The lower parts of the lift cylinders are fixed to the outer
mast, while their upper parts are fixed to the inner mast - one on the
right and one on the left of the mast.
A sensor that measures hydraulic pressure in the lift cylinder is situat-
ed on the left lift cylinder.
The lift cylinder is fastened in the mast with nuts in the bottom and a
washer and screw in the top.
The lift cylinders are connected in parallel and fed from lift and tilt con-
trol valve, see Control valve, lift and tilt, description page 15.
009916
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Machine in service position, see section B Safety.
2 Depressurize the hydraulic systems, See section B Safety.
3 Detach the wiring from the lift cylinder hydraulic pressure sensor.
4 Remove the lift cylinder hydraulic pressure sensor.
NOTE
Plug all connections immediately to protect the hydraulic
system from impurities.
5 Fit a new sensor.
NOTE
Check that the O-rings are intact and fitted correctly.
6 Connect the wiring to the hydraulic pressure sensor.
009188
CAUTION
Air in the hydraulic system may cavitate and result in
product damage.
CAUTION
Overfilling of oil.
12 Check pressure and signals with the diagnostic menu, see sec-
tion 8 Control system , group 8.4.5.3 HYD, menu 3 or group
8.4.10.1 OLS, menu 1.
7.2.9 Mast
Lift masts, description
page
–
The mast, which is a free-view mast, lifts the load. The lifting carriage
1 runs along the mast. This, in turn, holds the side lifting attachment.
The lower part of the mast is fixed to the frame by two shafts in two
double lugs on the front of the frame. The mast is also fixed to the
2
frame by two tilt cylinders.
The mast consists of an outer mast and an inner mast, made from high
strength steel, with a minimum number of welds for highest strength.
3 The inner mast runs inside the outer mast, and is lifted and lowered by
the lift cylinders. Mast wheels and slide plates between the inner and
outer masts guide the inner mast in the outer mast and reduce friction
between the two parts of the mast.
4 The lower parts of the lift cylinders are fixed to the outer mast, while
their upper sections are fixed to the inner mast. When oil is forced into
the lift cylinders, the piston rods in the cylinders are forced out and the
inner mast is lifted. The chain which is fixed to the carriage (and the
outer mast), runs over sprockets at the top of the inner mast. This also
lifts the carriage at the same time as the inner mast.
Hydraulic hoses and cables for the lifting carriage and side lifting at-
tachment functions run along the left side.
009918
1. Inner mast
2. Lifting eye
3. Outer mast
4. Lift cylinder
Mast, removing
page
–
NOTE
Read the safety instructions for oil before working, see section B
Safety.
NOTE
It is possible to remove the lifting carriage and the side lifting at-
tachment as a unit.
1 Remove the side lifting attachment; see Side lifting attachment,
removing page 53.
009974
NOTE
Plug all connections immediately to protect the hydraulic
system from impurities.
9 Mark up and detach the electrical connections of the mast.
009980
NOTE
Plug all connections immediately to protect the hydraulic
system from impurities.
009981
14 Undo the nuts and bolts and remove the shafts which fix the mast
to the frame.
009979
WARNING
The mast can swing out when it is released from the
machine.
009983
17 Place the mast on the ground and detach the lifting equipment
(overhead crane).
009975
Mast, installing
page
–
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Stop the engine
2 Turn the start key to position I and activate the hydraulic functions
to depressurise the hydraulic system.
3 Turn the start key to position 0 and turn off the main electric pow-
er.
4 Connect lifting equipment to the the mast in a secure manner so
the mast does not tip when lifted.
009975
NOTE
The mast is attached to the machine’s frame with strong
shafts which run in maintenance-free bearings.
It is most important that bearing surfaces are absolutely
clean when the mast is installed.
009977
7 Suspend the mast vertically. Align the mast and position the
shafts in the mast mountings.
009978
13 Lift the tilt cylinders with lifting equipment (overhead crane) and
align the tilt cylinders with the mast.
009982
15 Grease the connectors with contact grease and join them up.
16 Remove the plugs and connect the mast’s hydraulic hoses on the
machine’s front panel.
009981
17 Remove the plugs and connect the hydraulic hoses to the lift cyl-
inders.
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 lifting carriage; see Lifting carriage, installing page 30.
22 Fit the side lifting attachment; see Side lifting attachment, install-
ing page 56.
009980
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Machine in service position, see section B Safety.
2 Remove the lifting carriage; see Lifting carriage, removing page
29.
3 Removing the mast, please refer to Mast, removing page 19.
4 Separate the outer and inner mast.
5 Clean the mast components.
6 Grind the affected surfaces with a band grinder until the surface
is smooth and bare. Start with grain size 36-40 and finish with 60-
80.
Grind in the longitudinal direction of the beam.
250 mm
7 Apply a thin layer of slide grease to the sliding surfaces of the out-
er mast and reassemble the inner and outer masts.
Mast beam size 250 mm. 8 Apply a thin layer of slide grease to the sliding surfaces of the in-
ner mast and fit the mast on the machine; see Mast, installing
page 23.
9 Fit the lifting carriage; see Lifting carriage, installing page 30.
10 Lift and lower the mast as follows to check its function.
Lift and lower the mast 20 times with 50% of the maximum load
at the right centre of gravity distance.
Lift and lower the mast 20 times with 75% of the maximum load
at the right centre of gravity distance.
Lift and lower the mast 20 times with the maximum load at the
right centre of gravity distance.
11 Check that contact surfaces look normal. If not, contact Kalmar
Industries.
NOTE
If the slide plate extends less than 3 mm from the holder, replace
it.
1 Lubricate the inner sliding surfaces of the outer mast with a thin
layer of slide grease.
2 Lift the inner mast 200 mm.
3 Adjust the slide plate in the bottom part of the outer mast so that
it lies against or has no more than 0.5 mm play to the outer mast.
Use a suitable number of shims in the rear and front of the slide
plate so that the slide plate lies evenly against the entire sliding
surface.
4 Raise the mast to its end position and check that the slide plates
do not pinch too hard against the sliding surface.
010152
Slide plates in outer mast, adjusting
page
–
NOTE
If the slide plate extends less than 3 mm from the holder, replace
it.
1 Lubricate the outer sliding surfaces of the inner mast with a thin
layer of slide grease.
2 Lower the inner mast to its bottom position.
3 Lift the inner mast 200 mm.
4 Adjust the slide plate in the top part of the outer mast so that it lies
against or has no more than 0.5 mm play to the inner mast.
Use a suitable number of shims in the rear and front of the slide
plate so that the slide plate lies evenly against the entire sliding
surface.
5 Raise the mast to its end position and check that the slide plates
do not pinch too hard against the sliding surface.
010130
4
NOTE
5 Rotate the mast wheel while tightening the clamping screw.
3 Slacken the clamping screw until the wheel can be rotated some-
what sluggishly. Turn the clamping screw to engage the spring
6 pin in the closest hole.
7
NOTE
Check that there is clearance between the mast wheel and the
mast beam.
4 Lock the clamping screw with the spring pin.
010126
1. Impeller
2. Circlip
3. Cover washer
4. Spring pin
5. Clamping screw
6. Inner bearing
7. Outer bearing
The mast position sensor (B7211-2) activates damping during lift. The
position sensor is used to deactivate the hydraulic oil pump for quick-
lift so that lifting is decelerated when the mast approaches its upper
end position.
For checking and adjusting, see Position sensor, adjusting page 4.
The position sensor sends a signal to the frame control unit (D797-1).
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.8.15 ELSERV, menu 15.
The lifting carriage holds via hydraulic cylinders in the side lifting at-
tachment and runs along the inner mast with slide plates and mast
wheels.
The following functions are controlled via the lifting carriage cylinders:
• Side shift - the attachment can be shifted to the side ± 600 mm.
• Mechanical levelling - the attachment can be levelled ± 3°.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Remove the side lifting attachment; see Side lifting attachment,
removing page 53.
2 Connect lifting equipment to the lifting carriage in a secure
manner.
3 Disconnect the main power supply.
4 Disconnect the lifting carriage cable by undoing the lock plate
screws.
Undo the connectors and protect the terminals by greasing them
with contact grease. Then loosely insert the connectors.
009995
NOTE
Plug all connections immediately to protect the hydraulic
system from impurities.
6 Raise the carriage with the lifting equipment (overhead crane) to
slacken the chains.
009987
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Park the machine with the mast vertical.
2 Raise the mast high enough to position the carriage in the inner
mast and lift it into place.
3 Lower the mast so that the carriage fastens in the inner mast.
Stop the mast in a position where the chains can be fastened to
the carriage. Fit the chain tensioners and adjust and fasten with
the nuts.
4 Lower the carriage as far as possible.
5 Stop the engine
6 Turn the start key to position I and activate the hydraulic functions
to depressurise the hydraulic system.
009986
7 Turn the start key to position 0 and turn off the main electric
power.
8 Remove the plugs and connect the mast’s hydraulic hoses and
the carriage wiring.
009987
9 Connect the lifting carriage cable.
Grease the connectors with contact grease and join them up.
Fasten the wiring with the lock plate.
10 Fit the side lifting attachment; see Side lifting attachment, install-
ing page 56.
11 Turn on the power supply and start the engine.
12 Check that the hydraulic connections are sealed tightly.
13 Check the lifting carriage functions.
009995
necessary, replacing
1 Remove the lifting carriage; see Lifting carriage, removing page
29.
NOTE
Minor adjustment to the clearance between the lifting carriage
A and inner mast is possible without removing the lifting carriage.
2 If the slide plate extends less than 3 mm from the holder, replace
it.
3 Use a gauge in the centre of the beam to measure the interior
width of the inner mast.
B
010123
D
010124
010125
1
2 6 Lubricate the inner sliding surfaces of the inner mast with a thin
1. Screws layer of slide grease.
2. Shim 7 Fit the lifting carriage; see Lifting carriage, installing page 30.
8 Lift the lifting carriage all the way up and check that the slide
plates do not clamp too hard against the sliding surfaces.
For mast wheel adjustment, see Mast wheel, adjusting page 28.
The signal can be checked from the diagnostic menu, see section 8
Control system, group 8.4.5.7 HYD, menu 7.
1b 1a D1
2
D790-1
D797-1 D791-1
3 8 D8
D3 11
9
C
P1 A
4
T1 B
10
5
C
6
7
009180
2 The cab control unit (D790-1) trans- Checked by control system, Section 11 Common electrics, group
mits side shift left or right on the CAN error shown with error code. 11.5.3.1 Cab control unit (D790-1)
bus.
3 The frame control unit (D797-1) acti- U = 24 V Section 11 Common electrics, group
vates the solenoid valve for main 11.5.3.2 Frame control unit (D797-1)
pump relief (Y6062-2). D3: Diagnostic menu, see section 8 Control
system, group 8.4.5.6 HYD, menu 6
4 The solenoid valve for main pump re- - Valve block, main pump relief, description
lief (Y6062-2) routes a relieved con- page 42
stant pressure to the hydraulic oil
pump for load handling. This serves
as a load signal.
6 The cab tilt shuttle valve sends the - Section 10 Common hydraulics, group
load signal on to the hydraulic oil 10.5.3 Shuttle valve
pump for load handling.
7 The hydraulic oil pump for load han- See pressure plate on left Section 10 Common hydraulics, group
dling pumps oil from the hydraulic oil frame beam. 10.4.2 Axial piston pump with variable dis-
tank. placement
9 The solenoid valve for side shift left - Control valve attachment, description page
(Y6020) or the solenoid valve for side 36
shift right (Y6021) pressurises the
side shift spool in the attachment
control valve.
11 The side shift cylinders push in the - Side shift cylinder, description page 40
main beam sideways in relation to the
lifting carriage.
1
2 6
4
5
7
8
10 9
11
13
14
12
15
009936
16 17
8 Solenoid valve spreading out left (Y6018L) 17 Connection, feed from hydraulic oil pump (P)
9 Connection to spreading cylinder left
• Levelling
• Spreading right extension beam
• Spreading left extension beam
• Twistlocks/lock tongues
• Side shift
The solenoid valve for side shift right (Y6021) is controlled electrically
and is activated by the attachment control unit (D791-1). The solenoid
valve guides servo pressure to the side shift spool in proportion to the
control current to the solenoid valve.
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.9.12 ATTACH, menu 12.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Machine in service position, see section B Safety.
2 Depressurize the hydraulic systems, See section B Safety.
3 Mark up and detach the hydraulic hoses from the control valve.
NOTE
Plug all connections immediately to protect the hydraulic
system from impurities.
4 Mark up and detach the wiring from the control valve.
5 Remove the attaching bolts and lift away the valve. Place the
valve on a clean and protected surface.
6 Transfer the connection adapters to the new control valve.
NOTE
Check that the O-rings are intact and fitted correctly.
NOTE
Transfer one adapter at a time so that the marking is not
mixed up.
009937
NOTE
Check that the O-rings are intact and fitted correctly.
11 Turn on the main electric power and start the engine.
12 Check that the valve's hydraulic connections are sealed.
CAUTION
Air in the hydraulic system may cavitate and result in
product damage.
14 Check the hydraulic oil level with all hydraulic pistons fully retract-
ed. The oil level should be at the top of the level glass. Top up as
necessary.
CAUTION
Overfilling of oil.
pressure
NOTE
Read the safety instructions for oil before working, see section B
Safety.
Function Pressure
20.0 MPa
Pressure check connection control valve attachment Levelling
6 Remove the pressure gauge and fit the protective cap on the
measuring outlet.
The side shift cylinder sits between the lifting carriage and the side lift-
ing attachment. It shifts the main beam laterally in relation to the lifting
carriage.
009923
NOTE
The thickness should be at least 10 mm.
8 Place the slide plate in the correct position.
Check the clearance between the side lifting attachment and the
lifting carriage. Clearance should be less than 1 mm with all slide
plates fitted.
Use a spacer plate to adjust the clearance.
1
NOTE
2 In general, the upper slide plates on the front of the lifting
carriage and the lower slide plates on the rear of the car-
riage are adjusted with shim plates.
NOTE
009190
The valve block for the main pump relief is an electrically regulated
valve that uses relieved constant pressure as a load signal, sending it
to the hydraulic oil pump for load handling when attachment functions
are activated. The valve block sits on the hydraulic plate in front of the
transmission in the engine compartment.
When the solenoid valve is activated, pressure is routed from the hy-
draulics’ supply through a shuttle valve to the hydraulic oil pump for
load handling. A restriction before the valve block ensures that pres-
sure for control of the hydraulic oil pump does not become too high.
009955
When the solenoid valve is not activated, the load signal is drained to
the tank and the inlet from the control valve’s supply is closed.
Valve block, main pump relief
The valve is regulated electrically by the solenoid valve for main pump
relief (Y6062-2), which is activated by the frame control unit (D797-1).
The signal can be checked from the diagnostic menu, see section 8
Control system, group 8.4.5.6 HYD, menu 6.
The attachment relief valve opens the connection between the attach-
ment’s pressure supply and the tank. This is used to drain the pressure
in the attachment hoses prior to work on the hydraulic system. The re-
lief valve sits on the spacer block at the hydraulic oil pump for load
handling.
009961
7.5 Spreading
Spreading, function description
page
–
Twistlocks/Lock tongues Unlocked or bypass Twistlocks, description page 69 or Lifting hook, description page 80
activated Section 8 Control system, group 8.2.2 Bypassing
D1
1b
1a
2
D790-1
D3 10,19 11,20
C
P1 12
4
T1 15
A B A B 21
D15 D16
5 15 16
C
6 13,22 14,22
7
009345
1b The control lever (S815-T1.1 and Spreading: US815-T4 = 24 Control lever, description page 6
S815-T1.2) sends a voltage signal V D1: Diagnostic menu, see section 8 Control
to the cab control unit (D790-1). system, group 8.4.9.2 ATTACH, menu 3
Out: US815-T1.2 = 24 V
2 The cab control unit (D790-1) trans- Checked by control sys- Section 11 Common electrics, group 11.5.3.1
mits spreading in or out on the CAN tem, error shown with error Cab control unit (D790-1)
bus. code.
4 The solenoid valve for main pump - Valve block, main pump relief, description page
relief (Y6062-2) routes a relieved 42
constant pressure to the hydraulic
oil pump for load handling. This
serves as a load signal.
5 The attachment shuttle valve sends - Section 10 Common hydraulics, group 10.5.3
the load signal on to the hydraulic oil Shuttle valve
pump for load handling or the cab tilt
shuttle valve.
6 The cab tilt shuttle valve sends the - Section 10 Common hydraulics, group 10.5.3
load signal on to the hydraulic oil Shuttle valve
pump for load handling.
7 The hydraulic oil pump for load han- See pressure plate on left Section 10 Common hydraulics, group 10.4.2
dling pumps oil from the hydraulic oil frame beam. Axial piston pump with variable displacement
tank to the attachment control valve.
8 The attachment control unit (D791- I = 350–600 mA Section 11 Common electrics, group 11.5.3.5
1) activates the solenoid valve for Attachment control unit (D791-1)
spreading out left (Y6018L) or the D8: Diagnostic menu, see section 8 Control
solenoid valve for spreading in left system, group 8.4.9.17 ATTACH, menu 17 and
(Y6019L). 8.4.9.18 ATTACH, menu 18
9 The attachment control unit (D791- I = 350–600 mA Section 11 Common electrics, group 11.5.3.5
1) activates the solenoid valve for Attachment control unit (D791-1)
spreading out right (Y6018R) or the D9: Diagnostic menu, see section 8 Control
solenoid valve for spreading in right system, group 8.4.9.19 ATTACH, menu 19 and
(Y6019R). 8.4.9.20 ATTACH, menu 20
10 The solenoid valve for spreading out - Control valve attachment, description page 36
left (Y6018L) or the solenoid valve
for spreading in left (Y6019L) pres-
surises the left spreader spool in the
attachment’s control valve.
11 The solenoid valve for spreading out - Control valve attachment, description page 36
right (Y6018T) or the solenoid valve
for spreading in right (Y6019T) pres-
surises the right spreader spool in
the attachment’s control valve.
12 The control valve’s spreader spools - Control valve attachment, description page 36
change position and direct pressure
to the spreader cylinders.
15 The sensor for end position 20’-40’ Sensor directly opposite Position sensor spreading, description page 58
left (B769L) sends a voltage signal indicator plate: U >24 V D15: Diagnostic menu, see section 8 Control
to the attachment control unit system, group 8.4.9.6 ATTACH, menu 6
(D791-1).
16 The sensor for end position 20’-40’ Sensor directly opposite Position sensor spreading, description page 58
right (B769R) sends a voltage signal indicator plate: U = 24 V D16: Diagnostic menu, see section 8 Control
to the attachment control unit system, group 8.4.9.6 ATTACH, menu 6
(D791-1).
17 The attachment control unit (D791- - Section 11 Common electrics, group 11.5.3.5
1) reduces the control current to the Attachment control unit (D791-1)
solenoid valve for spreading out left D8: Diagnostic menu, see section 8 Control
(Y6018L) or the solenoid valve for system, group 8.4.9.17 ATTACH, menu 17 and
spreading in left (Y6019L). 8.4.9.18 ATTACH, menu 18
18 The attachment control unit (D791- - Section 11 Common electrics, group 11.5.3.5
1) reduces the control current to the Attachment control unit (D791-1)
solenoid valve for spreading out D9: Diagnostic menu, see section 8 Control
right (Y6018R) or the solenoid valve system, group 8.4.9.19 ATTACH, menu 19 and
for spreading in right (Y6019R). 8.4.9.20 ATTACH, menu 20
19 The solenoid valve for spreading out - Control valve attachment, replacement page
left (Y6018L) or the solenoid valve 38
for spreading in left (Y6019L) reduc- D8: Diagnostic menu, see section 8 Control
es the pressure to the left spreader system, group 8.4.9.17 ATTACH, menu 17 and
spool in the attachment’s control 8.4.9.18 ATTACH, menu 18
valve.
20 The solenoid valve for spreading out - Control valve attachment, replacement page
right (Y6018R) or the solenoid valve 38
for spreading in right (Y6019R) re- D9: Diagnostic menu, see section 8 Control
duces the pressure to the right system, group 8.4.9.19 ATTACH, menu 19 and
spreader spool in the attachment’s 8.4.9.20 ATTACH, menu 20
control valve.
21 The control valve’s spreader spools - Control valve attachment, description page 36
change position and reduce the
pressure to the spreader cylinders.
Twistlocks/Lock tongues Unlocked or by- Twistlocks, description page 69 or Lifting hook, description page 80
pass activated Section 8 Control system, group 8.2.2 Bypassing
D1 D2
2b 2a 1
35
30-
3
D790-1
D791-1
4,7,9,11 D5
D8 30' 30'
009346
4,7 4,7 5 6 8 10
2a The switch for spreading 20’-40’ U = 24 V DC Switch, spreading 20’-40’, description page
(S1012) sends a voltage signal to the 7
cab control unit (D790-1). D2: Diagnostic menu, see section 8 Control
system , group 8.4.9.3 ATTACH, menu 3
2b The control lever (S815-T1.2) sends a Spreading: US815-T4 = 24 Control lever, description page 6
voltage signal to the cab control unit V D2: Diagnostic menu, see section 8 Control
(D790-1). system, group 8.4.9.2 ATTACH, menu 2
Out: US815-T1.2 = 24 V
5 When the left spreader beam ap- Sensor directly opposite Position sensor spreading, description page
proaches the 30’ mark, the sensor for indicator plate: U = 24 V 58
30’ end position left (B777L) sends a D5: Diagnostic menu, see section 8 Control
voltage signal to the attachment control system, group 8.4.9.6 ATTACH, menu 6
unit (D791-1).
6 When the right spreader beam ap- Sensor directly opposite Position sensor spreading, description page
proaches the 30’ mark, the sensor for indicator plate: U = 24 V 58
30’ end position left (B777R) sends a D5: Diagnostic menu, see section 8 Control
voltage signal to the attachment control system, group 8.4.9.6 ATTACH, menu 6
unit (D791-1).
8 When the left spreader beam is at the Sensor directly opposite Position sensor spreading, description page
30’ mark, the sensor for 20’-40’ end po- indicator plate: U = 24 V 58
sition (B769L) sends a voltage signal to D8: Diagnostic menu, see section 8 Control
the attachment control unit (D791-1). system, group 8.4.9.5 ATTACH, menu 5
9 The attachment control unit (D791-1) U=0V Control valve attachment, description page
cuts off the current to the solenoid valve 36
for spreading out left (Y6018L) or the
solenoid valve for spreading in left
(Y6019L).
10 When the right spreader beam is at the Sensor directly opposite Position sensor spreading, description page
30’ mark, the sensor for 20’-40’ end po- indicator plate: U = 24 V 58
sition (B769R) sends a voltage signal to D8: Diagnostic menu, see section 8 Control
the attachment control unit (D791-1). system, group 8.4.9.5 ATTACH, menu 5
11 The attachment control unit (D791-1) U=0V Control valve attachment, description page
cuts off the current to the solenoid valve 36
for spreading out right (Y6018R) or the
solenoid valve for spreading in right
(Y6019R).
description
Twistlocks/Lock tongues Unlocked or bypass Twistlocks, description page 69 or Lifting hook, description page 80
activated
Doors Closed Section 9 Frame, body, cab and accessories, group 9.10.2 Doors.
Parking brake Released Section 4 Brakes, group 4.5 Parking brake system.
2
D1 D2
1b 1a
3 7
D790-1 D795
D791-1 D9
D10 D8 D11 4, 5, 8 9 D13 D12
10 8 11 6 13 9 12
009347
D5
1b The control lever (S815-T1.1 and Spreading: US815/T4 = 24 Control lever, description page 6
S815-T1.2) sends a voltage signal to V D1: Diagnostic menu, see section 8 Control
the cab control unit (D790-1). system, group 8.4.9.2 ATTACH, menu 2
Out: US815/T1.2 = 24 V
2 The switch for automatic spreading Switch in on position: Switch automatic spreading, description page 8
20’-40’ (S1012-2) sends a voltage US199-2/2 = 0 V D2: Diagnostic menu, see section 8 Control
signal to the cab control unit (D790- system, group 8.4.9.4 ATTACH, menu 3
1). US199-2/5 = 24 V
US199-2/5 = 24 V
5 The attachment control unit (D791- Buzzer active: U = 24 V Buzzer automatic spreading 20’-40’, descrip-
1) activates the automatic spreading tion page 58
buzzer (H9003). D5: Diagnostic menu, see section 8 Control
system, group 8.4.9.21 ATTACH, menu 21
6 Buzzer automatic spreading Buzzer active: U = 24 V Buzzer automatic spreading 20’-40’, descrip-
(H9003) generates acoustic warning tion page 58
signal.
8 When the left spreader beam ap- Sensor directly opposite Spreading, function description page 43
indicator plate: U = 24 V
proaches the 20’, 30’ ( ) or 40’ 30-foot stop, function description page 46
mark, the sensor for 20’-40’ end po-
D8: Diagnostic menu, see section 8 Control
sition left (B769L) sends a voltage
system, group 8.4.9.6 ATTACH, menu 6
signal to the attachment control unit
(D791-1), which activates damping
for the left spreader beam the same
way as in steps 16-22 of normal
spreading.
9 When the right spreader beam ap- Sensor directly opposite Spreading, function description page 43
indicator plate: U = 24 V
proaches the 20’, 30’ ( ) or 40’ 30-foot stop, function description page 46
mark, the sensor for 20’-40’ end po-
D9: Diagnostic menu, see section 8 Control
sition right (B769R) sends a voltage
system, group 8.4.9.6 ATTACH, menu 6
signal to the attachment control unit
(D791-1), which activates damping
for the right spreader beam the
same way as in steps 16-22 of nor-
mal spreading.
10 When the left spreader beam is at Sensor directly opposite Position sensor spreading, description page 58
indicator plate: U = 24 V D10: Diagnostic menu, see section 8 Control
the 20’, 30’ ( ) or 40’ mark, the
sensor for end position 30’ left system, group 8.4.9.6 ATTACH, menu 6
(B777L) sends a voltage signal to
the attachment control unit (D791-1)
12 When the right spreader beam is at Sensor directly opposite Position sensor spreading, description page 58
indicator plate: U = 24 V D12: Diagnostic menu, see section 8 Control
the 20’, 30’ ( ) or 40’ mark, the
sensor for end position 30’ right system, group 8.4.9.6 ATTACH, menu 6
(B777R) sends a voltage signal to
the attachment control unit (D791-1)
13 The attachment control unit (D791- I = 0 mA Section 11 Common electrics, group 11.5.3.5
1) cuts off the control current the so- Attachment control unit (D791-1)
lenoid valve for spreading out right D13: section 8 Control system, group 8.4.9.19
(Y6018R) or the solenoid valve for ATTACH, menu 16 and 8.4.9.20 ATTACH,
spreading in right (Y6019R). menu 20
Spreader spool
The valve spool controls the direction and speed of spreading. The
valve spool is controlled by a solenoid valve for spreading out and a
solenoid valve for spreading in.
The spreader cylinders pull the spreader beams in and out of the at-
tachment’s main beam. The attachment control unit (D791-1) sends a
signal to the attachment control valve, which pressurises the spreader
cylinders.
The spreader cylinders are fastened in the spreader beams and the
main beam.
Openings in the sides of the spreader beams and the attachment’s
main beam make it possible to access the spreader cylinders for main-
tenance purposes.
009925
Spreader cylinders
The spreader beams are the part of the attachment that grip the con-
tainers. Two spreader beams run along the main beam. The spreader
beams are extended and retracted with hydraulic cylinders.
The spreader beam houses twistlocks, see Twistlocks, function de-
scription page 70 or Lifting hook, description page 80.
009926
Spreader beams
2
NOTE
The thickness should be at least 10 mm.
8 Place the slide plate in the correct position.
Check the clearance between the spreader beam and the slide
plate. Clearance should be less than 1 mm with all slide plates
fitted.
Use a spacer plate to adjust the clearance.
009189
1 NOTE
The illustration depicts the inner slide plates on the In general, the upper slide plates on the front of the spreader
side lifting attachment’s spreader beam. beam/main beam and the lower slide plates on the rear of
1. Slide plates the spreader beam/main beam are adjusted with shim
2. Attaching bolts and steerings crews for slide plates plates.
NOTE
Do not add too many shims as this increases slide plate
wear.
NOTE
Check that the attaching bolts for all glide plates are
tightened.
9 Fit the slide plate bracket.
10 Fit the slide plate steering screw.
11 Check that the sliding surface is clean and lubricate the sliding
surface on the spreader beam.
12 Start the machine and check the function of the spreader. Try lift-
ing a container and then recheck the spreader beam’s clearance
in the attachment’s main beam.
The side lifting attachment’s main beam is fastened in the lifting car-
riage with hydraulic cylinders. The main beam houses equipment for
spreading (spreader beams, hydraulic cylinders, slide plates and
sensors).
009927
Main beam
NOTE
Read the safety instructions for oil before working, see section B
Safety.
NOTE
If the lifting carriage will also be removed, e.g. to make it possible
to replace or service the mast, it is a good idea to remove the lift-
ing carriage and the side lifting attachment as a unit.
1 Park the machine with the mast vertical and the attachment in its
lowest position.
2 Stop the engine
009998
6 Detach the side shift cylinder from the attachment.
Remove the cylinder shaft from the mounting on the lifting car-
riage. If necessary, used the threaded hole and a puller to press
out the shaft.
Start the engine and retract the cylinder so that it comes loose
from the mounting in the lifting carriage. Switch off the engine.
Save the circlips. Refit the shaft in the cylinder.
009951
10 Mark up and detach hydraulic connections from the side lifting at-
tachment and the side shift cylinder.
NOTE
Plug all connections immediately to protect the hydraulic
system from impurities.
009952
13 Lift aside the side lifting attachment. Position it so that the twist-
locks/lock tongues are not damaged.
009999
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Park the machine with the mast vertical.
2 Lower the lifting carriage to its lowest position.
3 Stop the engine
4 Turn the start key to position I and activate the hydraulic functions
to depressurise the hydraulic system.
5 Turn the start key to position 0 and turn off the main electric
power.
6 Lift the side lifting attachment into place.
009999
7 Fit the lifting carriage’s front panels to fix the side lifting attach-
ment in position.
8 Check that the side lifting attachment runs correctly in the lifting
carriage; see Slide plates in lifting carriage, adjusting/replacing
page 41.
010000
9 Clean and apply a layer of lubricating grease to the side shift cyl-
inder shaft prior to installation.
10 Connect the side shift cylinder to the side lifting attachment.
Align the side shift cylinder, press in the shaft and secure with
with the circlips.
NOTE
Use an anti-recoil plastic or copper mallet.
If necessary, detach the hydraulic connections on the side shift
cylinder to make it possible to adjust cylinder length.
009951
11 Attach the cable harness of the attachment to the attachment
control unit.
Grease the connectors with contact grease and join them up.
Fasten the wiring with clamps.
12 Remove plugs and connect hydraulic hoses for the side lifting at-
tachment and side shift cylinder using the markings as a guide.
13 Turn on the power supply and start the engine.
14 Check that the hydraulic connections are sealed tightly.
15 Check the functions of the side lifting attachment.
009952
16 Check the hydraulic oil level with all hydraulic pistons fully retract-
ed. The oil level should be at the top of the level glass. Top up as
necessary.
CAUTION
Overfilling of oil.
4 3 damping.
5
With the 30-foot stop option, two extra sensors are mounting - sensor
1. Sensor for end position 20’ and 40’
for end position 30’ (B777R and B777L) - along with two additional in-
2. Sensor for end position 30’ dicator plates. The sensor is used to activate the 30-foot stop.
3. Indicator plate 20’
The sensors are supplied power by and send as 24 V signal to the at-
4. Indicator plate 30’ tachment control unit (D791-1) when the indicator plates pass the sen-
5. Indicator plate 40’ sor. Indicator plates on the spreader units are mounted so that the
sensors generate a signal when the spreader unit passes the sensor.
The indicator plates and the position of the sensors are designed so
that the distance between the spreaders becomes 20’ (30’) and 40’.
The signals can be checked from the diagnostic menu, see section 8
Control system , group 8.4.9.6 ATTACH, menu 6.
The buzzer for automatic spread 20’-40’ (H9003) sits on the underside
of the lifting carriage on machines with automatic spreading 20’-40’.
The buzzer is activated during automatic spreader movement.
7.7 Tilt
Tilt, function description
page
–
D5
5b 5a 6
D790-1
10
D797-1 11
7
D7
8
10
11
P A1
B1
T1
P PS 9
3
4
EF
C P
1 1
009957
2 The pressure reducer reduces the pres- See pressure plate on left Pressure reducer, description page 13
sure from one of the hydraulic pumps to frame beam.
servo pressure.
3 The accumulator stores servo pressure. See pressure plate on left Accumulator servo circuit, description page
The non-return valve in the pressure re- frame beam. 14
ducer makes it possible to store the
pressure when the engine is shut off.
4 The servo filter cleans the oil upstream - Servo filter, description page 12
of the lift and tilt control valve.
5b The control lever (S815-P2) sends the US815-P2 = 0.5-4.5 V Control lever, description page 6
cab control unit (D790-1) a voltage sig- In: US815-P2 <2.5 V D5: Diagnostic menu, see section 8 Control
nal proportional to lever movement. system , group 8.4.8.1 ELSERV, menu 1
Out: US815-P2 = >2.5 V
6 The cab control unit (D790-1) transmits Checked by control sys- Section 11 Common electrics, group
tilt in or tilt out on the CAN bus. tem, error shown with er- 11.5.3.1 Cab control unit (D790-1)
ror code.
7 The frame control unit (D797-1) acti- U = 24 V Section 11 Common electrics, group
vates the servo valve for tilt in (Y6011) 11.5.3.2 Frame control unit (D797-1)
or the servo valve for tilt out (Y6010). D7: Diagnostic menu, see section 8 Control
system , group 8.4.8.5 ELSERV, menu 5 and
8.4.8.6 ELSERV, menu 6
8 The solenoid valve for tilt in (Y6011) or - Control valve, lift and tilt, description page 15
the solenoid valve for tilt out (Y6010)
pressurises the tilt spool in the lift and tilt
control valve.
9 The control valve’s tilt spool changes - Control valve, lift and tilt, description page 62
position and pressurises the load reten-
tion valve.
10 The load retention valve opens and di- - Load holding valve, description page 63
rects the pressure on to the tilt cylinders.
11 The tilt cylinders angle the mast in rela- - Tilt cylinder, description page 63
tion to the frame. Lift masts, description page 19
7.7.2 Accumulator
Accumulator, description
page
–
Tilt is controlled by a separate section of the lift and tilt control valve.
See also Control valve, lift and tilt, description page 15.
For more information about tilting, see Tilt, function description page
60.
Tilt spool
When the solenoid valves are activated, the tilt spool is pressurised
and controls the direction and flow of oil from the hydraulic oil pumps
to the tilt cylinders.
The load retention valves are mounted on the tilt cylinders, by the hy-
draulic connection to the rod side. The load retention valve prevents
the tilt cylinders from moving faster than the pressure applied from the
load handling control valve. This prevents unwanted tilting forwards,
which can occur if there is a heavy load or high lift height. The load re-
tention valve also makes the tilting movement more controlled.
009929
The tilt cylinders sit between the mast and the frame and angle the
mast in relation to the machine.
2
009930
1. Tilt cylinder
2. Mast
3. Lower mast anchorage on frame
7.7.8 Mast
Lift masts, description
page
–
7.8 Levelling
Mechanical levelling, function description
page
–
1b 1a
D1
2 11
+ D790-1
D797-1 D791-1
3 8 D3
D2
9 11
C
P1 A
4
T1 B
10
5
C
6
7
009348
2 The cab control unit (D790-1) trans- Checked by control sys- Section 11 Common electrics, group 11.5.3.1
mits side shift left or right on the CAN tem, error shown with er- Cab control unit (D790-1)
bus. ror code.
3 The frame control unit (D797-1) acti- U = 24 V Section 11 Common electrics, group 11.5.3.2
vates the solenoid valve for main Frame control unit (D797-1)
pump relief (Y6062-2). D3: Diagnostic menu, see section 8 Control
system, group 8.4.5.6 HYD, menu 6
4 The solenoid valve for main pump re- - Valve block, main pump relief, description
lief (Y6062-2) routes a relieved con- page 42
stant pressure to the hydraulic oil
pump for load handling. This serves
as a load signal.
5 The attachment shuttle valve sends - Section 10 Common hydraulics, group 10.5.3
the load signal on to the hydraulic oil Shuttle valve
pump for load handling or the cab tilt
shuttle valve.
6 The cab tilt shuttle valve sends the - Section 10 Common hydraulics, group 10.5.3
load signal on to the hydraulic oil Shuttle valve
pump for load handling.
7 The hydraulic oil pump for load han- See pressure plate on Section 10 Common hydraulics, group 10.4.2
dling pumps oil from the hydraulic oil left frame beam. Axial piston pump with variable displacement
tank.
8 The attachment control unit (D791-1) U = 24 V Section 11 Common electrics, group 11.5.3.5
activates the solenoid valve for level- Attachment control unit (D791-1)
ling right (Y6035) or the solenoid valve D8: Diagnostic menu, see section 8 Control
for levelling left (Y6036). system, group 8.4.9.13 ATTACH, menu 13
and 8.4.9.14 ATTACH, menu 14
9 The solenoid valve for levelling right - Control valve attachment, description page 36
(Y6035) or the solenoid valve for level-
ling left (Y6036) pressurises the level-
ling spool in the attachment control
valve.
10 The control valve’s levelling spool - Control valve attachment, description page 36
changes position and pressurises the
levelling cylinders.
11 The levelling cylinders push in the side - Levelling cylinder, description page 68
lifting attachments sideways in rela-
tion to the lifting carriage.
Levelling spool
The valve spool controls the direction and speed of attachment
levelling.
The valve spool is controlled by a solenoid valve for levelling right
(Y6035) and a solenoid valve for levelling left (Y6036).
The levelling cylinders sit between the lifting carriage and the side lift-
ing attachment. They change the angle of the side lifting attachment in
relation to the machine.
009924
Levelling cylinders
The container is held in place on the side lifting attachment with two
twistlocks.
Twistlocks are controlled with the twistlock switch. A section of the at-
tachment control valve pressures two hydraulic cylinders connected in
parallel on opposite sides of the side lifting attachment. Each hydraulic
cylinder actuates a linkage that rotates a twistlock. Four positions sen-
sors (two on each side side of the side lifting attachment) detect the
position of the linkage and indicate whether the twistlocks are open or
locked. The status of the twistlocks is shown by indicator lights on the
side lifting attachment and in the cab as well as a mechanical indicator
on the side lifting attachment.
A contact pin and a sensor at each twistlock indicate when the attach-
ment is in contact with the container. This is used to control when the
twistlocks can be activated. An indicator light on the side lifting attach-
ment and another one in the cab indicate when the side lifting attach-
ment has full contact. An event menu shows which twistlocks have
contact (1-2). Both twistlocks must have contact for them to be
activated.
2b 1 D1
20
2a
8 7,22
D2 5,23
D790-1 D790-2 D795
D6 D20
D797-1 D791-1 D3
4,6,14, 21
9
D14
D9 19
15 D19 18 3
P1 A
D10
10 B
T1
17
16
11 18 3
19
D6
13 12
009365
2b The control lever (S815-T2) sends a US815/T2 = 24 V Control lever, description page 6
voltage signal to the cab control unit D2: Diagnostic menu, see section 8 Control
(D790-1) for twistlock opening. system , group 8.4.9.3 ATTACH, menu 3
If Switch, lock twistlocks (S1003) is in
manual position no signal is needed
from control lever to open twistlock.
3 The alignment left sensor (B7203L) and Sensor directly opposite Sensor alignment, description page 77
alignment right sensor (B7203R) detect indicator plate: U = 24 V D3: Diagnostic menu, see section 8 Control
position and send a voltage signal to the system , group 8.4.9.6 ATTACH, menu 6
attachment control unit (D791).
4 The attachment control unit (D791-1) Checked by control sys- Section 11 Common electrics, group
transmits alignment on the CAN bus. tem, error shown with er- 11.5.3.5 Attachment control unit (D791-1)
ror code.
5 The KID control unit (D795) activates - Section 11 Common electrics, group
the alignment event menu. 11.5.3.12 KID control unit (D795)
6 The attachment control module (D791) U = 24 V D6: Diagnostic menu, see section 8 Control
activates the alignment indicator light on system , group 8.4.9.10 ATTACH, menu 10
the mast light panel.
7 The KIT control module (D790-2) acti- - Section 11 Common electrics, group
vates the alignment indicator light on the 11.5.3.11 KIT control unit (D790-2)
cab light panel.
8 The cab control unit (D790-1) transmits Checked by control sys- Section 11 Common electrics, group
"open twistlocks" or "lock twistlocks" on tem, error shown with er- 11.5.3.1 Cab control unit (D790-1)
the CAN bus. ror code.
9 The frame control unit (D797-1) acti- U = 24 V Section 11 Common electrics, group
vates the solenoid valve for main pump 11.5.3.2 Frame control unit (D797-1)
relief (Y6062-2). D9: Diagnostic menu, see section 8 Control
system , group 8.4.5.6 HYD, menu 6
10 The solenoid valve for main pump relief - Valve block, main pump relief, description
(Y6062-2) routes a relieved constant page 42
pressure to the hydraulic oil pump for D10: Diagnostic menu, see section 8 Control
load handling. This serves as a load system , group 8.4.5.6 HYD, menu 6
signal.
11 The attachment shuttle valve sends the - Section 10 Common hydraulics, group
load signal on to the hydraulic oil pump 10.5.3 Shuttle valve
for load handling or the cab tilt shuttle
valve.
13 The hydraulic oil pump for load handling See pressure plate on left Section 10 Common hydraulics, group
pumps oil from the hydraulic oil tank. frame beam. 10.4.2 Axial piston pump with variable
displacement
15 The "open twistlocks" solenoid valve - Control valve attachment, description page
(Y6039) or the "lock twistlocks" solenoid 36
valve (Y6040) pressurises the twistlock D15: Diagnostic menu, see section 8 Control
spool with servo pressure. system , group 8.4.9.9 ATTACH, menu 9
16 The twistlock spool of the control valve - Control valve attachment, description page
changes position and pressurises the 36
lock cylinders via the overcentre valve.
18 The lock cylinders rotate the twistlocks. - Lock cylinder, description page 86
19 The "unlocked twistlocks" sensor Sensor directly opposite Sensor twistlocks, description page 78
(B7204 L and R) or the "locked twist- indicator plate: U = 24 V D19: Diagnostic menu, see section 8 Control
locks" sensor (B7205 L and R) sends a system , group 8.4.9.7 ATTACH, menu 7
signal to the attachment control unit
(D791).
20 The attachment control unit (D791-1) U = 24 V D20: Diagnostic menu, see section 8 Control
supplies voltage to the "unlocked twist- system , group 8.4.9.10 ATTACH, menu 10
locks" indicator light (H562) or the
"locked twistlocks" indicator light (H563)
on the mast light panel.
21 The attachment control unit (D791-1) Checked by control sys- Section 11 Common electrics, group
transmits "twistlocks unlocked" or "twist- tem, error shown with er- 11.5.3.5 Attachment control unit (D791-1)
locks locked" on the CAN bus. ror code.
22 The KIT control unit (D790-2) supplies - Section 11 Common electrics, group
voltage to the "unlocked twistlocks" indi- 11.5.3.11 KIT control unit (D790-2)
cator light or the "locked twistlocks" indi-
cator light on the cab light panel.
23 The KID control unit (D795) activates - Section 11 Common electrics, group
the twistlocks event menu. 11.5.3.12 KID control unit (D795)
009931
The lock cylinder pulls the lock mechanism so that the twistlocks are
rotated. Two lock cylinders connected in parallel - one in the right and
one in the left spreader beam - actuate a linkage that twists a twistlock.
009932
The lock mechanism transfers the force of the lock cylinders to the
twistlocks. Two lock mechanisms - one in the right and one in the left
spreader beam - actuate the twistlocks. The lock mechanism operates
in the 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
009935
1 2 3 2 twistlocks.
1. Linkage bearing
2. Rotary plate
3. Lock cylinder mounting
7.9.1.6 Twistlocks
Twistlocks, description
page
–
3 4
1
2 WARNING
Dropped load.
Fatal danger!
5
6
1. Mechanical indicator for locking Twistlocks secure the load and are located in the corners of the
2. "Unlocked twistlock" sensor spreader beam’s longitudinal part.
3. Sensor alignment
Twistlocks are manufactured from high-strength steel according to in-
4. "Locked twistlock" sensor
ternational standards. The lift pins are marked with serial numbers.
5. Lift pin
6. Alignment pin Twistlocks are connected via a linkage system to a hydraulic cylinder
which in turn is controlled via a section in the attachment’s control
valve. Inductive sensors send signals when the twistlocks are locked
and unlocked, respectively.
Twistlock, replacement
page
–
WARNING
Twistlocks are heavy. Risk of crushing, product dam-
age.
NOTE
Remember the washer.
8 Check the positions of the parts and that the twistlock can move.
9 Tighten the screws of the clamp halves.
10 Lubricate the twistlock and lock mechanism with lubricating
grease.
11 Check that the twistlock mechanism can move.
12 Turn on the main electric power and start the machine.
13 Check that the twistlock is working.
009958
The alignment sensors (B7203L and B7203R) detect when the attach-
ment has contact with the container. Two inductive position sensors
are used to indicate contact.
The sensor senses the position of a spring pin which is pressed in
when the attachment has contact up against the container. The sensor
is located behind the pin. The position of the sensor can be adjusted
so that it gives a signal when the pin is pressed in and the head is level
with the lower edge of the spreader beam. The clearance between the
attachment and the container’s corner boxes means the sensors stop
sending signals when the attachment is lifted.
The sensors are supplied power and send a 24 V signal to the attach-
ment control unit (D791-1) when the indicator pin is pressed in.
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.9.7 ATTACH, menu 7.
009933
1 2
1. Alignment pin
2. Sensor alignment
1 Check that the alignment pins in the corner boxes can freely
move up and down. The alignment pins must spring down when
they are not loaded.
2 Check that the sensor is free of damage and dirt.
3 Turn the start key to position I and check that the LED on the sen-
sor is unlit.
4 Lower the attachment onto a container and check that the align-
ment indicator light comes on.
5 Lift the container a little bit so that the alignment indicator light
goes out.
009770
1 2
6 With the container lifted, check how much alignment pin move-
Right side ment is needed to detect contact (LED on the sensor lights). The
1. Sensor alignment movement should be 3–4 mm.
2. Alignment pin
7 If necessary, slacken the lock nut and screw the sensor in/out un-
1 2
til the distance between the sensor and the alignment pin is 5
±1 mm.
009771
Left side
1. Sensor alignment
2. Alignment pin
2
009934
009772
1 2 If necessary, slacken the lock nut and screw the sensor in/out un-
til the distance between the sensor and the indicator plate is 5
Right side ±1 mm.
1. "Unlocked twistlock" sensor
6 Check that the "twistlocks locked" indicator light is lit.
2. "Locked twistlock" sensor
1 2
009773
Left side
1. "Unlocked twistlock" sensor
2. "Locked twistlock" sensor
The container is held in place on the side lifting attachment with two
fixed lifting hooks that are positioned in the corner boxes of the con-
tainer (in the side holes on the long side) and two movable lock
tongues that are positioned in the corner boxes of the container (in the
side holes on the short side). These secure that side lifting attachment
to the container.
The lock tongues are controlled with the lock tongue switch. One sec-
tion in the attachment control valve pressurises two hydraulic cylinders
connected in parallel - one in each spreader boom. Each hydraulic cyl-
inder acts on a linkage that turns a lock tongue. Four position sensors
- two in each spreader boom - sense the position of the linkage and
indicate if the lock tongues are open or closed. Indicator lights on the
side lifting attachment and in the cab show the status of the lock
tongues.
The lock tongues are activated manually or automatically and can be
opened if the machine is driven at a speed below 5 km/h. If the lock
tongues are not locked when the attachment is carrying a load, the
speed of the machine’s hydraulic functions is limited and machine
speed is limited to max. 5 km/h.
Two detection sensors (one at each lifting hook) use ultrasound to de-
tect distance (and informs that system) if one or two containers will be
lifted. At each lifting hook, there is a sensor that indicates contact with
the lower container and another that indicates contacts with the upper
container.
Two indicator lights on the side lifting attachment and one in the cab
indicate when the side lifting attachment has full contact. An event
menu shows when the lifting hook has contact (1-2).
Contact by both of the lifting hooks is not required to activate the lock
tongues. But, unless there is contact and correct locking, the ma-
chine’s hydraulic functions and speed will be limited.
2b 1
D1
2a
8,23 21
D2 9
6
D790-1 D790-2 D795
D4 D21
D797-1 D791-1
5,7,15,22
10
D15 4
D10 16 D20 D3 19 3
P1 A
18 20
11 B
T1
17
12 19 3
C 4
14 13
009959
2b The control lever (S815-T2) sends a US815/T2 = 24 V Control lever, description page 6
voltage signal to the cab control unit D2: Diagnostic menu, see section 8 Control
(D790-1) for lock tongue opening. system , group 8.4.9.5 ATTACH, menu 5
If the switch for locking the lock tongue
(S1003) is in the manual position, no
signal is needed from the control lever to
open lock tongues.
3 The sensor for lower left alignment Sensor directly opposite Alignment and detection sensor, description
(B7203LL), sensor for upper left align- indicator plate: U = 24 V page 90
ment (B7203LU-2), the sensor for lower D3: Diagnostic menu, see section 8 Control
right alignment (B7203RL) and the sen- system , group 8.4.9.23 ATTACH, menu 23
sor for upper right alignment (B7203RU-
2) detect position and send a voltage
signal to the attachment control unit
(D791).
4 The sensor for upper container right de- - Alignment and detection sensor, description
tection (B7203RU) and the sensor for page 90
upper container left detection D4: Diagnostic menu, see section 8 Control
(B7203LU) detect position and send a system , group 8.4.9.22 ATTACH, menu 22
voltage signal to the attachment control
unit (D791).
5 The attachment control unit (D791-1) Checked by control sys- Section 11 Common electrics, group
transmits alignment/detection on the tem, error shown with er- 11.5.3.5 Attachment control unit (D791-1)
CAN bus. ror code.
6 The KID control unit (D795) activates - Section 11 Common electrics, group
the alignment event menu. 11.5.3.12 KID control unit (D795)
7 The attachment control module (D791) U = 24 V D6: Diagnostic menu, see section 8 Control
activates the alignment indicator light system , group 8.4.9.10 ATTACH, menu 10
(H564) on the mast light panel.
8 The KIT control module (D790-2) acti- - Section 11 Common electrics, group
vates the alignment indicator light on the 11.5.3.11 KIT control unit (D790-2)
cab light panel.
9 The cab control unit (D790-1) transmits Checked by control sys- Section 11 Common electrics, group
"open lock tongue" or "lock lock tongue" tem, error shown with er- 11.5.3.1 Cab control unit (D790-1)
on the CAN bus. ror code.
11 The solenoid valve for main pump relief - Valve block, main pump relief, description
(Y6062-2) routes a relieved constant page 42
pressure to the hydraulic oil pump for
load handling. This serves as a load
signal.
12 The attachment shuttle valve sends the - Section 10 Common hydraulics, group
load signal on to the hydraulic oil pump 10.5.3 Shuttle valve
for load handling or the cab tilt shuttle
valve.
13 The cab tilt shuttle valve sends the load - Section 10 Common hydraulics, group
signal on to the hydraulic oil pump for 10.5.3 Shuttle valve
load handling.
14 The hydraulic oil pump for load handling See pressure plate on left Section 10 Common hydraulics, group
pumps oil from the hydraulic oil tank. frame beam. 10.4.2 Axial piston pump with variable
displacement
16 The "open lock tongue" solenoid valve - Control valve attachment, description page
(Y6039) or the "lock lock tongue" sole- 36
noid valve (Y6040) pressurises the lock
tongue spool with servo pressure.
17 The lock tongue spool of the control - Control valve attachment, description page
valve changes position and pressurises 36
the lock cylinders via pilot-controlled
non-return valves.
19 The lock cylinders rotate the lock - Lock cylinder, description page 86
tongues.
20 The "unlocked lock tongue" sensor Sensor directly opposite Sensor twistlocks, description page 78
(B7204 L and R) or the "locked lock indicator plate: U = 24 V D20: Diagnostic menu, see section 8 Control
tongue" sensor (B7205 L and R) sends system , group 8.4.9.8 ATTACH, menu 8
a signal to the attachment control unit
(D791).
22 The attachment control unit (D791-1) Checked by control sys- Section 11 Common electrics, group
transmits "lock tongues unlocked" or tem, error shown with er- 11.5.3.5 Attachment control unit (D791-1)
"lock tongues locked" on the CAN bus. ror code.
23 The KIT control unit (D790-2) supplies - Section 11 Common electrics, group
voltage to the "unlocked lock tongues" 11.5.3.11 KIT control unit (D790-2)
indicator light or the "locked lock
tongues" indicator light on the cab light
panel.
description
Pilot-controlled non-return valves prevent the uncontrolled opening or
closing of the lock tongues. There is one non-return valve at each lock
cylinder on the side lifting attachment.
009938
The lock cylinder pulls the lock mechanism so that the twistlocks are
rotated. Two lock cylinders connected in parallel - one in the right and
one in the left spreader beam - each actuate a lock tongue.
009939
The lock mechanism transfers the force of the lock cylinders to the lock
2 tongues. Two lock mechanisms - one in the right and one in the left
spreader beam - actuate the lock tongues. The lock mechanism oper-
ates in the corner box.
3
The lock mechanism consists of a lock cylinder that rotates the lock
tongue, which is fastened to the corner box with a shaft bolt.
1
009940
4
WARNING
7
6 Dropped load.
5
Fatal danger!
4
3 Lock tongues together with lifting hooks hold the load
in place during load handling. It is therefore vital that
the lock tongues and lifting hooks are checked as
specified and replaced if there is any sign or damage
2
or wear whatsoever.
009941
1
1. Sensor, locked lock tongue (B7205LL/RL) The lock tongues secure the load and are located in the corners of the
2. Lock tongue spreader beam’s longitudinal part.
3. Sensor, unlocked lock tongue (B7204L/R) The lock tongues are made of high-strength steel.
4. Alignment pin for alignment sensor, lower container
The lock tongues are connected via a linkage system to a hydraulic
(B7203LL/RL)
cylinder which in turn is controlled via a section in the attachment’s
5. Lifting hook
control valve. Inductive sensors send signals when the lock tongues
6. Alignment pin for alignment sensor, upper container
are locked and unlocked, respectively.
(B7203LU-2/RU-2)
6. Detection sensor, upper container (B7203LU/RU)
1
009942
WARNING
Lock tongues are heavy. Risk of crushing, product
1. Lock cylinder mounting damage.
2. Shaft bolt for lock tongue
NOTE
Use a new lock nut and new washers.
Apply lubricating grease to the parts before fitting.
11 Check the positions of the parts and that the lock tongues can
move.
12 Apply lubricating grease to the lock tongue’s shaft bolt and the
lock cylinder mounting.
13 Check that the lock tongue mechanism can move.
14 Turn on the main electric power and start the machine.
15 Check that the lock tongues work properly and connect with and
secure the container correctly when lifting.
WARNING
7
6 Dropped load.
5
Fatal danger!
4
3 Lock tongues together with lifting hooks hold the load
in place during load handling. It is therefore vital that
the lock tongues and lifting hooks are checked as
specified and replaced if there is any sign or damage
2
or wear whatsoever.
009941
1
1. Sensor, locked lock tongue (B7205LL/RL) The lifting hooks secure the load and are located in the corners of the
2. Lock tongue spreader beam’s longitudinal part.
3. Sensor, unlocked lock tongue (B7204L/R) The lifting hooks are manufactured from high-strength steel according
4. Alignment pin for alignment sensor, lower container to international standards. The lifting hooks are marked with serial
(B7203LL/RL) number.
5. Lifting hook
6. Alignment pin for alignment sensor, upper container
(B7203LU-2/RU-2)
7. Detection sensor, upper container (B7203LU/RU)
WARNING
1 Lifting hooks are heavy. Risk of crushing, product
009948
2 damage.
1. Lifting hook
2. Shaft bolt for lifting hook 6 Lift away the lifting hook.
7 Position a new lifting hook in the guide pin.
8 Place the lift pin and guide pin in the spreader beam. Place the
guide pin so that the grease cup is accessible through the holes
in the spreader beam.
NOTE
Use a new lock nut and new washers.
9 Check the positions of the parts and that the lifting hooks can
move.
10 Turn on the main electric power and start the machine.
11 Check that the lifting hooks are working.
5 The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.9.7 ATTACH, menu 7.
1. Sensor, upper container alignment (B7203LU-2/
RU-2)
2. Sensor, lower container alignment (B7203LL/RL)
3. Alignment pin, upper container
4. Detection sensor, upper container (B7203LU/RU)
5. Alignment pin, lower container
the exact position that makes the light (B1) come on.
B2 7 Adjusting:
009375
Fix the contact pin so that the measurement (B) is 18 mm. Then
move the sensor along the oval retaining hole and screw it into
Lights on the side lifting attachment
the exact position that makes the light (B2) come on.
A Green light Lock tongues locked
3
ment control unit (D791-1) when the indicator plate is in front of the
Right side sensor.
1. Detection sensor, upper container (B7203LU/RU) The signal can be checked from the diagnostic menu, see section 8
2. Sensor, unlocked lock tongue (B7204R/L) Control system , group 8.4.9.8 ATTACH, menu 8.
3. Sensor, locked lock tongue (B7205LL/RL), lower
D1
1, 4, 7
10
D790-1 D795
D797-1 D791-1
3,6,9 D5
D2
2,8 5 009956
3 The attachment control unit (D791-1) Checked by control sys- Section 11 Common electrics, group 11.5.3.5
transmits alignment on the CAN bus. tem, error shown with Attachment control unit (D791-1)
error code.
5 The sensor for locked twistlocks/lock Sensor directly opposite Sensor twistlocks, description page 78 or
tongue left (B7205L) and the sensor for indicator plate: U = 24 V Lock tongue sensor, description page 92
locked twistlocks/lock tongue right D5: Diagnostic menu, see section 8 Control
(B7205R) send a voltage signal to the system , group 8.4.9.8 ATTACH, menu 8
attachment control unit (D791-1).
6 The attachment control unit (D791-1) Checked by control sys- Section 11 Common electrics, group 11.5.3.5
transmits "locked twistlocks/lock tem, error shown with Attachment control unit (D791-1)
tongues" on the CAN bus. error code.
7 The container is lifted with the function - Lift and lower, function description page 9
7.2 Lift and lower.
9 The attachment control unit (D791-1) Checked by control sys- Section 11 Common electrics, group 11.5.3.5
transmits no alignment on the CAN bus. tem, error shown with Attachment control unit (D791-1)
error code.
8 Control system
8 Control system
mm mm mm mm mm mm
The control system’s display is divided into four fields that show infor-
C mation (see figure to the left).
• Warning
C Indicates machine malfunction that should be taken care of as
soon as possible. After finished work shift with the machine, con-
D E
tact service as soon as possible.
The error code is shown automatically on the display.
000351
• Information
C Information to the operator that something should be taken care
of as soon as possible, e.g., defective light bulb. Take action to fix
D E the cause of the error code as soon as possible.
The error code is stored in the error code list under operating
000352
B
000389
• Engine:
C Shown with error code number XXX/YY on display.
D
NOTE
B If several error codes come from the engine, the error code
001343
level is shown for the most serious error code.
• Transmission:
C Shown with error code number XX/YY on display.
B
001344
10 11
002058
8.2 Monitoring
8.2.1 Overload protection
Overload protection, description
page
–
Not used.
8.2.2 Bypass
Bypassing, description
page
–
DANGER
Bypassing the safety systems results in a risk of tip-
ping. Use at your own risk.
000056
PRESENT XXXXh
8.4 Diagnostics
Diagnostic test, general
page
–
005263
OLS EXTRA
The diagnostic test is divided into the following groups:
• Voltage feed and communication for the Control system, CAN/
POWER, description page 11.
• Lighting, LIGHTS, description page 26.
• Cab functions, CAB, description page 37.
• Air conditioning, CLIMATE, description page 45.
• Hydraulic functions, HYD, description page 51.
• Engine, ENGINE, description page 58.
• Transmission, TRANSM, description page 65.
• Functions for electric servo, ELSERV, description page 76.
• Attachment functions, ATTACH, description page 90.
• Overload protection, OLS, description page 137.
• Optional functions, EXTRA, description page 139.
– Reversible driver’s seat, VBFS, menu 1 page 139.
– Mini-wheel or lever steering, EL-STEERING, menu 1 page
147
– External attachment, EXT-ATTACH, menu 1 page 151.
– Freelift, FREELIFT, menu 1 page 157
– Tiltable cab and sliding cab, MOVE-CAB, menu 1 page 159
– RMI, RMI, menu 1 page 168
Diagnostic tests show how the control units interpret input signals as
1 2 3 4
well as which signals that the control units send.
008873
FEEDBACK 0
2 Number of current menu. Every menu group consists of several menus in a loop.
(X) Total number of menus in the group. The number of menus depends on machine configuration, so the
number of menus is specified as (X) in this manual.
Variable The signal that is measured. Different signals are designated in different ways:
SWITCH: a digital input signal, e.g., a switch.
OUTPUT: a digital output signal, e.g., feed to a motor.
INPUT: an analogue input signal, e.g., from a sensor.
REFERENCE: status for an analogue output signal.
REQUIRED: triggered output signal for a control current
FEEDBACK: either feedback signal from a motor or measured current on the minus side for an analogue
output signal.
Signal value Measurement value or status for signal for variable. On the same row there are different types that are
interpreted in different ways.
SWITCH: 1 or 0 where 1 means closed circuit.
OUTPUT: two characters where the first number is 1 if the output signal is active. The second number is
status for the circuit, 1=circuit OK, 0=open circuit or short-circuiting.
INPUT: numerical value corresponding to the signal.
REFERENCE: two characters where the first number is 1 if the input signal is active. The second number
is status for the circuit, 1=circuit OK, 0=open circuit or short-circuiting.
REQUIRED: numerical value corresponding to the signal.
FEEDBACK: numerical value corresponding to the signal.
Menu heading Description of the function for which the menu reads signals.
8.4.1 CAN/POWER
CAN/POWER, description
page
–
This group handles redundant power supply to control units and CAN
DIAGNOSIS bus communication.
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE Confirm selection with function key for Enter.
TRANSM ELSERV ATTACH
005263
OLS EXTRA
SEGMENT ERROR X
Function: 11.6.2 Redundant CAN-bus
Signal value:
3 Ok.
2 Segment check
0 Error.
0 No open circuit.
Description: Indicates which control units have contact with the cab
DIAG CAN/POWER 2(X) control unit (D790-1) via the redundant CAN bus. Note that certain
PRESENT REDCAN STATUS control units are optional and may not be installed on the machine.
CONNECTED CITIES
D797-1 D797-2 XX Circuit diagram: 11.6-1, 11.6-2B, 11.6-2C
005267
D795 D791-1 XX Connection:
D795: K1:10, K1:11, K1:12 and K1:13
D797-1, D797-2, D791-1: K2:2, K2:3, K2:4 and K2:5
Function: 11.5.3.2 Frame control unit (D797-1), 11.5.3.3 Frame con-
trol unit (D797-2), 11.5.3.5 Attachment control unit, 11.5.3.12 KID con-
trol unit, 11.6.2 Redundant CAN bus
Signal value:
TRANSMISSION X
D794/1 and 2
Volvo TAD950VE: CAN J1939 from D790-1/K13:1 and K13:2 to
D794/1 and 2
Volvo TAD1250VE: CAN J1939 from D790-1/K13:1 and K13:2 to
D794/1 and 2
NOTE
The cable harness for CAN bus drivetrain is common to the en-
gine and transmission from the cab electronic box to the frame
electronic box. The cable branches in the frame electronic box. If
communication with both the engine and transmission is cut off,
start troubleshooting at the cable harness between the cab elec-
tronic box and the frame electronic box. If there is communication
(either engine or transmission), this rules out a fault in the cable
harness between the cab electronic box and the frame electronic
box.
TRANSMISSION
Description: Indicates status for transmission in drivetrain’s CAN bus.
Circuit diagram: Transmission circuit group 2.0, CAN bus circuit group
11.6
Connection: CAN J1939 from D790-1/K13:1 and K13:2 to D793/L2
and M2
Function: 11.6.3 Communication
Signal value:
NOTE
The cable harness for CAN bus drivetrain is common to the en-
gine and transmission from the cab electronic box to the frame
electronic box. The cable branches in the frame electronic box. If
communication with both the engine and transmission is cut off,
start troubleshooting at the cable harness between the cab elec-
tronic box and the frame electronic box. If there is communication
(either engine or transmission), this rules out a fault in the cable
harness between the cab electronic box and the frame electronic
box.
007126
RELAY K315-2 XY
Signal value:
0 No signal.
007127
RELAY K3009-2 XY
Signal value:
0 No signal.
0 No signal.
005275
3. -
4. -
5. Circuits 4.0-1, 7.5-1, 7.9-1, 8.2-1, 9.1-1, 9.3-3, 9.10-1 and 11.5-6
6. Circuit 5-2_1
7. -
8. Circuit 9.7-1
9. Circuit 9.5-1
10. Circuit 9.5-1
Connection:
1. signal from digital out D790-1/K4:14 to M650-1/53a
2. signal from digital out D790-1/K5:1 to S100/5, S110/5, S105-1/5,
S105-2/5, S105-3/5, S143/5, S199-1/5, S199-3/5, S199-4/5,
S220-1/1
3. signal from digital out D790-1/K6.13 not connected
4. signal from digital out D790-1/K7:12 not connected
5. signal from digital out D790-1/K8:16 to S107/5, S169/3, S199-2/5,
S250/1, S1002/2, S1003/3, S1004/5, S1005/5, S1010/3, S1012/
3, S1037/5
6. signal from digital out D790-1/K9:1 to S113/5, S149-2/5, S160-2/3
7. signal from digital out D790-1/K10:1 not connected
8. signal from digital out D790-1/K11:12 to S230/2
9. signal from digital out D790-1/K12:1 to M650-2/53a
10. signal from digital out D790-1/K12:3 to M650-3/53a
Function:
1. 9.5.5 Wiper motor front
2. 2.0 Transmission, 9.3 Seats, 9.6 Lighting
3. -
4. -
5. 11.5.1.4 Emergency stop switch voltage; 4.5 Parking brake sys-
tem; 8.2.2 Bypassing; 9.10.4 Tiltable cab/Hydraulic sliding cab;
7.5 Spreading; 7.8 Levelling; 7.9.1 Twistlocks
6. 5 Steering
7. -
8. 9.3.14 Sensor operator in seat
9. 9.5.7 Wiper motor rear
10. 9.5.6 Wiper motor roof
Signal value:
1 Feed active.
0 No feed.
005277
POWER 2 X
Function: 11.5.1.3 Ignition voltage (15)
Signal value: XX.XXV = voltage on connection. The signal value
should be 22-30 V (battery voltage).
1 Feed active.
0 No feed.
1 Feed active.
0 No feed.
Function: 7.2.8 Hydraulic pressure sensor, lift cylinder and 7.7.8 Hy-
draulic pressure sensor, tilt cylinder
Signal value: X.XXV = 5.00 V. Important that signal value is stable (not
varying).
005279
SENSOR SUPPLY XX.XXV
Signal value: XX.XXV = voltage on the connection. The signal value
should be 22-30 V (battery voltage).
1 Feed active.
0 No feed.
1 Feed active.
0 No feed.
005281
Connection: signal from digital out D797-2/K1:7 to S720-F/2 and
S720-R/2.
Function: 9.3.9 Sensor, reversible driver’s seat
Signal value:
Not used.
EME POWER 2 X
Function: 11.5.1.4 Control switch voltage (15E)
Signal value:
XX.XXV = voltage on the connection. The signal value should be
22-30 V (battery voltage).
1 Feed active.
0 No feed.
1 Feed active.
0 No feed.
005283
Connection: digital out from 791-1/K1:10 to B769-1, B777-1, B7202L,
B7202R, B7203L, B7203R, B7204L, B7204R, B7205L and B7205R
Function: 7.5.8 Spreading position sensor, 7.9.1.6 Alignment position
sensor, 7.9.1.7 Twistlocks sensor
DCF 90-100 with twistlock attachment
Connection: digital out from 791-1/K1:10 to B769L, B769R, B777L,
B777R, B7203L, B7203R, B7204L, B7204R, B7205L and B7205R
Function: 7.5.6 Spreading position sensor, 7.9.1.7 Alignment position
sensor, 7.9.1.8 Twistlocks sensor
DCF 90-100 with lifting hook
Connection: digital out from 791-1/K1:10 to B769L, B769R, B777L,
B777R, B7203LU-2, B7203RU-2, B7203LL, B7203RL, B7203LU,
B7203RU, B7204L, B7204R, B7205LL and B7205RL
Function: 7.5.6 Spreading position sensor, 7.9.2.8 Alignment and de-
tection sensor, 7.9.2.9 Lock tongue sensor
Signal value:
Not used.
Description: Control function from the redundant CAN bus. The cab
DIAG CAN/POWER 17(X) control unit (D790-1) performs a segment check to determine whether
REDCAN STATUS CHECK all control units have contact and are connected in the right order. The
PRESS ENTER control system indicates the fault by numbering the cables between
the control units (segments) from 1 onwards. Segment 1 is always be-
005284
SEGMENT ERROR X
tween the cab control unit (D790-1) and the next control unit in se-
quence. The last segment is always between the KID control unit
(D795) and the cab control unit (D790-1). The segments in between
vary depending on machine configuration.
Circuit diagram: Circuit CAN bus group 11.6
D790-1 D791 D797-2 D797-1 Connection: -
CAN L CAN R CAN L CAN R CAN L CAN R CAN L CAN R
D795
0 No errors.
DCF360-450CSG >0 X > 0, the number indicates incorrect segment. Use circuit di-
Segment numbering with maximum number of control agram to find the incorrect segment.
units. Control units marked with dashes are optional.
1 2
4 3
CAN R CAN L
008879
D795
8.4.2 LIGHTS
LIGHTS, description
page
–
OLS EXTRA
005286
Signal value:
0 No signal.
REAR LIGHTS XY
Function: 9.6.2 Running lights
Signal value:
005288
DIMMED LE/RI XY
Signal value:
0 No signal.
005289
Signal value:
0 No signal.
0 No signal.
RIGHT F/R XY
( Hazard)
Signal value:
R
Description: Voltage feed to direction indicator, right-hand side.
Circuit diagram: Circuit 9.6-7
Connection: digital out from D797-1/K1:31 to H423 and H427
Function: 9.6.6 Direction indicators, 9.6.7 Flashing hazard lights
( Hazard)
Signal value:
Signal value:
0 No signal.
005292
Signal value:
0 No signal.
0 No signal.
REVERSE ALARM XY
• RI: digital out from D797-1/K1:9 to H411R
Function: 9.6.4 Brake lights
Signal value:
ALARM
Description: Voltage feed to back-up alarm.
Circuit diagram: Circuit 9.7-2
Connection: digital out from D797-1/K1:10 to H965
Function: 9.7.5 Back-up alarm
Signal value:
OUTPUT XXX
Signal value:
0 No signal.
0 No signal.
Signal value:
0 No signal.
D797-2 C1 P42 XY
working light, attachment, 9.1.6 Switch for working light, mast
Signal value:
0 No signal.
008895
Signal value:
0 No signal.
Connection:
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
50 Means 4-5 V.
Signal value:
0 No signal.
8.4.3 CAB
CAB, description
page
–
OLS EXTRA
005541
OUTPUT REAR ROOF XY
Signal value:
0 No signal.
005542
FEEDBACK X
X = 2 Interval less slow: signal from S162/J2, digital in D790-2/
K3:7
X = 3 Interval continuous: signal from S162/53, digital in D790-2/
K3:8
Function: 9.5 Wiper/washer system
Signal value:
1 Long interval.
2 Normal interval.
3 Continuous operation.
Description: Signal from motor wiper front, indicates when wiper mo-
tion is completed.
Circuit diagram: Circuit 9.5-1
Connection: signal from M650-1/31B to digital in D790-1/K4:13
Function: 9.5.5 Wiper motor front
Signal value:
005543
FEEDBACK X
Function: 9.5 Wiper/washer system
Signal value:
0 No signal.
005544
FEEDBACK X
Signal value:
0 No signal.
Description: Signal from motor wiper roof, indicates when wiper mo-
tion is completed.
Circuit diagram: Circuit 9.5-1
Connection: signal from M650-3/31B to digital in D790-1/K12:4
Function: 9.5.6 Wiper motor roof
Signal value:
005545
OUTPUT XY
Signal value:
0 No signal.
HORN, SWITCH 2
page
–
0 No signal.
HORN, OUTPUT
page
–
005546
OP X
Signal value:
SWITCH SEAT
page
–
ALARM
page
–
OP
page
–
FUEL, PROC
page
–
Signal value:
0 No signal.
8.4.4 CLIMATE
CLIMATE, description
page
–
OLS EXTRA
Description: Temperature of the air out from the fan. The sensor is lo-
DIAG CLIMATE 2(X) cated in the air distributor.
TEMP COIL XXX
TEMP COOLANT XXX Circuit diagram: Circuit 9.4-1
TEMP AMBIENT XXX Connection: signal from B775-2 to input D790-1/K4:10
005550
TEMP COOLANT
page
–
TEMP AMBIENT
page
–
TEMP DE-ICE
page
–
005551
Signal value:
REQ. FAN SPEED XX.XXV Connection: signal from S117/3 to analogue in D790-1/K5:8
Function: 9.4 Heating, ventilation and air conditioning
Signal value: XX.XXV ∼ 2.4 / 0 / 5.0 V = Increase / - / decrease
COMPRESSOR XY
Function: 9.4.3 cab fan
Signal value: XXX = 0-255 = Fan speed (255 = max. fan speed).
Description: Voltage feed to water valve, for opening. The valve is con-
DIAG CLIMATE 7(X) nected to an H-bridge. The signal can only be diagnosed when the
OUTPUT WATER VALVE valve’s position changes. The valve’s opening and closing is control-
CLOCKWISE XY XY led by the climate control unit’s software depending on desired tem-
ANTI-CLOCKWISE XY XY perature, outside temp. cab temperature and coolant temperature,
thereafter it may be difficult to determine if the valve is working as it
should.
24V
Circuit diagram: Circuit 9.4-2
Connection: digital out from D790-1/K4:1 via R3 to Y673/5 and from
D790-1/K4:2 via R4 to Y673/6
Function: 9.4.5 Water valve
M Signal value: motor runs clockwise row 1: 11 11 row 2: 00 11
Description: Voltage feed to water valve, for closing. The valve is con-
nected to an H-bridge. The signal can only be diagnosed when the
valve’s position changes. The valve’s opening and closing is control-
led by the climate control unit’s software depending on desired tem-
perature, outside temp. cab temperature and coolant temperature,
thereafter it may be difficult to determine if the valve is working as it
should.
Circuit diagram: Circuit 9.4-2
Connection: digital out from D790-1/K4:1 via R3 to Y673/5 and from
D790-1/K4:2 via R4 to Y673/6
Function: 9.4.5 Water valve
Signal value: motor runs counter-clockwise row 1: 00 11, row 2: 11 11
Description: Voltage feed to motor for the air distributor, rotation clock-
DIAG CLIMATE 8(X) wise. Is connected to an H-bridge. Signal can only be diagnosed when
OUTPUT DRAUGHT VALVE the air distributor’s position changes.
CLOCKWISE XY XY
ANTI-CLOCKWISE XY XY Circuit diagram: Circuit 9.4-2
Connection: digital out from D790-1/K4:3 via R5 to Y672/5 and from
D790-1/K4:4 via R6 to Y672/6
24V
Function: 9.4.14 Air distributor
Signal value: motor runs clockwise row 1: 11 11, row 2: 00 11
Description: Voltage feed to motor for the air distributor, rotation coun-
ter-clockwise. Motor is connected to an H-bridge. Signal can only be
diagnosed when the air distributor’s position changes.
Circuit diagram: Circuit 9.4-2
Connection: digital out from D790-1/K4:3 via R5 to Y672/5 and from
D790-1/K4:4 via R6 to Y672/6
Function: 9.4.14 Air distributor
Signal value: motor runs counter-clockwise row 1: 00 11, row 2: 11 11
8.4.5 HYD
HYD, description
page
–
OLS EXTRA
SET OUTPUT + - X
Signal value: XXX = Temperature in tenths of degrees (200 = 20 °C).
SET OUTPUT + - X
SET OUTPUT + - X
90-100 4.8.10 Hydraulic oil temperature sensor
Menu for DCF 90-100 Signal value: XXX = Temperature in tenths of degrees (200 = 20 °C).
C+
007239
Description: Pressure on the tilt cylinders’ rod side (C-). For voltage
value, see PRESENT INPUT SIGNAL, TILT CYLINDER page 137.
Circuit diagram: Circuit 8.2-2
Connection: signal from B768-2/3, analogue in D797-1/K1:22
Function: 7.7.8 Hydraulic pressure sensor, tilt cylinder
Signal value: XXX = 0-250 = Hydraulic pressure 0 - 25 MPa. (255 =
incorrect signal.)
007240
DECLUTCH PRESSURE X
Signal value:
0 No signal.
0 No signal.
0 No signal.
Description: Signals from switch parking brake. Two signals, one for
DIAG HYDRAULIC 5(X) released parking brake and one for applied parking brake. Both sig-
P-BRAKE nals must be valid to enable release of parking brake.
SWITCH X/Y
FEEDBACK SWITCH X Circuit diagram: Circuit 4.0-1
007241
VALVE XY Connection: signal from S107/1 to digital in D790-1/K8:13 and from
S107/7 to digital in D790-1/K8:5
Function: 4.5 Parking brake system
Signal value:
0 No signal.
P-BRAKE, VALVE
page
–
007242
PUMP ATTACHMENT XY
Function: 10.4.3 Vane pump with fixed displacement
Signal value:
010073
SET OUTPUT + - X
Function: 10.4.2 Axial piston pump with variable displacement
Signal value:
0 No output signal.
OUTPUT +/-
Description: Activate or deactivate the quick-lift pump
Circuit diagram: 10.4-1
Connection: digital out from D797-1/K1:39 to solenoid valve Y6062 is
activated or deactivated with +/-
Function: 10.4.2 Axial piston pump with variable displacement
Signal value:
0 No output signal.
VALVE
Only applies to DCF 90-100
DIAG HYDRAULIC 8(X)
Description: Voltage feed to solenoid valve for main pump relief (pres-
PRESENT OUTPUT SIGNAL
PRESSURE TO ATTACHM. surised attachment).
VALVE XY Circuit diagram: 10.4-1
010074
SET OUTPUT + - X
Connection: digital out from D797-1/K1:35 to solenoid valve Y6062-2
Function: 10.4.2 Axial piston pump with variable displacement
Signal value:
0 No output signal.
0 No output signal.
8.4.6 ENGINE
ENGINE, description
page
–
OLS EXTRA
Description: Required engine speed (in percent) which is sent from the
cab control unit (D790-1) to the engine control unit (D794) via the CAN
bus drivetrain.
Circuit diagram: -
Connection: -
Function: 1.9 Control system, engine
Signal value: XXXX = 0 - 100%
Description: Required engine speed in rpm which is sent from the cab
control unit (D790-1) to the engine control unit (D794) via the CAN bus
drivetrain.
Circuit diagram: -
Connection: -
Function: 1.9 Control system, engine
Signal value: XXXX = 0-2010 rpm
Description: Engine speed from engine control unit (D794) to the cab
DIAG ENGINE 2(X) control unit (D790-1) via the CAN bus drivetrain. The actual value for
PRESENT INPUT SIGNAL engine speed.
ENGINE SPEED EDC XXXX
ENGINE SPEED TCU XXXX Circuit diagram: -
005308
Connection: -
Function: 1.9.2 Sensor engine rpm
Signal value: XXXX = active speed in rpm.
D+ X
Connection: signal from S150/19 to digital in D790-2/K2:2
Function: 1 Engine, 1.10.1 Preheating
Signal value:
0 No signal.
0 No signal.
0 No signal.
007639
CRANK ENGINE WIRE XY
Cummins: controlled by engine’s control system.
Function: 1.10.1 Preheating
Signal value:
0 No output signal.
0 No output signal.
Description: Engine oil pressure. CAN bus message from engine con-
DIAG ENGINE 6(X) trol unit (D794) to cab control unit (D790-1).
PRESENT INPUT SIGNAL
OIL PRESSURE XX.X Circuit diagram: see supplier documentation, engine
BOOST PRESSURE XX.X Connection:
008899
OIL LEVEL XXX
Volvo TAD760VE: signal from "2 oil pressure sensor" to engine
control unit (D794) "Connector B" sleeve 11
Volvo TAD950VE, TAD952VE, TAD1250VE: signal from "28 oil
temperature and oil pressure sensor" to engine control unit (D794)
"Connector B" sleeve 11
Cummins QSM11: signal from "oil pressure/temperature sensor"
to engine control unit (D794) "Sensor connector" sleeve 44
Function: 1.8.3 Sensor oil pressure engine
Signal value= XX.X = pressure in bar.
Description: Charge air pressure. CAN bus message from engine con-
trol unit (D794) to cab control unit (D790-1).
Circuit diagram: See supplier documentation, engine
Connection:
Volvo TAD760VE: signal from "33 charge air pressure sensor" to
engine control unit (D794) "Connector A" sleeve 22
Volvo TAD950VE, TAD952VE, TAD1250VE: signal from "23
charge air pressure/temperature sensor" to engine control unit
(D794) "Connector A" sleeve 22
Cummins QSM11: signal from "Intake manifold (boost) pressure
sensor" to engine control unit (D794) "Sensor connector" sleeve
39
Function: 1.6.5 Sensor boost pressure
Signal value= XX.X = pressure in bar.
005313
INTAKE MAIN.TEMP XXX
Volvo TAD760VE: signal from "1 oil temperature/level sensor" to
engine control unit (D794) "connector A" sleeve 31
Volvo TAD950VE, TAD952VE, TAD1250VE: signal from "28 oil
temperature/pressure sensor" to engine control unit (D794) "Con-
nector A" sleeve 31
Cummins QSM11: signal from "oil pressure/temperature sensor"
sleeve 4 to engine control unit (D794) "Sensor connector" sleeve
42
Function: 1.8.7 Sensor oil temperature
Signal value: XXX = 200 equals 20 °C.
FMI XX
Function: 1.9 Control system
Signal value: XX = number of active error codes.
Description: SPN number for the first error code from engine control
unit (D794). SPN indicates the malfunction area, i.e. what component
or signal is defective. Error codes are shown with SPN/FMI in error
code menus.
Circuit diagram: -
Connection: -
Function: 8.3 Error codes
Signal value: XXXX = error code number. Use the error code list; see
section D Error codes.
Description: FMI number for the first error code from the engine control
unit (D794). FMI indicates error type, e.g. short circuit or low value. Er-
ror codes are shown with SPN/FMI in error code menus.
Circuit diagram: -
Connection: -
Function: 8.3 Error codes
Signal value: XX = fault type number. Use the error code list; see sec-
tion D Error codes.
005315
Signal value: XXX = fuel consumption in l/h
8.4.7 TRANSM
TRANSM, description
page
–
OLS EXTRA
0 No signal.
0 No signal.
005326
SHIFT MODE X
Signal value:
0 No signal.
SWITCHES, REVERSE
page
–
0 No signal.
005327
GEAR X Connection: -
Function: 2.8 Control system, transmission
Signal value:
0 No output signal.
0 No output signal.
OPERATING MODE X
Function: 2.8 Control system, transmission
Signal value:
1 Automatic.
0 Manual.
1 Active error.
0 No errors.
0 Not used.
2 Not used.
3 Not used.
OLD FAULT X
Function: 2.8 Control system, transmission
Signal value:
1 Shifting in progress.
0 No activity.
0 No error codes.
1 There are inactive error codes that have not been acknowl-
edged.
5
005330
4
1. Sensor, drum rpm (B752)
2. Temperature monitor torque converter (S221)
3. Sensor engine rpm and temperature transmission
(B758/766)
4. Sensor rpm turbine transmission (B751)
5. Sensor rpm output shaft (B758)
OUTPUT SPEED
page
–
ENGINE SPEED
page
–
Description: Rpm signal from sensor rpm engine speed (position 3).
Circuit diagram: Circuit 2.0-2A2
Connection: signal from B758/766 to D793/H3
Function: 2.2.5 Sensor engine rpm and oil temperature transmission
Signal value: XXXXHz = frequency, indicates pulses from the sensor
in Hz (pulses /second). To convert to rpm, divide frequency by number
of teeth on input shaft’s gear.
TURBINE SPEED
page
–
Description: Status high and low side for control of solenoid valve RSP
DIAG TRANSM. 7(X) Drive.
OUTPUT STATUS
RSP DRIVE X X Circuit diagram: Circuit 2.0-2A3
2/4 VFS SELECTION X Connection: signal from D793/K1 and D793/K2 to Y6066
005331
00 No signal.
1 Activated.
0 No signal.
1 Activated.
0 No signal.
1/3 SUPPLY X
transmission
Signal value:
1 Activated.
0 No signal.
REV SUPPLY
page
–
1 Activated.
0 No signal.
2/4 SUPPLY
page
–
1 Activated.
0 No signal.
1/3 SUPPLY
page
–
1 Activated.
0 No signal.
REV FEEDBACK
page
–
2/4 FEEDBACK
page
–
1/3 FEEDBACK
page
–
CONV OUT TEMP XXXXXmV Connection: signal from "pressure feedback sensor" to D793/A2
Function: 2.6.2 Sensor oil pressure
Signal value:
Description: Signal from oil temperature sensor out from the transmis-
sion to the radiator. The transmission uses a temperature-sensitive
NO contact and two resistors in the cable harness to generate different
voltage levels.
RADIUS
page
–
FRAME XX X XX Connection: -
Function: 8.2.3 Speed limitation
Signal value:
SPD, XX = speed in km/h.
GEAR, X = current gear.
LOG, XX = code which specifies what has caused the speed lim-
itation.
Description: Indicates malfunction area active error, first part of the er-
DIAG TRANSM. 13(X) ror code. In case of several error codes, the most serious error code
ACT ERROR AREA XXX is shown.
TYPE XXX
NUMBER OF OCCU. XXXXX Circuit diagram: -
005337
TYPE
page
–
NUMBER OF OCCU.
page
–
TIME AGO
page
–
007622
Function: 2.8 Control system, transmission
Signal value: XXXX = Torque in Nm.
8.4.8 ELSERV
ELSERV, description
page
–
DIAGNOSIS
CAN/POWER LIGHTS CAB This group covers electric servo functions.
CLIMATE HYD ENGINE
Confirm selection with function key for Enter.
TRANSM ELSERV ATTACH
005400
OLS EXTRA
P3 XX.XXV
Signal value: XX.XXV = 0,50 - 4,50 V. 2,5 V in zero position.
P5 XX.XXV
Signal value: XX.XXV = 0,50 - 4,50 V. 2,5 V in zero position.
005403
FEEDBACK XXXmA machines with freelift).
Function: 7.2.5 Control valve, lift and tilt (DCF360-450CSG and DCF
90-100)
7.2.6 Control valve, load handling (DCF280-330, DCF370-500)
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
005404
FEEDBACK XXXmA machines with freelift).
Function: 7.2.5 Control valve, lift and tilt (DCF360-450CSG and DCF
90-100)
7.2.6 Control valve, load handling (DCF280-330, DCF370-500)
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
005405
FEEDBACK XXXmA
Function: 7.7.5 Control valve, lift and tilt (DCF360-450CSG and DCF
90-100)
7.7.5 Control valve, load handling (DCF280-330, DCF370-500)
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
005406
FEEDBACK XXXmA
Function: 7.7.5 Control valve, lift and tilt (DCF360-450CSG and DCF
90-100)
7.7.5 Control valve, load handling (DCF280-330, DCF370-500)
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
005407
FEEDBACK XXXmA
Function: 7.4.5 Control valve, load handling (DCF280-330, DCF370-
500)
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
005408
FEEDBACK XXXmA
Function: 7.4.5 Control valve, load handling (DCF280-330, DCF370-
500)
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
005409
FEEDBACK XXXmA
Function: 7.5.5 Control valve, load handling (DCF280-330, DCF370-
500)
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
005410
FEEDBACK XXXmA
Function: 7.5.5 Control valve, load handling (DCF280-330, DCF370-
500)
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
005411
FEEDBACK XXXmA
Function: 7.2.6 Control valve, load handling (DCF280-330, DCF370-
500)
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
005412
FEEDBACK XXXmA
Function: 7.2.6 Control valve, load handling (DCF280-330, DCF370-
500)
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
007128
UNLOCK TW X
OUT: Signal from S815/16 to digital in D790-1/K7:13 (spreading
out)
Function: 7.1.1 Control lever
Signal value:
0 No signal.
0 No signal.
0 No signal.
007129
Signal value:
0 No signal.
0 No signal.
OUTPUT RIGHT XY
Signal value:
0 No signal.
OLS EXTRA
005416
P7 XX.XXV
Function: 7.1.1 Control levers
Signal value: XX.XXV = 0,50 - 4,50 V. 2,5 V in zero position.
005418
30/35 STOP X
(spreading in)
OUT: Signal from S1012/7 (S815/16) to digital in D790-1/K7:13
(spreading out)
Function: 7.1.3 Switch, spreading 20’-40’, 7.1.1 Control lever
Signal value:
0 No signal.
0 No signal.
0 No signal.
007130
Signal value:
0 No signal.
LOCK LEVELLING X
Function: 7.9.1 Twistlocks
Signal value:
0 No signal.
0 No signal.
0 No signal.
008902
30/35 STOP X
Function: 7.5.8 Position sensor spreading
Signal value:
0 No signal.
0 No signal.
Description: Signals from sensors alignment right front and left front.
DIAG ATTACHMENT 7(X)
Circuit diagram: Circuit 7.9-2
PRESENT INPUT SIGNALS
ALIGNMENT LE RI Connection:
FRONT X X
LE: signal from B7202L/C to digital in D791-1/K1:13
005422
REAR X X
RI: signal from B7202R/C to digital in D791-1/K1:40
Function: 7.9.1.6 Alignment sensor
Signal value:
0 No signal.
Description: Signals from sensors alignment right rear and left rear.
Circuit diagram: Circuit 7.9-2
Connection:
LE: signal from B7203L/B to digital in D791-1/K1:27
RI: Signal from B7203R/B to digital in D791-1/K1:26
Function: 7.9.1.6 Alignment sensor
Signal value:
0 No signal.
UNLOCKED TW X X
RI: Signal from B7205R/B to digital in D791-1/K1:24
Function: 7.9.1.7 Sensor twistlock
Signal value:
0 No signal.
0 No signal.
005424
Function: 7.9.1.2 Attachment control valve
Signal value:
IND. ALIGNMENT XY
005426
FEEDBACK XXXmA
Function: 7.4.2 Control valve attachment
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
005427
FEEDBACK XXXmA
Function: 7.4.2 Control valve attachment
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
005428
FEEDBACK XXXmA
Function: 7.5.2 Control valve attachment
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
005429
FEEDBACK XXXmA
Function: 7.5.2 Control valve attachment
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
005430
Signal value:
FEEDBACK XXXmA
Function: 7.3.2 Control valve attachment
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
FEEDBACK XXXmA
Function: 7.3.2 Control valve attachment
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
005434
FEEDBACK XXXmA
Function: 7.3.2 Control valve attachment
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
005435
FEEDBACK XXXmA
Function: 7.3.2 Control valve attachment
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
009181
Connection: digital out from D791-1/K1:28 to H9003/1
Function: 7.5 Spreading
Signal value:
OLS EXTRA
P7 XX.XXV
Function: 7.1.1 Control levers
Signal value: XX.XXV = 0,50 - 4,50 V. 2,5 V in zero position.
30/35 STOP X
(spreading in)
OUT: Signal from S1012/7 (S815/16) to digital in D790/K7:13
(spreading out)
Function: 7.1.3 Switch, spreading 20’-40’, 7.1.1 Control lever
Signal value:
0 No signal.
0 No signal.
0 No signal.
Signal value:
0 No signal.
Signal value:
0 No signal.
0 No signal.
010080
30/35 STOP X X from inductive sensor B769R to digital in D791/K1:40
Function: 7.5.6 Position sensor spreading
Signal value:
0 No signal.
Description: Signal from position sensor for end position 30’ right or
left.
Circuit diagram: Circuit 5
Connection: from inductive sensor B777L to digital in D791/K1:20 or
from inductive sensor B777R to digital in D791/K1:37
Function: 7.5.6 Position sensor spreading
Signal value:
0 No signal.
LOWER X X
LE: signal from B7203RU-2 to digital in D791/K1:36
RI: Signal from B7203LU-2 to digital in D791/K1:11
Function: 7.9.2.8 Alignment and detection sensor
Signal value:
0 No signal.
Description: Signals from sensors alignment right lower and left lower.
Circuit diagram: Circuit 11B
Connection:
LE: signal from B7203LL to digital in D791/K1:27
RI: Signal from B7203RL to digital in D791/K1:26
Function: 7.9.2.8 Alignment and detection sensor
Signal value:
0 No signal.
Description: Signals from sensors locked lock tongue right and left.
DIAG ATTACHMENT 8(X)
Circuit diagram: Circuit 9
PRESENT INPUT SIGNALS
LE RI Connection:
LOCKED CONT X X
LE: signal from B7205LL to digital in D791/K1:23
010082
UNLOCKED CONT X X
RI: Signal from B7205RL to digital in D791/K1:24
Function: 7.9.2.9 Lock tongue sensor
Signal value:
0 No signal.
Description: Signals from sensors open lock tongue right and left.
Circuit diagram: Circuit 9
Connection:
LE: signal from B7204L to digital in D791-1/K1:22
RI: signal from B7204R to digital in D791-1/K1:41
Function: 7.9.2.9 Lock tongue sensor
Signal value:
0 No signal.
010083
Function: 7.4.2 Control valve attachment
Signal value:
Description: Voltage feed, indicator light for locked lock tongues - lo-
DIAG ATTACHMENT 10(X) cated on carriage.
PRESENT OUTPUT SIGNAL
IND. LOCKED CONT XY Circuit diagram: Circuit 10A
IND. UNLOCKED CONT XY Connection: digital out from D791/K1:29 to H563
010084
IND. ALIGNMENT XY
Function: 7.9.2 Lifting hook
Signal value:
Description: Voltage feed, indicator light for unlocked lock tongues - lo-
cated on carriage.
Circuit diagram: Circuit 10A
Connection: digital out from D791/K1:25 to H562
Function: 7.9.2 Lifting hook
Signal value:
FEEDBACK XXX
Function: 7.4.2 Control valve attachment
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
FEEDBACK XXX
Function: 7.4.2 Control valve attachment
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
010085
FEEDBACK XXX
Function: 7.8.2 Control valve attachment
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
010086
FEEDBACK XXX
Function: 7.8.2 Control valve attachment
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
010077
8.4.9.16 ATTACH, menu 16
Not used.
page
–
FEEDBACK XXX
Function: 7.5.2 Control valve attachment
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
FEEDBACK XXX
Function: 7.5.2 Control valve attachment
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
010091
FEEDBACK XXX
Function: 7.5.2 Control valve attachment
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
010092
FEEDBACK XXX
Function: 7.5.2 Control valve attachment
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
009181
Connection: digital out from D791/K1:28 to H9003
Function: 7.5 Spreading
Signal value:
X X
RI: Signal from B7203RU to digital in D791-1/K1:21
Function: 7.9.2.8 Alignment and detection sensor
Signal value:
0 No signal.
0 No signal.
005339
OLS EXTRA
P7 XX.XXV
Function: 7.1.1 Control levers
Signal value: XX.XXV = 0,50 - 4,50 V. 2,5 V in zero position.
005418
30/35 STOP X
(spreading in)
OUT: Signal from S1012/7 (S815/16) to digital in D790-1/K7:13
(spreading out)
Function: 7.1.3 Switch, spreading 20’-40’, 7.1.1 Control lever
Signal value:
0 No signal.
0 No signal.
0 No signal.
007130
Signal value:
0 No signal.
Signal value:
0 No signal.
0 No signal.
010080
30/35 STOP X X from inductive sensor B769R to digital in D791/K1:40
Function: 7.5.6 Position sensor spreading
Signal value:
0 No signal.
Description: Signal from position sensor for end position 30’ right or
left.
Circuit diagram: Circuit 5
Connection: from inductive sensor B777L to digital in D791/K1:20 or
from inductive sensor B777R to digital in D791/K1:37
Function: 7.5.6 Position sensor spreading
Signal value:
0 No signal.
0 No signal.
010082
UNLOCKED CONT X X
RI: Signal from B7205RL to digital in D791/K1:24
Function: 7.9.1.8 Twistlocks sensor
Signal value:
0 No signal.
0 No signal.
IND. ALIGNMENT XY
Function: 7.9.1 Twistlocks
Signal value:
FEEDBACK XXX
Function: 7.4.2 Control valve attachment
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
FEEDBACK XXX
Function: 7.4.2 Control valve attachment
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
FEEDBACK XXX
Function: 7.8.2 Control valve attachment
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
010086
FEEDBACK XXX
Function: 7.8.2 Control valve attachment
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
010077
8.4.9.16 ATTACH, menu 16
Not used.
page
–
FEEDBACK XXX
Function: 7.5.2 Control valve attachment
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
FEEDBACK XXX
Function: 7.5.2 Control valve attachment
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
010091
FEEDBACK XXX
Function: 7.5.2 Control valve attachment
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
FEEDBACK XXX
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
8.4.10 OLS
OLS, description
page
–
DIAGNOSIS
CAN/POWER LIGHTS CAB This group covers overload protection functions.
CLIMATE HYD ENGINE
Confirm selection with function key for Enter.
TRANSM ELSERV ATTACH
005436
OLS EXTRA
Signal value:
0 No signal.
008903
MAST POS SENSOR X
Function: 8.2.1 Overload protection
Signal value: XXXXX = Weight, kg
PRESENT LOAD
page
–
0 No signal.
8.4.11 EXTRA
EXTRA, description
page
–
005440
OLS EXTRA
• Freelift, FREELIFT
• Cab tipping, MOVE-CAB
• Auxiliary equipment, OPT
• Inputs and outputs, control units, I/O
• Remote machine interface, RMI
Confirm selection in main menu with function key for Enter.
8.4.11.1 VBFS
VBFS, description
page
–
DIAGNOSIS EXTRA
VBFS EL-STEERING This group covers reversible driver’s seat functions.
EXT-ATTACH FREELIFT
Confirm selection with function key for Enter.
MOVE-CAB OPT I/O RMI
008904
VBFS, menu 1
page
–
SWITCH CCW X
Connection: signal from S169/1 to digital in D790-1/K8:6
Function: 9.3.9 Reversible driver’s seat
Signal value:
0 No signal.
0 No signal.
VBFS, menu 2
page
–
SEAT CCW XY
Connection: digital out from D797-2/K1:29 to A798/6
Function: 9.3.9 Reversible driver’s seat
Signal value:
VBFS, menu 3
page
–
0 No signal.
0 No signal.
VBFS, menu 4
page
–
007623
REQUIRED SPD RPM XXXX
Connection: signal from B690-2/2 to analogue in D790-1/K6:12
Function: 1 Engine
Signal value: X.XXV = 0.50 - 4.50 V
Description: Required engine speed (in percent) which is sent from the
cab control unit (D790-1) to the engine control unit (D794) via the CAN
bus drivetrain.
Circuit diagram: -
Connection: -
Function: 1.9 Control system, engine
Signal value: XXX = 0-100%
Description: Required engine speed in rpm which is sent from the cab
control unit (D790-1) to the engine control unit (D794) via the CAN bus
drivetrain.
Circuit diagram: -
Connection: -
Function: 1.9 Control system, engine
Signal value: XXXX = 0-2010 rpm
VBFS, menu 5
page
–
005565
VALVE CAB REAR XY
Connection: digital out from D797-2/K1:9 to Y636-1/1
Function: 9.3.12 Directional valve, reversible driver’s seat
Signal value:
VBFS, menu 6
page
–
005566
DIMMED LE/RI XY Connection: signal from S100/1 to digital in D790-1/K6:5
Function: 9.6.1 Headlights.
Signal value:
0 No signal.
VBFS, menu 7
page
–
FRONT LE/RI XY Connection: digital out from D797-2/K1:25 to H413L/1 and H413R/1
Function: 9.6.3 Rear lights
Signal value:
VBFS, menu 8
page
–
005568
FRONT LE XY RI XY Connection:
LE: digital out from D797-2/K1:37 to H410L/1
RI: digital out from D797-2/K1:36 to H410R/1
Function: 9.6.4 Brake lights
Signal value:
VBFS, menu 9
page
–
DAMP SPEED XY
Circuit diagram: Circuit 9.3-7
Connection: digital out from D797-2/K1:35 to Y676/1
Function: 9.3.9 Reversible driver’s seat
8.4.11.2 EL-STEERING
EL-STEERING, description
page
–
DIAGNOSIS EXTRA
VBFS EL-STEERING This group handles functions for lever steering/mini-wheel steering.
EXT-ATTACH FREELIFT
Confirm selection with function key for Enter.
MOVE-CAB OPT I/O RMI
008911
EL-STEERING, menu 1
page
–
LOGIC X.XXV
Signal value: XX.XXV = 0.50 - 4.50 V
EL-STEERING, menu 2
page
–
SWITCHES, ON/OFF
Description: Signal from switch mini-wheel/steering lever.
DIAG STEERING 2(X)
Circuit diagram: Circuit 5.2-1
SWITCHES
ON/OFF X Connection: signal from S113/1 to digital in D790-1/K9:5
FORWARD X
Function: 5.2 Power-steering system
005569
REVERSE X
Signal value:
0 No signal.
SWITCHES, FORWARD
Description: Signal from mini-wheel or steering lever (travel direction
selector forward).
Circuit diagram: Circuit 5.2-1
Connection: signal from S160-2/1 to digital in D790-1/K9:4
Function: 5.2 Power-steering system
Signal value:
0 No signal.
SWITCHES, REVERSE
Description: Signal from mini-wheel or steering lever (travel direction
selector reverse).
Circuit diagram: Circuit 5.2-1
Connection: signal from S160-2/7 to digital in D790-1/K9:3
Function: 5.2 Power-steering system
Signal value:
0 No signal.
EL-STEERING, menu 3
page
–
007624
Signal value:
0 No signal.
0 No signal.
EL-STEERING, menu 4
page
–
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
EL-STEERING, menu 5
page
–
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
8.4.11.3 EXT-ATTACH
EXT-ATTACH, description
page
–
DIAGNOSIS EXTRA
VBFS EL-STEERING This group cover external attachment functions.
EXT-ATTACH FREELIFT
Confirm selection with function key for Enter.
MOVE-CAB OPT I/O RMI
007625
EXT-ATTACH, menu 1
page
–
0 No signal.
EXT-ATTACH, menu 2
page
–
Signal value:
0 No signal.
0 No signal.
EXT-ATTACH, menu 3
page
–
Signal value:
0 No signal.
0 No signal.
EXT-ATTACH, menu 4
page
–
UNLOCKED TW X
Function: 7.10.5 Separate top lift attachment
Signal value:
0 No signal.
0 No signal.
0 No signal.
EXT-ATTACH, menu 5
page
–
4:E IN XY
Signal value:
EXT-ATTACH, menu 6
page
–
SPREADING ACTIVE XY
Signal value:
EXT-ATTACH, menu 7
page
–
FEEDBACK XXX
Function: 7.5.5 Control valve, load handling
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
EXT-ATTACH, menu 8
page
–
FEEDBACK XXX
Function: 7.5.5 Control valve, load handling
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
8.4.11.4 FREELIFT
FREELIFT, description
page
–
DIAGNOSIS EXTRA
VBFS EL-STEERING This group covers freelift functions.
EXT-ATTACH FREELIFT
Confirm selection with function key for Enter.
MOVE-CAB OPT I/O RMI
008912
FREELIFT, menu 1
page
–
0 No signal.
0 No signal.
FREELIFT, menu 2
page
–
007636
CARR UP XY DOWN XY Connection:
MAST UP: digital out from D797-1/K1:4 to solenoid valve Y6005-1
MAST DOWN: digital out from D797-1/K1:4 to solenoid valve
Y6004-1
CARR UP: digital out from D797-1/K1:5 to solenoid valve Y6005-2
CARR DOWN: digital out from D797-1/K1:5 to solenoid valve
Y6004-2
Function: 7.2.5 Freelift shift valve
Signal value:
Mast position: up 11 11
Carriage position: up
8.4.11.5 MOVE-CAB
MOVE-CAB, description
page
–
DIAGNOSIS EXTRA
VBFS EL-STEERING This group covers tiltable cap functions.
EXT-ATTACH FREELIFT
Confirm selection with function key for Enter.
MOVE-CAB OPT I/O RMI
008913
MOVE-CAB, menu 1
page
–
INPUT SWITCHES, UP
Description: Signal from switch for manual cab tilt, cab up.
DIAG MOVE-CAB 1(X) Circuit diagram: Circuit 9.10-1
INPUT SWITCHES
UP/RIGHT X Connection: signal from S1010/1 to digital in D790-1/K8:6
DOWN/LEFT X Function: 9.10.4 Cab tilt
007133
OPEN DOORS X
Signal value:
0 No signal.
0 No signal.
0 No signal.
MOVE-CAB, menu 2
page
–
Signal value:
0 No signal.
0 No signal.
MOVE-CAB, menu 3
page
–
Signal value:
0 No signal.
0 No signal.
MOVE-CAB, menu 4
page
–
005449
Signal value:
MOVE-CAB, menu 5
page
–
007134
Signal value:
MOVE-CAB, menu 6
page
–
FEEDBACK XXX
Function: 9.10.4 Hydraulic sliding cab
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
MOVE-CAB, menu 7
page
–
FEEDBACK XXX
Function: 9.10.4 Hydraulic sliding cab
Signal value:
NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.
8.4.11.6 OPT
OPT, description
page
–
008914
OPT, menu 1
page
–
S199-3 X
Signal value:
0 No signal.
0 No signal.
0 No signal.
Function: -
Signal value:
0 No signal.
OPT, menu 2
page
–
ATTACHMENT XY
Signal value:
OPT, menu 3
page
–
005490
Signal value:
OPT, menu 4
page
–
Signal value:
OPT, menu 5
page
–
Signal value:
8.4.11.7 RMI
RMI, description
page
–
007657
RMI, menu 1
page
–
MIU SW VER
Description: Software version in RMI interface.
DIAG RMI 1(X) Circuit diagram: -
MIU SW VER XXXX.XXXX
MIU TIME XX.XX.XX Connection: -
Function: 11.6.5 RMI (Remote Machine Interface)
010094
MIU TIME
Description: Date setting in RMI interface.
Circuit diagram: -
Connection: -
Function: 11.6.5 RMI (Remote Machine Interface)
Signal value: xxxx.xx.xx = Date in format YYYY.MM.DD.
RMI, menu 2
page
–
RMI, menu 3
page
–
ERROR
Description: Internal error code for the RMI interface
DIAG RMI 3(X) Circuit diagram: Circuit 8.2-4
ERROR XX.XX.XX.XX
ERR.VALID XX.XX.XX.XX Connection: -
ACT ERR XX.XX.XX.XX Function: 11.6.5 RMI (Remote Machine Interface)
007660
ERR.VALID
Description: Internal error code for the RMI interface
Circuit diagram: Circuit 8.2-4
Connection: -
Function: 11.6.5 RMI (Remote Machine Interface)
Signal value: XX.XX.XX.XX = Error code
ACT.ERR
Description: Internal error code for the RMI interface
Circuit diagram: Circuit 8.2-4
Connection: -
Function: 11.6.5 RMI (Remote Machine Interface)
Signal value: XX.XX.XX.XX = Error code
8.5 Settings
Settings, general
page
–
Settings are built-in functions to adapt the functions to the unique ma-
chine individual. Settings are performed via menus in the display. Set-
tings are divided into initiation and calibration.
Initiation
Initiation, which involves setting start and stop currents for the steering
and hydraulic functions, is performed before the machine is used in
work. This is done to compensate for mechanical and electrical toler-
ances (variations between different machines).
Calibration
Calibration is performed after the machine has started to be used for
work, after change of control units, and in certain cases, service or
change of components. Calibration is performed so that certain func-
tions shall function properly and show correct values.
8.5.1 Initiation
Initiation, description
page
–
1 2
DANGER
INIT ELSERVO 1(X)
START CURRENT The settings influence the functions. Adjustments
LIFT may impair the function. If uncertain, contact Kalmar
4 STORED VALUE XXXmA 3 Industries Service.
008891
PRESENT
Displays the stored value when the menu is opened. Adjust the value
with the plus and minus keys. Save the set value with the Enter key.
Go to the next menu with the arrow keys. Go back with the R-key.
STORED
States the stored value for the current variable.
START CURRENT
I [mA]
Specifies the start current to the solenoid valve for the selected func-
1 tion. The start current is the lowest current that can be actuated. In
2 practice, this controls how slowly a function can be operated. On func-
tions with analogue control activation (variable), e.g. lift, this is the cur-
3
006299
rent that is triggered when the lever leaves the zero position. On
t [s] certain functions with digital activation (off/on) which are soft-started,
1. Max. current (END CURRENT) this is the current which is triggered immediately the function is
2. Damping (PROC DAMPING) activated.
3. Start current (START CURRENT)
END CURRENT
Specifies the max. current to the solenoid valve for the selected func-
tion. The max. current is the highest current that can be triggered. In
practice, it controls how quickly a function can be operated. On func-
tions with analogue control activation (controllable), e.g. lift, this is the
current when the lever is in the end position. On certain functions with
digital activation (off/on) which are soft-started, this is the current
which is triggered after the ramp time when the function is activated.
The interval between START CURRENT and END CURRENT is the
active range for controlling the solenoid valve.
PROC DAMPING
Specifies how much the control current shall be reduced during damp-
ing. The interval is specified as 0-100% of the active range between
START CURRENT and END CURRENT.
Overview, initiations DCF360-450CSG
Function Menu
INIT DRIVE-TRAIN, menu 9 page
1 Engine, speed limitation (limitation of engine speed
203
1 Engine, automatic engine speed increase for lifting INIT DRIVE-TRAIN, menu 13 page
204
2 Transmission, speed limit shifting forward - reverse INIT DRIVE-TRAIN, menu 2 page
200
2 Transmission, engine speed limit shifting forward - reverse INIT DRIVE-TRAIN, menu 3 page
201
2 Transmission, engine speed limit shifting neutral - gear INIT DRIVE-TRAIN, menu 4 page
201
2 Transmission, engine speed limit kickdown to 1st INIT DRIVE-TRAIN, menu 5 page
202
Function Menu
INIT DRIVE-TRAIN, menu 10 page
2 Transmission, speed limitation (gear lock-out)
203
Function Menu
INIT DRIVE-TRAIN, menu 9 page
1 Engine, speed limitation (limitation of engine speed
203
1 Engine, automatic engine speed increase for lifting INIT DRIVE-TRAIN, menu 13 page
204
2 Transmission, speed limit shifting forward - reverse INIT DRIVE-TRAIN, menu 2 page
200
2 Transmission, engine speed limit shifting forward - reverse INIT DRIVE-TRAIN, menu 3 page
201
2 Transmission, engine speed limit shifting neutral - gear INIT DRIVE-TRAIN, menu 4 page
201
2 Transmission, engine speed limit kickdown to 1st INIT DRIVE-TRAIN, menu 5 page
202
5.2 Power-assisted steering system (product option lever steering or mini-wheel), INIT STEERING, menu 1 page 195
lever response
5.2 Power-assisted steering system (product option lever steering or mini-wheel), INIT STEERING, menu 2 page 196
speed dependent INIT STEERING, menu 3 page 196
INIT STEERING, menu 4 page 197
INIT STEERING, menu 5 page 197
INIT STEERING, menu 6 page 198
5.2 Power-assisted steering system (product option lever steering or mini-wheel), INIT STEERING, menu 7 page 198
steering angle right INIT STEERING, menu 8 page 198
5.2 Power-assisted steering system (product option lever steering or mini-wheel), INIT STEERING, menu 9 page 199
steering angle left INIT STEERING, menu 10 page 199
Function Menu
7.2 Lifting/lowering, lift carriage INIT ELSERVO, menu 13 page 183
INIT ELSERVO, menu 14 page 184
Function Menu
INIT DRIVE-TRAIN, menu 9 page
1 Engine, speed limitation (limitation of engine speed
203
1 Engine, automatic engine speed increase for lifting INIT DRIVE-TRAIN, menu 13 page
204
2 Transmission, speed limit shifting forward - reverse INIT DRIVE-TRAIN, menu 2 page
200
2 Transmission, engine speed limit shifting forward - reverse INIT DRIVE-TRAIN, menu 3 page
201
2 Transmission, engine speed limit shifting neutral - gear INIT DRIVE-TRAIN, menu 4 page
201
2 Transmission, engine speed limit kickdown to 1st INIT DRIVE-TRAIN, menu 5 page
202
Function Menu
7.8 Levelling INIT ATTACH, menu 7 page 188
INIT ATTACH, menu 8 page 188
000056
3 Enter the code for initiation.
Code is obtained from Kalmar Industries Support.
1 23
4 5 NOTE
000060
RETURN the desired menus with the arrow keys (1 and 2).
5 Change the current value with the plus and minus keys.
INIT ELSERVO 1(X)
START CURRENT
LIFT NOTE
STORED VALUE XXXmA Current values can only be adjusted within specific limits.
005494
PRESENT VALUE XXXmA 6 Use the function key for Enter to store the desired current value
setting, "STORED".
The menu group for this function covers initiation of the electric servo
INITIATION functions for load handling.
ELSERVO ATTACHMENT
STEERING DRIVE-TRAIN For DCF360-450CSG and DCF 90-100, settings are made for lift, low-
SLIDING-CAB er, tilt in and tilt out. For other load handling functions, see INIT AT-
007169
RETURN TACH page 186.
For DCF 280-330, DCF 370-500, settings are made for lift, lower, tilt
in, tilt out, side shift left, side shift right, spreading in and spreading out.
DANGER
The settings affect the functions lift, lower, tilt, and,
for DCF370-500, spreading and side shift. Adjustment
can impair functionality. If in doubt, contact Kalmar
Industries Service.
NOTE
Initiation does not need to be performed in one process but each
step can be performed separately, independently of other steps.
PRESENT VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE: indicates stored value for start current.
Function: 7.2.5 Control valve, lift and tilt (DCF360-450CSG)
7.2.6 Control valve, load handling (DCF 280-330, DCF 370-500)
Component: Solenoid valve, lift mast (Y6005)
Signal value: XXXmA = 0 - 999 mA.
005495
PRESENT VALUE XXXmA the value with the plus and minus keys. Save the set value with the En-
ter key. Go to the next menu with the arrow keys. Exit initiation with the
R-key.
STORED VALUE indicates stored value for max. current.
Function: 7.2.5 Control valve, lift and tilt (DCF360-450CSG)
7.2.6 Control valve, load handling (DCF 280-330, DCF 370-500)
Component: Solenoid valve, lift mast (Y6005)
Signal value: XXXmA = 0 - 999 mA.
PRESENT VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE: indicates stored value for start current.
Function: 7.2.5 Control valve, lift and tilt (DCF360-450CSG)
7.2.6 Control valve, load handling (DCF 280-330, DCF 370-500)
Component: Solenoid valve, lower mast(Y6004)
Signal value: XXXmA = 0 - 999 mA.
PRESENT VALUE XXXmA the value with the plus and minus keys. Save the set value with the En-
ter key. Go to the next menu with the arrow keys. Exit initiation with the
R-key.
STORED VALUE indicates stored value for max. current.
Function: 7.2.5 Control valve, lift and tilt (DCF360-450CSG)
7.2.6 Control valve, load handling (DCF 280-330, DCF 370-500)
Component: Solenoid valve, stand (Y6004)
Signal value: XXXmA = 0 - 999 mA.
007139
PRESENT VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE: indicates stored value for start current.
Function: 7.7.5 Control valve, lift and tilt (DCF360-450CSG)
7.7.6 Control valve, load handling (DCF 280-330, DCF 370-500)
Component: Solenoid valve, tilt in (Y6011)
Signal value: XXXmA = 0 - 999 mA.
PRESENT VALUE XXXmA the value with the plus and minus keys. Save the set value with the En-
ter key. Go to the next menu with the arrow keys. Exit initiation with the
R-key.
STORED VALUE indicates stored value for max. current.
Function: 7.7.5 Control valve, lift and tilt (DCF360-450CSG)
7.7.6 Control valve, load handling (DCF 280-330, DCF 370-500)
Component: Solenoid valve, tilt in (Y6011)
Signal value: XXXmA = 0 - 999 mA.
PRESENT VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE: indicates stored value for start current.
Function: 7.7.5 Control valve, lift and tilt (DCF360-450CSG)
7.7.6 Control valve, load handling (DCF 280-330, DCF 370-500)
Component: Solenoid valve, tilt out (Y6010)
Signal value: XXXmA = 0 - 999 mA.
007142
PRESENT VALUE XXXmA the value with the plus and minus keys. Save the set value with the En-
ter key. Go to the next menu with the arrow keys. Exit initiation with the
R-key.
STORED VALUE indicates stored value for max. current.
Function: 7.7.5 Control valve, lift and tilt (DCF360-450CSG)
7.7.6 Control valve, load handling (DCF 280-330, DCF 370-500)
Component: Solenoid valve, tilt out (Y6010)
Signal value: XXXmA = 0 - 999 mA.
PRESENT VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE: indicates stored value for start current.
Function: 7.4.5 Control valve, load handling (DCF 280-330, DCF 370-
500)
Component: Solenoid valve for side shift left (Y6020) and solenoid
valve for side shift right (Y6021)
Signal value: XXXmA = 0 - 999 mA.
PRESENT VALUE XXXmA PRESENT VALUE: Indicates the current value for max. current. Adjust
the value with the plus and minus keys. Save the set value with the En-
ter key. Go to the next menu with the arrow keys. Exit initiation with the
R-key.
STORED VALUE indicates stored value for max. current.
Function: 7.4.5 Control valve, load handling (DCF 280-330, DCF 370-
500)
Component: Solenoid valve for side shift left (Y6020) and solenoid
valve for side shift right (Y6021)
Signal value: XXXmA = 0 - 999 mA.
007145
PRESENT VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE: indicates stored value for start current.
Function: 7.5.5 Control valve, load handling
Component: Solenoid valve for spreading in (Y6019) and solenoid
valve for spreading out (Y6018)
Signal value: XXXmA = 0 - 999 mA.
PRESENT VALUE XXXmA PRESENT VALUE: Indicates the current value for max. current. Adjust
the value with the plus and minus keys. Save the set value with the En-
ter key. Go to the next menu with the arrow keys. Exit initiation with the
R-key.
STORED VALUE indicates stored value for max. current.
Function: 7.5.5 Control valve, load handling
Component: Solenoid valve for spreading in (Y6019) and solenoid
valve for spreading out (Y6018)
Signal value: XXXmA = 0 - 999 mA.
PRESENT VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE: indicates stored value for start current.
Function 7.2.6 Solenoid valve, load handling
Component: Solenoid valve, lift carriage (Y6022)
Signal value: XXXmA = 0 - 999 mA.
007148
PRESENT VALUE XXXmA the value with the plus and minus keys. Save the set value with the En-
ter key. Go to the next menu with the arrow keys. Exit initiation with the
R-key.
STORED VALUE indicates stored value for max. current.
Function 7.2.6 Solenoid valve, load handling
Component: Solenoid valve, lift carriage (Y6022)
Signal value: XXXmA = 0 - 999 mA.
PRESENT VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE: indicates stored value for start current.
Function 7.2.6 Solenoid valve, load handling
Component: Solenoid valve, lower carriage (Y6023)
Signal value: XXXmA = 0 - 999 mA.
PRESENT VALUE XXXmA the value with the plus and minus keys. Save the set value with the En-
ter key. Go to the next menu with the arrow keys. Exit initiation with the
R-key.
STORED VALUE indicates stored value for max. current.
Function 7.2.6 Solenoid valve, load handling
Component: Solenoid valve, lower carriage (Y6023)
Signal value: XXXmA = 0 - 999 mA.
8.5.1.2 ATTACHMENT
INIT ATTACH
page
–
007170
RETURN
DANGER
The settings affect the functions extension, side shift,
spreading, rotation and controllable levelling for
DCF360-450CSG and the functions side shift, spread-
ing and controllable levelling for DCF 90-100. Adjust-
ments could impair functionality. In the event of
uncertainty, contact Kalmar Industries Service.
NOTE
Initiation does not need to be performed in one process but each
step can be performed separately, independently of other steps.
PRESENT VALUE XXXmA PRESENT VALUE: Indicates the current value for the start current.
Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE: indicates stored value for start current.
Function: 7.3.2 Control valve attachment
Component: Solenoid valve, extend left side out (Y6046-2), Solenoid
valve, extend right side out (Y6046-4).
Signal value: XXXmA = 0 - 999 mA
005510
PRESENT VALUE XXXmA PRESENT VALUE: Indicates the current value for max. current. Adjust
the value with the plus and minus keys. Save the set value with the En-
ter key. Go to the next menu with the arrow keys. Exit initiation with the
R-key.
STORED VALUE indicates stored value for max. current.
Function: 7.3.2 Control valve attachment
Component: Solenoid valve, extend left side out (Y6046-2), Solenoid
valve, extend right side out (Y6046-4).
Signal value: XXXmA = 0 - 999 mA
PRESENT VALUE XXXmA PRESENT VALUE: Indicates the current value for the start current.
Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE: indicates stored value for start current.
Function: 7.3.2 Control valve attachment
Component: Solenoid valve, extend left side out (Y6046-1), Solenoid
valve, extend right side out (Y6046-3).
Signal value: XXXmA = 0 - 999 mA
PRESENT VALUE XXXmA PRESENT VALUE: Indicates the current value for max. current. Adjust
the value with the plus and minus keys. Save the set value with the En-
ter key. Go to the next menu with the arrow keys. Exit initiation with the
R-key.
STORED VALUE indicates stored value for max. current.
Function: 7.3.2 Control valve attachment
Component: Solenoid valve, extend left side out (Y6046-1), Solenoid
valve, extend right side out (Y6046-3).
Signal value: XXXmA = 0 - 999 mA
005513
PRESENT VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE: indicates stored value for start current.
Function: 7.4.2 Control valve attachment
Component: Solenoid valve for side shift left (Y6020) and solenoid
valve for side shift right (Y6021).
Signal value: XXXmA = 0 - 999 mA
PRESENT VALUE XXXmA PRESENT VALUE: Indicates the current value for max. current. Adjust
the value with the plus and minus keys. Save the set value with the En-
ter key. Go to the next menu with the arrow keys. Exit initiation with the
R-key.
STORED VALUE indicates stored value for max. current.
Function: 7.4.2 Control valve attachment
Component: Solenoid valve for side shift left (Y6020) and solenoid
valve for side shift right (Y6021).
Signal value: XXXmA = 0 - 999 mA
PRESENT VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE: indicates stored value for start current.
Function: 7.4.2 Control valve attachment
Component: Solenoid valve for side shift left (Y6020) and solenoid
valve for side shift right (Y6021).
Signal value: XXXmA = 0 - 999 mA
PRESENT VALUE XXXmA PRESENT VALUE: Indicates the current value for max. current. Adjust
the value with the plus and minus keys. Save the set value with the En-
ter key. Go to the next menu with the arrow keys. Exit initiation with the
R-key.
STORED VALUE indicates stored value for max. current.
Function: 7.4.2 Control valve attachment
Component: Solenoid valve for side shift left (Y6020) and solenoid
valve for side shift right (Y6021).
Signal value: XXXmA = 0 - 999 mA
010067
PRESENT VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE: indicates stored value for start current.
Function: 7.4.2 Control valve attachment
Component: Solenoid valve for levelling left (Y6036), solenoid valve
for levelling right (Y6035).
Signal value: XXXmA = 0 - 999 mA
PRESENT VALUE XXXmA PRESENT VALUE: Indicates the current value for max. current. Adjust
the value with the plus and minus keys. Save the set value with the En-
ter key. Go to the next menu with the arrow keys. Exit initiation with the
R-key.
STORED VALUE indicates stored value for max. current.
Function: 7.4.2 Control valve attachment
Component: Solenoid valve for levelling left (Y6036), solenoid valve
for levelling right (Y6035).
Signal value: XXXmA = 0 - 999 mA
t [s] Component: Solenoid valve for spreading out left (Y6018L) and sole-
1. Max. current (END CURRENT) noid valve for spreading out right (Y6018R).
2. Damping (PROC DAMPING) Signal value: XXX = 0 - 100%. 100% means no damping, i.e. max. cur-
3. Start current (START CURRENT) rent. 0% means full damping, i.e. start current
t [s] Component: Solenoid valve for spreading in left (Y6019L) and sole-
1. Max. current (END CURRENT) noid valve for spreading in right (Y6019R).
2. Damping (PROC DAMPING) Signal value: XXX = 0 - 100%. 100% means no damping, i.e. max. cur-
3. Start current (START CURRENT) rent. 0% means full damping, i.e. start current
8.5.1.3 STEERING
INIT STEERING
page
–
007171
RETURN
The settings affect the function of lever steering or
mini-wheel. Adjustments can impair functionality.
Contact Kalmar Industries Service in the event of
uncertainty.
NOTE
Initiation does not need to be performed in one process but each
step can be performed separately, independently of other steps.
steering or mini-wheel)
X Component: -
Y = Output signal to solenoid valve
Signal value: XX = 0-31.
X = Lever movement
V [kph] Component: -
BP1 BP2 BP3
I [mA] = control current to solenoid valve Signal value: XX.X = speed for BP2 in km/h.
V [kph] = machine’s speed in km/h
BP1 = speed setting for break point 1
BP2 = speed setting for break point 2
BP3 = speed setting for break point 3
%BP2 = per cent of control current to solenoid valve at
BP2
%BP2 = per cent of control current to solenoid valve at
BP2
I [mA] PRESENT VALUE: indicates present speed setting for cut-off point 1.
100% Change speed with plus or minus keys. Save set speed with the Enter-
key. Go to the next menu with arrow keys. Exit initiation with the R-key.
% BP2 STORED VALUE: indicates saved speed for break point 3.
% BP3 Function: 5.2 Power-assisted steering system (product option lever
005575
V [kph] steering or mini-wheel)
BP1 BP2 BP3
Component: -
I [mA] = control current to solenoid valve
V [kph] = machine’s speed in km/h Signal value: XX.X = speed for BP3 in km/h.
BP1 = speed setting for break point 1
BP2 = speed setting for break point 2
BP3 = speed setting for break point 3
%BP2 = per cent of control current to solenoid valve at
BP2
%BP2 = per cent of control current to solenoid valve at
BP2
PRESENT VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R key.
STORED VALUE: indicates stored value for start current.
Function: 5.2.10 Control valve, lever steering/mini wheel
Component: Solenoid valve for steering right (Y636-3)
Signal value: XXXmA = 0 - 999 mA
PRESENT VALUE XXXmA the value with the plus and minus keys. Save the set value with the En-
ter key. Go to the next menu with the arrow keys. Exit initiation with the
R key.
STORED VALUE indicates stored value for max. current.
Function: 5.2.10 Control valve, lever steering/mini wheel
Component: Solenoid valve for steering right (Y636-3)
Signal value: XXXmA = 0 - 999 mA
005580
PRESENT VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE: indicates stored value for start current.
Function: 5.2.10 Control valve, lever steering/mini wheel
Component: Solenoid valve for steering left (Y636-4)
Signal value: XXXmA = 0 - 999 mA
PRESENT VALUE XXXmA the value with the plus and minus keys. Save the set value with the En-
ter key. Go to the next menu with the arrow keys. Exit initiation with the
R-key.
STORED VALUE indicates stored value for max. current.
Function: 5.2.10 Control valve, lever steering/mini wheel
Component: Solenoid valve for steering left (Y636-4)
Signal value: XXXmA = 0 - 999 mA
8.5.1.4 DRIVETRAIN
INIT DRIVE-TRAIN
page
–
007172
RETURN
The settings affect engine and transmission function.
Adjustments can impair the functionality. Contact Ka-
lmar Industries Service in the event of uncertainty.
NOTE
Initiation does not need to be performed in one process but each
step can be performed separately, independently of other steps.
The machine must be stationary with applied parking brake to en-
able access to the menus.
After changes have been made, the ignition must be turned off
and on for the changes to be saved and start to apply.
START IN 2ND
INIT DRIVE-TRN 1(X)
Description: Setting to get transmission to start in 2nd gear instead of
START IN 2:ND
1=YES 0=NO in 1st. Kick-down to 1st takes place as needed.
STORED VALUE XXX PRESENT VALUE: Indicates the current setting. Change the value
005525
PRESENT VALUE XXX with the plus and minus keys. Save the set value with the Enter key.
Go to the next menu with the arrow keys. Exit initiation with the R-key.
STORED VALUE: indicates saved setting.
Function: 2 Transmission
Component: -
Signal value: XXX = 1= yes, XXX = 0 = no
PRESENT VALUE XXX with the plus and minus keys. Save the set value with the Enter key.
Go to the next menu with the arrow keys. Exit initiation with the R-key.
STORED VALUE: indicates saved setting.
Function: 2 Transmission
Component: -
Signal value: XXX = speed in km/h
005583
PRESENT VALUE XXX NOTE
If the rpm is set lower than the engine’s idle rpm, shifting will not
be allowed.
PRESENT VALUE: Indicates the current setting. Change the value
with the plus and minus keys. Save the set value with the Enter key.
Go to the next menu with the arrow keys. Exit initiation with the R-key.
STORED VALUE: indicates saved setting.
Function: 2 Transmission
Component: -
Signal value: XXX = engine speed (rpm)
007152
PRESENT VALUE XXX NOTE
If the rpm is set too low, kick-down may take place before the ma-
chine has used the engagement on the selected gear.
If the rpm is set too high, kick-down takes place slowly or not at
all.
PRESENT VALUE: Indicates the current setting. Change the value
with the plus and minus keys. Save the set value with the Enter key.
Go to the next menu with the arrow keys. Exit initiation with the R-key.
STORED VALUE: indicates saved setting.
Function: 2 Transmission
Component: -
Signal value: XXX = engine speed (rpm)
PRESENT VALUE XXX with the plus and minus keys. Save the set value with the Enter key.
Go to the next menu with the arrow keys. Exit initiation with the R-key.
STORED VALUE: indicates saved setting.
Function: 2 Transmission
Component: -
Signal value: XXX = speed (km/h)
Not used.
Not used.
005587
PRESENT VALUE XXX PRESENT VALUE: Indicates the current setting. Change the value
with the plus and minus keys. Save the set value with the Enter key.
Go to the next menu with the arrow keys. Exit initiation with the R-key.
STORED VALUE: indicates saved setting.
Function: 2 Transmission
Component: -
Signal value: XXX = speed (km/h)
PRESENT VALUE XXX PRESENT VALUE: Indicates the current setting. Change the value
with the plus and minus keys. Save the set value with the Enter key.
Go to the next menu with the arrow keys. Exit initiation with the R-key.
STORED VALUE: indicates saved setting.
Function: 1 Engine
Component: -
Signal value: XXX = time in seconds before engine shutdown.
005590
PRESENT VALUE X celerator pedal. Engine speed drops to that set in menu 3 (see INIT
DRIVE-TRAIN, menu 3 page 201). If no value is set in menu 3, engine
speed goes 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
8.5.1.5 SLIDING-CAB
INIT SLIDING-CAB
page
–
007161
RETURN by means of the control current being reduced.
DANGER
The settings affect the function of the hydraulic slid-
ing cab. Adjustments can impair functionality. Con-
tact Kalmar Industries Service in the event of
uncertainty.
NOTE
Initiation does not need to be performed in one process but each
step can be performed separately, independently of other steps.
Not used.
Not used.
8.5.2 Calibration
Calibration, description
page
–
SCALE
This menu handles calibration of sensors to weight indication.
CALIBRATION
Fixed scale, calibration page 210
SCALE STEERING
DRIVE-TRAIN RETURN 000062
STEERING
This menu handles calibration of the steering lever for lever steering,
CALIBRATION see:
NOTE
Calibration does not need to be performed in one process but
each step can be performed separately, independently of other
steps.
DRIVETRAIN
This function handles calibrations for engine and transmission. The
CALIBRATION menu loop contains two different calibrations which are not connected
to each other, see:
SCALE STEERING
DRIVE-TRAIN RETURN Accelerator pedal, calibration page 212
000078
NOTE
Calibration does not need to be performed in one process but
each step can be performed separately, independently of other
steps.
008892
PRESENT VALUE X.XXV
LEVER CENTRE POSITION signal/control signal.
1. Menu group Description: Setting the centre po- A short description of what is
2. Sequence number. Because the number of menus sition of the lever steering control calibrated and the meaning
depends on machine configuration, it is specified as (R825). of the variables.
(X) in this manual.
STORED VALUE: Gives the stored
3. Signal value
signal value for lever steering con-
4. STORED indicates stored value, PRESENT indi-
trol (R825), centre position.
cates current value of the signal to be calibrated
5. Heading of menu figure PRESENT VALUE: Gives the
present signal value for lever steer-
ing control (R825), centre position.
1 Park the machine on level ground with the mast vertical and with-
out load.
NOTE
Calibration does not need to be performed in one process but
each step can be performed separately, independently of other
steps.
To calibrate the accelerator pedal for forward driving, use steps 1-7.
To calibrate accelerator pedal 2 (if there is a reversible driver’s seat),
use step 1 + 8-13.
DRIVE-TRAIN, menu 1
2 Go into the calibration menus and select DRIVE-TRAIN, menu 1,
CALIBR DRIVE-TRN 1(X) see Calibration, work instructions page 209.
ACCELERATOR,
RELEASE THE PEDAL ACCELERATOR, RELEASE THE PEDAL
STORED VALUE X.XXV Description: setting accelerator’s pedal zero position.
005532
DRIVE-TRAIN, menu 2
5 ACCELERATOR, PRESS THE PEDAL TO FLOOR
CALIBR DRIVE-TRN 2(X) Description: Setting of full-throttle position of Accelerator pedal
ACCELERATOR, PRESS (B690-1).
THE PEDAL TO FLOOR
STORED VALUE X.XXV STORED VALUE: Indicates current calibrated control value from
PRESENT VALUE X.XXV accelerator pedal (R690-1).
00
DRIVE-TRAIN, menu 5
8
CALIBR DRIVE-TRN 5(X)
ACCELERATOR 2, Go into the calibration menus and select DRIVE-TRAIN, menu 5,
RELEASE THE PEDAL see Calibration, work instructions page 209.
STORED VALUE X.XXV
ACCELERATOR 2, RELEASE THE PEDAL
005534
PRESENT VALUE X.XXV
Description: Calibration of accelerator pedal 2, for driving rear-
ward on machines with reversible driver’s seat. Setting of accel-
erator pedal’s zero position.
STORED VALUE: Indicates current calibrated control value from
accelerator pedal (R690-2).
PRESENT VALUE: Indicates present signal value from Acceler-
ator pedal (B690-2).
Function: 1 Engine
Component: Accelerator pedal (B690-2).
9 Release the accelerator pedal.
10 Store the position with function key for Enter.
DRIVE-TRAIN, menu 6
11
CALIBR DRIVE-TRN 6(X)
ACCELERATOR 2, PRESS ACCELERATOR 2, PRESS THE PEDAL TO FLOOR
THE PEDAL TO FLOOR Description: Calibration of accelerator pedal 2 for driving rear-
STORED VALUE X.XXV
ward on machines with a reversible driver’s seat. Setting of full
005535
Transmission, calibration
page
–
DANGER
Do not leave the machine during calibration. The ma-
chine may start to move.
005610
TARGET TEMP XXX
A. Apply the service brake so that the machine is stationary.
B. Select travel direction forward and apply full throttle for 20
seconds.
C. Engage neutral position, apply full throttle for 10 seconds
and then run the engine at idling speed.
D. Repeat steps B and C until the oil is hot.
The engine speed may be reduced towards the end of heating as
the oil from the gearbox is too hot. If this occurs, maintain neutral
position and maintain an engine speed of 1200 rpm for 20 sec-
onds.
When the temperature is correct, MODE changes from 0 to 1.
4 Select DRIVE-TRAIN, menu 3.
CALIBR DRIVE-TRN 3(X) GEARBOX TUNING
START AUTO CALIBR
PHASE X SUB-PH X Description: Calibration of transmission couplings.
CLUTCH X STATUS X
005609
NOTE
If the machine starts to move during calibration, use the
service brake to keep the machine stationary.
IMPORTANT
Calibration can be interrupted at any time by selecting
travel direction reverse.
accessories
9.1 Controls and instruments
Controls and instruments, overview
page
–
1 2 3 4 5
15
12 13 12 11 10 9 8 7 6
008108
14
Overview
1 Left-hand instrument panel
2 Gear and multi-function lever (S162)
3 Steering wheel panel
4 Steering wheel
5 Switch direction indicators (S161)
6 Panel for hydraulic functions
7 Switch control switch (S250)
8 Switch for parking brake (S107)
9 Hydraulic control
10 Driver’s seat
11 Accelerator pedal (B690)
12 Brake pedals
13 Declutch pedal (S220-1)
14 Fuse box with fuses and relays
15 Hour meter (P708)
004394
17
16 Auxiliary work lights, carriage and attachment
Left-hand instrument panel 21 Switch, work lights on mast (S105-3)
31 Socket 12 VDC
61 60 59 58 57 53 Ignition switch
54 Switch, defroster
Steering wheel panel
55 Switch, windscreen wiper at roof, interval
56 Switch, windscreen wiper at roof, continuous
57 Switch, interior lighting
58 Switch, rear windscreen wiper, interval
59 Switch, rear windscreen wiper, continuous
60 Function keys, control system
61 Travel direction indicator, Forward Neutral Reverse
62 Shifting program A, automatic shifting
63 Shifting program 1, locked to 1st gear
64 Shifting program 2, locked to 2nd gear
69 68 Levelling (R8074)
70 69 Opening of twistlock / Opening and locking of lock tongues (at-
tachment) (S1002)
71
70 Switch, horn (S149)
72
73 71 Switch for twistlock/lock tongues, automatic/manual locking
74 (S1003)
75
76 72 Switch, spreading 20’-40’ (S1012)
77
73 Switch for spreader stop at 30’ or 35’ (S1004)
74 Spare
008130
77
008131
78 8 79 70
1 2 3 4
9 8 7 6
10
009174
11 12 13 14
3. Operating menu for oil temperature 10. Operating menu, code lock
4. Operating menu electrical system 11. Operating menu statistics, operating hours
5. Operating menu container counter 12. Operating menu statistics, fuel consumption
6. Operating menu service interval 13. Operating menu statistics, driving distance
1 2 3 4
009176
1. Event menu start interlock
2. Event menu, twistlock alignment
3. Event menu twistlocks
1 2 3 4
009781
1. Event menu start interlock
2. Event menu, alignment
The following functions are handled by the gear and multi-function le-
2 ver (position 2).
3 1
0 Movement Function
Forward/ Travel direction (for selecting shifting program and
Reverse travel direction, see section 2 Transmission).
Inward, Washing of windshield, roof window and rear win-
000338
handle dow.
The signal can be checked from the diagnostic
menu, see section 8 Control system, group 8.4.3.1
CAB, menu 1.
Rotation Windshield wiper front.
0 – No wiping front windshield. If wiper rear or roof
are active, these run at slow interval wiping.
1 – Slow interval wiping windscreen, controls slow
interval wiping for roof window and rear window.
2 – Fast interval wiping front windshield, controls
fast interval wiping for roof window and rear win-
dow.
3 – Continuous wiping front windshield. If wiper rear
or roof are active, these run at fast interval wiping.
The signal can be checked from the diagnostic
menu, see section 8 Control system, group 8.4.3.2
CAB, menu 2.
The fire extinguisher sits at the entry on the left frame beam or inside
the cab. Instructions on use are found on the fire extinguisher.
The roof grating protects the operator from falling objects. This consti-
tutes protection that goes beyond the legal requirements.
9.3 Seat
Seats, general
page
–
seat)
The seat’s function is to give the operator a good sitting position and
contribute to a good work environment. The cab’s seat has several ad-
justment possibilities and meets high comfort standards.
1 2 The seat has the following equipment:
• mechanical adjustment
3
• right armrest
• left armrest
4
• seat heating
• seat belt
• head restraint
5
8 6
006825
7
Controls, standard seat
1. Lumber support adjustment
2. Right armrest adjustment
3. Left armrest adjustment
4. Backrest rake adjustment
5. Springing position adjustment
6. Seat cushion angle adjustment
7. Seat cushion height adjustment
8. Front/rear adjustment
9120)
Bege 9120 is the same as the standard seat, but is equipped with air
1 2 suspension. Air suspension automatically adjusts seat height and
springing to the operator’s weight. Air suspension is supplied by a spe-
cial compressor installed on the underside of the cab.
3
The seat’s function is to give the operator a good sitting position and
contribute to a good work environment. The cab’s seat has several ad-
justment possibilities and meets high comfort standards.
4
The seat has the following equipment:
• mechanical adjustment
• air suspension (with external compressor)
5 • right armrest
• left armrest
8 6
006826
7 • seat heating
Controls, Bege 9120 • seat belt
1. Lumber support adjustment
2. Right armrest adjustment • head restraint
Isringhausen 6800)
The seat’s function is to give the operator a good sitting position and
contribute to a good work environment. The cab’s seat has several ad-
justment possibilities and meets high comfort standards.
The Isringhausen 6800 seat has the following equipment:
• head restraint
• armrest
• air suspension (with external compressor)
• air-adjusted lumbar support
• seat belt
• seat heating
11
10
34 567
004691
9 8 2
Controls, Isringhausen 6800
1. Front/rear adjustment
2. Seat cushion adjustment
3. Lowering seat cushion height
4. Seat cushion angle
5. Raising seat cushion height
6. Backrest rake
7. Damping adjustment
8. Seat heating
9. Plane damping off/on
10. Lumber support adjustment
11. Armrest
Seat, changing
page
–
3 Slide the seat to its front position, remove the rear attaching bolts.
4 Disconnect the seat’s connectors from the machine’s cabling.
5 Remove the seat.
6 Fit in the reverse order.
NOTE
The seat’s heating coil is glued to the padding. Be careful if
3
the padding is to be replaced but the heating coil is to be re-
used, or if only the coil is to be replaced.
5 Assemble in reverse order.
1
006276
The heating coil’s function is to warm the back and seat cushions in
the driver’s seat. The heating coil is located under the upholstery on
the seat.
The heating coil (E803) is supplied power upon warm-up of the cab
control unit (D790-1) via the seat heating relay (K383). The signal can
be checked with the diagnostic menu, see section 8 Control system ,
group 8.4.3.8 CAB, menu 8.
GE)
Bege 9120:
The compressor is part of the air suspension driver’s seat and is locat-
ed inside the seat’s suspension unit.
001621
Isringhausen 6800:
Compressed air-suspended seat
9.3.9 Armrest
Armrests, description
page
–
• Mini-wheel
• Lever steering
description
The heating system controls heating and ventilation of the cab. The
F cab can also be equipped with a climate control system ( ).
The temperature in the cab is thermostat-controlled by the cab control
unit (D790-1). The cab temperature is regulated to the set tempera-
2 ture. The temperature can be set between 16 and 27 °C. The unit is
4 operated with controls on the instrument panel.
D
C Heating system (EHC)
The heating system (EHC) handles heating and ventilation. (The heat-
E E
ing system cannot provide cooling.)
3
The heating system uses heat from the engine’s cooling system via a
heating coil to heat ambient air. The fan forces the ambient air through
the heating coil on through ducts in the cab interior. It is then directed
to the windscreen (defroster) or the feet.
heating system.
Principle illustration, climate control system The function of the climate control system is to:
1. Fluid reservoir/filter dryer with built-in pressure • heat the air when it is cold
switch
• dehumidify the air when it is damp
2. Heater and evaporator
3. Fan • clean the air of impurities
4. Expansion valve • cool the air when it is hot
5. Condenser • defrost (defroster function)
6. Compressor
A. High-pressure gas
B. High-pressure fluid
C. Low-pressure fluid
D. Low-pressure gas
E. Ambient air for cab ventilation
F. Heated or cooled air to the cab
G. Ambient air for removal of heat
function description
2 1 3 26
D D 25
D
4 °C D
D
°C
6
7 D790-1 D790-2 D795
D D D797-1
16
D D794
15 D
12
M D D
14 22 23
5 °C Pa °C
M D
D 19 21
13 20 C 24
M 18
17
D
D 9
M
°C
8 11
10
007690
2 The fan switch (S118) sends a voltage Raise: U = 2.0–2.5 V Controls and instruments, overview page 5
signal to the cab control unit (D790-1). Unaffected: U = 0-0.5 V D2: Diagnostic menu, see section 8 Control
Lower: U = 4.5-5.0 V system , group 8.4.4.5 CLIMATE, menu 5
3 The air distribution switch (S139) sends Scroll up: U = 2.0–2.5 V Controls and instruments, overview page 5
a voltage signal to the cab control unit Unaffected: U = 0 V D3: Diagnostic menu, see section 8 Control
(D790-1). system , group 8.4.4.5 CLIMATE, menu 5
Scroll down: U = 4.5-5.0
V
5 The outlet fan temperature sensor R = 10 kΩ at 25 °C Sensor, temperature outlet fan, description
(B775-2) sends the cab control unit page 56
(D790-1) a voltage signal proportional to D5: Diagnostic menu, see section 8 Control
temperature. system , group 8.4.4.2 CLIMATE, menu 2
7 The cab control unit (D790-1) regulates Checked by control sys- Section 11 Common electrics, group
temperature and air distribution with sig- tem, error shown with er- 11.5.3.1 Cab control unit (D790-1)
nals from sensors and controls. ror code.
9 The cab control unit (D790-1) controls U = 0.5–4.5 V Water valve, description page 41
the water valve (Y673), which directs D9: Diagnostic menu, see section 8 Control
hot water to heat exchanger heating. system , group 8.4.4.7 CLIMATE, menu 7
The water valve’s opening (%) is sent and 8.4.4.4 CLIMATE, menu 4
back to the cab control unit (D790-1).
This gives information for controlling the
water valve’s position.
10 The engine temperature sensor sends Checked by control sys- Section 1 Engine
the engine control unit (D794) a voltage tem, error shown with er- D10: Diagnostic menu, see section 8 Con-
signal proportional to engine tempera- ror code. trol system , group 8.4.4.2 CLIMATE, menu
ture. 2
11 Heat exchanger heat adds heat to the - Heat exchanger heat, description page 38
cab air. Heat is transferred from the en-
gine’s cooling system to the cab air.
12 The engine control unit (D794) transmits Checked by control sys- Section 11 Common electrics, group
engine temperature in the cooling sys- tem, error shown with er- 11.5.3.10 Engine control unit (D794)
tem on the CAN bus. ror code.
13 The cab control unit (D790-1) controls Checked by control sys- Fresh air filter or recirculation damper, de-
the recirculation actuator motor (M612) tem, error shown with er- scription page 32
which sets the fresh air or recirculation ror code. D13: Diagnostic menu, see section 8 Con-
damper in the required position. trol system , group 8.4.4.6 CLIMATE, menu
6
15 The cab control unit (D790-1) controls U = 0.5–4.5 V Air distributor, description page 54
the actuator motor (Y672), which sets D15: Diagnostic menu, see section 8 Con-
the air distributor to the required posi- trol system , group 8.4.4.8 CLIMATE, menu
tion. 8 and 8.4.4.4 CLIMATE, menu 4
The air distributor’s position is sent back
to the cab control unit (D790-1). This
gives information for controlling the air
distributor’s position.
16 The frame control unit (D797-1) controls Checked by control sys- Section 11 Common electrics, group
AC compressor engagement. tem, error shown with er- 11.5.3.3 Frame control unit (D797-1)
ror code.
20 The moisture filter absorbs any moisture - Moisture filter, description page 47
from the cooling circuit. The fluid reser-
voir stores the refrigerant.
21 The pressure switch (S246) sends a sig- U = 24 V Pressure switch, description page 48
nal to the frame control unit (D797-1) if D21: Diagnostic menu, see section 8 Con-
the pressure in the system becomes ab- trol system , group 8.4.4.3 CLIMATE, menu
normally high or low. 3
22 The expansion valve adjusts the amount - Expansion valve, description page 49
of refrigerant that is let in to the evapora-
tor. If the temperature in the evapora-
tor’s outlet pipe increases, the
evaporator valve increases flow of re-
frigerant so that heat dissipation in the
evaporator increases.
25 The defroster switch on the KIT control Checked by control sys- Section 11 Common electrics, group
unit (D790-2) activates the defroster tem, error shown with er- 11.5.3.11 KIT control unit (D790-2)
program of the climate control system ror code.
for six minutes.
26 The KID control unit (D795) shows the Checked by control sys- Section 11 Common electrics, group
heating and ventilation settings in the tem, error shown with er- 11.5.3.12 KID control unit (D795)
display. ror code.
checking
1 Machine in service position, see section B Safety.
2 Navigate to the service menu and press Enter.
000056
1 23
4 5 NOTE
000060
OLS EXTRA
Menu 2
6 Check of Sensor temperature outlet fan (B775-2), engine temper-
DIAG CLIMATE 2(8) ature, Sensor outdoor temperature (B774), Check of Sensor tem-
TEMP COIL XXX perature refrigerant (B775-1).
TEMP COOLANT XXX
TEMP AMBIENT XXX TEMP COIL: temperature that the air has in the air distributor is
000133
Menu 3
The sensor is located on the dryer filter which is fitted right rear in
the frame.
Menu 4
8 Checks Water valve (Y673) and Air distributor (Y642).
DIAG CLIMATE 4(8)
WATER VALVE: should work between 1.0-1.24 V and 2.95-3.2
PRESENT INPUT SIGNAL
WATER VALVE XX.XXV V. This is checked by turning the temperature control and chang-
DRAUGHT VALVE XX.XXV ing temperature setting from min. to max.
000135
NOTE
Air to the round panel vents is not controlled by the air con-
ditioning unit.
Menu 5
9 Checks switches for temperature, air distribution and fan speed.
DIAG CLIMATE 5(8)
REQUIRED TEMP: resting position U = 0 V; raise U = 2-2.5 V;
PRESENT INPUT SIGNAL
REQUIRED TEMP XX.XXV lower U = 4.5-5 V.
REQ. DRAUGHT XX.XXV REQ. DRAUGHT: resting position U = 0 V; against windshield U
000136
REQ. FAN SPEED XX.XXV = 2-2.5 V; against floor U = 4.5-5 V.
REQ. FAN SPEED: resting position U = 0 V; raise U = 2-2.5 V;
lower U = 4.5-5 V.
Menu 6
10 Checks cab fan (M657), fresh air and recirculation damper
DIAG CLIMATE 6(8)
PRESENT OUTPUT SIGNAL (M612) and compressor’s electromagnetic clutch (M645) .
FAN SPEED XXX FAN SPEED: increase and decrease fan speed, value should in-
RECIRKULATION XY crease from 0 to 255 in steps.
000137
COMPRESSOR XY
RECIRCULATION: press in the bypass switch (S1005) (on the
panel for load handling functions). When checking, the display
should show "11". Check that the damper really moves as it
should by removing the fresh air filter at the front of the climate
control system casing and feeling with your hand.
NOTE
Compressor activation can only be tested when the engine
is running and the system is filled.
Menu 7
11 Checks direction selector for Water valve (Y673).
DIAG CLIMATE 7(8) CLOCKWISE: When temperature is increased and the water
OUTPUT WATER VALVE valve opens shows "CLOCKWISE 11 11" and "COUNTER-
CLOCKWISE XY XY
ANTI-CLOCKWISE XY XY CLOCKWISE 00 11".
COUNTER-CLOCKWISE: When temperature is lowered and the
water valve closes shows "CLOCKWISE 00 11" and "COUNTER-
24V CLOCKWISE 11 11".
NOTE
The ones are only showed for a moment when the water
valve changes position, zeros are shown when the valve is
M not changing position. The water valve does not open if en-
gine temperature is low, or if outdoor temperature is high.
000138
0V
Menu 8
12 Checks direction selector for air distributor.
DIAG CLIMATE 8(8)
CLOCKWISE: when the air is directed against the windshield and
OUTPUT DRAUGHT VALVE
CLOCKWISE XY XY the air distributor changes position shows "CLOCKWISE 00 11"
ANTI-CLOCKWISE XY XY and "COUNTER-CLOCKWISE 11 11".
COUNTER-CLOCKWISE: when the air is directed against the
feet and the air distributor changes position shows "CLOCKWISE
24V 11 11" and "COUNTER-CLOCKWISE 00 11".
NOTE
The ones are only shown for a moment when the air distrib-
utor changes position, zeros are shown when the air distrib-
M utor is not changing position.
000139
0V
The fresh air filter is located under a cover in the external unit for fresh
air intake into the cab - in front of the cab fan. A finer filter can be used
( ), but this may affect maximum airflow.
1 004999
The damper is controlled electrically and controls the air between fully
open for fresh air to recirculation of air. The damper is located in the
external unit for fresh air intake into the cab.
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.4.6 CLIMATE, menu 6 .
2 004999
replacement
1 Machine in service position, see section B Safety.
2 Remove the wiper arms.
3 Remove the nuts which hold the wiper motor in the protective
plate.
4 Remove the protective plate.
6 Remove the bolts which secure the arm and motor in the plate.
7 Detach the connector from the motor.
8 Replace the motor.
9 Fit in the reverse order. Tighten the wiper arm to 16-20 Nm.
The cab fan is located in the external unit for fresh air intake into the
cab. The fan consists of two single fans that are driven by a motor.
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.4.6 CLIMATE, menu 6.
1
003209
3 Remove the bolts which secure the wiper motor in the protective
plate.
4 Remove the protective plate.
7 Remove the bolts which secure the plate and cab fan.
The heat from the engine’s coolant is transmitted to the cab via the
heat exchanger. The heat exchanger is located behind the fan in the
external unit for fresh air intake into the cab.
1, 2
3
003210
WARNING
Personal injury, environmental damage
IMPORTANT
Working on the air conditioning requires special au-
thorization.
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,
with the intended equipment.
For volume, see section F Technical data.
IMPORTANT
Connection points for cooling hoses. Working on the air conditioning requires special au-
thorization.
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, see 8 Control
system , group 8.4.4.1 CLIMATE, menu 1, 8.4.4.4 CLIMATE, menu 4
and 8.4.4.7 CLIMATE, menu 7.
010021
1. Water valve
2. Steering valve
The coolant temperature sensor sits on the engine and detects engine
coolant temperature. See supplier documentation, engine.
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.4.2 CLIMATE, menu 2.
For location, see section 1 Engine.
9.4.7 Compressor
AC compressor, description
page
–
1 2 3 NOTE
For tightening torque of refrigerant hoses and pressure switch,
see section F Technical data.
The compressor drives the climate control system by working as a
pump. It draws in cold, low-pressure gas from the evaporator, com-
presses the gas which then becomes warm, and then forces out high-
pressure gas to the condenser.
The compressor is driven by V-belts directly by the machine’s engine.
Activation and deactivation of the compressor is handled by an elec-
4
tromagnetic clutch, which is controlled by a thermostat.
009116
5 The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.4.6 CLIMATE, menu 6.
The illustration depicts the compressor for Cummins
QSB 6.7
1. Rigging screw (belt tensioner)
2. Compressor
3. Connections
4. Screw and nut
5. Drive belt
AC compressor, replacement
page
–
2
WARNING
Personal injury, environmental damage
NOTE
Fill new oil through the compressor’s suction connection.
10 Fit the new compressor and other equipment in reverse order.
11 Check for leaks and refill the AC-system with refrigerant R134a,
with the intended equipment.
For volume, see the plate for the climate control system.
IMPORTANT
Working on the air conditioning requires special au-
thorization.
006264
1. Lock ring
2. Locking washer
1. Groove
1. Electromagnetic clutch
9.4.8 Condenser
Condenser, description
page
–
NOTE
For tightening torque of refrigerant hoses and pressure switch,
see section F Technical data.
The condenser is located on the radiator in the engine compartment.
The function of the condenser is to convert the hot, high-pressure gas
from the compressor to liquid form. Pipes and cooling fins in the con-
denser battery absorb the heat, which is dissipated with a fan.
The temperature of the refrigerant in the condenser varies from ap-
prox. 50 °C to 70 °C and the pressure varies between 12 and 14 bar
depending on ambient temperature and airflow through the condens-
er. When the refrigerant has been condensed to liquid, it is directed on
to the fluid reservoir/filter dryer.
010023
Condenser, replacement
page
–
WARNING
Personal injury, environmental damage
IMPORTANT
Working on the air conditioning requires special au-
thorization.
IMPORTANT
Working on the air conditioning requires special au-
thorization.
NOTE
2 3 For tightening torque of refrigerant hoses and pressure switch,
1
see section F Technical data.
The moisture filter collects the liquid refrigerant, binds moisture and fil-
ters impurities. The reservoir functions as an expansion tank in the
cooling circuit.
When the refrigerant has passed through the dryer in the bottom of the
fluid reservoir, it rises through a standpipe. Through a sight glass, it is
possible to check that flow is without bubbles and that the system is
adequately filled with refrigerant.
010024
NOTE
2 3 For tightening torque of refrigerant hoses and pressure switch,
1
see section F Technical data.
The pressure switch cuts off the current to the compressor’s electro-
magnetic clutch if the pressure in the cooling circuit becomes abnor-
mally high or low.
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.4.3 CLIMATE, menu 3.
010024
WARNING
2 3
1 Personal injury, environmental damage
IMPORTANT
Working on the air conditioning requires special au-
thorization.
010024
1. Fluid reservoir moisture filter 4 Unscrew the pressure switch from its mounting.
2. Pressure switch. 5 Replace the pressure switch.
3. Sight glass
6 Check for leaks and refill the AC-system with refrigerant R134a,
with the intended equipment.
For volume, see section F Technical data.
IMPORTANT
Working on the air conditioning requires special au-
thorization.
The expansion valve is the part in the circuit that separates the high-
pressure side from the low-pressure side. The refrigerant arrives at the
expansion valve under high pressure and leaves it under low pres-
sure. After the expansion valve, the refrigerant converts to a gaseous
state and is transported to the compressor once again.
The amount of refrigerant that passes the evaporator varies depend-
ing on the heat load. The valve works from fully open to fully closed
and searches between these for an optimal evaporation point.
WARNING
Personal injury, environmental damage
IMPORTANT
Working on the air conditioning requires special au-
thorization.
IMPORTANT
Working on the air conditioning requires special au-
thorization.
1
3
005001
2
WARNING
Personal injury, environmental damage
NOTE
Requires special authorization.
1 Machine in service position, see section B Safety.
2 Drain the AC system of refrigerant.
IMPORTANT
Working on the air conditioning requires special au-
thorization.
IMPORTANT
Working on the air conditioning requires special au-
thorization.
The heat exchanger for cooling consists of pipes and cooling fins. The
cab air is cooled as it passes through the cooling heat exchanger. The
heat exchanger is located behind the fan in the external unit for fresh
air intake into the cab.
1, 2
3
003210
The air distributor controls the air between defroster and floor and is
located behind the panel inside the cab. The damper is controlled elec-
trically by the control system.
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.4.4 CLIMATE, menu 4 and 8.4.4.5 CLI-
MATE, menu 5 and 8.4.4.8 CLIMATE, menu 8.
002230
1. Instrument panel
2. Steering wheel shaft adjustment
3. Lower protective cover
7 Remove the air distributor from its mounting.
8 Replace the air distributor, fitting it in the reverse order.
Air distributor
There are a number of fixed air vents in the cab’s interior: at the front
of the doors and the defroster for the windshield. There are also two
adjustable air vents (flow and direction) in the instrument panel’s out-
side corners.
There is an air inlet towards the cab’s lower part (floor).
001839
3 The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.4.2 CLIMATE, menu 2.
005001
1. Instrument panel
2. Steering wheel shaft adjustment
3. Lower protective cover
1
3
005001
007985
1
Pause heating is an option for the heating unit, which uses residual
heat in the engine's cooling system to keep the cab warm.
An extra electrically operated water pump pumps the coolant through
the heater unit when the engine is stopped. The cabin fan forces air
into the cab. The pause heater is automatically switched off when the
temperature in the cab is six degrees below the value set on the cli-
mate control system. The pause heater is activated with the pause
2 heater switch when the ignition is on.
3
004909
The wipers automatically switch off 2 minutes after the operator has
left the driver’s seat.
The front wiper is the parallel wiper type, i.e. the wiper blade is moved
in a constant vertical manner over the windscreen.
Wiper roof are of the type sector wiper. Wiping angle is approx. 180
degrees.
The rear wiper is a sector wiper type. The wiping angle is approx. 180
degrees.
Washer motors are located on the washer fluid reservoir. There are
non-return valves on the lines from the reservoir to the washer noz-
zles, preventing the washer fluid from draining back in the line be-
tween washings. This minimizes the time from activation of switch
washing and washer fluid spraying on the windshield.
The washer nozzles are mounted on the wiper arms.
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.3.1 CAB, menu 1.
003619
A B
A. Washer fluid reservoir
B. Washer motors
The wiper motor drives the front windscreen wiper. The wiper arm is
mounted on the motor. The motor produces the movement of the wip-
er.
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.3.2 CAB, menu 2.
The wiper motor drives the roof window’s wiper. The wiper arm is
mounted on the motor. The motor produces the movement of the
wiper.
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.3.4 CAB, menu 4.
3 Detach the washer hose and the connector to the wiper motor.
4 Undo the lock nut securing the wiper arm and disconnect the
washer fluid hose.
5 Remove and replace the wiper motor.
6 Fit in the reverse order. Tighten the wiper arm to 16-20 Nm.
The wiper motor drives the rear window wiper. The wiper arm is
mounted on the motor. The motor produces the movement of the wip-
er.
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.3.3 CAB, menu 3.
6 Remove the screws securing the motor and the lock nut on the
motor.
7 Replace the wiper motor.
8 Fit in the reverse order. Tighten the wiper arms to 16-20 Nm.
Work lights are shut off automatically after 5 minute’s idling in order to
prevent discharge of the batteries. Auxiliary work lights are shut off af-
ter 2 minutes. Lighting is activated automatically again when the oper-
ator sits in the seat, a gear is selected or the accelerator pedal is
pressed.
NOTE
It is important that the right type of bulb is used for each area. See
section F Technical data.
1 2 3 5 4
D1 D2 D3 D5 D4 9
10
14 D15 11
6 D9
D6 18
D18 D19 15 15
D7 19 D11
7 16
17 M D16 D10
D17 D790-1 D790-2
21 8, 13 30 12 32
D22 D23 D24 D25 D26 D797-1 D797-2 D791-1
Pa 20
D27
D20 D31 D33 D34
D28
010025
D29
22 23 24 25 26 27 28 29 31 33 34
2 The switch for attachment work lights (S105-2) Switch in ON position: U D2: Diagnostic menu, see section 8
sends a voltage signal to the cab control unit = 24 V Control system group 8.4.2.13
(D790-1). LIGHTS, menu 13
3 The switch for mast work lights (S105-3) sends Switch in ON position: U D3: Diagnostic menu, see section 8
a voltage signal to the cab control unit (D790- = 24 V Control system group 8.4.2.10
1). LIGHTS, menu 10
4 The headlights switch (S100) sends a voltage Switch in ON position: U D4: Diagnostic menu, see section 8
signal to the cab control unit (D790-1). = 24 V Control system group 8.4.2.1 LIGHTS,
menu 1
5 The revolving beacon switch (S110) sends a Switch in ON position: U D5: Diagnostic menu, see section 8
voltage signal to the cab control unit (D790-1). = 24 V Control system group 8.4.2.6 LIGHTS,
menu 6
6 The door NC switch (S266-LE & S266-RI) Door open: U = 24 V Interior lighting cab, description page
sends a voltage signal to the cab control unit 73
(D790-1). D6: Diagnostic menu, see section 8
Control system group 8.4.2.9 LIGHTS,
menu 9
7 The switch for entry lighting (S141) sends a Switch in ON position: U Entry lighting, description page 74
voltage signal to the cab control unit (D790-1). = 24 V D7: Diagnostic menu, see section 8
Control system , group 8.4.2.15
LIGHTS, menu 15
8 The cab control unit (D790-1) transmits a Checked by control sys- Section 11 Common electrics, group
"switch on lights" message on the CAN bus. tem, error shown with 11.5.3.1 Cab control unit (D790-1)
error code.
9 The multi-function lever (S162) sends a volt- Lever in high beam posi- Gear and multi-function lever, descrip-
age signal to the KIT control unit (D790-2). tion: US162/56a = 24 V tion page 11
D9: Diagnostic menu, see section 8
Control system , group 8.4.2.3
LIGHTS, menu 3
10 The direction indicator lever (S161) sends a Left: US161/6 = 24 V D10: Diagnostic menu, see section 8
voltage signal to the KIT control unit (D790-2). Control system , group 8.4.2.4
Right: US161/1 = 24 V
LIGHTS, menu 4
11 The interior lighting switch of the KIT control Checked by control sys- D11: Diagnostic menu, see section 8
unit (D790-2) sends a voltage signal to the KIT tem, error shown with Control system , group 8.4.2.9
control unit (D790-2). error code. LIGHTS, menu 9
12 The KIT control unit (D790-2) transmits a Checked by control sys- Section 11 Common electrics, group
"switch on lights" message on the CAN bus. tem, error shown with 11.5.3.11 KIT control unit (D790-2)
error code.
13 The cab control unit (D790-1) supplies voltage Checked by control sys- Section 11 Common electrics, group
to the lights in and around the cab. tem, error shown with 11.5.3.1 Cab control unit (D790-1)
error code.
14 The relay for cab roof work lights (K3017-1 and UK3017/30 = 24 V Working lights, cab, description page
K3017-2) is activated when the cab roof work 72
UK3017/85 = 0 V
lights are activated. It supplies voltage to the
cab roof work lights (E406L-1 E406R-1, Cab roof work lights on:
E406L-2 & E406R-2). UK3017/86 = 24 V
UK3017/87 = 24 V
UK3017/87 = 0 V
15 The cab roof work lights (E406L-1 E406R-1, Light on: U = 24 V Working lights, cab, description page
E406L-2 & E406R-2) come on when the cab 72
roof work lights are activated. D15: Diagnostic menu, see section 8
Control system , group 8.4.2.12
LIGHTS, menu 12
16 The white reversing lights (E405L & E405R) Light on: U = 24 V Reversing light, description page 71
come on when reverse gear is selected. D16: Diagnostic menu, see section 8
Control system , group 8.4.2.8
LIGHTS, menu 8
17 Rotating beacon (H428) is lit when rotating Light on: U = 24 V Rotating beacon, description page 71
work light is activated. D17: Diagnostic menu, see section 8
Control system , group 8.4.2.6
LIGHTS, menu 6
18 Interior lighting (E434-1) comes on when a Light on: U = 24 V Interior lighting cab, description page
door is opened or if activated when the switch 73
on the KIT control unit (D790-2). D18: Diagnostic menu, see section 8
Control system , group 8.4.2.9
LIGHTS, menu 9
19 Entry lighting (E433) comes on when activated Light on: U = 24 V Entry lighting, description page 74
with the entry lighting switch or when the inte- D19: Diagnostic menu, see section 8
rior lighting comes on. Control system , group 8.4.2.15
LIGHTS, menu 15
20 The brake light NO switch (S216) sends a volt- Brake pressure over 0.2 Section 4 Brakes, group 4.3.8 NO
age signal to the frame control unit (D797-1). MPa: U = 24 V (normally open) switch, brake lights
D20: Diagnostic menu, see section 8
Control system , group 8.4.2.7
LIGHTS, menu 7
21 The frame control unit (D797-1) supplies volt- Checked by control sys- Section 11 Common electrics, group
age to the machine lights. tem, error shown with 11.5.3.2 Frame control unit (D797-1)
error code.
22 The direction indicators (H422, H423, H426 & Light on: U = 24 V Driving direction indicator, description
H427) come on when they or the warning lights page 71
are activated. D22: Diagnostic menu, see section 8
Control system , group 8.4.2.5
LIGHTS, menu 5
23 The running lights (H416-1, H416-2, H417-1 & Light on: U = 24 V Running lights, description page 70
H417-2) come on together with the headlights. D23: Diagnostic menu, see section 8
Control system , group 8.4.2.2
LIGHTS, menu 2
24 Headlights low beams (E400L & E400R) are lit Light on: U = 24 V Headlights, description page 70
when headlights are activated. D24: Diagnostic menu, see section 8
Control system , group 8.4.2.3
LIGHTS, menu 3
25 Headlights high beam (E402L-1 & E402R-1) Light on: U = 24 V Headlights, description page 70
are lit when high beam is activated. D25: Diagnostic menu, see section 8
Control system , group 8.4.2.3
LIGHTS, menu 3
26 Tail lights (H412L & H412R) red are lit when Light on: U = 24 V Tail light, description page 70
headlights are activated. D26: Diagnostic menu, see section 8
Control system , group 8.4.2.2
LIGHTS, menu 2
27 Brake lights (H411L & H411R) are lit when the Light on: U = 24 V Brake light, description page 70
brake is activated. D27: Diagnostic menu, see section 8
Control system , group 8.4.2.8
LIGHTS, menu 8
28 The mast work lights (E404L-1 & E404R-1) Light on: U = 24 V Mast working lights, description page
come on when activated. 72
D28: Diagnostic menu, see section 8
Control system , group 8.4.2.10
LIGHTS, menu 10
29 The auxiliary mast work lights (E404L-4 & Light on: U = 24 V Mast working lights, description page
E404R-4) come on when the mast work lights 72
are activated. D29: Diagnostic menu, see section 8
The front wing auxiliary work lights (E404L-4 & Control system , group 8.4.2.11
E404R-4) come on when the cab roof work LIGHTS, menu 11
lights are activated.
30 The frame control unit (D797-2) supplies volt- Checked by control sys- Section 11 Common electrics, group
age to the machine lights. tem, error shown with 11.5.3.3 Frame control unit (D797-2)
error code.
31 The auxiliary mast work lights (E404L-2 & Light on: U = 24 V Mast working lights, description page
E404R-2) come on when the mast work lights 72
are activated. D31: Diagnostic menu, see section 8
The front wing auxiliary work lights (E404L-2 & Control system , group 8.4.2.11
E404R-2) come on when the cab roof work LIGHTS, menu 11
lights are activated.
32 The attachment control unit (D791-1) supplies Checked by control sys- Section 11 Common electrics, group
voltage to the attachment lights. tem, error shown with 11.5.3.5 Attachment control unit
error code. (D791-1)
33 The twistlock attachment work lights (E404L-3 Light on: U = 24 V Work lights attachment, description
& E404R-3) come on when activated. page 73
The work lights for lifting hook attachment with D33: Diagnostic menu, see section 8
lock tongues (E404UL, E404UR, E404LL and Control system , group 8.4.2.13
E404LR) come on when activated. LIGHTS, menu 13
34 The twistlock attachment auxiliary work lights Light on: U = 24 V Work lights attachment, description
(E404L-5 and E404R-5) come on when acti- page 73
vated. D34: Diagnostic menu, see section 8
Control system , group 8.4.2.11
LIGHTS, menu 11
NOTE
It is important that the right type of bulb is used for each area. See
section F Technical data.
The machine has the following lights:
1 4 5 6 6 7 9
30 3,8,10
12
29
28
27
26
008397
22,23,24,25 21 19,20 18 17 16 15 11,13,14
1. Mast work lights (E404L-1 & E404R-1) 16. Entry lighting (E433)
2. Auxiliary mast work lights (E404L-4 & E404R-4) 17. Switches, see Controls and instruments, overview page 5
2. Relay, cab roof work lights (K3017-1 & K3017-2) 18. Switch, entry lighting (S141)
8. Auxiliary cab roof work lights (E406L-2 & E406R-2) 23. Front running lights (H416-1 & H417-1)
9. Rotating beacon (H428) 24. Headlights, low beam (E400L & E400R)
Headlights, high beam (E402L-1 & E402R-1)
10. Control unit cab (D790-1) 25. Auxiliary front wing work lights (E404L-4 & E404R-4)
11. Rear running lights (H416-2 & H417-2) 26. Lifting hook attachment work lights (E404LL & E404LR)
12. Reversing lights (E405L & E405R), white 27. Control unit attachment (D791-1)
13. Tail lights (H412L & H412R) red 28. Twistlock attachment work lights (E404L & E404R)
Brake lights (H411L & H411R)
14. Direction indicators rear (H426 & H427) 29. Auxiliary carriage work lights (E404L & E404R)
15. Door NC (normally closed) switch (S266-LE & S266-RI) 30. Lifting hook attachment work lights (E404UL & E404UR)
9.6.1 Headlights
Headlights, description
page
–
Headlights are located in the front of the machine to give the operator
enhanced vision when operating in darkness, and to provide surround-
ing traffic and the environment an indication of the machine’s position.
Headlights have high beam and low beam (for meeting other traffic).
Switch between low and high beam with the gear and multi-function le-
ver. The signal goes to the cab control unit (D790-1).
The low and high beam signals can be checked from the diagnostic
menu, section 8 Control system , group 8.4.2.3 LIGHTS, menu 3.
The running lights are located on the right and left-hand sides of the
machine to provide surrounding traffic and the environment an indica-
tion of the machine’s position and direction of travel.
The running lights are controlled by selecting with the headlight switch.
The signal travels to the cab control unit (D790-1).
The lights and their signal can be checked from the diagnostic menu,
section 8 Control system , group 8.4.2.2 LIGHTS, menu 2.
Tail lights are located in the rear of the machine to provide surrounding
traffic and the environment an indication of the machine’s position, and
a limited enhancement of the view for the operator in darkness.
The tail lights are controlled by selecting with the headlight switch. The
signal travels to the cab control unit (D790-1).
The lights and their signal can be checked from the diagnostic menu,
section 8 Control system , group 8.4.2.2 LIGHTS, menu 2.
The brake lights are located in the rear of the machine to provide sur-
rounding traffic and the environment an indication that the machine is
braking and consequently slowing down.
The brake lights are regulated by brake pedal position (via actuated
NC switch). The signal travels to the frame control unit (D797-1), which
supplies power to the brake lights.
The lights and their signal can be checked from the diagnostic menu,
see section 8 Control system , group 8.4.2.7 LIGHTS, menu 7 and
8.4.2.8 LIGHTS, menu 8.
The reversing lights are located in 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 en-
hanced view when operating in darkness.
The reversing lights are controlled by the direction of travel. The signal
travels via the CAN bus.
The lights and their signal can be checked from the diagnostic menu,
see section 8 Control system , group 8.4.2.7 LIGHTS, menu 7 and
8.4.2.8 LIGHTS, menu 8.
The direction indicators are located on both the front and rear of the
machine to provide surrounding traffic and the environment an indica-
tion that the machine is changing direction, i.e. turning.
The direction indicator is controlled by selecting with the switch (lever)
for direction indicators. The signal travels to the frame control unit
(D797-1).
The lights and their signal can be checked from the diagnostic menu,
see section 8 Control system , group 8.4.2.4 LIGHTS, menu 4 and
8.4.2.5 LIGHTS, menu 5.
Machines for the North American market are equipped with flashing
brake lights front and rear during operation.
The lights and their signal can be checked from the diagnostic menu,
section 8 Control system , group 8.4.2.6 LIGHTS, menu 6.
Work lights on the mast provide enhanced view when load handling in
darkness.
The work lights are controlled by selecting with the mast work light
switch. The signal travels to the cab control unit (D790-1).
The lights and their signal can be checked from the diagnostic menu,
see section 8 Control system , group 8.4.2.10 LIGHTS, menu 10 and
8.4.2.11 LIGHTS, menu 11.
lights)
DANGER
Xenon lights are activated with high voltage. Always
turn off the main electric power before working on xe-
non lights.
NOTE
The xenon light is filled with different gases and metals. Replaced
xenon headlights should be considered as hazardous waste and
should be deposited for recycling.
Work lights on the cab provide visibility when handling a load in dark-
ness.
The work lights are controlled by selecting with the switch for cab roof
work lights. The signal travels to the cab control unit (D790-1) which in
turn supplies power to the work lights.
The lights and their signal can be checked from the diagnostic menu,
section 8 Control system , group 8.4.2.12 LIGHTS, menu 12.
lights)
See Work lights, changing (product alternative Xenon lights) page 72.
The interior lighting illuminates the cab when the doors are opened or
when activated with the interior lighting switch.
There is background illumination in all switches, function keys and ro-
tary controls. This is so that the driver will be able to read their func-
tions 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.
Work lights on the attachment provide enhanced view when load han-
dling in darkness.
The work lights are controlled by selecting with the attachment work
light switch. The signal travels to the cab control unit (D790-1).
The lights and their signal can be checked from the diagnostic menu,
section 8 Control system , group 8.4.2.13 LIGHTS, menu 13.
lights)
See Work lights, changing (product alternative Xenon lights) page 72.
2
1
010026
2 Entry lighting
Work lights on the front wing provide enhanced view when load han-
dling in darkness.
The work lights are controlled by selecting with the switch for cab roof
work lights.The signal travels to the cab control unit (D790-1).
The lights and their signal can be checked from the diagnostic menu,
section 8 Control system , group 8.4.2.11 LIGHTS, menu 11.
lights)
See Work lights, changing (product alternative Xenon lights) page 72.
NOTE
It is important that the right type of bulb is used for each area. See
section F Technical data.
1 2 3 4
D2 D3 D17 17 6
7
D1 D4
15
16
D6
D6
D15 D13 D18
13 18
14 M
8 19
D790-1 D790-2 D795
D14 5
9
D797-1 D791-1
D10 20
D11
10 11 D21
21
010027
12
D12
2 The switch for warning lights (haz- Switch in ON position: U = D2: Diagnostic menu, see section 8 Control
ard) (S109) sends a voltage signal to 24 V system , group 8.4.2.4 LIGHTS, menu 4
the cab control unit (D790-1).
3 The parking brake switch (S107) Switch in ON position: U = D3: Diagnostic menu, see section 8 Control
sends a voltage signal to the cab 24 V system, group 8.4.5.4 HYD, menu 4
control unit (D790-1).
4 The horn switch (S149-3) sends a Switch in ON position: U = D4: Diagnostic menu, see section 8 Control
voltage signal to the cab control unit 24 V system , group 8.4.3.5 CAB, menu 5
(D790-1).
5 The cab control unit (D790-1) trans- Checked by control sys- Section 11 Common electrics, group 11.5.3.1
mits activation messages on the tem, error shown with er- Cab control unit (D790-1)
CAN bus ror code.
6 The multi-function lever (S162) Signal button pressed in: Gear and multi-function lever, description
sends a voltage signal to the KIT US162/H = 24 V page 11
control unit (D790-2). D6: Diagnostic menu, see section 8 Control
system , group 8.4.3.5 CAB, menu 5
8 The KIT control unit (D790-2) trans- Checked by control sys- Section 11 Common electrics, group
mits activation messages on the tem, error shown with er- 11.5.3.11 KIT control unit (D790-2)
CAN bus. ror code.
9 The frame control unit (D797-1) sup- Checked by control sys- Section 11 Common electrics, group 11.5.3.2
plies voltage to the machine lights tem, error shown with er- Frame control unit (D797-1)
and buzzers. ror code.
10 The direction indicators (H422, Light on: U = 24 V Driving direction indicator, description page 71
H423, H426 and H427) come on D10: Diagnostic menu, see section 8 Control
when the warning lights are activat- system , group 8.4.2.5 LIGHTS, menu 5
ed.
11 The reversing lights (E405L and Light on: U = 24 V Reversing light, description page 71
E405R) come on when reverse gear D11: Diagnostic menu, see section 8 Control
is selected. system , group 8.4.2.8 LIGHTS, menu 8
12 Back-up alarm (H965) is activated Reverse gear engaged: U Reversing alarm, description page 79
when reverse gear is selected. = 24 V D12: Diagnostic menu, see section 8 Control
system , group 8.4.2.8 LIGHTS, menu 8
13 Horn (H850) sounds when the horn Horn active: U = 24 V Horn, description page 78
is activated. D13: Diagnostic menu, see section 8 Control
system , group 8.4.3.5 CAB, menu 5
14 Rotating beacon (H428) is lit when Light on: U = 24 V Rotating beacon, description page 71
hazard lights are activated. D14: Diagnostic menu, see section 8 Control
system , group 8.4.2.6 LIGHTS, menu 6
UK3016/87 = 24 V
16 Loud horn (H850-1) sounds when Horn active: U = 24 V Horn, description page 78
the horn is activated.
17 The operator-in-seat NO switch Operator in seat: U = 24 V Sensor operator in seat, description page 22
(S230) sends a voltage signal to the D17: Diagnostic menu, see section 8 Control
cab control unit (D790-1) when there system , group 8.4.3.6 CAB, menu 6
is a load on the driver’s seat.
18 In the event of warnings, the cab Checked by control sys- D18: Diagnostic menu, see section 8 Control
buzzer (H853) is supplied voltage by tem, error shown with er- system , group 8.4.3.6 CAB, menu 6
the KIT control unit (D790-2) to draw ror code.
the operator’s attention to the warn-
ing message.
20 The attachment control unit (D791-1) Checked by control sys- Section 11 Common electrics, group 11.5.3.5
supplies voltage to the automatic tem, error shown with er- Attachment control unit (D791-1)
spreading buzzer during automatic ror code.
spreading.
21 The automatic spreading buzzer Buzzer active: U = 24 V Section 7 Load handling group 7.5.10 Buzzer,
(H9003) is activated when automatic automatic spreading 20’-40’
spreading 20’-40’ is activated. D21: Diagnostic menu, see section 8 Control
system , group 8.4.9.21 ATTACH, menu 21
NOTE
On machines with side lifting attachment, an audible signal can also be given with the open twistlock button (S1002) on
the panel for hydraulic functions or the open twistlock button on the joystick, provided that the "open twistlocks upon
contact" function is not active.
1 2 3 4 5 6
008395
19 18 17 16 15 14 13 12 10,11 9 8 7
9. Direction indicators rear (H426 & H427) 19. Buzzer automatic spreading (H9003)
9.7.1 Horn
Horn, description
page
–
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.3.5 CAB, menu 5..
If the operator leaves the machine without applying the parking brake,
a buzzer sounds to alert the operator, i.e. to ensure the operator ap-
plies the parking brake.
A sensor in the driver’s seat (see Sensor operator in seat, description
page 22) indicates to the control system if the operator leaves the seat.
The buzzer is located in the steering wheel panel.
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.3.6 CAB, menu 6..
When reverse is selected, a warning sound and the back-up lights are
activated. This is to give others in traffic an indication that the machine
is reversing. Indication to bystanders to take caution.
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.2.8 LIGHTS, menu 8.
9.9 Glass/windows/mirrors
Glass/windows/mirrors, description
page
–
The windows are designed to both enclose the cab and provide the op-
C erator with a good view.
The windows on the Spirit Delta cab are made of tinted hardened
D
glass, except the roof window which is made of polycarbonate plastic.
A E B 001512
A. Side windows
B. Windshield (front window)
C. Roof window
D. Rear window
E. Windshield (Side window front)
The window panes are secured with key adhesive and silicone adhe-
sive.
NOTE
The purpose of this instruction is to describe how silicone adhe-
sive 923854.0100 should be handled in connection with replace-
ment of the windscreen and roof window on the Spirit Delta cab.
• Silicone adhesive 923854.0100 is a quick-hardening, two-
component silicone adhesive that can withstand tempera-
tures between -50 °C and +200 °C. The hardening properties
of the adhesive are extremely dependent on the ambient
temperature. An increase of 10 °C cuts hardening time in
half.
Silicone adhesive 923854.0100 is mixed at a ratio of 1:10 in
a static mixer. Change mixer after every interruption that
lasts more than 5 minutes. The short setting time means that
work has to be planned carefully to avoid undesired harden-
ing.
Fixing time:
10-20 minutes at 20 °C
approx. 5 minutes at 60 °C
Hardening time:
approx. 24 hours at 20 °C
approx. 1 hour at 60 °C
Full strength is obtained after 7 days.
• In warm climates, it is advantageous to cool the container to
increase hardening time. The silicone adhesive should not
be used at temperatures above +75 °C.
• In cold climates, the hardening time can be shortened by
covering the joints so that cooling is prevented. The window
pane can be warmed with defroster or cab heater.
• The recommended storage temperature is between -30 °C
and +20 °C. Storage in a refrigerator or a colder environment
is recommended.
9.9.1 Windscreen
Windscreen, description
page
–
The windshield consists of the front window and side windows. The
windshield is attached to the cab with a key strip and is glued to the
roof window with silicone adhesive. Front and side windows are joined
with silicone adhesive to give good allround visibility from the opera-
tor’s station.
For location, see Glass/windows/mirrors, description page 81.
Windscreen, replacement
page
–
NOTE
Read the handling advice for silicone adhesive before starting
work. See Silicone adhesive, handling advice page 81.
NOTE
Make sure that no silicone adhesive remains between the
window pane and the strip by the window pane’s lower front
edge.
CAUTION
Acetone may not come into contact with a roof win-
dow made of polycarbonate plastic. Acetone has a
chemical effect on the polycarbonate plastic which
reduces the roof window’s strength.
1
006268
1,0
1
Figure 2: Adjusting side window - cab window
1. Side window
2. Rubber strip
3. Cab frame / door opening
006269
1,0
NOTE
There must be silicone between the window panes, to avoid
contact between the window panes.
out the joints with a finger, wet with water or soapy water.
The side windows are secured in the cab and doors with key strips.
For further details, see Glass/windows/mirrors, description page 81.
NOTE
The method describes a general procedure.
3 Remove the wedge strip which runs around the whole window.
4 Carefully remove any glass remains from the rubber strip.
7 Thread the rubber strip around the whole window; use special
tools.
WARNING
The strength of the roof window may be significantly
reduced in case of exposure to substances contain-
ing: aromatic hydrocarbons, ketones, esters and
chlorinated hydrocarbons.
The cab has one rearview mirror located in the cab and external rear-
view mirrors out on the machine. The rearview mirrors give the opera-
tor a view around the machine.
The monitor shows picture and sound from the back-up camera. The
CA.SE
L
1 picture is shown in colour and light intensity is automatically adjusted
according to light conditions in the cab. The monitor can handle sig-
MENU
BRI
4
007416
5
1. Choice of camera
2. Menu
3. Light intensity
4. Volume setting
5. On and off
3
003206
4
Cab Spirit Delta
1. Cab frame
2. Door
3. Cab suspension
4. Cab undercarriage
The cab frame is made of high-strength steel sheet profiles. The cab
is dimensioned to handle impacts and, to some degree, dropped
loads. The frame must not be modified!
002210
9.10.2 Doors
Doors, description
page
–
The cab has two doors - the left is the operator’s door and the right is
the emergency exit. The door has:
• rail
• handle
• key lock
WARNING
If anybody goes under the tilted cab.
Fatal danger!
NOTE
Operate the cab when the machine is stationary!
The cab can be hydraulically tilted 10° along its length axis.
When the load is to be lifted high up, the cab can be tilted backwards
to improve visibility and make the working position more ergonomic.
With the automatic/manual cab tilt switch in the automatic cab tilt po-
sition, the cab will be tilted when the mast reaches a predetermined lift
height.
The cab can be tilted up or down with the manual cab tilt switch. This
switch is also operative when the cab tilt switch is in the automatic po-
sition.
For the cab to be tilted, the machine speed must not exceed 5 km/h,
the driver’s doors must be closed and the parking brake or emergency
stop switch for servo circuits must not be activated.
If the cab is not in the lowest position, machine speed is limited to not
more than second gear and 5 km/h.
Speed < 5 km/h Section 8 Control system , group 8.2.3 Speed limitation
Emergency stop switch Disengaged Section 11 Common electrics, group 11.5.1.4 Emergency stop switch
voltage
6
3 1 4 1
0
0 2
D3 D4 D6
5 7
D790-1 D797-1
8
D797-2 12
9 D8
10
D9 12
B
T
A
TP
P LS LSPB
11
2
010028
1 The cab tilt shuttle valve sends a load P = 3.5 MPa Section 10 Common hydraulics, group
signal to the hydraulic oil pumps. 10.5.3 Shuttle valve
2 The hydraulic oil pumps pump oil from P = 19 ±0.5 MPa Hydraulic oil pump, description page 95
the hydraulic oil tank.
3 The automatic/manual cab tilt switch U = 24 V Controls and instruments, overview page 5
(S199-2) sends a voltage signal to the D3: Diagnostic menu, see section 8 Control
cab control unit (D790-1). system , group 8.4.11.5 MOVE-CAB, menu
2
4 The manual cab tilt switch (S1010) cab U = 24 V Controls and instruments, overview page 5
up/down sends a voltage signal to the
cab control unit (D790-1).
5 If manual cab tilt is selected, the cab Checked by control sys- Section 11 Common electrics , group
control unit (D790-1) transmits cab up or tem, error shown with er- 11.5.3.1 Cab control unit (D790-1)
cab down on the CAN bus. ror code.
6 If automatic cab tilt is selected, sensor U = 0-5 V Sensor for automatic cab tilt (B7211-1), de-
B7211-1 sends information to the frame scription page 99
control unit (D797-1) when the attach- D8: Diagnostic menu, see section 8 Control
ment reaches a predetermined lifting system , group 8.4.11.5 MOVE-CAB, menu
height. 2
7 If automatic cab tilt is selected, the Checked by control sys- Section 11 Common electrics, group
frame control unit (D797-1) transmits tem, error shown with er- 11.5.3.2 Frame control unit (D797-1)
cab up or cab down on the CAN bus. ror code.
8 The cab up sensor (B769-1) and cab Sensor, cab up/cab down, description page
down sensor (B769-2) provide voltage 100
information on cab position to the frame D10: Diagnostic menu, see section 8 Control
control unit (D797-2). system , group 8.4.11.5 MOVE-CAB, menu
3
9 The frame control unit (D797-2) acti- Checked by control sys- Section 11 Common electrics, group
vates the cab up servo valve (Y6047) or tem, error shown with er- 11.5.3.3 Frame control unit (D797-2)
the cab down servo valve. (Y6048). ror code. D11: Diagnostic menu, see section 8 Control
system , group 8.4.11.5 MOVE-CAB, menu
4
10 The servo valve for cab up (Y6047) or Cab tilt control valve, description page 95
servo valve for cab down (Y6048) pres-
surises the tilt spool in the cab tilt control
valve.
11 The control valve’s tilt spool changes - Cab tilt control valve, description page 95
position and pressurises the tilt cylin-
ders.
12 The tilt cylinders angle the cab in rela- - Cab tilt hydraulic cylinders, description page
tion to the cab undercarriage. 99
The tiltable cab is supplied pressure from a hydraulic oil pump; see
1 section 10 Common hydraulics , group 10.4.2 Axial piston pump with
variable displacement.
2
3
008082
The control valve controls the speed and direction of the cab tilt func-
tion. The control valve is located on the right of the frame, in the area
beside the gearbox.
Electrically controlled pressure reduction valves (servo valves) con-
vert electric current to a small hydraulic pressure which is proportional
1 to the current, so-called servo pressure. The servo pressure operates
a spring-centred control spool in the control valve, and thus controls
2
the main flow.
1 Tilt spool
The tilt spool controls the direction and flow of oil to the tilt cylinders.
The signals can be checked from the diagnostic menu, see section 8
Control system , group 8.4.11.5 MOVE-CAB, menu 4.
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Machine in service position, see section B Safety.
2 Depressurize the hydraulic systems, See section B Safety.
3 Mark up and detach the hydraulic hoses from the control valve.
NOTE
Plug all connections immediately to protect the hydraulic
system from impurities.
4 Mark up and detach the wiring from the control valve.
5 Remove the control valve.
Remove the attaching bolts and lift away the valve. Place the
valve on a clean and protected surface.
6 Transfer parts to the new control valve.
NOTE
Check that the O-rings on the hydraulic connections are in-
tact and in place.
NOTE
Transfer one part at a time so that the marking is not mixed
up.
7 Mark up the servo valves on the new control valve.
8 Fit the valve.
9 Connect the wiring to the control valve in accordance with the
marking.
10 Connect the hydraulic hoses to the control valve in accordance
with the marking.
NOTE
Check that the O-rings are intact and fitted correctly.
11 Start the engine and check for leaks.
CAUTION
Air in the hydraulic system may cavitate and result in
product damage.
13 Check the oil level in the hydraulic oil tank with the lift cylinders
completely down and the extension cylinder completely in. The
oil level should be in the top of the level glass. Top up as needed.
CAUTION
Overfilling of oil, leakage, and environmental damage.
There are two brake valves situated between the cab tilt control valve
and the cab tilt cylinders. The brake valves are adjustable and choke
pressure to the tilt cylinders, which reduces the speed of cab tilting.
The brake valves are located on the control valve’s connections to the
hydraulic cylinders.
010032
The lower parts of the hydraulic cylinders are fixed to the cab under-
carriage and the upper parts are fixed to the cab. The hydraulic cylin-
ders lift the front edge of the cab, thereby tilting it.
010033
The cab undercarriage for cab tilt comes in two sections, the part that
holds the cab has a hinge at the trailing edge which is located on the
frame, and the hydraulic cylinders are located at the leading edge be-
tween the parts.
adjustment
Check and adjust the position sensor as follows:
1 Machine in service position, see section B Safety.
2 Check that the sensor is clean and free from dirt.
3 Check that the distance between the sensor and the indicator is
15 ±1 mm.
4 Adjust if necessary.
Left instrument panel is located in the left corner of the cab. It contains
rotary controls, switches, and ventilation.
The panel, which is mounted on the driver’s seat, houses switches and
controls for load handling functions and a emergency stop switch to in-
terrupt load handling functions in progress.
On machines equipped with a control lever, it is located next to the
panel .
9.11.5 Insulation
Insulation, description
page
–
Sun blinds can be chosen for the front window (windscreen) and the
roof window.
1. Sun visor, front window: Can be raised and lowered using a cord
on the right-hand side. Stops in selected position.
2. Sun visor, roof window: Extends forward to fasten in two hooks in
the front edge of the window.
9.11.8 Reading-lamp
Reading lamp, description
page
–
The reading lamp is fitted on a jointed bracket to the right in front of the
door in the cab.
008228
9.12 Chassis
Frame, description
page
–
1 2 3 4
5
010030
1. Frame’s front part with drive axle mounting
2. Mounting for front wing
3. Engine compartment with mountings for engine and transmission
4. Cab mounting (4 points)
5. Frame’s rear part with counterweights
6. Steering axle mounting
9.13 Body
Body, description
page
–
1 2 3
010031
1. Fenders
2. Hood engine compartment
3. Counterweight
9.13.1 Fenders
Fenders, description
page
–
There are fenders over the wheels to protect from dirt thrown up by the
wheels during operation. The design of the counterweight (see Coun-
terweight, description page 107) acts as a mudguard for the rear
wheels.
The fenders can be equipped with extra mudguards when the ma-
chine’s work environment requires such ( ).
The cab area has footsteps for easy access. There is a rail by the cab
area.
9.13.4 Counterweights
Counterweight, description
page
–
DANGER
The counterweights are factory fitted and are adapted
according to the machine's properties.
1 Check that no grease has been forced out through the safety
valve (position 2).
If grease has been forced out through the safety valve it means
that there is a stop in the system. Determine which line is clogged
by feeling the connections at the distribution blocks. A clogged
hose remains pressurised and the connection becomes hard.
NOTE
If several distribution blocks are connected in series, a
clogged line will be pressurised all the way to the first distri-
bution block.
2 Turn the start key to position I.
3 Operate the pump manually and check that the indicator pin
moves in and out on the distribution blocks.
To operate the pump, loosen the cover and press in the switch for
manual operation (position 5).
If the indicator pins do not move even when the pump is running,
Overview of central lubrication pump unit and distribu-
troubleshoot the pump unit.
tion box. Example image.
1. Grease nipple, filling of lubricating grease
2. Safety valve
NOTE
3. Grease nipple, manual system lubrication The system can be lubricated manually through the grease
4. Indicator pin nipple on the distribution block (position 3).
5. Switch, manual operation 4 Fill grease in the pump unit through the filler nipple, see section
F Technical data.
The central lubrication’s pause and run-time must be set after replace-
ment, the setting is unique to each machine, depending on the ma-
chine’s equipment. At replacement, the new pump unit should be set
in the same way as the old.
If the machine is not greased correctly, pause and run-time can be ad-
justed. Primarily, run-time should be adjusted so that all grease points
on the machine are greased every time. If large amounts of grease are
pressed out at all grease points, pause-time can be increased.
NOTE
Adjust only one step each time. Small adjustments make a big
difference.
Pause-time
Pause-time is the length of the interval between greasings. The inter-
Example figure
val is adjusted in whole hours between 1 and 15 hours. Pause-time is
1. Setting pause-time (red)
adjusted with the red handle (position 1)
2. Setting run-time (blue)
3. Manual operation of pump
Switch position 1 2 3 4 5 6 7 8 9 A B C D E F
Pause-time [hours] 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Run-time
Run-time is how long the pump is activated every time. Run-time can
be adjusted between 2 and 30 minutes. Pause-time is adjusted with
the blue handle (position 2).
Switch position 1 2 3 4 5 6 7 8 9 A B C D E F
Run-time [minutes] 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
The pump unit consists of containers with stirrer, pump housing with
built-in motor, timer, pump element, filler nipple, and safety valve.
The central lubrication works with lubrication cycles (pause and run-
ning time as well as read-in time). In the pump there is a circuit board
with a timer with which one can set the pump motor’s run and pause
time.
When the central lubrication works, it greases the grease points one
at a time in series. If a stop should occur in a grease point, the pres-
sure will increase and the safety valve will release grease and also the
following grease points will not be greased.
NOTE
The safety valve will press out grease if a grease point cannot be
greased. If a grease point is not greased, none of the following
grease points will be greased Therefore, it is very important to
check the safety valve.
The distribution blocks distribute grease from the pump unit to grease
points or on to other distribution blocks. The number of distribution
blocks can vary depending on how may (and which) grease points
have been selected.
The distribution blocks consist of pistons that meter out grease to each
grease point. The pistons are driven by the grease and do not have
springs and gaskets. It is the grease that drives the pistons inside the
distributor. The shape of the pistons and channels in the distribution
block enable the pistons to move in a predetermined way. Each piston
must have completed its motion before the next piston can move. The
pistons are dependent on each other. It is technically impossible to
skip any connected grease point. If a grease point cannot be greased,
the whole system is blocked and grease is pressed out through the
safety valve.
The system’s first distribution block (i.e. the block closest to the pump)
has an indicator pin. If the pin moves forward and backward (in time
with the piston movements), this indicates that grease is pumped
Example figure components central lubrication through the system. If a distribution block is unable to supply grease
1. Pump unit to any of its lubrication points, the pin stops and accordingly the entire
2. Safety valve system.
3. Distribution block
If there is clogging in the system, that line will be pressurized, from the
pump to the stop, through all the distribution blocks on the way. This
makes it easy to find a block in the system. By feeling the distribution
blocks’ connections and feeling which connection is stiff, the blockage
can be traced. Keep in mind that several distribution blocks may be
connected in series.
9.14.3 Lines
Lines, description
page
–
Central lubrication works under very high pressure, only use lines that
meet the following specifications.
Main hose
Diameter 8.4 mm
9.15 Paint/coatings
Paint/coatings, description
page
–
10 Common hydraulics
10 Common hydraulics....................................................................................... 3
10.2 Safety valves .............................................................................................. 3
10.2.1 Accumulator drain valve ........................................................................ 3
10.2.2 Attachment relief valve .......................................................................... 3
10.2.3 Pressure limiting valve ........................................................................... 4
10.2.4 Pipes and hoses .................................................................................... 4
10.3 Tanks and accumulators ............................................................................ 5
10.3.1 Tank ....................................................................................................... 5
10.3.2 Pipes and hoses .................................................................................... 5
10.4 Pumps ........................................................................................................ 6
10.4.1 Gear pump with fixed displacement ....................................................... 6
10.4.2 Axial piston pump with variable displacement ....................................... 9
10.4.3 Pipes and hoses .................................................................................. 18
10.5 Hoses, pipes and valves .......................................................................... 19
10.5.1 Pipes and hoses .................................................................................. 19
10.5.2 Priority valve ........................................................................................ 20
10.5.3 Shuttle valve ........................................................................................ 20
10.5.5 Collecting block, unfiltered returns ....................................................... 21
10.6 Temperature control, cleaning and hydraulic oil ....................................... 22
10.6.1 Tank heater .......................................................................................... 25
10.6.2 Cooler hydraulic oil .............................................................................. 26
10.6.3 Cooling fan ........................................................................................... 27
10.6.4 Sensor hydraulic oil temperature ......................................................... 27
10.6.5 Cooler bypass valve ............................................................................ 29
10.6.6 Breather filter hydraulic oil tank ........................................................... 30
10.6.7 Oil filter ................................................................................................. 30
10.6.8 Hydraulic oil ......................................................................................... 32
10.6.9 Hydraulic oil fine-filter .......................................................................... 33
10.6.10 Pipes and hoses .................................................................................. 34
10.7 Auxiliaries ................................................................................................. 35
10.7.1 Hydraulic cylinders ............................................................................... 35
10 Common hydraulics
mm mm mm mm mm mm
009960
The relieve valve sits on the pressure supply to the attachment on hy-
draulic oil pump 2. See section 7 Load handling, group 7.4.7 Attach-
ment relief valve.
009961
The pressure limiting valve leads too high pressure in the hydraulic oil
supply to tank, protecting the hydraulic system against excessive
pressures.
The pressure limiting valve sits on the collecting block for pressure
supply from the load handling hydraulic oil pump and the quick-lift hy-
draulic oil pump on the hydraulics plate in front of the transmission.
009962
1 2 1 3 2 4 5 The hydraulic oil tank forms part of the side panel on the right-hand
side of the machine. The oil filters for the working hydraulics sits 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 Tech-
nical data. The entire filter unit can be removed to facilitate access for
cleaning. There is a drain plug at the bottom of the tank.
The tank has filtered venting which allows changes in the tank volume
due to usage and temperature variations.
The oil level is checked on the level glass on the tank’s side when all
hydraulic cylinders are in the bottom position.
1
008086
008087
1. Accumulator
10.4 Pumps
10.4.1 Gear pump with fixed displacement
Gear pump with fixed displacement, description
page
–
2
3
008082
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Machine in service position, see section B Safety.
2 Depressurize the hydraulic systems, See section B Safety.
3 Mark up and release the hydraulic hoses from the gear pump.
009963
009964
6 Remove the spacer ring from the gear pump or axial piston pump.
Clean the O rings’ contact surfaces on the spacer ring.
7 Check the O-rings and replace as needed. Install the O-rings on
the spacer ring. Brush heat-resistant sealing silicone on the seal-
ing face against the gear pump, see section F Technical data.
NOTE
Only use silicon on the side facing the gear pump.
NOTE
Check that the O-rings are intact and are fitted correctly.
009963
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
13 Turn on the main electric power and start the engine.
14 Check that the hose connections and seal between gear pump
and axial piston pump are airtight.
008049
NOTE
If the pump is replaced due to malfunction, change the oil
and filter as well.
16 Check the brake pressure; see section 4 Brakes, group 4.3.1 Hy-
draulic oil pump.
description
The hydraulic oil pumps that supply the working hydraulics are of the
1
2 type variable axial piston pump, and are controlled by load signals de-
pending on the flow demand from each function.
Three pumps, of which two are assembled with a junction block, sup-
ply the working hydraulics. The junction block controls oil to and from
the pumps. On the junction block, there is a spacer block that contains
test connections for checking pump pressure. There are non-return
valves on the spacer block that prevent oil from being pumped around
between the pumps instead of out in the hydraulic system. On the
3 spacer block between the quick-lift hydraulic oil pump (position 2) and
4 the load handling hydraulic pump (position 1), there is a branching to
the attachment hydraulics with a separate non-return valve. The non-
009967
return valve houses the attachment relief valve; see Attachment relief
1. Hydraulic oil pump for load handling. valve, description page 3.
2. Hydraulic oil pump for quick-lift.
3. Hydraulic oil pump for brake system, cooling and
filtering.
4. Hydraulic oil pump for steering and load handling.
function description
D790-1 D790-2
LS (21)
D797-1 D795 P
8,12,18 P (16)
LS
D8 D12 P
6 26
C 7 P
T
PS TP
5 1
P LS LSPB
EF PP
14 2 P
CF P
9 13,17,19,22 4 T LS
LS
15,20
T
23
11
24,27
C C
009148
10 16,21 3,25,28
2 The steering shuttle valve sends the - Shuttle valve, description page 20
load signal on to the hydraulic oil pump
for steering and load handling.
3 The hydraulic oil pump for steering and See pressure plate Max. Axial piston pump with variable displace-
load handling increases the flow. pressure hydraulic oil ment, description page 9
pumps on left frame
member.
4 The priority valve prioritises pressure See pressure plate Steer- Section 5 Steering, group 5.2.2 Priority valve
from the hydraulic pump for steering ing pressure, on left
and load handling to the steering valve frame member.
or the lever steering control valve over
the lift and tilt control valve.
6 Accumulator servo pressure stores the See pressure plate servo Section 7 Load handling, group 7.2.4 Accu-
servo pressure. pressure, on left frame mulator servo circuit
member.
7 The servo filter cleans the servo oil up- - Section 7 Load handling, group 7.2.2 Servo
stream of the lift and tilt control valve. filter
8 If the quick-lift conditions are fulfilled, U = 24 V Section 7 Load handling, group 7.2 Lifting/
the KDU frame control unit (D797-1) lowering
activates the solenoid valve for quick- D8: Diagnostic menu, see section 8 Control
lift engagement (Y6062). system, group 8.4.5.6 HYD, menu 6.
9 The solenoid valve for quick-lift en- - Section 7 Load handling, group 7.2.12
gagement (Y6062) opens and sends a Quick-lift valve block
load signal to the quick-lift hydraulic oil
pump.
If the conditions for quick-lift are not ful-
filled, the LS signal is directed to the
tank (quick-lift hydraulic oil pump off).
10 The quick-lift hydraulic oil pump in- See pressure plate Max. Axial piston pump with variable displace-
creases the flow. pressure hydraulic oil ment, description page 9
pumps on left frame
member.
11 The pressure limiting valve drains - Pressure limiting valve, description page 4
pressure to tank if the pressure in the
hydraulic system becomes too high.
13 The solenoid valve for main pump relief - Section 7 Load handling, group 7.4.6 Valve
(Y6062-2) routes a relieved constant block, main pump relief
pressure to the hydraulic oil pump for
load handling. This serves as a load
signal.
14 The attachment shuttle valve sends the - Shuttle valve, description page 20
load signal on to the hydraulic oil pump
for load handling.
15 The cab tilt shuttle valve sends the load - Shuttle valve, description page 20
signal on to the hydraulic oil pump for
load handling.
17 When solenoid valve for main pump re- - Section 7 Load handling, group 7.4.6 Valve
lief (Y6062-2) is not activated, the re- block, main pump relief
lieved pressure is directed to tank.
18 If cab tilt is activated, the KDU frame U = 24 V Section 11 Common electrics, group
control unit option (D797-1) activates 11.5.3.2 Frame control unit (D797-1)
the solenoid valve for main pump relief D12: Diagnostic menu, see section 8 Control
(Y6062-2). system, group 8.4.5.6 HYD, menu 6.
19 The solenoid valve for main pump relief - Section 7 Load handling, group 7.4.6 Valve
(Y6062-2) routes a relieved constant block, main pump relief
pressure to the hydraulic oil pump for
load handling. This serves as a load
signal.
20 The cab tilt shuttle valve sends the load - Shuttle valve, description page 20
signal on to the hydraulic oil pump for
load handling.
21 The hydraulic oil pump for load han- See pressure plate Max. Axial piston pump with variable displace-
dling increases the flow to the cab tilt pressure hydraulic oil ment, description page 9
control valve. pumps on left frame
member.
22 When solenoid valve for main pump re- - Section 7 Load handling, group 7.4.6 Valve
lief (Y6062-2) is not activated, the re- block, main pump relief
lieved pressure is directed to tank.
23 The steering valve sends a load signal - Section 5 Steering, group 5.2.3 Steering
when the steering wheel is turned. valve
24 The shuttle valve signal cable sends a - Shuttle valve, description page 20
load signal on to the hydraulic oil pump
for steering and load handling.
25 The hydraulic oil pump for steering and See pressure plate Steer- Axial piston pump with variable displace-
load handling increases the flow. ing pressure, on left ment, description page 9
frame member.
26 For control valve for lever steering - Section 5 Steering, group 5.2.10 Control
sends a load signal to the shuttle valve valve, mini-wheel/lever steering
when a function is activated.
27 The shuttle valve signal cable sends a - Shuttle valve, description page 20
load signal to the hydraulic oil pump for
steering and load handling.
28 The hydraulic oil pump for steering and - Axial piston pump with variable displace-
load handling increases the flow. ment, description page 9
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Operate and warm up the machine so that the hydraulic oil reach-
es operating temperature, approx. 50 °C.
2 Stop the engine
3 Connect pressure gauge to test outlet on hydraulic oil pump 1.
4 Start the engine and run it at idling speed.
5 Check the stand-by pressure for one pump at a time in the follow-
3 ing order:
2
1
Hydraulic oil pump for steering and load handling: 3.0 MPa
Hydraulic oil pump for quick-lift: 2.8 MPa
Hydraulic oil pump for load handling: 2.6 MPa
The settings apply to standard machine, certain machines can
have higher stand-by pressure. For correct stand-by pressure,
see pressure plate. However, the difference in pressure between
009965
change
NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Park the machine with the mast fully extended and spreading
halfway extended.
CAUTION
Make sure that the oil level in the hydraulic oil tank is
below the mouth of the axial piston pump’s suction
hose.
If there is not enough room to lift the mast, the hydraulic oil tank
must be drained; see Hydraulic oil, changing page 32.
2 Disconnect the main power supply.
3 Depressurize the hydraulic systems, See section B Safety.
4 Detach the gear pump from the hydraulic oil pump (see Gear
pump, changing page 6) in order to replace the pump for steering
and load handling.
5 Suspend the gear pump.
6 Use a plastic bag or similar to protect the connection on the gear
pump.
7 Mark the hydraulic hoses and disconnect them from the axial pis-
ton pump.
NOTE
Plug all unions at once to protect the hydraulic system from
contamination.
009969
CAUTION
Be careful and make sure that no gasket remains fall
down into the transmission.
NOTE
Check that the O-rings are intact and fitted correctly.
12 Apply sealing silicone on the axial piston pump flange where it
mates with the gearbox, see section F Technical data.
13 Fit the axial piston pump in place.
Place the axial piston pump so that the pump shaft engages the
transmission’s gears. Install the attaching bolts.
14 Connect the suction hose to the axial piston pump.
NOTE
Check that the O-rings are intact and fitted correctly.
009969
16 If the spacer ring is still on the axial piston pump. Remove the
spacer ring between the gear pump and axial piston pump.
If the spacer ring remains in place on the gear pump, go to step
20.
Clean the O rings’ contact surfaces on the spacer ring.
17 Check the O-rings and replace as needed. Install the O-rings on
the spacer ring. Brush sealing silicone on the sealing face against
the gear pump, see section F Technical data.
NOTE
Only use silicon on one side, the side against the brake
pump.
CAUTION
Vent the axial piston pump before starting the engine.
The illustration shows a separate pump. The oil in the axial piston pump may cavitate and
cause product damage.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
23 Turn on the main electric power and start the engine.
24 Check that the hose connections and seal between gear pump
and axial piston pump are airtight.
25 Check the pump pressures, see Hydraulic oil pump, checking
page 13.
008049
26 Check the oil level in the hydraulic oil tank. The oil level shall be
at the top of the level glass. Top up as needed.
NOTE
If the pump is replaced due to malfunction, change the oil
and filter in the hydraulic system as well.
CAUTION
Overfilling of oil.
venting
NOTE
Read the safety instructions for oil before working, see section B
Safety.
009970
3 Loosen the hoses to the hydraulic system’s feed from the axial
piston pump one at a time and let oil flow out. Tighten the connec-
tions when oil free of air flows out.
4 Remove the compressed air from the tank and fit the breather fil-
ter.
5 Turn on the main electric power and start the engine.
6 Let the engine idle for at least one minute. Check that all connec-
tions seal tight.
7 Lower the mast and raise it again very slowly so that the pump
009969
Hoses with ORFS couplings are used almost exclusively. For maxi-
mum service life and function, the following should be observed when
replacing hoses.
1. To avoid stresses in the connection, there should be a length of
straight hose after the connection.
2. The hose may not be twisted. (A twist of 7% reduces service life
by 90%.)
3. Minimise the number of bends by using correct couplings.
4. Avoid sharp bends.
5. Keep the hoses clean internally. Leave the plugs in place as long
as possible when installing.
6. Check the position of the O-rings and tighten to the correct torque,
See section F Technical data.
NOTE
Straight coupling requires a counterhold wrench to prevent
damage to the O-ring.
7. The O-rings must not be oiled when fitted.
Hose length
C/L
Hose length is measured on a laid-out hose between the sealing sur-
faces. On angled connections, measure from the sealing surface's
centre line [C/L] according to the figure.
Cleanliness
The function and service life of hydraulic components depend to a
great extent on how clean the hydraulic oil is. Therefore, it is very im-
portant to prevent dirt from entering the brake and hydraulic system.
Some simple advice to keep the hydraulic system clean.
• Always clean the area around a component before starting to
001015
work.
C/L line for measuring hose length • Plug hose connections immediately after disconnecting. If possi-
ble, use correct plugs for the connection type. If plugs are missing,
use clean plastic bags and cable ties or tape to seal the connec-
tion.
• Never reuse oil that has been drained from the machine.
• If possible, filter the oil before pouring it into the machine. Oil bar-
rels often contain impurities.
When filling hydraulic oil, fill through the caps at the hydraulic oil
filters in the tank so that the oil is filtered.
1. Chooses between the load signal from the lift and tilt control valve
and the control signal from the attachment control valve. The shut-
tle valve sends control signals on to the steering shuttle valve or
the hydraulic oil pump for steering and load handling; see Axial
piston pump with variable displacement, description page 9.
2. Chooses between the load signal from the control valve for lifting/
lower and extension and control pressure from the control valve.
The shuttle valve sends the control signal on to control the hydrau-
lic oil pump for load handling; see Axial piston pump with variable
displacement, description page 9.
3.
Chooses between the load signal from the attachment shuttle
valve (position 1) or the cab tilt control valve to the hydraulic oil
pump for steering and load handling; see Axial piston pump with
variable displacement, description page 9.
This shuttle valve is fitted if the machine is equipped with a tiltable
cab.
The block collects several return lines from different valves and leads
these directly back to the tank.
The drain lines are very sensitive to back-pressure, if pressure builds
up in the drain lines the valves will not work properly.
The block is located on the hydraulic plate in front of the transmission.
010020
function description
The oil of the hydraulic system is cooled and cleaned through circula-
tion through the radiator and filters. The radiator has a temperature-
regulated electric fan that prevents overheating.
Temperature control consists of a hydraulic oil tank, hydraulic oil
pump, hydraulic oil cooler, cooling fan, hydraulic oil filter, fine filter, hy-
draulic oil temperature sensor and bypass valve.
The hydraulic oil pump for the brake system pumps oil (from the tank)
through the brake system’s cooling circuit to be cooled in the hydraulic
oil cooler. Some of the oil is filtered by the fine filter. An electric cooling
fan increases airflow through the cooler when a temperature reduction
is needed. When the oil is cold, a bypass valve opens and leads the
oil directly to the tank so that resistance through the cooler and filter
does not become too great. The bypass valve closes when the oil gets
hot and then instead leads the oil through the cooler and filter. The
temperature sensor regulates fan activation and temperature display.
The return oil from load handling and steering is filtered through the
hydraulic oil filter in the hydraulic oil tank.
˚C
˚C
P
P
T
EF PP
14 9, 15
P D790-2
P CF D795
LS
T LS
T D797-1
L R
8, 10, 13
16
D7 D8
11 M
P T
6
2 3 4 12
1 1 1 1
5
008090
˚C 7
2 The brake oil filter cleans the oil. - See Section 4 Brakes, group 4.3.2
Brake oil filter
3 The accumulator charging valve directs oil Charge: P = 20.5 See Section 4 Brakes, group 4.3.3 Ac-
to charging of accumulators or through the ±0.5 MPa cumulator charging valve
brake system's cooling circuit. Cooling: P < 0.1 MPa
4 The oil passes through the drive axle block. - See Section 4 Brakes, group 4.3.6 Drive
axle block
5 A small amount of oil is guided through the Fine filter hydraulic oil, description page
fine filter and back to the hydraulic oil tank. 33
6 The hydraulic oil cooler cools the oil. - Hydraulic oil cooler, description page 26
7 The hydraulic oil temperature sensor - Sensor hydraulic oil temperature, de-
(B776) sends the frame control unit (D797- scription page 27
1) a voltage signal proportional to the hy- D7: Diagnostic menu, see section 8
draulic oil temperature. Control system, group 8.4.5.1 HYD,
menu 1
9 The KID control unit (D795) shows oil tem- - Section 9 Frame, body, cab and acces-
perature in the operating menu hydraulic oil sories, group 9.1 Controls and instru-
temperature. ments
10 If the hydraulic oil temperature is high, the U = 24 V Cooling fan, description page 27
frame control unit (D797-1) supplies volt- D8: Diagnostic menu, see section 8
age to the cooling fan. Control system, group 8.4.5.1 HYD,
menu 1
11 The cooling fan increases the airflow - Cooling fan, description page 27
through the hydraulic oil cooler, thus in-
creasing cooling output
12 If the pressure through the cooler is too P = 0.2 MPa Cooler bypass valve, description page
high, the thermal bypass valve opens and 29
directs the oil past the cooler
13 If the hydraulic oil temperature is too high, Checked by the control Section 11 Common electrics, group
the frame control unit (D797-1) transmits a system; error shown with 11.5.3.2 Frame control unit (D797-1)
warning for high hydraulic oil temperature error code. D8: Diagnostic menu, see section 8
on the CAN bus. Control system, group 8.4.5.1 HYD,
menu 1
14 The KIT control unit (D790-2) activates the - Section 9 Frame, body, cab and acces-
hydraulic oil temperature warning light. sories, group 9.1 Controls and instru-
ments
15 The KID control unit (D795) shows the er- Checked by the control Section 11 Common electrics, group
ror code on the display. system; error shown with 11.5.3.12 KID control unit (D795)
error code.
16 Return oil from the lift and tilt control valve - Cooler bypass valve, description page
and the attachment control valve is cleaned 29
by the oil filters in the hydraulic oil tank.
CAUTION
The tank heater is connected to high voltage. Connec-
tion and reconnection of the tank heater may only be
performed by personnel authorized for work with high
voltage.
The tank can be equipped with a heater. The tank heater is designed
for cold climates.
The tank heater runs off high current. Heater output is adapted through
different connections and adaptation to different operating voltages -
110, 230 or 400 V AC. Higher voltage generates higher heater output.
The heater is mounted in a hole in the connection cover at the bottom
of the short side of the tank.
The tank heater can be equipped with a programmable thermostat
which maintains the temperature at an even level. The thermostat is
fitted directly onto the heating element and can be adjusted with a
knob on the junction box. Recommended temperature setting is 50-
009988
70°C.
009989
NOTE
Read the safety instructions for oil before working, see section B
Safety.
2 NOTE
3 Plug all unions at once to protect the hydraulic system from
contamination.
4 Disconnect the cabling from the cooling fan.
5 Remove the attaching bolts and lift away the cooler.
6 Transfer the cooling fan to the new cooler.
7 Install the cooler.
8 Connect the cabling to the cooling fan.
009990
10 Fill the hydraulic oil tank with oil; see Hydraulic oil, changing page
32. The oil level should be visible in the sight glass.
CAUTION
The hydraulic oil level is checked with the boom com-
pletely lowered and retracted.
The electric cooling fan is suctioning. The cooling fan is located at the
rear of the cooler. The fan draws air from the machine’s outside
through the cooler. Openings in the side cover allows air to pass
through the cooler.
The cooler is supplied voltage by the rear frame control unit (D797-1)
upon activation. The cooling fan is activated when temperature of the
oil in the hydraulic oil tank is 65 °C and is deactivated when the tem-
perature is 55 °C.
The signal can be checked from the diagnostic menu, see section 8
Control system, group 8.4.5.1 HYD, menu 1.
009991
NOTE
Read the safety instructions for oil before working, see section B
Safety.
NOTE
Check that the O-rings are intact and fitted correctly.
5 Connect the cabling to the sensor.
009992
CAUTION
The hydraulic oil level is checked with the boom com-
pletely lowered and retracted.
The bypass valve protects the cooler from overpressure. The valve
opens a passage past the cooler directly to the tank if resistance in the
cooler becomes too high.
009993
NOTE
Read the safety instructions for oil before working, see section B
Safety.
IMPORTANT
Ensure cleanliness around the filter and filling point
when working on the hydraulic tank.
NOTE
Note how the bypass valve faces; the valve is marked with
an arrow.
5 Install the new bypass valve, turning the valve to face the same
way as the old. Use Loctite when fitting the bypass valve.
009993
Bypass valve
6 Fill the hydraulic oil tank with oil; see Hydraulic oil, changing page
32. The oil level should be visible in the sight glass.
IMPORTANT
The hydraulic oil level is checked with the boom com-
pletely lowered and retracted.
The oil in the hydraulic system is cleaned by two return filters located
inside the hydraulic oil tank. The oil is pumped through the cooler and
back through the filters by the cooling pump. Some of the return oil
from the load handling functions also passes through the filters.
009994
NOTE
Read the safety instructions for oil before working, see section B
Safety.
IMPORTANT
Ensure cleanliness around the filter and filling point
when working on the hydraulic tank.
NOTE
Magnetic rod
Check the hydraulic oil level with the mast fully lowered and
the side lifting attachment retracted.
NOTE
Read the safety instructions for oil before working, see section F
Technical data.
IMPORTANT
Ensure cleanliness around the filter and filling point
when working on the hydraulic tank.
The fine filter sits behind the hydraulic oil tank on the right side of the
machine. The filter is connected in parallel with the hydraulic oil filters
in the hydraulic oil tank.
Oil is pumped from the hydraulic oil tank through the fine filter and then
back to the hydraulic oil tank.
The fine filter cleans a smaller amount of oil but with a higher degree
of filtration when the machine is running.
009968
NOTE
Read the safety instructions for oil before working, see section B
Safety.
IMPORTANT
Make sure that the area around the filter is clean when
working.
10.7 Auxiliaries
10.7.1 Hydraulic cylinders
Hydraulic cylinders, repairs
page
–
CAUTION
All fault tracing should be carried out with as low a
pressure in the system as possible so that the leak-
age can be detected. High pressure causes the seals
to close tighter, which prevents detection of leaks.
1 Carefully check the source of the leakage before taking any ac-
tion. It may be possible to rectify the fault without disassembly.
2 Check for external leakage:
• At cylinder 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 an 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.
1. Piston
2. Scraper This could be due to a worn piston seal.
3. Cylinder head
4. Piston rod seal
5. O-ring with thrust ring
6. Cylinder barrel
7. Sleeve coupling
8. Welded cylinder end
9. Piston
10. Piston seal, double-acting
11. Example of weld
Dismantling of cylinders
CAUTION
Before dismantling always check that the piston rod
is clean and free from all residual paint. Also check
that connections and couplings are free from burrs
and impact marks. Make sure that the chamfer up to
the chromium surface of the piston rod is free from
burrs and residual paint.
1 Remove the cylinder from its mounting and undo the connec-
tions.
2 Plug the cylinder connections and hoses without delay.
3 If the cylinder is opened - observe the strictest cleanliness!
Inspection of surfaces
1 Inspect the sealing surfaces. Always bearing mind the function of
the seals and the type of sealing surfaces they have. See the fol-
lowing descriptions:
• O-ring groove, internal and external
• piston rod seal in the cylinder head
• sealing groove on the piston
• cylinder barrel surface
• piston rod surface. The piston rod is chromium plated with a
layer thickness of 20-50 my. Slight damage to the chromium
plating may not necessarily be the direct cause of leakage.
• all sliding surfaces (dynamic surfaces), e.g. cylinder barrel
and piston rod. These are always the hardest to seal.
CAUTION
When fitting the cylinder head:
1. Hydraulic pressure
2. The sealing lip is pressed outward toward the piston
rod
3. The sealing lip is pressed inward toward the cylin-
der head
4. Piston rod sealing surface
5. Cylinder head sealing surface
6. Screwdriver
001498
5
1. Hydraulic pressure
2. The sealing lip is pressed outward toward the piston
rod
3. The sealing lip is pressed inward toward the cylin-
der head
4. Piston rod sealing surface
5. Cylinder head sealing surface
6. Screwdriver
7. O-ring
6
4
5
001499
5
1. Hydraulic pressure
2. The sealing lip is pressed outward toward the piston
rod
3. The sealing lip is pressed inward toward the cylin-
der head
4. Piston rod sealing surface
5. Cylinder head sealing surface
6. Screwdriver
1
1. Hydraulic pressure
2. O-ring
3. Support ring
4. Cylinder head sealing surface
Scraper
øD+10
The purpose of the scraper is to scrape the piston rod clean and pre-
1 vent impurities from entering the cylinder barrel.
The scraper is fitted with a special fitting tool, which has a greater outer
diameter than the scraper so that the press force against the scraper
2 ceases right when the scraper is pressed into position. If the scraper
were to be pressed in further, the metal capsule will be deformed (see
lower illustration), which would impair the function of the scraper.
4
To prevent the scraper from bottoming in its recess in the cylinder
3 head, the recess is slightly deeper than the width of the scraper.
øD
6
001496
CAUTION
3 No tool must 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. Screwdriver
2. Scraper
3. Cylinder head
On the single-acting V-ring seal it is always the long side that seals
2
against the fixed surface and the short side that seals against the mov-
ing surface.
1 To remove, use a screwdriver to prise the seal outward and bend it up
(see illustration). It is extremely important that the screwdriver is al-
ways inserted in the V shape so that it cannot touch and thereby dam-
age a sealing surface. A mark from a screwdriver on a sealing surface
3 can have a devastating effect and cause major leakage.
6 4
002370
5
1. Hydraulic pressure
2. Seal is pressed outward towards the cylinder barrel
3. Seal is pressed inward toward the piston
4. Cylinder barrel sealing surface
5. Piston sealing surface
6. Screwdriver
The seal must always be fitted as an assembly together with the thrust
ring.
Always assemble by hand. No tools should be used as they could eas-
ily damage the surface of the piston.
For easier assembly the seal can be heated in hot water to make it
soft.
Lubricate with hydraulic oil.
002950
5 4 3 1 6 Double-acting piston seal
The double-acting seal functions with pressure from both sides, e.g. in
a steering cylinder.
All of the interior surface of the cylinder barrel is a sealing surface and
it is therefore extremely important that it is completely free from dam-
age.
Exercise care when fitting the piston in the cylinder barrel, making sure
2
002951
Assembly:
1 All double-acting piston seals are of similar design: a middle seal-
ing body. then thrust rings and farthest out guide rings.
2 First fit the sealing body, then the thrust rings and finally the guide
rings - all must be done by hand without tools to avoid damage.
11 Common electrics
11 Common electrics
mm mm mm mm mm mm
IMPORTANT
Never turn off the voltage with the battery disconnect
switch when the engine is running. This could dam-
age the alternator.
11.2.2 Fuses
Fuses, replacement
page
–
11.3 Batteries
11.3.1 Start battery
Start battery, description
page
–
WARNING
Battery electrolyte contains corrosive sulphuric acid
WARNING
Risk of explosion!
Personal injury!
WARNING
Risk of explosion if the battery short circuits (also
causes loss of capacity).
NOTE
Take great care when reconnecting the cables to prevent
short circuiting.
11.4 Alternator
11.4.1 Alternator
Alternator, description
page
–
Alternator, replacement
page
–
operation
1 2 3 4 5
D1 D3 D4 D5
D2
D793 D794
- +
D10 D9
008686
D11 D8
2 The interior lighting switch of the U = 24 V Section 9 Frame, body, cab and accessories , group
KIT control unit (D790-2) sends a 9.6.12 Interior lighting
voltage signal to the cab control D2: Diagnostic menu, see section 8 Control system,
unit (D790-1). group 8.4.2.13 LIGHTS, menu 13
3 The switch for warning lights U = 24 V Section 9 Frame, body, cab and accessories , group
(S109) sends a voltage signal to 9.6.7 Warning lights
the cab control unit (D790-1). D3: Diagnostic menu, see section 8 Control system,
group 8.4.2.5 LIGHTS, menu 5
4 When the ignition switch (S150) is U = 24 V Section 9 Frame, body, cab and accessories , group
turned to position I, it sends a volt- 9.1 Controls and instruments
age signal to the cab control unit D4: Diagnostics menu, see section 8 Control system,
(D790-1). group 8.4.1.5 CAN/POWER, menu 5
6 The cab control unit (D790-1) acti- - Cab control unit (D790-1), description page 18
vates a hold circuit, which acti-
vates the control unit’s control
logic.
7 The cab control unit (D790-1) acti- UK11:7 = 24 V Cab control unit (D790-1), description page 18
vates a redundant voltage feed to
UK11:8 = 24 V
other control units.
UK11:9 = 24 V
The cab control unit (D790-1) has
4 outputs for redundant voltage UK11:10 = 24 V
feed while other control units have
two inputs for redundant voltage
feed. In case of a malfunction of
one voltage feed the control unit is
supplied by the other feed.
8 The cab control unit (D790-1) sup- UK2:7 = 24 V Frame control unit (D797-1), description page 19
plies voltage to the control logic of D8: Diagnostic menu, see section 8 Control system,
UK2:8 = 24 V
the other control units via the re- group 8.4.1.10 CAN/POWER, menu 10
dundant voltage feed.
9 UK2:7 = 24 V Frame control unit (D797-2), description page 20
Redundant voltage feed Activated. Redundant voltage feed for control units, description of op-
eration page 7
Redundant CAN bus Communication estab- Redundant CAN bus, description page 41
lished.
- +
K315-2
1 2 K315-1
7 3, 6
D1 D2 D3 3
D794
D793
11 D11
4, 5
D8 D10
D790-1 D791 D797-2
2, 8 10
9
D795 D790-2 D797-1
008687
D9
2 When the ignition switch U = 24 V Section 9 Frame, body, cab and accessories, group 9.1
(S150) is turned to position I, Controls and instruments
it sends a voltage signal to D2: Diagnostic menu, see section 8 Control system,
the cab control unit (D790- group 8.4.1.5 CAN/POWER, menu 5
1).
3 The cab control unit (D790- U = 24 V Cab control unit (D790-1), description page 18
1) supplies voltage to igni- D3: Diagnostic menu, see section 8 Control system,
tion voltage relay K315-1 in group 8.4.1.5 CAN/POWER, menu 5
the frame electrical distribu-
tion box and ignition voltage
relay K315-2.
6 Ignition voltage relay K315- U = 24 V Engine control unit (D794), description (Volvo
2 supplies voltage to the en- TAD760VE engine) page 23
gine control unit (D794).
7 Drivetrain’s CAN-bus estab- Checked by control sys- Drivetrain CAN bus, description page 43
lishes communication. tem, error shown with
error code.
8 Ignition voltage to the cab UK1:2 = 24 V Cab control unit (D790-1), description page 18
control unit (D790-1). D8: Diagnostic menu, see section 8 Control system,
UK1:3 = 24 V
group 8.4.1.7 CAN/POWER, menu 7
UK1:4 = 24 V
9 Ignition voltage to the frame UK2:1 = 24 V Frame control unit (D797-1), description page 19
control unit (D797-1). D9: Diagnostic menu, see section 8 Control system,
UK2:9 = 24 V
group 8.4.1.10 CAN/POWER, menu 10
UK2:10 = 24 V
10 Ignition voltage to the frame UK2:1 = 24 V Frame control unit (D797-2), description page 20
control unit (D797-2). D10: Diagnostic menu, see section 8 Control system,
UK2:9 = 24 V
group 8.4.1.13 CAN/POWER, menu 13
UK2:10 = 24 V
11 Ignition voltage to the trans- UA1 = 24 V Transmission control unit (D793), description page 22
mission control unit (D793). D11: Diagnostic menu, see section 8 Control system,
group 8.4.1.12 CAN/POWER, menu 12
Emergency stop Not activated Section 9 Frame, body, cab and accessories, group 9.1 Controls and instru-
switch ments
D794
D793
D5
K3007
3, 4 6
K3009-1 K3009-2
- +
K3002
D4
D2
D7
D8
D790-1 D797-2 D797-1
1, 2, 5 7
8
D795 D790-2 D791
008688
Pos Explanation Signal description Reference
1 Ignition voltage is activated by the cab con- Checked by control Ignition voltage (15), description of opera-
trol unit (D790-1) system, error shown tion page 9
with error code.
2 The cab control unit (D790-1) supplies volt- UK3009-1/86 = 24 V Cab control unit (D790-1), description page
age to the emergency stop switch voltage 18
relay (K3009-1) in the frame electrical distri- D2: Diagnostic menu, see section 8 Control
bution box. system, group 8.4.1.6 CAN/POWER,
menu 6
3 The emergency stop switch voltage relay UK3009-2/87 = 24 V Electrical distribution box frame, descrip-
(K3009-1) supplies voltage to the emergen- tion page 16
cy stop switch voltage relay (K3009-2) in the
frame electrical distribution box.
5 The cab control unit (D790-1) activates the UK3009-2/86 = 24 V Cab control unit (D790-1), description page
emergency stop switch voltage relay 18
(K3009-2) in the electrical distribution box. D5: Diagnostic menu, see section 8 Control
system, group 8.4.1.6 CAN/POWER,
menu 6
6 The emergency stop switch voltage relay UK3009-2/87 = 24 V Electrical distribution box frame, descrip-
K3009-2 supplies voltage to emergency tion page 16
stop switch circuit.
7 The control units are suppled with emergen- Emergency stop Frame control unit (D797-2), description
cy stop switch voltage as long as emergen- switch in home posi- page 20
cy stop switch is not pressed in. tion: UK2:1 = 24 V D7: Diagnostic menu, see section 8 Control
The control unit on the attachment is only system, group 8.4.1.13 CAN/POWER,
supplied emergency stop switch voltage, menu 13
thus all attachment functions stop if the
8 Emergency stop Attachment control unit (D791), description
emergency stop switch is activated.
switch in home posi- page 21
If the emergency stop switch is pressed, ig- tion: UK2:1 = 24 V D8: Diagnostic menu, see section 8 Control
nition voltage to the cab control unit (D790-
Emergency stop system, group 8.4.1.15 CAN/POWER,
1) is cut off, thereby cutting off control cur-
switch in home posi- menu 15
rent to emergency stop switch voltage relay
K3009-1, emergency stop switch voltage re- tion: UK2:9 = 24 V
lay K3009-2, the tilt relay (K3002 ) and the Emergency stop
lift/lower relay (K3007). The power supply to switch in home posi-
the control units is cut off and the functions tion: UK2:10 = 24 V
cease.
Emergency stop
As an extra safety measure, the cab control switch in home posi-
unit (D790-1) also transmits the status of the tion: UK2:11 = 24 V
emergency stop switch the CAN bus. Thus,
functions are also cut off at the signal level.
004770
CAUTION
The max. output of the voltage converter is 12 V/20 A.
The electrical distribution box is mounted on the rear wall of the cab,
7 on the left. Located there are:
• Control unit cab (D790-1).
6 • Circuit fuses for cab battery voltage (30), ignition voltage (15) F58-
4 and circuit fuses for cab ignition voltage (15) F58-5.
• Buzzer for alarm if, for example, the operator leaves the machine
without the parking brake being applied.
• Connectors.
• Relays.
•
Voltage converter 24 V to 12 V
1 • Connector customer accessory. Output voltage 24 V, max. 10 A.
Connector 9-pin Universal mate-n-lock. For part number see
2
Spare parts catalogue.
NOTE
1. Control unit cab (D790-1) This connector is not on the machine if the machine is
2. Diagnostic socket, machine equipped with voltage converter.
3. Diagnostic socket, CAN bus, drivetrain
4. Fuse holder for circuit fuses, cab battery voltage
(30) and ignition voltage (15) F58-4 (upper) and circuit
fuses, cab ignition voltage (15) F58-5 (lower).
CAUTION
5. Voltage converter
Connector X067 is to be used to connect auxiliary
6. Termination resistor
electrical equipment. Use of other connections could
7. Connector customer accessory 24V / 10A
overload the wiring and cause product damage.
14
1. Circuit fuses, emergency stop switch voltage
(15E)F58-3
2. Circuit fuses, ignition voltage (15) F58-2
3. Circuit fuses, battery voltage (30) F58-1
4. Engine diagnostic socket, VODIA (Volvo engine)
5. Transmission diagnostic socket
6. Main fuses
7. Transmission control unit (D793)
8. Attachment connection terminal
9. Lift/lower relay K3007
10. Tilt in/out relay K3002
11. Ignition switch relay K315-2
12. Ignition switch power relay K315-1
13. Emergency stop switch power relay K3009-1
14. Emergency stop switch power relay K3009-2
-
1
-
2
- 1
3
-
4
5 -
-
6
007184
1. Termination resistor
1 2 3 4
009172
9 8 7 6
The cab control unit (D790-1) is the central control unit of the control
2 1
system. The cab control unit (D790-1) sends activation signals to other
units and controls and monitors their functions. It administrates work
in the control unit network. The control unit controls the redundant volt-
age feed and handles communication via a redundant CAN bus and
gateway for the drivetrain CAN bus. The cab control unit (D790-1) also
processes all input signals from cab controls and transmits these sig-
5 6 nals on the CAN bus.
4
3
000041
2 The cab control unit has four indicator lights that indicate the control
1. Connection terminals for fan, work lights, wind- unit’s function (see illustration).
screen wiper
2. Connection terminals, other Light 1 Green light on when there is battery voltage to the unit.
3. Light 1, battery voltage The light is physically controlled by voltage feed to the
4. Light 2, redundant voltage feed, redundant CAN control unit.
bus and power supply Light 2 Flashes green when the redundant voltage feed to the
5. Light 3, communication control units and redundant CAN bus communication
6. Light 4, fault indication are active. No power in the system.
Shines with a steady green when power electronics
and 15-voltage are supplied voltage.
The frame control unit (D797-1) processes input data from sensors
1 and sends control signals to relays and solenoid valves.
The control unit has four indicator lights that indicate the control unit’s
2
function (see illustration).
3
Light 1 Green light on when there is battery voltage to the unit.
4 The light is physically controlled by voltage feed to the
control unit.
The frame control unit (D797-2) processes input data from sensors
1 and sends control signals to relays and solenoid valves.
The control unit has four indicator lights that indicate the control unit’s
2
function (see illustration).
3
Light 1 Green light on when there is battery voltage to the unit.
4 The light is physically controlled by voltage feed to the
control unit.
The attachment control unit (D791) processes input data from sensors
1 and sends control signals to relays and solenoid valves of the side lift-
ing attachment.
2
The control unit has four indicator lights that indicate the control unit’s
3 function (see illustration).
007959
engine)
The engine control unit (D794) is part of drivetrain control and handles
1 2 3
engine function, fuel injection, etc.
The engine control unit EDC (D794) is connected via separate CAN
bus communication to the transmission, which is connected to the cab
control unit (D790-1). The cab control unit (D790-1) sends drivetrain
information on to other units.
The control unit is mounted on the engine and has no function buttons
or display. Everything is handled via the CAN bus and an external con-
trol system. The diagnostic socket for direct communication with the
engine via Volvo’s diagnostic tool VODIA is found in the frame electri-
007423
engine)
The engine control unit (D794) is part of drivetrain control and handles
engine function, fuel injection, etc.
1 The engine control unit EDC (D794) is connected via separate CAN
bus communication to the transmission, which is connected to the cab
control unit (D790-1). The cab control unit (D790-1) sends drivetrain
2 information on to other units.
The control unit is located on the engine has no function keys or dis-
play. All functions are controlled via the CAN bus and an external con-
3
trol system.
The control unit monitors the following values to optimize engine per-
formance.
4
• engine rpm
• camshaft’s position
010053
• boost pressure
1. Connector from Cummins wiring • charge-air temperature
2. Connector XD794-3 • coolant temperature
3. Connector from Cummins wiring
4. Connector XD794-3 • oil pressure
• water in fuel
• fuel pressure
• coolant level
The data gives exact information about the operating conditions and
makes it possible for the control unit to, for example, calculate the cor-
rect fuel volume and to check the condition of the engine.
CAUTION
Each control unit is individually calibrated to the en-
gine in question. Switching of control units between
engines is absolutely forbidden.
The KIT control unit (D790-2) handles functions for the gear selector
1 2
and multi-function lever, the direction indicator switch and start key po-
sitions II and III. It also handles the key panel (2) for the control system
and its panel for warning and indicator lights (1).
The KIT control unit (D790-2) has several individual function keys and
indicator lights (see illustration).
See the operator’s manual for detailed information on warning and in-
dicator lights and function keys.
000049
The KID control unit (D795) displays to the operator information sent
1 2 by the control unit, such as speed, in the form of messages, status, er-
ror indications, etc.
There is an indicator light to the right of the display that is activated
with a red light when there is a serious malfunction in the control sys-
tem. The error code and information are shown on the display.
See the operator’s manual for detailed information on the display.
000051
1. LCD display
2. Series of diodes that constitute the indicator light for
a serious fault.
11.5.5 Cables
Connectors, overview
page
–
The list includes all connectors on the machine with a brief description
of their locations and to which functions the signals in them are related.
X050 Electrical distribution box cab RS232 Control unit cab (D790-1)
X061 Electrical distribution box cab Earth connection, Control unit KID (D795)
Power supply, Control unit KIT (D790-2)
X168 Electrical distribution box frame Power supply attachment control unit
X201 Electrical distribution box frame Earth connection and power supply, Control unit transmission (D793)
X209 Front edge of frame Power supply, cab control unit (D790-1)
CAN bus, frame control unit (D797-1)
CAN bus, frame control unit (D797-2)
CAN bus, attachment control unit (D791)
X210 Between engine and gearbox Power supply and earth connection, Control unit engine (D794)
CAN bus, Control unit engine (D794)
X211 Frame control unit (D797-1) 42-pin connector to frame control unit (D797-1)
X214 Front edge of frame CAN bus, frame control unit (D797-2)
CAN bus, attachment control unit (D791)
X215 Electrical distribution box frame Power supply attachment control unit
X221 Frame control unit (D797-2) 42-pin connector to frame control unit (D797-2)
X222 Frame control unit (D797-2) Power supply and ground connection, frame control unit (D797-2)
CAN bus, frame control unit (D797-2)
Emergency stop switch voltage
X252 Control unit transmission (D793), 18-pin connector for Transmission control unit (D793)
electrical distribution box frame
X261 Electrical distribution box frame RS232 Control unit transmission (D793)
X279 Engine control unit (D794) Power supply and earth connection, Control unit engine (D794)
CAN-bus Drivetrain
X400 Attachment control unit (D791) Power supply and ground connection, attachment control unit (D791)
X401 Attachment control unit (D791) CAN bus, attachment control unit
X421 Attachment control unit (D791) 42-pin connector for Control unit attachment (D791)
X422 Attachment control unit (D791) Power supply and earth connection, Control unit attachment (D791)
CAN bus Control unit attachment option (D791)
Emergency stop switch voltage
Analogue inputs
Rheostat Resistance input 0–200 Ω. Linear work range with accuracy of 3%. E.g. fuel level sensor.
Temperature Rheostat input with non-linear work area. The resistance value is equiva- E.g. hydraulic oil temper-
lent to temperature and the work range of approx. -40 to 150 °C. ature sensor and climate
There are two different resistance curves - one for the cab control unit control system tempera-
(D790-1) and one for the frame and attachment control units. ture sensor.
Voltage An analogue signal 0–5 V. The work range is 0.5 to 4.5 V. E.g. accelerator pedal
and analogue cab con-
trols (operating lever and
heater controls).
Analogue outputs
Current feedback A modulated signal between 0 V and system voltage, i.e. 24 V. The work Hydraulics, e.g. lifting/
voltage out, PWM range is 0 to 2 A. lowering of the boom.
A modulated signal is a digital signal translated to an analogue (continu- Used when the output
ous) signal adapted for a purpose, such as solenoid valve control. signal actuates propor-
When the spool in a solenoid valve gets hot, resistance drops. This gen- tional solenoid valves.
erates a lower current through the valve spool, which can cause the
valve’s servo pressure to remain constant. An internal ampermeter meas-
ures current in the circuit and regulates the voltage level in order to main-
tain the desired current value in the valve spool.
Voltage out, PNP A modulated signal between 0 V and system voltage, i.e. 24 V. Requires E.g. interior lighting and
PWM a grounding point as reference. background illumination
in switches.
Voltage out, re- A modulated signal between 0 V and system voltage, i.e. 24 V. Requires E.g. cab fan.
versed polarity, 24 V as reference.
NPN PWM
Digital inputs
Digital input signal Signal in, U < 5 V generates logic zero (0) E.g. input signal from a
with pull down and Signal in, U > 16 V generates logic one (1) breaker with search light-
search lighting ing.
If there is no signal in, the input is grounded.
Digital input signal Signal in, U < 5 V generates logic zero (0) E.g. position sensors (in-
with pull down Signal in, U > 12 V generates logic one (1) ductive sensors) and
brake pressure (pressure
If there is no signal in, the input is grounded. switches).
Bandwidth 300 Hz, i.e. designed for slow sensors.
Digital outputs
High side driver, Logic one (1) generates voltage out, U >= 22.5 V E.g. side marker lights,
1.5 A Max. load 1.5 A solenoid valves.
High side driver, 5 Logic one (1) generates voltage out, U >= 22.5 V E.g. work lighting and
A Max. load 5 A wiper motors.
High side driver, Logic one (1) generates voltage out, U >= 22.5 V E.g. cooling fan.
10 A Max. load 10 A This output is only found
Open load 1.9 A on the frame and attach-
ment control units.
Max. instantaneous current load, 70 A
H-bridge Logic one (1) generates voltage out, U >= 22.5 V or grounded output, E.g. climate control sys-
U=0V tem water valve (works in
Max. load 0.5 A both directions).
11.6 Communication
11.6.1 CAN-bus
CAN bus, description
page
–
a sharp signal.
• that the signal valve is given as the potential difference between
3 the cables, CAN + and CAN - (position 2 and 3).
000026
t [S]
• form of signal messages.
Messages run in time and signal goes high (voltage
high) or low (voltage low).
1. Termination resistor (120 ohm)
2. CAN + (voltage high)
3. CAN - (voltage low)
4. Pulse
5. Control unit
Message
There are two types of messages:
A
• CAN Standard, has identity field of 11 bits
• CAN Extended, has identity field of 29 bits
plete message is approx. 100 bits long. The illustration depicts how a
t [S]
message is structured.
Messages run in time and signal goes high (voltage
high) or low (voltage low). Start bit (B)
A. Length message Indicates that the transmission of a frame, i.e. a message, is now be-
B. Start bit ginning.
C. Identity field/Priority Identity field (C)
D. Control field (length of data segment)
Indicates what kind of information the message contains, e.g. meas-
E. Data segment
urement information on engine speed.
F. Checksum for error detection
G. Acknowledge bit Does not indicate address to control unit. CAN does not work with ad-
dressing. All control units receive messages and send them on.
Communication
The CAN network consists of control units and segment. The segment
(bus) is a twisted pair cable that leads CAN + and CAN - signal levels
from control unit to control unit.
Each control unit measures the potential difference of its two inputs.
3,5 V The potential difference generates logic zero and logic one. The illus-
tration depicts an approved interval according to the standard for po-
tential levels. CAN + has a recommended value of 3.5 V and CAN -
U [V]
t [S] receipt (sets an acknowledge bit). The transmitting control unit then
knows that the message has been received by at least one control
Potential levels CAN + and CAN -
unit.
One control unit at a time sends the message. Other control units lis-
ten and wait until the bus is available. If two messages are to be sent
simultaneously then the sending of the message with the lowest prior-
ity (highest value in identity field) is concluded. This means that mes-
sages do not need to be re-sent in the event of a communication
conflict but only in the event of a bus error (erroneous message).
The CAN bus exchanges around 100 messages per second in the net-
work.
Different bus systems can be used e.g. random sending or primary
(master) / secondary (slave),
D797-2 D797-1
D795
in a loop.
Segment numbering with optional equipment without The redundant CAN bus can handle the loss of a segment. The link is
cab tilt analysed upon start-up. If a segment is faulty, messages are sent via
another route.
If several segments are lost, one or more control units lose communi-
cation and work independently, often with significantly limited function-
ality.
CAN bus faults are indicated with an error code and a warning in the
display. If several CAN bus segments are faulty, the system only
shows an error code for the first faulty out segment.
Redundant voltage feed Activated. Redundant voltage feed for control units, description of operation page 7
2 1, 7 5
S2
D790-2
6
3 4
009754
D797-2 S3 D797-1
2 The attachment control unit (D791) A clicking sound is audi- Attachment control unit (D791), description
sends a response back on the CAN bus ble when then termina- page 21
via CAN L and sends the request on via tion resistor is activated. Diagnostic menu, see section 8 Control sys-
CAN R. tem, group 8.4.1.1 CAN/POWER, menu 1
Termination resistors in the control and 8.4.1.2 CAN/POWER, menu 2
nodes ensure communication segment
by segment.
3 The frame control unit (D797-2) sends a A clicking sound is audi- Frame control unit (D797-2), description
response back on the CAN bus via CAN ble when then termina- page 20
L and sends the request on via CAN R. tion resistor is activated. Diagnostic menu, see section 8 Control sys-
Termination resistors in the control tem, group 8.4.1.1 CAN/POWER, menu 1
nodes ensure communication segment and 8.4.1.2 CAN/POWER, menu 2
by segment.
4 The frame control unit (D797-1) sends a A clicking sound is audi- Frame control unit (D797-1), description
response back on the CAN bus via CAN ble when then termina- page 19
L and sends the request on via CAN R. tion resistor is activated. Diagnostic menu, see section 8 Control sys-
Termination resistors in the control tem, group 8.4.1.1 CAN/POWER, menu 1
nodes ensure communication segment and 8.4.1.2 CAN/POWER, menu 2
by segment.
6 The KIT control unit (D790-2) is not con- A clicking sound is audi- KIT control unit (D790-2), description page
nected to the redundant CAN bus. The ble when then termina- 25
KIT control unit (D790-2) does not com- tion resistor is activated.
municate until ignition voltage (15) is ac-
tivated.
7 If all control units have responded, the Checked by control sys- Diagnostic menu, see section 8 Control sys-
cab control unit (D790-1) deactivates tem, error shown with er- tem, group 8.4.1.1 CAN/POWER, menu 1
the segment to the attachment control ror code. and 8.4.1.2 CAN/POWER, menu 2
unit (D791).
If a control unit has not responded, the
cab control unit (D790-1) uses both
CAN L and CAN R to keep communica-
tion open and analyses which segment
is faulty.
The drivetrain CAN bus is based on the SAE J1939 standard where
4 6
selected messages are used to control engine and transmission.
SAE J1939 is a standard from SAE (Society of Automotive Engineers)
for data communication in vehicles. The standard regulates hardware
interface, bit times and message composition.
D790-1 3 5
The engine and transmission control units come from the respective
engine and transmission suppliers.
The machine uses only one model of gearbox, but there are several
engine alternatives. All engine alternatives use the standard, therefore
the messages are based on the same structure regardless of which
engine is used.
Communication with engine control unit (D794) and transmission con-
trol unit (D793) are separate from the redundant CAN bus.
The signals can be checked from the diagnostic menu, see section 8
Control system, group 8.4.1.4 CAN/POWER, menu 4.
000033
1 2
1. Redundant CAN bus
2. CAN bus drivetrain
3. Engine control unit (D794)
4. Engine
5. Transmission control unit (D793)
6. Gear box
description
The machine has three or four sockets for communication between
control units and PC. Two are located in electrical distribution cab and
1
one or two in electrical distribution cab frame. It is the socket for com-
munication with engine alternative Volvo that varies.
2 Sockets for programming control units in electrical distribution box cab
(position 1) are used for programming the control units in the cab, on
the frame, and on the attachment.
Socket for drivetrain CAN bus in the electrical distribution box cab (po-
sition 2) is used for communicating with the engine and transmission
via CAN bus.
The VODIA socket in the frame electrical distribution box (position 3)
is used to connect Volvo’s VODIA diagnostic tool.
The socket for transmission control unit (D793) programming in the
frame electrical distribution box (position 4) is used to program the
transmission control unit (D793).
For further details on communication between computer and machine,
3 contact Kalmar Industries AB.
4
010054
007443
the machine, antenna for communication and GPS-antenna ( ) for
positioning.
RMI-interface
The interface records the communication on the CAN-bus and sends
the information to a central RMI-server. The control unit in the machine
can sends the information via GSM, GPRS, WLAN, Radio-modem,
SMS, or e-mail in case of a malfunction.
From the RMI-server, data from the machine can be analysed and
processed to read out different values. For example, when it is time for
service or if there are error codes stored in the machine.
NOTE
RMI only sends data from the machine, no data can be sent to
the machine. RMI cannot be used to control the machine.
D Error codes
Error codes
mm mm mm mm mm mm
The error codes are explained in table form for Engine, Transmission
as well as Control system. They are sorted according to error code
number.
The error code table has the following information:
• Code, error code's number, shown in field C on display.
C
• Description, explanation of the error code and when it's generat-
D E ed.
• Limitation, in case of certain error codes certain functions are im-
B
000389
The control system’s display is divided into four fields that show infor-
C mation (see figure to the left).
000389
• Field D: Indicates type of error.
• Field E: Indicates which function is affected by error code.
• The book symbol means that there's information in the operator's
manual.
• Warning
C Indicates machine malfunction that should be taken care of as
soon as possible. After finished work shift with the machine, con-
D E
tact service as soon as possible.
The error code is shown automatically on the display.
000351
• Information
C Information to the operator that something should be fixed, e.g.,
broken bulb. Fix the cause of the error code as soon as possible.
D E See section 6 Inspection and maintenance in the Operator’s man-
ual.
000352
The error code is stored in the error code list under operating
menu for service.
000389
• Engine:
C Shown with error code number XXX/YY on display.
D
NOTE
B If several error codes come from the engine, the error code
001343
• Transmission:
C Shown with error code number XX/YY on display.
B
001344
7
000396
NOTE
In case of an error code, perform the actions recommended in the
error code table to find the problem.
Error codes are stored as active and inactive. Active errors are
shown in the error code menu.
Always use error code menus for reading out error codes, other-
wise there is a risk of missing error codes.
WARNING
Risk of machine damage.
3 Safety menu is shown. Hold Enter depressed for at least two sec-
onds.
1 23
4 5
000060
4 The error code list is shown on the display. Active error code is
shown on display where field C shows error code number togeth-
er with X(Y). X shows sequence number for shown error code
and (Y) shows number of active error codes.
Scroll between error codes with key 1 and 2 (arrow function).
001998
Error codes disappear from the list when the cause has been
remedied.
000389
• Function affected by the error is shown with a symbol in field
E
The book symbol is an instruction for the operator to read the
operator’s manual.
6 Use the error code tables to find more information about the error
code.
7 After action, check that no active error codes remain for the func-
tion in question.
1 Engine
mm mm mm mm mm mm
1 Too low value. Valid data, but lower than normal operating range.
15 Too high value. Data valid but above normal operating range - Least severe level
16 Too high value. Data valid but above normal operating range - Moderately severe
level
17 Too low value. Data valid but below normal operating range - Least severe level
18 Too low value. Data valid but below normal operating range - Moderately severe
level
84 / 10 P084 / Machine Speed Sensor Cir- Engine speed limit- Check cabling D794 ENGINE,
10 cuit Tampering Has Been ed to Maximum En- between con- menu 2
Detected - Abnormal Rate of gine Speed without trol unit and
Change. Invalid or inappro- VSS parameter val- component.
priate machine speed signal. ue. Cruise control, Check the sen-
Signal indicates an intermit- Gear-Down Protec- sor.
tent connection or VSS tam- tion, and Road
pering. Speed Governor
will not work.
100 / 1 P100 / 1 Engine Oil Rifle Pressure - Progressive power Check oil level - ENGINE,
Data Valid but Below Normal derate increasing in in the engine, menu 6
Operational Range - Most severity from time top up as need-
Severe Level. Oil pressure after alert. If the En- ed.
signal indicates oil pressure gine Protection
is below the engine protec- Shutdown feature is
tion critical limit. enabled, engine will
shut down 30 sec-
onds after the red
STOP lamp starts
flashing.
100 / 2 P100 / 2 Oil Pressure Switch Sensor None on perform- Check cabling D794 ENGINE,
Circuit - Data Erratic, Inter- ance. No engine between con- menu 6
mittent or Incorrect. An error protection for oil trol unit and
in the engine oil pressure pressure. component.
switch signal was detected Check the sen-
by the ECU 794. sor.
100 / 4 P100 / 4 Oil Pressure Sensor Circuit - None on perform- Check cabling D794 ENGINE,
Voltage Below Normal, or ance. No engine between con- menu 6
Shorted to Low Source. Low protection for oil trol unit and
signal voltage detected at pressure. component.
the engine oil pressure cir- Check the sen-
cuit. sor.
100 / 18 P100 / 1 Engine Oil Rifle Pressure - None on perform- Check oil level - ENGINE,
Data Valid but Below Normal ance. in the engine, menu 6
Operational Range - Moder- top up as need-
ately Severe Level. Engine ed.
oil pressure signal indicates
engine oil pressure is below
the engine protection warn-
ing limit.
102 / 2 P102 /2 Intake Manifold Pressure Engine power der- Check cabling D794 ENGINE,
Sensor Circuit - Data Erratic, ate. between con- menu 6
Intermittent or Incorrect. The trol unit and
ECU 794 has detected an in- component.
take manifold pressure sig- Check the sen-
nal that is too high or low for sor.
current engine operating
conditions.
102 / 2 P102 /2 Intake manifold pressure Derate in power Check cabling D794 ENGINE,
sensor circuit - data incor- output of the en- between con- menu 6
rect. An error in the intake gine. trol unit and
manifold pressure sensor component.
signal was detected by the Check the sen-
ECU 794. sor.
102 / 3 P102 / 3 Intake Manifold Pressure Derate in power Check cabling D794 ENGINE,
Sensor Circuit - Voltage output of the en- between con- menu 6
Above Normal or Shorted to gine. trol unit and
High Source. High signal component.
voltage detected at the in- Check the sen-
take manifold pressure cir- sor.
cuit.
103 / 16 P103 / 0 Turbocharger Number 1 Engine power der- Check the D794 -
speed high - warning level. ate. The ECU 794 component
High turbocharger speed uses an estimated
has been detected. turbocharger
speed.
103 / 18 P103 / 1 Turbocharger number 1 Engine power der- Check the D794 -
speed low - warning level. ate. The ECU 794 component
Low turbocharger speed de- uses an estimated
tected by the ECU 794. turbocharger
speed.
105 / 0 P105 / 0 Intake Manifold 1 Tempera- Progressive power Check the - ENGINE,
ture - Data Valid but Above derate increasing in coolant level in menu 7
Normal Operational Range - severity from time the engine, top
Most Severe Level. Intake after alert. If the En- up as needed.
manifold air temperature sig- gine Protection Check that the
nal indicates intake manifold Shutdown feature is charge-air
air temperature above en- enabled, engine will cooler is clean,
gine protection critical limit. shut down 30 sec- clean as need-
onds after the red ed.
STOP lamp starts
Check that fan
flashing.
belts are intact.
Check the sen-
sor.
105 / 3 P105 / 3 Intake Manifold Air Temper- Possible white Check cabling D794 ENGINE,
ature Sensor Circuit - Volt- smoke. Fan will stay between con- menu 7
age Above Normal or ON if controlled by trol unit and
Shorted to High Source. the ECU 794. No component.
High signal voltage detected engine protection Check the sen-
at intake manifold air tem- for intake manifold sor.
perature circuit. air temperature
105 / 15 P105 / 0 Intake Manifold Tempera- Progressive power Check the D794 ENGINE,
ture High - Data Valid but derate increasing in coolant level in menu 7
Above Normal Operational severity from time of the engine, top
Range - Least Severe Level. alert. up as needed.
Intake manifold air tempera- Check that the
ture signal indicates intake charge-air
manifold air temperature cooler is clean,
above engine protection clean as need-
warning limit. ed.
Check that fan
belts are intact.
Check the sen-
sor.
108 / 2 P108 / 2 Barometric pressure: Data Engine power der- Check cabling - -
erratic, intermittent, or incor- ate. between con-
rect. The ambient air pres- trol unit and
sure sensor reads an erratic component.
value upon activation. Check the sen-
sor.
108 / 3 P108 / 3 Barometric Pressure Sensor Engine power der- Check cabling D794 -
Circuit - Voltage Above Nor- ate. between con-
mal, or Shorted to High trol unit and
Source. High signal voltage component.
detected at barometric pres- Check the sen-
sure circuit. sor.
108 / 4 P108 / 4 Barometric Pressure Sensor Engine power der- Check cabling D794 -
Circuit - Voltage Below Nor- ate. between con-
mal, or Shorted to Low trol unit and
Source. Low signal voltage component.
detected at barometric pres- Check the sen-
sure circuit. sor.
110 / 2 P110 / 2 Engine Coolant Tempera- The ECU 794 will Check cabling D794 ENGINE,
ture - Data Erratic, Intermit- estimate engine between con- menu 7
tent, or Incorrect. The coolant tempera- trol unit and
engine coolant temperature ture. component.
reading is not changed with Check the sen-
engine operating conditions. sor.
110 / 3 P110 / 3 Engine Coolant Tempera- Possible white Check cabling D794 ENGINE,
ture 1 Sensor Circuit - Volt- smoke. Fan will stay between con- menu 7
age Above Normal or ON if controlled by trol unit and
Shorted to High Source. ECU 794. No en- component.
High signal voltage or open gine protection for Check the sen-
circuit detected at engine engine coolant tem- sor.
coolant temperature circuit. perature.
110 / 4 P110 / 4 Engine Coolant Tempera- Possible white Check cabling D794 ENGINE,
ture 1 Sensor Circuit - Volt- smoke. Fan will stay between con- menu 7
age Below Normal or ON if controlled by trol unit and
Shorted to Low Source. Low ECU 794. No en- component.
signal voltage detected at gine protection for Check the sen-
engine coolant temperature engine coolant tem- sor.
circuit. perature.
110 / 16 P110 / 0 Engine Coolant Tempera- Progressive power Check coolant D794 ENGINE,
ture - Data Valid but Above derate increasing in level. menu 7
Normal Operational Range - severity from time of Check that ra-
Moderately Severe Level. alert. diator is clean.
Engine coolant temperature
Check if there’s
signal indicates engine cool-
air in coolant
ant temperature is above en-
system.
gine protection warning limit.
Check the cap
on the expan-
sion tank.
Check the sen-
sor.
Check thermo-
stat.
111 / 1 P111 / 1 Coolant Level - Data Valid Progressive power Check the - -
but Below Normal Opera- derate increasing in coolant level,
tional Range - Most Severe severity from time top up if need-
Level. Low engine coolant after alert. If the en- ed.
level detected. gine protection Check the sen-
shutdown feature is sor.
enabled, engine will
shut down 30 sec-
onds after the red
STOP lamp starts
flashing.
111 / 4 P111 / 4 Coolant Level Sensor Circuit None on perform- Check cabling D794 -
- Voltage Below Normal or ance. between con-
Shorted to Low Source. Low trol unit and
signal voltage detected at component.
the engine coolant level cir- Check the sen-
cuit. sor.
157 / 2 P157 / 2 Injector Metering Rail 1 The ECU 794 will - D794 -
Pressure - Data Erratic, In- estimate fuel pres-
termittent, or Incorrect. the sure, and power is
ECU 794 has detected that reduced.
the fuel pressure signal is
not changing.
167 / 1 P167 / 1 Electrical Charging System Warning lamp illu- Check batter- D794 -
Voltage Low - Data Valid but minated until very ies and alterna-
Below Normal Operational low battery voltage tor.
Range - Most Severe Level. condition is correct-
Very low battery voltage de- ed.
tected by the battery voltage
monitor feature.
167 / 16 P167 / 0 Electrical Charging System Amber warning Check fuses. D794 -
Voltage High - Data Valid lamp illuminated un- Check batter-
but Above Normal Opera- til high battery volt- ies and alterna-
tional Range - Moderately age condition is tor.
Severe Level. High battery corrected.
voltage detected by the bat-
tery voltage monitor feature.
167 / 18 P167 / 1 Electrical Charging System Amber lamp will Check batter- D794 -
Voltage Low - Data Valid but light until low bat- ies and alterna-
Below Normal Operational tery voltage condi- tor.
Range - Moderately Severe tion is corrected.
Level. Low battery voltage
detected by the battery volt-
age monitor feature.
168 / 16 P168 / 0 Battery 1 Voltage - Data Val- Possible electrical Check fuses. D794 -
id but Above Normal Opera- damage to all elec- Check batter-
tional Range - Moderately trical components. ies and alterna-
Severe Level. ECU 794 sup- tor.
ply voltage is above the
maximum system voltage
level.
190 / 0 P190 / 0 Engine Crankshaft Speed/ Fuel injection disa- Ease off throt- - -
Position - Data Valid but bled until engine tle or select
Above Normal Operational speed fails below higher gear.
Range - Most Severe Level. the overspeed limit.
Engine speed signal indi-
cates engine speed above
engine protection limit.
190 / 2 P190 / 2 Engine Crankshaft Speed/ Engine can exhibit Check cabling D794 -
Position - Data Erratic, Inter- misfire as control between con-
mittent, or Incorrect. Crank- switches from the trol unit and
shaft engine speed sensor primary to the back- component.
intermittent synchronization. up speed sensor. Check the sen-
Engine power is re- sor.
duced while the en-
gine operates on
the backup speed
sensor.
190 / 2 P190 / 2 Engine Crankshaft Speed/ Engine can run Check cabling D794 -
Position - Data Erratic, Inter- rough. Possibly between con-
mittent, or Incorrect. Loss of poor starting capa- trol unit and
signal from crankshaft sen- bility. Engine runs component.
sor. using backup speed Check the sen-
sensor. Engine sor.
power is reduced.
441 / 3 P441 / 3 Auxiliary Temperature Sen- None on perform- Check cabling D794 -
sor Input 1 - Voltage Above ance. between con-
Normal, or Shorted to High trol unit and
Source. High signal voltage component.
or open circuit detected at Check the sen-
the OEM auxiliary tempera- sor.
ture circuit.
441 / 4 P441 / 4 Auxiliary Temperature Sen- None on perform- Check cabling D794 -
sor Input 1 Circuit - Voltage ance. between con-
Below Normal, or Shorted to trol unit and
Low Source. Low signal volt- component.
age detected at OEM auxil- Check the sen-
iary temperature circuit. sor.
558 / 2 S230 / 2 Accelerator Pedal or Lever Engine will only idle. Check cabling D794 -
Idle Validation Circuit - Data between con-
Erratic, Intermittent or Incor- trol unit and
rect. Voltage detected simul- component.
taneously on both idle Check compo-
validation and off-idle valida- nent.
tion switches.
558 / 4 S230 / 4 Accelerator Pedal or Lever Engine will only idle. Check cabling D794 -
Idle Validation Circuit - Volt- between con-
age Below Normal or Short- trol unit and
ed to Low Source. No component.
voltage detected simultane- Check compo-
ously on both the idle valida- nent.
tion off-idle and on-idle
circuits.
558 / 13 S230 / Accelerator Pedal or Lever Engine will only idle. Check cabling D794 -
13 Idle Validation Circuit - Out between con-
of Calibration. Voltage at idle trol unit and
validation on-idle and off-idle component.
circuit does not match accel- Check compo-
erator pedal position. nent.
611 / 3 S232 / 3 Sensor Supply Voltage 4 Engine will only idle. - D794 -
Circuit - Voltage Above Nor-
mal or Shorted to High
Source. High voltage detect-
ed at +5 volt sensor supply
circuit to the accelerator
pedal position sensor.
611 / 4 S232 / 4 Sensor Supply Voltage 4 Engine will only die. - D794 -
Circuit - Voltage Below Nor-
mal or Shorted to Low
Source. Low voltage detect-
ed at +5 VDC sensor supply
circuit to the accelerator
pedal position sensor.
627 / 2 S251 / 2 Power Supply Lost With Ig- Possible no notice- Check fuses. D794 -
nition On - Data Erratic, In- able performance Check batter-
termittent or Incorrect. effects or engine ies and alterna-
Supply voltage to the ECU dying or hard start- tor.
794 fell below 6.2 VDC mo- ing. Fault informa-
mentarily, or the ECU 794 tion, trip
was not allowed to power information, and
down correctly (retain bat- maintenance moni-
tery voltage for 30 seconds tor data can be in-
after key OFF). accurate.
627 / 2 S254 / Injector Power Supply - Bad Possible smoke, Check fuses. D794 -
12 Intelligent Device or Compo- low power, engine Check batter-
nent. The ECU 794 meas- misfire, and/or en- ies and alterna-
ured injector boost voltage is gine will not start. tor.
low.
629 / 12 S254 / Engine Control Module - crit- Engine may not Check the con- D794 -
12 ical internal failure. Error in- start. trol unit
ternal to the ECU 794
related to memory hardware
failures or internal ECU 794
voltage supply circuits.
629 / 12 S254 / Engine Control Module No performance ef- Check the con- D794 -
12 Warning Internal Hardware fects or possible se- trol unit
Failure - Bad Intelligent De- vere power derate.
vice or Component.
639 / 9 S231 / 9 SAE J1939 Multiplexing One or more multi- Use diagnostic - CAN/POW-
PGN Timeout Error - Abnor- plexed devices will menu to find in- ER, menu
mal Update Rate. The Cum- not operate proper- correct seg- 2
mins ECU 794 did not ly. One or more ment.
receive a multiplexed mes- symptoms will occur
sage from an OEM VECU
within the time limit or did not
receive it at all.
639 / 13 S231 / SAE J1939 Multiplexing At least one multi- Use diagnostic - CAN/POW-
13 Configuration Error - Out of plexed devices will menu to find in- ER, menu
Calibration. The ECU 794 not operate proper- correct seg- 2
expected information from a ly. ment.
multiplexed device but only
received a portion of the
necessary information.
641 / 4 S027 / 4 VGT actuator driver circuit - Possible low power. - D794 -
voltage below normal, or Power removed
shorted to low source. from the turbo-
charger actuator
motor.
647 / 3 S033 / 3 Fan Control Circuit - Voltage The fan may stay on Check cabling D794 -
Above Normal or Shorted to continuously or not between con-
High Source. Open circuit or run at all. trol unit and
high voltage detected at the component.
fan control circuit. Check compo-
nent.
647 / 4 S033 / 4 Fan Control Circuit - Voltage The fan may stay on Check cabling D794 -
Below Normal or Shorted to continuously or not between con-
Low Source. Low signal volt- run at all. trol unit and
age detected at the fan con- component.
trol circuit when commanded Check compo-
on. nent.
651 / 5 S001 / 5 Injector Solenoid Driver Cyl- Engine can misfire Check cabling D794 -
inder 1 Circuit - Current Be- or possibly run between con-
low Normal, or Open Circuit. rough. trol unit and
High resistance or no cur- component.
rent detected at Number 1 Check the in-
injector DRIVER or RE- jector.
TURN pin.
652 / 5 S002 / 5 Injector Solenoid Driver Cyl- Engine can misfire Check cabling D794 -
inder 2 Circuit - Current Be- or possibly run between con-
low Normal, or Open Circuit. rough. trol unit and
High resistance or no cur- component.
rent detected at Number 2 Check the in-
injector driver or return pin. jector.
652 / 7 S002 / 7 Injector Solenoid Driver Cyl- Engine will shut Check cabling D794 -
inder 2 - Mechanical System down. between con-
Not Responding Properly or trol unit and
Out of Adjustment. Unin- component.
tended fueling detected in Check the in-
cylinder number 2. jector.
653 / 5 S003 / 5 Injector Solenoid Driver Cyl- Engine can misfire Check cabling D794 -
inder 3 Circuit - Current Be- or possibly run between con-
low Normal, or Open Circuit. rough. trol unit and
High resistance or no cur- component.
rent detected at Number 3 Check the in-
injector or return pin. jector.
653 / 7 S003 / 7 Injector Solenoid Driver Cyl- Engine will shut Check cabling D794 -
inder 3 - Mechanical System down. between con-
Not Responding Properly or trol unit and
Out of Adjustment. Unin- component.
tended fueling detected in Check the in-
cylinder number 3. jector.
654 / 5 S004 / 5 Injector Solenoid Driver Cyl- Engine can misfire Check cabling D794 -
inder 4 Circuit - Current Be- or possibly run between con-
low Normal or Open Circuit. rough. trol unit and
High resistance or no cur- component.
rent detected at Number 1 Check the in-
injector driver or return pin. jector.
655 / 5 S005 / 5 Injector Solenoid Driver Cyl- Engine can misfire Check cabling D794 -
inder 5 Circuit - Current Be- or possibly run between con-
low Normal, or Open Circuit. rough. trol unit and
High resistance or no cur- component.
rent detected at Number 5 Check the in-
injector DRIVER or RE- jector.
TURN pin.
655 / 7 S005 / 7 Injector Solenoid Driver Cyl- Engine will shut Check cabling D794 -
inder 5 - Mechanical System down. between con-
Not Responding Properly or trol unit and
Out of Adjustment. Unin- component.
tended fueling detected in Check the in-
cylinder Number 5. jector.
656 / 5 S006 / 5 Injector Solenoid Driver Cyl- Engine can misfire Check cabling D794 -
inder 6 Circuit - Current Be- or possibly run between con-
low Normal, or Open Circuit. rough. trol unit and
High resistance or no cur- component.
rent detected at Number 6 Check the in-
injector driver or return pin. jector.
656 / 7 S006 / 7 Injector Solenoid Driver Cyl- Engine will shut Check cabling D794 -
inder 6 - Mechanical System down. between con-
Not Responding Properly or trol unit and
Out of Adjustment. Unin- component.
tended fueling detected in Check the in-
cylinder Number 6. jector.
677 / 3 S39 / 3 Starter Relay Circuit - Volt- Either the engine Check cabling D794 ENGINE,
age Above Normal or Short- will not start or the between con- menu 5
ed to High Source. Open engine will not have trol unit and
circuit or high voltage detect- starter lockout pro- component.
ed at starter lockout circuit. tection. Check the re-
lay.
703 / 11 S051 / Auxiliary Equipment Sensor Possible engine Check cabling D794 -
11 Input #3 (OEM Switch) - power derate. between con-
Root Cause Not Known. trol unit and
component.
Check the
component.
723 / 2 S064 / 2 Backup Engine Speed/Posi- Possible low power. Check cabling D794 -
tion Sensor Number 2 - Data between con-
Erratic, Intermittent, or Incor- trol unit and
rect. Camshaft engine component.
speed sensor intermittent Check the sen-
synchronization. sor.
723 / 2 S064 / 2 Engine Speed Sensor Possible poor start- Check cabling D794 -
(Camshaft) Error - Data Er- ing. Engine power between con-
ratic, Intermittent, or Incor- derate. trol unit and
rect. The ECU 794 has component.
detected an error in the cam- Check the sen-
shaft position sensor signal. sor.
729 / 3 S070 / 3 Intake Air Heater #1 Circuit - The intake air heat- Check cabling D794 -
Voltage Above Normal or ers may be ON or between con-
Shorted to High Source. OFF all the time. trol unit and
High voltage detected at the component.
intake air heater signal cir- Check compo-
cuit. nent.
729 / 4 S070 / 4 Intake Air Heater #1 Circuit - The intake air heat- Check cabling D794 -
Voltage Below Normal or ers may be ON or between con-
Shorted to Low Source. Low OFF all the time. trol unit and
voltage detected at the in- component.
take air heater signal circuit. Check compo-
nent.
974 / 3 P974 / 3 Remote Accelerator Pedal Remote accelera- Check cabling D794 -
or Lever Position Sensor 1 tor will not operate. between con-
Circuit - Voltage Above Nor- Remote accelera- trol unit and
mal, or shorted to High tor position will be component.
Source. High voltage detect- set to zero percent. Check compo-
ed at remote accelerator nent.
pedal position circuit.
974 / 4 P974 / 4 Remote Accelerator Pedal Remote accelera- Check cabling D794 -
or Lever Position Sensor 1 tor will not operate. between con-
Circuit - Voltage Below Nor- Remote accelera- trol unit and
mal, or Shorted to Low tor position will be component.
Source. Low voltage detect- set to zero percent. Check compo-
ed at remote accelerator nent.
pedal position signal.
974 / 19 P29 SAE J1939 Multiplexing Re- The engine will not Use diagnostic - CAN/POW-
mote Accelerator Pedal or respond to the re- menu to find in- ER, menu
Lever Data Error - Received mote throttle. En- correct seg- 2
Network Data Error. The gine may only idle. ment.
OEM machine electronic The primary or cab
control unit (VECU) detected accelerator may be
a fault with the remote accel- able to be used.
erator.
1043 / 4 S221 / 4 Accelerator Pedal or Lever Engine will only die. Check cabling D794 -
Position Sensor Supply Volt- between con-
age Circuit - Voltage Below trol unit and
Normal or Shorted to Low component.
Source. Low voltage detect- Check compo-
ed at sensor supply circuit to nent.
the accelerator pedal or le-
ver position sensor.
1043 / 4 S221 / 4 Engine Speed/Position Sen- Possible hard start- Check cabling D794 -
sor (Crankshaft) Supply ing and rough run- between con-
Voltage Circuit - Voltage Be- ning. trol unit and
low Normal or Shorted to component.
Low Source. Low voltage Check compo-
detected on the ECU 794 nent.
voltage supply line to engine
speed sensor.
1072 / 3 S028 / 3 Engine Brake Actuator Cir- Engine brake on Check cabling D794 -
cuit #1 - Voltage Above Nor- cylinders 1, 2, and 3 between con-
mal or Shorted to High can not be activated trol unit and
Source. Open circuit or high or exhaust brake component.
voltage detected at the en- will not operate. Check compo-
gine brake solenoid number nent.
1 signal circuit.
1072 / 4 S028 / 4 Engine Brake Actuator Cir- Engine brake on Check cabling D794 -
cuit #1 - Voltage Below Nor- cylinders 1, 2, and 3 between con-
mal or Shorted to Low can not be activated trol unit and
Source. Low voltage detect- or exhaust brake component.
ed at the engine brake sole- will not operate. Check compo-
noid number 1 signal circuit. nent.
1073 / 4 S029 / 4 Engine Brake Actuator Cir- Engine brake on Check cabling D794 -
cuit #2 - Voltage Below Nor- cylinders 4, 5, and 6 between con-
mal or Shorted to Low can not be activat- trol unit and
Source. Low voltage detect- ed. component.
ed at the engine brake sole- Check compo-
noid number 2 signal circuit. nent.
1075 / 3 S126 / 3 Electric Lift Pump for Engine Engine can be diffi- - D794 -
Fuel Supply Circuit - Voltage cult to start.
Above Normal, or Shorted to
High Source. High voltage or
open detected at the fuel lift
pump signal circuit.
1075 / 4 S126 / 4 Electric Lift Pump for Engine Engine can be diffi- - D794 -
Fuel Supply Circuit - Voltage cult to start.
Below Normal, or Shorted to
Low Source. Low signal volt-
age detected at the fuel lift
pump circuit.
1079 / 3 S212 / 3 Sensor Supply Voltage Engine power der- Check cabling D794 -
number 1 Circuit - Voltage ate. between con-
Above Normal or Shorted to trol unit and
High Source. High voltage component.
detected at sensor supply Check the sen-
number 1 circuit. sor.
1079 / 4 S212 / 4 Sensor Supply Voltage Engine power der- Check cabling D794 -
Number 1 Circuit - Voltage ate. between con-
Below Normal or Shorted to trol unit and
Low Source. Low voltage component.
detected at sensor supply Check the sen-
number 1 circuit. sor.
1080 / 4 S232 / 4 Sensor Supply Voltage Engine power der- Check cabling D794 -
Number 2 Circuit - Voltage ate. between con-
Below Normal, or Shorted to trol unit and
Low Source. Low voltage component.
detected at the sensor sup- Check the sen-
ply number 2 circuit. sor.
1347 / 3 S126 / 3 High Fuel Pressure Solenoid Engine will run - D794 -
Valve Circuit - Voltage poorly but will be
Above Normal or Shorted to severely derated.
High Source. Electronic fuel Rail pressure will be
control actuator shorted higher than com-
high. manded.
1347 / 7 S126 / 7 Fuel Pump Pressurizing As- Engine will not run - D794 -
sembly 1 - Mechanical Sys- or possible low
tem Not Responding power
Properly or Out of Adjust-
ment. A pumping imbalance
between the front and rear
pumping plungers has been
detected.
1347 / 7 S126 / 7 Fuel Pumping Element Engine will not run - D794 -
Number 1 (Front) - Mechan- or possible low
ical System Not Responding power
Properly or Out of Adjust-
ment.
94/3 3.6 PID94/3 Sensor fuel pres- No limitation. Check cabling be- D794/B:16 -
sure, short- tween control unit and
circuited to volt- component.
age. Check the sensor.
94/5 3.6 PID94/5 Sensor fuel pres- No limitation. Check cabling be- D794/B:16 -
sure, short- tween control unit and
circuited to ground component.
or open circuit. Check the sensor.
94/7 3.8 PID94/7 Sensor fuel pres- No limitation. Change fuel filter. D794/B:16 -
sure, short- Change fuel pre-filter.
circuited to volt-
age, ground, or Check if pressure can
be built up with the
open circuit.
hand pump.
97/4 2.9 PID97/4 Sensor water in No limitation. Check cabling be- D794/B:8 -
fuel short- tween control unit and
circuited to ground component.
or open circuit. Check the sensor.
100/3 3.1 PID100/ Sensor oil pres- No limitation. Check cabling be- D794/B:11 EN-
3 sure, short- tween control unit and GINE,
circuited to volt- component. menu 6
age. Check the sensor.
100/5 3.1 PID100/ Sensor, oil pres- No limitation. Check cabling be- D794/B:11 EN-
5 sure, open circuit. tween control unit and GINE,
component. menu 6
Check the sensor.
105/0 6.2 PID105/ High charge-air Engine will shut Check that the - EN-
0 temperature. down. charge-air cooler is GINE,
clean. menu 7
Check the sensor.
105/4 3.2 PID105/ Sensor charge-air No limitation. Check cabling be- D794/A:47 EN-
4 temperature, ca- tween control unit and GINE,
ble short-circuited component. menu 7
to ground. Check the sensor.
105/5 3.3 PID105/ Sensor charge-air No limitation. Check cabling be- D794/A:47 EN-
5 temperature, ca- tween control unit and GINE,
ble open circuit. component. menu 7
Check the sensor.
106/0 3.5 PID106/ Boost pressure Reduced engine Check the turbocharg- - EN-
0 too high. power. er. GINE,
Check the sensor. menu 6
106/3 3.4 PID106/ Sensor boost Reduced engine Check cabling be- D794/A:22 EN-
3 pressure, cable power. tween control unit and GINE,
short-circuited to component. menu 7
voltage. Check the sensor.
108/2 - PID108/ Faulty signal from No limitation. Check cabling be- - EN-
2 charge air pres- tween control unit and GINE,
sure sensor. component. menu 6
Check the sensor.
108/3 - PID108/ Sensor boost No limitation. Check cabling be- D794/A:29 EN-
3 pressure, short- tween control unit and GINE,
circuited to volt- component. menu 6
age. Check the sensor.
108/4 - PID108/ Sensor boost No limitation. Check cabling be- D794/A:29 EN-
4 pressure, short- tween control unit and GINE,
circuited to frame component. menu 6
ground or open Check the sensor.
circuit.
110/0 6.1 PID110/ High coolant tem- No limitation. Check coolant level. - EN-
0 perature. Check that radiator is GINE,
clean. menu 7
Check thermostat.
Check the cap on the
expansion tank.
Check if there’s air in
coolant system.
Check the sensor.
110/4 3.3 PID110/ Sensor coolant Preheating is ac- Check cabling be- D794/B:27 EN-
4 temperature, tivated even if en- tween control unit and GINE,
short-circuited to gine is warm. component. menu 7
ground. Check the sensor.
110/5 3.3 PID110/ Sensor coolant Preheating is ac- Check cabling be- D794/B:27 EN-
5 temperature, ca- tivated even if en- tween control unit and GINE,
ble open circuit. gine is warm. component. menu 7
Check the sensor.
111/1 2.2 PID111/ Low coolant level. No limitation. Check the coolant lev- - -
1 el, top up if needed.
Check the sensor.
164/0 - PID164/ High fuel pres- No limitation. Check the fuel pump. - -
0 sure. Check the sensor.
164/2 - PID164/ Faulty signal from Engine speed Check cabling be- D794/B:16 -
2 fuel pressure sen- limited to 1100 tween control unit and
sor. rpm. component.
Check the sensor.
164/4 - PID164/ Sensor fuel pres- Engine speed Check cabling be- D794/B:16 -
4 sure, short- limited to 1100 tween control unit and
circuited to rpm. component.
ground. Check the sensor.
164/5 - PID164/ Sensor fuel pres- Engine speed Check cabling be- D794/B:16 -
5 sure, open circuit. limited to 1100 tween control unit and
rpm. component.
Check the sensor.
190/0 2.6 PID190/ Engine rpm too No limitation. Ease off throttle or se- - -
0 high. lect higher gear.
626/3 5.4 PID45/3 Preheating relay, Preheating can- Check cabling be- D794/B:25 EN-
short-circuited to not be activated. tween control unit and GINE,
voltage. White smoke at component. menu 5
cold-start. Check the relay.
Start problems in
cold weather.
626/4 5.4 PID45/4 Preheating relay, Preheating relay Check cabling be- D794/B:25 EN-
short-circuited to is activated con- tween control unit and GINE,
ground. stantly. Fuse for component. menu 5
preheating may Check the relay.
blow.
626/5 5.4 PID45/5 Preheating relay, Preheating can- Check cabling be- D794/B:25 EN-
open circuit or de- not be activated. tween control unit and GINE,
fective compo- White smoke at component. menu 5
nent. cold-start. Check the relay.
Start problems in
cold weather.
629/8 9.9 SID254/ Engine control The engine will Change the control - -
8 unit (D794), inter- not start. unit.
nal fault.
629/ 9.9 SID254/ Engine control The engine will Change the control - -
12 12 unit (D794), inter- not start. unit.
nal fault.
636/2 9.9 SID21/3 Faulty signal from Engine takes Check cabling be- D794/A:45, -
camshaft speed longer time to tween control unit and A:46
sensor. start than normal. component.
Engine runs nor- Check the sensor.
mally when it has
started.
636/3 2.5 SID21/3 Sensor rpm cam- Engine takes Check cabling be- D794/A:45, -
shaft, no signal. longer time to tween control unit and A:46
start than normal. component.
Engine runs nor- Check the sensor.
mally when it has
started.
636/8 2.5 SID21/8 Sensor engine Engine takes Check cabling be- D794/A:45, -
rpm, camshaft, longer time to tween control unit and A:46
abnormal fre- start than normal. component.
quency. Engine runs nor- Check the sensor.
mally when it has
started.
637/2 2.4 SID22/2 Faulty signal from Engine is difficult Check cabling be- D794/A:37, EN-
engine speed sen- to start and runs tween control unit and A:38 GINE,
sor, flywheel. rough, if it starts. component. menu 2
Check the sensor.
637/3 2.4 SID22/3 Sensor engine Engine is difficult Check cabling be- D794/A:37, EN-
rpm, flywheel, ab- to start and runs tween control unit and A:38 GINE,
normal frequency. rough, if it starts. component. menu 2
Check the sensor.
637/8 2.4 SID22/8 Sensor engine Engine is difficult Check cabling be- D794/A:37, EN-
rpm, flywheel, ab- to start and runs tween control unit and A:38 GINE,
normal frequency. rough, if it starts. component. menu 2
Check that the sensor
is connected correctly.
639/2 9.9 SID240/ Communication It may not be pos- Re-program the con- - -
2 error with Engine sible to start the trol unit.
control unit engine.
(D794), configura-
tion error.
639/7 9.9 SID240/ Communication It may not be pos- Re-program the con- - -
7 error with Engine sible to start the trol unit.
control unit engine.
(D794), configura-
tion error.
639/ 9.9 SID240/ Communication It may not be pos- Re-program the con- - -
11 11 error with Engine sible to start the trol unit.
control unit engine.
(D794), configura-
tion error.
639/ 9.9 SID240/ Communication It may not be pos- Re-program the con- - -
14 14 error with Engine sible to start the trol unit.
control unit engine.
(D794), configura-
tion error.
651/3 7.1 SID1/3 Electric failure, in- Engine runs on 5 Check cabling be- D794/A:24 -
jector cylinder 1. cylinders, sounds tween control unit and
rough and has re- component.
duced power. Check the injector.
651/5 7.1 SID1/5 Electric failure, in- Engine runs on 5 Check cabling be- D794/A:24 -
jector cylinder 1. cylinders, sounds tween control unit and
rough and has re- component.
duced power. Check the injector.
651/7 7.1 SID1/7 Incorrect com- Runs rough at Check fuel pressure. D794/A:24 -
pression or defec- low rpms and low Check valve clear-
tive injector load. ance.
cylinder 1.
Check cabling be-
tween control unit and
component.
Check the injector.
Perform compression
test and check cylin-
der 1.
651/ 7.1 SID1/12 Electric failure, in- Engine runs on 5 Check cabling be- D794/A:24 -
12 jector cylinder 1. cylinders, sounds tween control unit and
rough and has re- component.
duced power. Check the injector.
652/3 7.2 SID2/3 Electric failure, in- Engine runs on 5 Check cabling be- D794/A:16 -
jector cylinder 1. cylinders, sounds tween control unit and
rough and has re- component.
duced power. Check the injector.
652/4 7.2 SID2/4 Electric failure, in- Engine runs on 5 Check cabling be- D794/A:16 -
jector cylinder 1. cylinders, sounds tween control unit and
rough and has re- component.
duced power. Check the injector.
652/5 7.2 SID2/5 Electric failure, in- Engine runs on 5 Check cabling be- D794/A:16 -
jector cylinder 1. cylinders, sounds tween control unit and
rough and has re- component.
duced power. Check the injector.
652/ 7.2 SID2/12 Electric failure, in- Engine runs on 5 Check cabling be- D794/A:16 -
12 jector cylinder 2. cylinders, sounds tween control unit and
rough and has re- component.
duced power. Check the injector.
653/3 7.3 SID3/3 Electric failure, in- Engine runs on 5 Check cabling be- D794/A:32 -
jector cylinder 3. cylinders, sounds tween control unit and
rough and has re- component.
duced power. Check the injector.
653/4 7.3 SID3/4 Electric failure, in- Engine runs on 5 Check cabling be- D794/A:32 -
jector cylinder 3. cylinders, sounds tween control unit and
rough and has re- component.
duced power. Check the injector.
653/5 7.3 SID3/5 Electric failure, in- Engine runs on 5 Check cabling be- D794/A:32 -
jector cylinder 3. cylinders, sounds tween control unit and
rough and has re- component.
duced power. Check the injector.
653/7 7.3 SID3/7 Incorrect com- Runs rough at Check fuel pressure. D794/A:32 -
pression or defec- low rpms and low Check valve clear-
tive injector load. ance.
cylinder 3.
Check cabling be-
tween control unit and
component.
Check the injector.
Perform compression
test and check cylin-
der 3.
654/3 7.4 SID4/3 Electric failure, in- Engine runs on 5 Check cabling be- D794/A:56 -
jector cylinder 4. cylinders, sounds tween control unit and
rough and has re- component.
duced power. Check the injector.
654/4 7.4 SID4/4 Electric failure, in- Engine runs on 5 Check cabling be- D794/A:56 -
jector cylinder 4. cylinders, sounds tween control unit and
rough and has re- component.
duced power. Check the injector.
654/5 7.4 SID4/5 Electric failure, in- Engine runs on 5 Check cabling be- D794/A:56 -
jector cylinder 4. cylinders, sounds tween control unit and
rough and has re- component.
duced power. Check the injector.
654/7 7.4 SID4/7 Incorrect com- Runs rough at Check fuel pressure. D794/A:56 -
pression or defec- low rpms and low Check valve clear-
tive injector load. ance.
cylinder 4.
Check cabling be-
tween control unit and
component.
Check the injector.
Perform compression
test and check cylin-
der 4.
654/ 7.4 SID4/12 Electric failure, in- Engine runs on 5 Check cabling be- D794/A:56 -
12 jector cylinder 4. cylinders, sounds tween control unit and
rough and has re- component.
duced power. Check the injector.
655/3 7.5 SID5/3 Electric failure, in- Engine runs on 5 Check cabling be- D794/A:48 -
jector cylinder 5. cylinders, sounds tween control unit and
rough and has re- component.
duced power. Check the injector.
655/4 7.5 SID5/4 Electric failure, in- Engine runs on 5 Check cabling be- D794/A:48 -
jector cylinder 5. cylinders, sounds tween control unit and
rough and has re- component.
duced power. Check the injector.
655/7 7.5 SID5/7 Incorrect com- Engine runs on 5 Check that cabling to D794/A:48 -
pression or defec- cylinders, sounds the injectors is not
tive injector rough and has re- damaged.
cylinder 5. duced power. Check cabling be-
tween control unit and
component.
Check the injector.
Perform compression
test and check cylin-
der 5.
655/ 7.5 SID5/12 Electric failure, in- Engine runs on 5 Check cabling be- D794/A:48 -
12 jector cylinder 5. cylinders, sounds tween control unit and
rough and has re- component.
duced power. Check the injector.
656/3 7.6 SID6/3 Electric failure, in- Engine runs on 5 Check cabling be- D794/A:40 -
jector cylinder 6. cylinders, sounds tween control unit and
rough and has re- component.
duced power. Check the injector.
656/4 7.6 SID6/4 Electric failure, in- Engine runs on 5 Check cabling be- D794/A:40 -
jector cylinder 6. cylinders, sounds tween control unit and
rough and has re- component.
duced power. Check the injector.
656/5 7.6 SID6/5 Electric failure, in- Engine runs on 5 Check cabling be- D794/A:40 -
jector cylinder 6. cylinders, sounds tween control unit and
rough and has re- component.
duced power. Check the injector.
656/ 7.6 SID6/12 Electric failure, in- Engine runs on 5 Check cabling be- D794/A:36, -
12 jector cylinder 6. cylinders, sounds tween control unit and A:40
rough and has re- component.
duced power. Check the injector.
677/3 6.3 SID39/3 Starter motor re- The engine will Check cabling be- D794/B:29 EN-
1675/ lay, short-circuited not start. tween control unit and GINE,
3 to voltage. Engine starts im- component. menu 5
mediately when Check the relay.
ignition is turned
on.
677/4 6.3 SID39/4 Starter motor re- The engine will Check cabling be- D794/B:29 EN-
1675/ lay, short-circuited not start. tween control unit and GINE,
4 to ground component. menu 5
Check the relay.
677/5 6.3 SID39/5 Starter motor re- The engine will Check cabling be- D794/B:29 EN-
1675/ lay, open circuit. not start. tween control unit and GINE,
5 component. menu 5
Check the relay.
679/0 - PSID97/ Faulty signal from Engine speed Check cabling be- - -
0 pressure relief limited to 1100 tween control unit and
valve. rpm. component.
Reduced engine Check the component.
power.
729/3 - SID70/3 Sensor preheat- Fuse blows. Check cabling be- D794/B:31 -
ing, short- tween control unit and
circuited to volt- component.
age. Check the component.
729/4 - SID70/4 Sensor preheat- Engine difficult to Check cabling be- D794/B:31 -
ing, short- start in cold tween control unit and
circuited to weather. component.
ground. Check the component.
729/5 - SID70/5 Sensor preheat- Engine difficult to Check cabling be- D794/B:31 -
ing, open circuit. start in cold tween control unit and
weather. component.
Check the component.
1079/ 9.3 SID 232/ Reference voltage No limitation. Check cabling be- D794/B:17 -
4 4 5 V no. 1 to sen- tween control unit and
sor, short- component.
circuited to Check the sensor.
ground.
1080/ - SID 211/ Reference voltage No limitation. Check cabling be- D794/A:7 -
3 3 5 V no. 2 to sen- tween control unit and
sor, short- component.
circuited to volt- Check the sensor.
age.
1080/ - SID 211/ Reference voltage No limitation. Check cabling be- D794/A:7 -
4 4 5 V no. 2 to sen- tween control unit and
sor, short- component.
circuited to Check the sensor.
ground.
1239/ - PSID 96/ Too high fuel Engine speed Check fuel feed. - -
0 0 pressure. limited to 1100
rpm.
High engine pow-
er. (Powerful en-
gine)
1239/ - PSID 96/ Too low fuel pres- Engine speed Check fuel filter, re- - -
1 1 sure limited to 1100 place if necessary.
rpm. Check fuel feed.
Reduced engine
power.
1239/ - PSID 96/ Sensor fuel pres- Engine speed Check cabling be- D794/B:16 -
4 4 sure, short- limited to 1100 tween control unit and
circuited to rpm. component.
ground. Reduced engine Check the sensor.
power.
Engine starting
difficulty.
1239/ - PSID 96/ Sensor fuel pres- Engine speed Check the sensor. - -
12 12 sure, defective limited to 1100
component. rpm.
Reduced engine
power.
Engine starting
difficulty.
2791/ - PPID19/ Internal EGR, Internal EGR not Check cabling be- D794/B:30 -
3 3 short-circuited to working. tween control unit and
voltage. component.
Check the component.
2791/ - PPID19/ Internal EGR, Internal EGR not Check cabling be- D794/B:30 -
4 4 short-circuited to working. tween control unit and
ground. component.
Check the component.
2791/ - PPID19/ Internal EGR, Internal EGR not Check cabling be- D794/B:30 -
5 5 open circuit. working. tween control unit and
component.
Check the component.
2791/ - PPID19/ Internal EGR, me- Internal EGR not Check sensor boost D794/B:30 -
7 7 chanical defect. working. pressure.
Check the component
(IEGR)
Contact Volvo Penta
workshop for more in-
formation.
52019 6.8 PPID6/5 Sensor piston No limitation. Check cabling be- D794/B:14 -
2/5 cooling pressure, tween control unit and
short-circuiting to component.
voltage, ground, Check the sensor.
or open circuit.
- - PPID Low fuel pressure. Engine speed Check fuel filter, re- - -
435/4 limited to 1100 place if necessary.
rpm. Check fuel feed.
Reduced engine
power.
2 Transmission
mm mm mm mm mm mm
Control unit transmission can generate two modes with reduced func-
tionality to protect the transmission in case of serious malfunctions:
• "Limp home", indicated in display with "LH".
In this mode only 1-2 gear in both directions can be used. If the
malfunction occurs in a higher gear then downshifting has to be
performed manually to 1st gear or 2nd.
• "Shutdown", indicated in display with "Sd".
In this mode, the transmission is in permanent neutral position as
there is no oil pressure to enable selection of a gear.
Connec-
tions
Diagnos-
Description Limitation Action and
tic menu
compo-
Code nents
20/60 Sensor oil pressure Transmission locked in Check cabling between D793/A:2 TRANSM,
(B253) indicates low neutral (shutdown). control unit and compo- - B253 menu 10
oil pressure when nent.
there should be pres- Check the solenoid valve.
sure.
20/61 The oil pressure sen- Transmission locked in Check cabling between D793/A:2 TRANSM,
sor (B253) indicates neutral (shutdown). control unit and compo- - B253 menu 10
oil pressure when nent.
there should not be Check the solenoid valve.
pressure.
21/02 Solenoid valves VFS Transmission locked in Check cabling between the D793/D1 - TRANSM,
short-circuiting to neutral (shutdown). control unit and the compo- Y6069, menu 7
voltage, ground, or nent with diagnostic menu. D793/F2 -
open circuit. Check the solenoid valve. Y6075
Connec-
tions
Diagnos-
Description Limitation Action and
tic menu
compo-
Code nents
30/04 Low battery voltage. Control unit saves stored Check cabling to control - CAN/
information to flash memo- unit. POWER,
ry and restarts to clear Check alternator, battery menu 12
memory. and cabling between bat-
tery and alternator.
30/05 High battery voltage. Control unit receives re- Check voltage feed. - CAN/
duced proportional control If auxiliary start equipment POWER,
precision depending on re- is connected, disconnect it. menu 12
duced PWM work cycle.
31/00 Reference voltage Control unit receives re- Check voltage feed. - CAN/
sensor 8 V, too low. duced sensor signals. Check the control unit. POWER,
menu 12
31/01 Reference voltage Control unit receives re- Check voltage feed. - CAN/
sensor 8 V, too high. duced sensor signals. Check the control unit. POWER,
menu 12
40/06 Incorrect direction Control unit locks trans- Check cabling to gear se- - TRANSM,
from gear selector. mission in neutral. lector with regards to for- menu 2
ward and reverse signal.
41/06 Incorrect gear selec- Control unit doesn’t allow Check cabling to gear se- - TRANSM,
tion from gear selec- change of range, however, lector with regards to signal menu 2
tor. operation of machine is range.
possible.
42/04 Actual gear ratio too Control unit indicates that Check transmission with - TRANSM,
low. one or several clutches are purpose to understand if menu 6
slipping. and, if that is the case,
which clutch is slipping.
Check the set gear ratio for
the control unit.
42/05 Actual gear ratio too Control unit indicates that Check transmission with - TRANSM,
high. one or several clutches are purpose to understand if menu 6
slipping. and, if that is the case,
which clutch is slipping.
Check the set gear ratio for
the control unit.
43/03 Signal from Sensor Control unit indicates the Check cabling between D793/H3 - TRANSM,
engine rpm and oil error. control unit and compo- B758/766 menu 10
temperature trans- nent.
mission (B758/766) Check the sensor.
outside valid interval.
Connec-
tions
Diagnos-
Description Limitation Action and
tic menu
compo-
Code nents
43/07 Torque converter Control unit indicates the Check transmission oil D793/H3 - TRANSM,
temperature exceeds error to make operator cooler, clean as needed. B758/766 menu 10
100 °C. aware of the warning’s lev- Check the thermostat in the
el. transmission oil cooler.
43/08 Torque converter The control unit protects Check transmission oil D793/H3 - TRANSM,
temperature exceeds the transmission and does cooler, clean as needed. B758/766 menu 10
125 °C. not allow the temperature Check the thermostat in the
in the torque converter to transmission oil cooler.
exceed the limit value.
The control unit locks the
transmission in neutral po-
sition, the engine is re-
stricted to 50% of max.
rpm.
44/10 Faulty signal for ac- - Use diagnostic menu to find - CAN/
celerator pedal posi- incorrect segment. POWER,
tion from engine menu 4
control unit (D794)
50/00 Sensor oil pressure Transmission in limp- Check cabling between D793/A:2 TRANSM,
(B253), short- home. control unit and compo- - B253 menu 10
circuited to ground. nent.
Check the sensor.
50/01 Sensor oil pressure Transmission in limp- Check cabling between D793/A:2 TRANSM,
(B253), not connect- home. control unit and compo- - B253 menu 10
ed or open circuit. nent.
Check the sensor.
51/00 Sensor engine rpm The control unit limits the Check cabling between D793/H3 - TRANSM,
and oil temperature transmission’s tempera- control unit and compo- B758/766 menu 10
transmission (B758/ ture measurement to the nent.
766) short-circuited to lowest value in its settings, Check the sensor.
ground. which results in poor tem-
perature compensation.
Connec-
tions
Diagnos-
Description Limitation Action and
tic menu
compo-
Code nents
51/01 Sensor engine rpm The control unit limits the Check cabling between D793/H3 - TRANSM,
and oil temperature transmission’s tempera- control unit and compo- B758/766 menu 10
transmission (B758/ ture measurement to the nent.
766) not connected or highest value in its set- Check the sensor.
open circuit. tings, which results in poor
temperature compensa-
tion.
52/00 Sensor oil tempera- The control unit limits the Check cabling between D793/J3 - TRANSM,
ture (S221) short- transmission’s tempera- control unit and compo- S221 menu 10
circuited to ground. ture measurement to the nent.
highest value in its set- Check the sensor.
tings, which results in poor
temperature compensa-
tion.
52/01 Sensor oil tempera- The control unit limits the Check cabling between D793/J3 - TRANSM,
ture (S221) open cir- transmission’s tempera- control unit and compo- S221 menu 10
cuit. ture measurement to the nent.
highest value in its set- Check the sensor.
tings, which results in poor
temperature compensa-
tion.
60/00 Sensor rpm drum When only one rpm signal Check cable between con- D793/C3 - TRANSM,
(B752) short-circuited that is not the engine rpm trol unit and component. B752 menu 6
to ground. signal is incorrect, the con- Check component.
trol unit calculates the
missing rpm.
If several rpm signals or if
the engine rpm signal are
defective, the control unit
activates Limp-home.
Connec-
tions
Diagnos-
Description Limitation Action and
tic menu
compo-
Code nents
60/01 Sensor rpm drum When only one rpm signal Check cable between con- D793/C3 - TRANSM,
(B752) not connect- that is not the engine rpm trol unit and component. B752 menu 6
ed. signal is incorrect, the con- Check component.
trol unit calculates the
missing rpm.
If several rpm signals or if
the engine rpm signal are
defective, the control unit
activates Limp-home.
61/00 Sensor rpm output When only one rpm signal Check cable between con- D793/D3 - TRANSM,
shaft (B758) short- that is not the engine rpm trol unit and component. B758 menu 6
circuited to ground. signal is incorrect, the con- Check component.
trol unit calculates the
missing rpm.
If several rpm signals or if
the engine rpm signal are
defective, the control unit
activates Limp-home.
61/01 Sensor rpm output When only one rpm signal Check cable between con- D793/D3 - TRANSM,
shaft (B758) not con- that is not the engine rpm trol unit and component. B758 menu 6
nected. signal is incorrect, the con- Check component.
trol unit calculates the
missing rpm.
If several rpm signals or if
the engine rpm signal are
defective, the control unit
activates Limp-home.
62/00 Sensor engine rpm When only one rpm signal Check cable between con- D793/F3 - TRANSM,
(B758/766), short- that is not the engine rpm trol unit and component. B758/766 menu 6
circuited to ground. signal is incorrect, the con- Check component.
trol unit calculates the
missing rpm.
If several rpm signals or if
the engine rpm signal are
defective, the control unit
activates Limp-home.
Connec-
tions
Diagnos-
Description Limitation Action and
tic menu
compo-
Code nents
62/01 Sensor engine rpm When only one rpm signal Check cable between con- D793/F3 - TRANSM,
(B758/766), not con- that is not the engine rpm trol unit and component. B758/766 menu 6
nected or has open signal is incorrect, the con- Check component.
circuit. trol unit calculates the
missing rpm.
If several rpm signals or if
the engine rpm signal are
defective, the control unit
activates Limp-home.
63/00 Sensor rpm turbine When only one rpm signal Check cable between con- D793/R2 - TRANSM,
(B751) short-circuited that is not the engine rpm trol unit and component. B751 menu 6
to ground. signal is incorrect, the con- Check component.
trol unit calculates the
missing rpm.
If several rpm signals or if
the engine rpm signal are
defective, the control unit
activates Limp-home.
63/01 Sensor rpm turbine When only one rpm signal Check cable between con- D793/R2 - TRANSM,
(B751) not connect- that is not the engine rpm trol unit and component. B751 menu 6
ed. signal is incorrect, the con- Check component.
trol unit calculates the
missing rpm.
If several rpm signals or if
the engine rpm signal are
defective, the control unit
activates Limp-home.
70/00 Solenoid valve VFS Transmission in limp- Check cabling between D793/B1 - TRANSM,
front (Y630), short- home. control unit and compo- Y630, C1 menu 8
circuited to each oth- nent. - Y630
er, signal cable short- Check the solenoid valve.
circuited to voltage, or
plus-cable short-
circuited to frame
ground.
70/01 Solenoid valve VFS Transmission in limp- Check cabling between D793/B1 - TRANSM,
forward (Y630) open home. control unit and compo- Y630, C1 menu 8
circuit or short- nent. - Y630
circuited voltage. Check the solenoid valve.
Connec-
tions
Diagnos-
Description Limitation Action and
tic menu
compo-
Code nents
70/02 Solenoid valve VFS Transmission in limp- Check cabling between D793/B1 - TRANSM,
forward (Y630), con- home. control unit and compo- Y630, C1 menu 9
trol current higher nent. - Y630
than 1400 mA. Check the solenoid valve.
70/03 Solenoid valve VFS Transmission in limp- Check cabling between D793/B1 - TRANSM,
forward (Y630), con- home. control unit and compo- Y630, C1 menu 9
trol current outside nent. - Y630
approved interval. In- Check the solenoid valve.
correct impedance.
71/00 Solenoid valve VFS Transmission in limp- Check cabling between D793/D1 - TRANSM,
2/4 (Y6069), short- home. control unit and compo- Y6069, menu 8
circuited to each oth- nent. E1 -
er, signal cable short- Check the solenoid valve. Y6069
circuited to voltage, or
plus-cable short-
circuited to frame
ground.
71/01 Solenoid valve VFS Transmission in limp- Check cabling between D793/D1 - TRANSM,
2/4 (Y6069) open cir- home. control unit and compo- Y6069, menu 8
cuit or short-circuited nent. E1 -
voltage. Check the solenoid valve. Y6069
71/02 Solenoid valve VFS Transmission in limp- Check cabling between D793/D1 - TRANSM,
2/4 (Y6069), control home. control unit and compo- Y6069, menu 9
current higher than nent. E1 -
1400 mA. Check the solenoid valve. Y6069
71/03 Solenoid valve VFS Transmission in limp- Check cabling between D793/D1 - TRANSM,
2/4 (Y6069), control home. control unit and compo- Y6069, menu 9
current outside ap- nent. E1 -
proved interval (incor- Check the solenoid valve. Y6069
rect impedance).
72/00 Solenoid valve VFS Transmission in limp- Check cabling between D793/F1 - TRANSM,
reverse (Y631), ca- home. control unit and compo- Y631, G1 menu 8
bles short-circuited to nent. - Y631
each other, signal ca- Check the solenoid valve.
ble short-circuited to
voltage, or plus-cable
short-circuited to
frame ground.
Connec-
tions
Diagnos-
Description Limitation Action and
tic menu
compo-
Code nents
72/01 Solenoid valve VFS Transmission in limp- Check cabling between D793/F1 - TRANSM,
reverse (Y631) open home. control unit and compo- Y631, G1 menu 8
circuit or short- nent. - Y631
circuited voltage. Check the solenoid valve.
72/02 Solenoid valve VFS Transmission in limp- Check cabling between D793/F1 - TRANSM,
reverse (Y631), con- home. control unit and compo- Y631, G1 menu 9
trol current higher nent. - Y631
than 1400 mA. Check the solenoid valve.
72/03 Solenoid valve VFS Transmission in limp- Check cabling between D793/F1 - TRANSM,
reverse (Y631), con- home. control unit and compo- Y631, G1 menu 9
trol current outside nent. - Y631
approved interval (in- Check the solenoid valve.
correct impedance).
73/00 Solenoid valve VFS Transmission in limp- Check cabling between D793/H1 - TRANSM,
1/3 (Y6067), cables home. control unit and compo- Y6067, J1 menu 8
short-circuited to nent. - Y6067
each other, signal ca- Check the solenoid valve.
ble short-circuited to
voltage, or plus-cable
short-circuited to
frame ground.
73/01 Solenoid valve VFS Transmission in limp- Check cabling between D793/H1 - TRANSM,
1/3 (Y6067) open cir- home. control unit and compo- Y6067, J1 menu 8
cuit or short-circuited nent. - Y6067
voltage. Check the solenoid valve.
73/02 Solenoid valve VFS Transmission in limp- Check cabling between D793/H1 - TRANSM,
1/3 (Y6067), control home. control unit and compo- Y6067, J1 menu 9
current higher than nent. - Y6067
1400 mA. Check the solenoid valve.
73/03 Solenoid valve VFS Transmission in limp- Check cabling between D793/H1 - TRANSM,
1/3 (Y6067), control home. control unit and compo- Y6067, J1 menu 9
current outside ap- nent. - Y6067
proved interval (incor- Check the solenoid valve.
rect impedance).
80/00 Solenoid valve RSP Transmission locked in Check cabling between D793/K1 - TRANSM,
Drive (Y6066), cable neutral (shutdown). control unit and compo- Y6066 menu 7
short-circuited to nent.
frame ground. Check the solenoid valve.
Connec-
tions
Diagnos-
Description Limitation Action and
tic menu
compo-
Code nents
80/01 Solenoid valve RSP Transmission locked in Check cabling between D793/K1 - TRANSM,
Drive (Y6066), cable neutral (shutdown). control unit and compo- Y6066 menu 7
is not connected or nent.
short-circuited to volt- Check the solenoid valve.
age.
81/00 Solenoid valve VFS Transmission in limp- Check cabling between D793/E2 - TRANSM,
2/4 (Y6074), cable home. control unit and Y6074 menu 7
short-circuited to component.
frame ground. Check the solenoid valve.
81/01 Solenoid valve VSF Transmission in limp- Check cabling between D793/E2 - TRANSM,
2/4 (Y6074), cable is home. control unit and compo- Y6074 menu 7
not connected or nent.
short-circuited to Check the solenoid valve.
voltage.
82/00 Solenoid valve VFS Transmission in limp- Check cabling between D793/F2 - TRANSM,
1/3 (Y6075), cable home. control unit and Y6075 menu 7
short-circuited to component.
frame ground. Check the solenoid valve.
82/01 Solenoid valve VSF Transmission in limp- Check cabling between D793/F2 - TRANSM,
1/3 (Y6075), cable is home. control unit and Y6075 menu 7
not connected or component.
short-circuited to Check the solenoid valve.
voltage.
83/00 Solenoid valve RSP Transmission locked in Check cabling to solenoid D793/K2 - TRANSM,
Drive (Y6066), cable neutral (shutdown). valve drive Y6066 menu 7
short-circuited to Check solenoid valve drive.
frame ground.
83/01 Solenoid valve RSP Transmission locked in Check cabling to solenoid D793/K2 - TRANSM,
Drive (Y6066), cable neutral (shutdown). valve drive Y6066 menu 7
is not connected or Check solenoid valve drive.
short-circuited to
voltage.
8 Control system
mm mm mm mm mm mm
11 Error in cable, CAN – Use diagnostic menu to Varies depend- CAN/ 11.6.2 Re-
network, segment find incorrect segment. ing on machine POWER, dundant
1. configuration. menu 1-3 CAN-bus
12 Error in cable, CAN – Use diagnostic menu to Varies depend- CAN/ 11.6.2 Re-
network, segment find incorrect segment. ing on machine POWER, dundant
2. configuration. menu 1-3 CAN-bus
13 Error in cable, CAN – Use diagnostic menu to Varies depend- CAN/ 11.6.2 Re-
network, segment find incorrect segment. ing on machine POWER, dundant
3. configuration. menu 1-3 CAN-bus
14 Error in cable, CAN – Use diagnostic menu to Varies depend- CAN/ 11.6.2 Re-
network, segment find incorrect segment. ing on machine POWER, dundant
4. configuration. menu 2 CAN-bus
and 3
15 Error in cable, CAN – Use diagnostic menu to Varies depend- CAN/ 11.6.2 Re-
network, segment find incorrect segment. ing on machine POWER, dundant
5. configuration. menu 1-3 CAN-bus
19 Accelerator pedal 2 Accelerator Calibrate the gas pedal, D790-1/K6:12 CALIBRA- 1. Engine
VBFS not pedal for rear- see the section 8 Con- – R690-2 TION:
calibrated ward opera- trol system, group DRIVE-
tion not 8.5.2.3 Calibrate TRAIN,
working. En- DRIVE-TRAIN. menu 5
gine speed and 6
limited to
idling speed.
21 Communication er- Gear selec- Use diagnostic menu to D790-1/K13:1 CAN/ 11.6.3 CAN-
ror with transmis- tion not work- check communication. – D793/M2 POWER, bus drivetrain
sion control unit ing. Check the wiring be- D790-1/K13:2 menu 4
(D793) tween cab control unit – D793/L2
(D790-1) and transmis-
sion control unit (D793).
22 Communication er- Engine does Use diagnostic menu to Volvo: D790-1/ CAN/ 11.6.3 CAN-
ror with Control unit not react to check communication. K13:1, K13:2 – POWER, bus drivetrain
engine (D794). commands Check the wiring be- D794/2, 1 menu 4
from cab. tween cab control unit Cummins:
(D790-1) and engine D790-1/K13:1,
control unit (D794) K13:2 – D794/
46, 37
23 Setup file cannot be No controls Contact Kalmar Indus- D790-1 – 11.5.3.1 Con-
read in cab control working in tries AB. trol unit cab
unit (D790-1). cab.
24 Electric power feed Cab fan not Check fuse F58-5/3 D790-1/K2:8 – – 9.4.3 Cab fan
to cab fan less than working. 58-5/3:2
18 V.
25 Interference during Error code Switch the ignition off D794 ENGINE, 11.5.3.10
software download. stored in en- and on. menu 8 Control unit
26
Buffer for error gine control Repeat software down- engine
27 codes from engine unit (D794). load.
control unit (D794),
28
active error code
29 when downloading.
30
31 Incorrect power Control in cab Check fuse F58-5/1. D790-1/K1:2, CAN/ 11.5.1.3 Igni-
supply to cab con- not working. Check cabling between K1:3, K1:4 – POWER, tion voltage
trol unit (D790-1). the control unit and the F58-5/1:1, 1:2 menu 7 (15)
Voltage under 18 V component with diag-
or over 32 V. nostic menu.
Check the control unit.
33 No feedback signal The emer- Check fuse F58-3/8. D790-1/K11:13 CAN/ 11.5.1.4
for emergency stop gency stop Check cabling between – K3009-1/87 POWER, Emergency
switch voltage from switch cannot the control unit and the menu 5 stop switch
emergency stop be disen- component with diag- voltage (15E)
switch voltage relay gaged. All hy- nostic menu.
(K3009-1). draulic
functions are
blocked.
34 Faulty signal from Parking brake Check cabling between D791-1/K8:5 – HYD, 4.5 Parking
parking brake cannot be re- the control unit and the S107/7 menu 5 brake
switch (S107); indi- leased. component with diag- D791-1/K8:13
cates released and nostic menu. – S107/1
applied at same Check the switch.
time or nothing at
all.
35 Interference during Error code Switch the ignition off D793 TRANSM, 11.5.3.9 Con-
software download. stored in and on. menu 13 trol unit trans-
36
Buffer for error transmission Repeat software down- mission
37 codes from trans- control unit load.
mission control unit (D793).
38
(D793), active error
39 code when down-
loading.
40
41 Transistor has Windshield Check cabling between D790-1/K2:4 – CAB, 9.5.7 Wiper
been triggered due wiper rear not the control unit and the M650-2/53 menu 3 motor rear
to short circuit or working. component with diag-
open circuit in cir- nostic menu.
cuit for rear wiper Check the motor.
motor (M650-2).
42 Transistor has Rotating bea- Check cabling between D790-1/K2:5 – LIGHTS, 9.6.8 Rotat-
been triggered due con not work- the control unit and the H428 menu 6 ing beacon
to short circuit or ing. component with diag-
open circuit in cir- nostic menu.
cuit for rotating Check the component.
beacon (H428).
44 Transistor has Right cab re- Check bulb. D790-1/K2:7 – LIGHTS, 9.6.5 Back-up
been triggered due versing light Check cabling between E405R menu 8 light
to short circuit or not working. the control unit and the
open circuit in cir- component with diag-
cuit for right revers- nostic menu.
ing light (E405R).
45 Transistor has Windshield Check cabling between D790-1/K2:1 – CAB, 9.5.5 Wiper
been triggered due wiper front not the control unit and the M650-1/53 menu 2 motor front
to short circuit or working. component with diag-
open circuit in cir- nostic menu.
cuit for front wiper Check the component.
motor (M650-1).
46 Transistor has Cab fan not Check cabling between D790-1/K2:2 – CLIMATE, 9.4.3 Cab fan
been triggered due working. the control unit and the M657/2 menu 6
to short circuit or component with diag-
open circuit in cir- nostic menu.
cuit for fan motor Check the motor.
(M657).
47 Transistor has Recirculation Check cabling between D790-1/K2:3 – CLIMATE, 9.4.2 Fresh
been triggered due damper to the control unit and the M612/3 menu 6 air filter and
to short circuit or ventilation not component with diag- recirculation
open circuit in cir- working. nostic menu. damper
cuit for recirculation Check the motor.
actuating motor
(M612).
48 Transistor has Heat in cab Check cabling between D790-1/K4:1 – CLIMATE, 9.4.5 Water
been triggered due cannot be ad- the control unit and the Y673/5 menu 7 valve
to short circuit or justed. component with diag-
open circuit in cir- nostic menu.
cuit for water valve Check the motor.
(Y673).
49 Transistor has Heat in cab Check cabling between D790-1/K4:2 – CLIMATE, 9.4.5 Water
been triggered due cannot be ad- the control unit and the Y673/6 menu 7 valve
to short circuit or justed. component with diag-
open circuit in cir- nostic menu.
cuit for water valve Check the motor.
(Y673).
51 Transistor has Air distribu- Check cabling between D790-1/K4:4 – CLIMATE, 9.4.14 Air dis-
been triggered due tion in cab the control unit and the Y672/6 menu 8 tributor
to short circuit or cannot be ad- component with diag-
open circuit in cir- justed. nostic menu.
cuit for actuating Check the motor.
motor (Y672).
53 Transistor has Windshield Check cabling between D790-1/K5:4 – CAB, 9.5.4 Washer
been triggered due washer rear the control unit and the M651-2 menu 1 motor and
to short circuit or and roof not component with diag- reservoir
open circuit in cir- working. nostic menu.
cuit for roof and Check the motor.
rear washer motor
(M651-2).
54 Transistor has Flashing haz- Check cabling between D790-1/K5:5 – LIGHTS, 9.6.7 Flash-
been triggered due ard lights not the control unit and the S109/ menu 7 ing hazard
to short circuit or working. component with diag- lights
open circuit in cir- nostic menu.
cuit for flashing Check the switch.
hazard light switch
(S109).
55 Transistor has Reduced or Check bulbs for back- D7901/K6:1, K LIGHTS, 9.1 Controls
been triggered due no back- ground lighting, change 8:15, K 9:2, all menu 14 and instru-
to short circuit or ground light- if needed. inputs of type A ments
open circuit in cir- ing in Check cable harness to Digital in
cuit for background switches and background lighting.
lighting in switches instruments
and instruments.
57 Transistor has Indicator light Check cabling between D790-1/ K7:9 – - 7.1.1 Control
been triggered due for levelling the control unit and the S815/7 levers/Joy-
to short circuit or lock in joy- component with diag- stick
open circuit in cir- stick not nostic menu.
cuit for indicator working. Check the component.
light for levelling
lock in joystick
(S815).
58 Transistor has Twistlock on Check cabling between D790-1/ K7:10 EXT-AT- 7.9.2 Twist-
been triggered due external top the control unit and the – K3005/86 TACH, locks
to short circuit or lift attachment component with diag- menu 6
open circuit in cir- does not nostic menu.
cuit for relay for work. Check the component.
twistlock on exter-
nal top lift attach-
ment (K3005).
59 Transistor has Spreading on Check cabling between D790-1/ K7:11 EXT-AT- 7.10.5.1
been triggered due external top the control unit and the – K3006/86 TACH, Spreading
to short circuit or lift attachment component with diag- menu 6
open circuit in cir- does not nostic menu.
cuit for relay for work. Check the component.
spreading on exter-
nal top lift attach-
ment (K3006).
60 Transistor has Seat heating Check cabling between D790-1/ K10:7 CAB, 9.3.3 Heating
been triggered due does not the control unit and the – K383/86 menu 8 coils
to short circuit or work. component with diag-
open circuit in cir- nostic menu.
cuit for relay for Check the component.
heating element in
driver’s seat
(K383).
61 Transistor has Work lights Check cabling between D790-1/ K10:8 LIGHTS, 9.6.10 Work-
been triggered due 40’ not work- the control unit and the – K3017-1/86 menu 12 ing lights, cab
to short circuit or ing. component with diag-
open circuit in cir- nostic menu.
cuit for relay for 40’ Check the component.
working lights
(K3017-1).
66 Transistor has Windshield Check cabling between D790-1/K10:13 CAB, 9.5.4 Washer
been triggered due washer not the control unit and the – M651-1, menu 1 motor and
to short circuit or working. component with diag- M651-2 reservoir
open circuit in cir- nostic menu.
cuit for windscreen Check the component.
washer motor
(M651-1, M651-2).
67 Transistor has Wiper roof not Check cabling between D790-1/K10:14 CAB, 9.5.6 Wiper
been triggered due working. the control unit and the – M650-3 menu 4 motor roof
to short circuit or component with diag-
open circuit in cir- nostic menu.
cuit for roof wiper Check the motor.
motor (M650-3).
68 Transistor has Pause heater Check cabling between D790-1/K10:15 - 9.4 Heating,
been triggered due not working. the control unit and the – M667 ventilation
to short circuit or component with diag- and air condi-
open circuit in cir- nostic menu. tioning
cuit for circulation Check the motor.
pump, pause heat-
er (M667).
71 Transistor has Interior light- Check bulb. D790-1/K11:6 LIGHTS, 9.6.11 Interior
been triggered due ing in cab not Check cabling between – E434-1 menu 9 lighting cab
to short circuit or working. the control unit and the
open circuit in cir- component with diag-
cuit for cab interior nostic menu.
lighting (E434-1).
75 Relay ignition volt- The cab con- Check cabling between - CAN/ 11.5.1.3 Igni-
age (K315-1) has trol unit the control unit and the POWER, tion voltage
jammed in position (D790-1) still component with diag- menu 5
on. has a power nostic menu.
supply and is Check the component.
thereby ac-
tive.
80 No signal from Air condition- Check drive belt for air D797-1/K1:40 CLIMATE, 9.4.10 Pres-
Pressure switch air ing not work- conditioning compres- – S246 menu 3 sure switch
conditioning ing. sor.
(S246), despite the Check that compressor
AC compressor be- for air conditioning is ac-
ing activated. tivated.
Check cabling between
the control unit and the
component with diag-
nostic menu.
81 Faulty signal from Air distribu- Check cabling between D790-1/K4:7 – CLIMATE, 9.4.6 Fresh
actuating motor tion cannot be the control unit and the Y672/9 menu 4 air and recir-
(Y672). Signal volt- changed. component with diag- culation
age under 0.2 V or nostic menu. damper
over 4.8 V. Check the motor.
85 Faulty signal from Accelerator Check cabling between D790-1/K6:11 ENGINE, 1 Engine
accelerator pedal pedal for for- the control unit and the – B690-1/2 menu 1
(B690-1). Signal ward opera- component with diag-
voltage under 0.2 V tion not nostic menu.
or over 4.8 V. working. En- Check the component.
gine speed
limited to
idling speed.
87 Faulty signal from Lift and lower Check cabling between D790-1/K7:3 – ELSERV, 7.1.1 Control
lifting/lower control not working. the control unit and the R8071/3 menu 1 lever
lever (R8071). Sig- component with diag- (P1)
nal voltage under nostic menu.
0.2 V or over 4.8 V. Check the lever.
88 Faulty signal from Tilt not work- Check cabling between D790-1/K7:4 – ELSERV, 7.1.1 Control
tilt control lever ing. the control unit and the R8072/3 menu 1 lever
(R8072). Signal component with diag- (P2)
voltage under 0.2 V nostic menu.
or over 4.8 V. Check the lever.
89 Faulty signal from Side shift not Check cabling between D790-1/K7:5 – ELSERV, 7.1.1 Control
side shift control le- working. the control unit and the R8073/3 menu 1 lever
ver (R8073). Signal component with diag- (P3)
voltage under 0.2 V nostic menu.
or over 4.8 V. Check the lever.
90 DCF370-500/ Spreading not Check cabling between D790-1/K7:6 – ELSERV, 7.1.1 Control
DCF90-100 working. the control unit and the R8074/3 menu 2 lever
Faulty signal from component with diag- (P4)
spreading control nostic menu.
lever (R8074). Sig- Check the lever.
nal voltage under
0.2 V or over 4.8 V.
92 Faulty signal from Joystick Check cabling between D790-1/K9:8 – EL- 5.1.2 Mini-
steering lever steering or the control unit and the R825-1/H1 STEER- wheel
(R825-1) or mini- mini-wheel component with diag- ING, menu 5.1.3 Joystick
wheel (R825-1). not working. nostic menu. 1
Signal voltage un- Check the switch.
der 0.2 V or over
4.8 V.
93 Faulty signal from Joystick Check cabling between D790-1/K9:9 – EL- 5.1.2 Mini-
mini-wheel (R825- steering or the control unit and the R825-2/H2 STEER- wheel
2). Signal voltage mini-wheel component with diag- ING, menu
under 0.2 V or over not working. nostic menu. 1
4.8 V. Check the switch.
94 Faulty signal from Cab heat can- Check cabling between D790-1/K10:4 CLIMATE, 9.4.5 Water
cab heater water not be adjust- the control unit and the – Y673/9 menu 4 valve
valve (Y673). Sig- ed. component with diag-
nal voltage under nostic menu.
0.2 V or over 4.8 V. Check the motor.
DCF360-450CSG Extension
Faulty signal from right not work-
control lever for ex- ing.
tension right
(R8075-2). Signal
voltage under 0.2 V
or over 4.8 V.
96 Faulty signal from Air condition- Check cabling between D790-1/K4:8 – CLIMATE, 9.4.17 Sen-
cab temperature ing not work- the control unit and the B775-1/2 menu 1 sor cab tem-
sensor (B775-1) ing. component with diag- perature
Sensor indicates nostic menu.
temperature under Check the sensor.
-43 °C or over
105°C.
97 Faulty signal from Air condition- Check cabling between D790-1/K4:9 – CLIMATE, 9.4.18 Sen-
outdoor tempera- ing not work- the control unit and the B774/2 menu 2 sor outdoor
ture sensor (B774). ing. component with diag- temperature
Temperature signal nostic menu.
over 105 °C. Check the sensor.
98 Faulty signal from Air condition- Check cabling between D790-1/K4:10 CLIMATE, 9.4.16 Sen-
outlet fan tempera- ing not work- the control unit and the – B775-2/2 menu 2 sor tempera-
ture sensor (B775- ing. component with diag- ture outlet fan
2) Sensor indicates nostic menu.
temperature under Check the sensor.
-43 °C or over
105°C.
99 Faulty signal from Air condition- Check cabling between D790-1/K4:11 CLIMATE, 9.4.12 Sen-
refrigerant temper- ing not work- the control unit and the – B775-3/2 menu 2 sor tempera-
ature sensor ing. component with diag- ture
(B775-3) Sensor in- nostic menu. refrigerant
dicates tempera- Check the sensor.
ture under -43 °C or
over 105 °C.
102 Redundant voltage – Check cabling between D797-1/K2:8 CAN/ 11.5.1.2 Re-
feed right to frame the control unit and the POWER, dundant volt-
control unit (D797- component with diag- menu 10 age feed of
1) does not reach nostic menu. control units
destination. Check the control unit.
103 Incorrect power No electric Check fuse F58-2/1, D797-1/K2:1, CAN/ 11.5.1.3 Igni-
supply to frame power feed to change if needed. K2:9, K2:10 – POWER, tion voltage
control unit (D797- components. Check cabling between F58-2/1:1, 1:2 menu 10 (15)
1). Voltage under the control unit and the
18 V or over 32 V. component with diag-
nostic menu.
104 Incorrect emergen- Functions Check fuse F58-2:1 and D797-1/K2:11 CAN/ 11.5.1.4
cy stop switch volt- normally sup- replace if necessary. – F58-2/1:1 POWER, Emergency
age to frame plied emer- Check the wiring be- menu 10 stop switch
control unit (D797- gency stop tween the control unit voltage
1) switch volt- and component with the
age have no diagnostic menu.
feed. All hy-
Check component.
draulic func-
tions blocked.
105 Incorrect 5 V refer- Incorrect Check cabling between D797-1/K1:8 – CAN/ 8.2.1 Over-
ence voltage to function, lift the control unit and the B768-1/1, POWER, load protec-
pressure sensor. and tilt sensor component with diag- B768-2/1 menu 11 tion
Voltage under 4.9 V nostic menu.
or over 5.1 V. Check the sensor.
106 Transistor has Cooling fan Check cabling between D797-1/K1:14 HYD, 10.6.3 Cool-
been triggered due hydraulic oil the control unit and the – M668/1 menu 1 ing fan
to short circuit or not working. component with diag-
open circuit in cir- nostic menu.
cuit for hydraulic oil Check the motor.
cooling fan (M668).
107 Transistor has Mast work Check bulb. D797-1/K1:1 – LIGHTS, 9.6.9 Working
been triggered due lights not Check the lamp holder. E404L-1, menu 10 lights mast
to short circuit or working. E404R-1
open circuit in cir- Check cabling between
cuit for mast work the control unit and the
lights (E404R-1, component with diag-
E404L-1). nostic menu.
109 Transistor has Low beams Check bulb. D797-1/K1:28 LIGHTS, 9.6.1 Head-
been triggered due not working. Check the lamp holder. – E400L, menu 3 lights
to short circuit or E400R
Check cabling between
open circuit in cir-
the control unit and the
cuit for low beam
component with diag-
(E400L, E400R).
nostic menu.
111 Transistor has Running Check bulb. D797-1/K1:2 – LIGHTS, 9.6.2 Run-
been triggered due lights not Check the lamp holder. H416-1, H416- menu 2 ning lights
to short circuit or working. 2, H417-1,
Check cabling between
open circuit in cir- H417-2
the control unit and the
cuit for running
component with diag-
lights (H416-1,
nostic menu.
H416-2, H417-1,
H417-2).
112 Transistor has Cooling fan Check cabling between D797-1/K1:3 – HYD, 4.8.9 Cooling
been triggered due brake oil not the control unit and the M674/1 menu 2 fan
to short circuit or working. component with diag-
open circuit in cir- nostic menu.
cuit for brake oil Check the motor.
cooling fan (M674).
Hydraulic servo, Mast lifting/ Check cabling between D797-1/K1:4 – FREEL- 7.2.5 Shuttle
freelift lowering not the control unit and the Y6004-1/1 IFT, menu valve, freelift
Transistor has working. component with diag- Y6005-1/1 2
been triggered due nostic menu.
to short circuit or Check the solenoid
open circuit in cir- valves.
cuit for solenoid
valve, lift mast
(Y6005-1) and so-
lenoid valve, lower
mast (Y6004-1).
Hydraulic servo Mast lifting/ Check cabling between D797-1/K1:4 – OLS, 7.10.5 Sepa-
Transistor has lowering not the control unit and the Y6045/1, menu 5 rate top lift
been triggered due working. component with diag- Y6076/1 and 6 mast
to short circuit or nostic menu.
open circuit in cir- Check the solenoid
cuit for solenoid valves.
valve, stop mast lift
(Y6045) and sole-
noid, stop mast
lower (Y6076).
Hydraulic servo Carriage Check cabling between D797-1/K1:5 – FREEL- 7.2.5 Shuttle
Transistor has freelift not the control unit and the Y6004-2/1 IFT, menu valve, freelift
been triggered due working. component with diag- Y6005-2/1 2
to short circuit or nostic menu.
open circuit in cir- Check the solenoid
cuit for solenoid valve.
valve, lift carriage
(Y6005-2) and so-
lenoid valve, lower
carriage (Y6004-2).
115 Transistor has Left direction Check bulb. D797-1/K1:30 LIGHTS, 9.6.6 Direc-
been triggered due indicator not Check the lamp holder. – H422/1, menu 4 tion indicators
to short circuit or working. H426/1
Check cabling between
open circuit in cir-
the control unit and the
cuit for left direction
component with diag-
indicator (H422,
nostic menu.
H426).
116 Transistor has Right direc- Check bulb. D797-1/K1:31 LIGHTS, 9.6.6 Direc-
been triggered due tion indicator Check the lamp holder. – H423/1, menu 4 tion indicators
to short circuit or not working. H427/1
open circuit in cir- Check cabling between
cuit for right direc- the control unit and the
component with diag-
tion indicator
(H423, H427). nostic menu.
117 Transistor has Starter motor Check cabling between D797-1/K1:32 ENGINE, 1.11 Start
been triggered due not working. the control unit and the – K315/85 menu 5 and stop
to short circuit or component with diag-
open circuit in cir- nostic menu.
cuit for start relay Check the component.
(K315) for starter
motor.
119 Transistor has Brake light left Check bulb. D797-1/K1:7 – LIGHTS, 9.6.4 Brake
been triggered due not working. Check the lamp holder. H411L/1 menu 8 lights
to short circuit or
Check cabling between
open circuit in cir-
the control unit and the
cuit for left brake
component with diag-
light (H411L).
nostic menu.
120 Transistor has Brake light Check bulb. D797-1/K1:9 – LIGHTS, 9.6.4 Brake
been triggered due right not work- Check the lamp holder. H411R/1 menu 8 lights
to short circuit or ing.
Check cabling between
open circuit in cir-
the control unit and the
cuit for right brake
component with diag-
light (H411R).
nostic menu.
121 Transistor has Back-up Check cabling between D797-1/K1:10 LIGHTS, 9.7.5 Back-up
been triggered due alarm not the control unit and the – H965/1 menu 8 alarm
to short circuit or working. component with diag-
open circuit in cir- nostic menu.
cuit for reversing Check the component.
warning device
(H965).
122 Transistor has Air condition- Check cabling between D797-1/K1:25 CLIMATE, 9.4.7 Com-
been triggered due ing not work- the control unit and the – M645/1 menu 6 pressor
to short circuit or ing. component with diag-
123 D797-1/K1:29
open circuit in cir- nostic menu.
– M645/1
cuit for electromag- Check the component.
netic clutch of AC
compressor
(M645).
NOTE! Error code
122 and 123 apply
to the same user.
124 Transistor has Disconnec- Check cabling between D797-1/K1:34 HYD, 10.4.3 Vane
been triggered due tion of pump 2 the control unit and the – Y6062/1 menu 6 pump with
to short circuit or not working. component with diag- fixed dis-
open circuit in cir- nostic menu. placement
cuit for solenoid Check the solenoid
valve, hydraulic valve.
pump disengage-
ment (Y6062).
126 Transistor has Regenera- Check cabling between D797-1/K1:12 ELSERV, 7.2.6 Valve
been triggered due tion not work- the control unit and the – Y6052/1 menu 15 block lift cylin-
to short circuit or ing. component with diag- der
open circuit in cir- nostic menu.
cuit for solenoid Check component.
valve regeneration,
lift, left (Y6052).
133 Faulty signal from Scales, re- Check the sensor. D797-1/K1:21 HYD, 7.2.8 Sensor
hydraulic pressure generation Check cabling between – B768-1/3 menu 3 hydraulic
sensor for lift cylin- and slack the control unit and the OLS, pressure lift
der (B768-1). chain logic, component with diag- menu 1 cylinder
not working. nostic menu.
Overload sys-
tem not work-
ing. Error
code 150 acti-
vated.
134 Faulty signal from Overload sys- Check the sensor. D797-1/K1:22 HYD, 7.7.8 Hydrau-
hydraulic pressure tem not work- Check cabling between – B768-2/3 menu 3 lic pressure
sensor for tilt cylin- ing. Error the control unit and the OLS, sensor, tilt
der (B768-2). code 150 acti- component with diag- menu 1 cylinder
vated. nostic menu.
135 No feedback signal - Check that cooling fan is D797-1/K2:6 – HYD, 4.8.9 Cooling
from brake oil cool- working. M674/2 menu 2 fan
ing fan (M674). Check cabling between
the control unit and the
component with diag-
nostic menu.
Hydraulic servo, Lift mast not Check cabling between D797-1/K1:16 FREEL- 7.2.5 Shuttle
freelift working. the control unit and the – Y6005-1/2 IFT, menu valve, freelift
Faulty signal from component with diag- 2
solenoid valve for nostic menu.
lift mast (Y6005-1). Check the solenoid
Return current valve.
does not match
control current.
Hydraulic servo Lift mast not Check cabling between D797-1/K1:16 OLS, 7.10.5 Sepa-
Faulty signal from working. the control unit and the – Y6045/2 menu 5 rate top lift at-
solenoid valve for component with diag- tachment
interrupt mast lift nostic menu.
(Y6045). Return Check the solenoid
current does not valve.
match control cur-
rent.
Hydraulic servo, Lower mast Check cabling between D797-1/K1:17 FREEL- 7.2.5 Shuttle
freelift not working. the control unit and the – Y6004-1/2 IFT, menu valve, freelift
Faulty signal from component with diag- 2
solenoid valve for nostic menu.
lower mast (Y6004- Check the solenoid
1). Return current valve.
does not match
control current.
Hydraulic servo Lower mast Check cabling between D797-1/K1:17 OLS, 7.10.5 Sepa-
Faulty signal from not working. the control unit and the – Y6076/2 menu 6 rate top lift at-
solenoid valve for component with diag- tachment
interrupt mast low- nostic menu.
ering (Y6076). Re- Check the solenoid
turn current does valve.
not match control
current.
139 Electric servo Tilt in not Check cabling between D797-1/K1:18 ELSERV, DCF370-500:
Faulty signal from working. the control unit and the – Y6011/2 menu 5 7.7.5 Control
solenoid valve for component with diag- valve, load
tilt in (Y6011). Re- nostic menu. handling
turn current does Check the solenoid DCF360-
not match control valve. 450CSG:
current. 7.7.5 Control
valve, lift and
tilt
Hydraulic servo Lift not work- Check cabling between D797-1/K1:18 FREEL- 7.2.5 Shuttle
Faulty signal from ing. the control unit and the – Y6005-2/2 IFT, menu valve, freelift
solenoid valve for component with diag- 2
lift carriage (Y6005- nostic menu.
2). Return current Check the solenoid
does not match valve.
control current.
Hydraulic servo Lower not Check cabling between D797-1/K1:19 FREEL- 7.2.5 Shuttle
Faulty signal from working. the control unit and the – Y6004-2/2 IFT, menu valve, freelift
solenoid valve for component with diag- 2
lower carriage nostic menu.
(Y6004-2). Return Check the solenoid
current does not valve.
match control cur-
rent.
141 Transistor has Parking brake Check cabling between D797-1/K1:34 HYD, 4.5.3 Sole-
been triggered due cannot be re- the control unit and the – Y642/1 menu 5 noid valve
to short circuit or leased. component with diag- parking brake
open circuit in cir- nostic menu.
cuit for parking Check the solenoid
brake solenoid valve.
valve (Y642).
143 Transistor has Spreading Check cabling between D797-1/K1:36 EXT-AT- 7.10.5 Sepa-
been triggered due and twistlocks the control unit and the – Y6039/6018/ TACH, rate top lift at-
to short circuit or on top lift at- component with diag- 1 menu 5 tachment
open circuit in cir- tachment not nostic menu.
cuit for solenoid working. Check the solenoid
valve, lock twist- valve.
locks/spreading out
(Y6039/6018).
144 Transistor has Spreading Check cabling between D797-1/K1:37 EXT-AT- 7.10.5 Sepa-
been triggered due and twistlocks the control unit and the – Y6040/6019/ TACH, rate top lift at-
to short circuit or on top lift at- component with diag- 1 menu 5 tachment
open circuit in cir- tachment not nostic menu.
cuit for solenoid working. Check the solenoid
valve, open twist- valve.
locks/spreading in
(Y6040/6019).
146 Faulty signal from Speed limited Check the sensor. D797-1/K2:6 – HYD, 4.8.10 Sen-
brake oil tempera- to 5 km/h. Check cabling between B772/1 menu 2 sor brake oil
ture sensor (B772). the control unit and the temperature
Signal voltage un- component with diag-
der 0.2 V or over nostic menu.
4.8 V.
147 High hydraulic oil No limitation. Check that cooling fan is D797-1/K2:13 HYD, 10.6.4 Sen-
temperature. working. – B776/1 menu 1 sor hydraulic
Check that cooler isn’t oil tempera-
clogged. ture
148 Faulty signal from Incorrect tem- Check the sensor. D797-1/K2:13 HYD, 10.6.4 Sen-
hydraulic oil tem- perature dis- Check cabling between – B776/1 menu 1 sor hydraulic
perature sensor play. the control unit and the oil tempera-
(B776). component with diag- ture
nostic menu.
149 Faulty signal from Incorrect dis- Check the sensor. D797-1/K2:15 CAB, 1.2.2 Sensor
fuel level sensor play of fuel Check cabling between –B757/1 menu 7 fuel level
(B757). Resistance amount (emp- the control unit and the
over 180 Ω. ty or full). component with diag-
nostic menu.
150 Defective overload Overload sys- Check if there are error – OLS, 8.2.1 Over-
protection. tem not work- codes for sensors in the menu 1 – 7 load protec-
This error code ing. All lift overload system. tion
cannot be removed functions op-
with Reset. erate at re-
duced speed.
151 Redundant voltage – Check cabling between D797-2/K2:7 CAN/ 11.5.1.2 Re-
feed left to frame the control unit and the POWER, dundant volt-
control unit option component with diag- menu 13 age feed of
(D797-2) does not nostic menu. Control units
reach destination. Check the control unit.
153 Incorrect power No electric Check fuse F58-2/3, D797-2/K2:1/9/ CAN/ 11.5.1.3 Igni-
supply to frame power feed to change if needed. 10 POWER, tion voltage
control unit option components. Check cabling between D797-2/K2:1, menu 13 (15)
(D797-2). Voltage the control unit and the K2:9, K2:10 –
under 18 V or over component with diag- F58-2/3:1, 3:2
32 V. nostic menu.
154 Incorrect control Functions Check fuse F58-3/5; re- D797-F/K2:11 CAN/ 11.5.1.4
switch voltage to normally sup- place if needed. – F58-3/5:1 POWER, Emergency
frame control unit, plied emer- Check cabling between menu 13 stop switch
option (D797-2). gency stop the control unit and the voltage
switch volt- component with diag-
age have no nostic menu.
feed. All hy-
draulic func-
tions blocked.
155 Incorrect 5 V refer- – Check cabling between D797-2/K1:8 CAN/ 11.5.1 Power
ence voltage to the control unit and the POWER, supply
pressure sensor. component with diag- menu 14
Voltage under 4.9 V nostic menu.
or over 5.1 V. Check the sensor.
157 Transistor has Rear high Check bulb. D797-2/K1:1 – VBFS, 9.6.1 Head-
been triggered due beam not Check the lamp holder. E402R-2/1, menu 6 lights
to short circuit or working. E402L-2/1
Check cabling between
open circuit in cir-
the control unit and the
cuit for rear high
component with diag-
beam (E402R-2,
nostic menu.
E402L-2).
158 Transistor has Rear low Check bulb. D797-2/K1:15 VBFS, 9.6.1 Head-
been triggered due beam not Check the lamp holder. – E401R/1, menu 6 lights
to short circuit or working. E401L/1
Check cabling between
open circuit in cir-
the control unit and the
cuit for rear low
component with diag-
beam (E401R,
nostic menu.
E401L).
161 Transistor has Joystick Check cabling between D797-2/K1:2 – EL- 5.2.10 Con-
been triggered due steering or the control unit and the Y636-3/1 STEER- trol valve joy-
to short circuit or mini-wheel component with diag- ING, menu stick steering/
open circuit in cir- not working. nostic menu. 5 mini-wheel
cuit for solenoid Check the solenoid
valve, steering right valve.
(Y636-3).
162 Transistor has Joystick Check cabling between D797-2/K1:3 – EL- 5.2.10 Con-
been triggered due steering or the control unit and the Y636-4 /1 STEER- trol valve joy-
to short circuit or mini-wheel component with diag- ING, menu stick steering/
open circuit in cir- not working. nostic menu. 4 mini-wheel
cuit for solenoid Check the solenoid
valve, steering right valve.
(Y636-4).
163 Transistor has Lift carriage Check cabling between D797-2/K1:4 – ELSERV, 7.2.6 Control
been triggered due not working. the control unit and the Y6022/1 menu 11 valve load
to short circuit or component with diag- handling
open circuit in cir- nostic menu.
cuit for solenoid Check the solenoid
valve, lift carriage valve.
(Y6022).
164 Transistor has Lower car- Check cabling between D797-2/K1:5 – ELSERV, 7.2.6 Control
been triggered due riage not the control unit and the Y6023/1 menu 12 valve load
to short circuit or working. component with diag- handling
open circuit in cir- nostic menu.
cuit for solenoid Check the solenoid
valve, lower car- valve.
riage (Y6023).
165 Transistor has Side shift right Check cabling between D797-2/K1:30 ELSERV, 7.4.5 Control
been triggered due not working. the control unit and the – Y6021/1 menu 8 valve load
to short circuit or component with diag- handling
open circuit in cir- nostic menu.
cuit for solenoid Check the solenoid
valve, side shift valve.
right (Y6021).
167 Transistor has Spreading in Check cabling between D797-2/K1:32 ELSERV, 7.5.5 Control
been triggered due not working. the control unit and the – Y6019/1 menu 9 valve load
to short circuit or component with diag- handling
open circuit in cir- nostic menu.
cuit for solenoid Check the solenoid
valve, spreading in valve.
(Y6019).
168 Transistor has Spreading out Check cabling between D797-2/K1:33 ELSERV, 7.5.5 Control
been triggered due not working. the control unit and the – Y6018/1 menu 10 valve load
to short circuit or component with diag- handling
open circuit in cir- nostic menu.
cuit for solenoid Check the solenoid
valve, spreading valve.
out (Y6018).
169 Reversible opera- Driver’s seat Check cabling between D797-2/K1:7 – CAN/ 9.3.9.2 Sen-
tor's seat position indi- the control unit and the S720-F/1, POWER, sor reversible
Transistor has cator not component with diag- S720-R/1 menu 14 driver’s seat
been triggered due working. nostic menu.
to short circuit or Check the sensor.
open circuit in cir-
cuit for reversible
driver’s seat sensor
(S720-F, S720-R).
Tiltable cab Cab position Check cabling between D797-2/K1:7 – CAN/ 9.10.4.7 Sen-
Transistor has indicator not the control unit and the B769-1/A, POWER, sor, cab up/
been triggered due working. component with diag- B769-2/A menu 14 cab down
to short circuit or nostic menu.
open circuit in cir- Check the sensor.
cuit for sensor for
cab tilt (B769-1,
B769-2).
170 Transistor has Change of Check cabling between D797-2/K1:9 – VBFS, 5.2.15 Direc-
been triggered due steering an- the control unit and the Y636-1/1 menu 5 tion valve, re-
to short circuit or gle for revers- component with diag- versible
open circuit in cir- ible driver’s nostic menu. driver’s seat
cuit for solenoid seat not work- Check the solenoid
valve, steering for- ing. valve.
ward (Y636–1).
172 Reversible opera- Front tail Check bulb. D797-2/K1:25 VBFS, 9.6.3 Rear
tor's seat lights, not Check the lamp holder. – H413R/1, menu 7 lights
Transistor has working H413L/1
Check cabling between
been triggered due the control unit and the
to short circuit or component with diag-
open circuit in cir- nostic menu.
cuit for front tail
light (H413R,
H413L).
Cab sliding Cab sliding Check cabling between D797-2/K1:25 - 9.10.4 Hy-
Transistor has not working. the control unit and the – Y6080/1 draulic slid-
been triggered due component with diag- ing cab
to short circuit or nostic menu.
open circuit in cir- Check the solenoid
cuit for solenoid valve.
valve, cab sliding
(Y6080).
173 Reversible opera- Rotation of Check cabling between D797-2/K1:29 VBFS, 9.3.10.1 Con-
tor's seat driver’s seat the control unit and the – Y646-1/1 menu 2 trol valve, re-
Transistor has not working component with diag- versible
been triggered due nostic menu. driver’s seat
to short circuit or Check the solenoid
open circuit in cir- valve.
cuit for solenoid
valve, reversible
driver’s seat, clock-
wise (Y646-1).
Tiltable cab Cab tilt up not Check cabling between D797-2/K1:29 MOVING- 9.10.4.5 Con-
Transistor has working. the control unit and the – Y6047/1 CAB, trol valve, cab
been triggered due component with diag- menu 4 tilt
to short circuit or nostic menu.
open circuit in cir- Check the solenoid
cuit for solenoid valve.
valve, cab tilt up
(Y6047).
Tiltable cab Cab tilt down Check the wiring be- D797-2/K1:39 MOVING- 9.10.4.5 Con-
Transistor has not working. tween the control unit – Y6048/1 CAB, trol valve, cab
been triggered due and component with the menu 4 tilt
to short circuit or diagnostic menu.
open circuit in cir- Check component.
cuit for solenoid
valve, cab tilt down
(Y6048).
187 Faulty signal from Joystick Check cabling between D797-2/K1:16 AUXILIA- 5.2.10 Con-
steering solenoid steering or the control unit and the – Y636-3/2, RY / EL- trol valve joy-
valve (Y636-3, mini-wheel component with diag- Y636-4/2 STEER- stick steering/
Y636-4). Return not working. nostic menu. ING, menu mini-wheel
current does not Check the solenoid 4 and 5
match control valve.
current.
188 Faulty signal from Carriage lift- Check cabling between D797-2/K1:17 ELSERV, 5.2.10 Con-
solenoid valve, lift ing/lowering the control unit and the – Y6022/2, menu 11 trol valve joy-
carriage (Y6022) not working. component with diag- Y6023/2 and 12 stick steering/
and solenoid valve, nostic menu. mini-wheel
lower carriage Check the solenoid
(Y6023). Return valve.
current does not
match control
current.
189 Faulty signal from Side shift not Check cabling between D797-2/K1:18 ELSERV, 7.4.5 Control
solenoid valve, side working. the control unit and the – Y6020/2, menu 7 valve load
shift left (Y6020) component with diag- Y6021/2 and 8 handling
and solenoid valve, nostic menu.
side shift right Check the solenoid
(Y6021). Return valve.
current does not
match control
current.
193 Transistor has Right front Check bulb. D797-1/K1:36 VBFS, 9.6.4 Brake
been triggered due brake light not Check the lamp holder. – H410R/1 menu 8 lights
to short circuit or working.
Check cabling between
open circuit in cir-
the control unit and the
cuit for right front
component with diag-
brake light
(H410R). nostic menu.
194 Transistor has Left front Check bulb. D797-1/K1:37 VBFS, 9.6.4 Brake
been triggered due brake light not Check the lamp holder. – H410L/1 menu 8 lights
to short circuit or working.
open circuit in cir- Check cabling between
cuit for left front the control unit and the
brake light (H410L). component with diag-
nostic menu.
251 Redundant voltage - Check cabling between D791-1/K2:7 CAN/ 11.5.1.2 Re-
feed left to frame the control unit and the POWER, dundant volt-
control unit (D791- component with diag- menu 15 age feed of
1) does not reach nostic menu. Control units
destination. Check the control unit.
252 Redundant voltage - Check cabling between D791-1/K2:8 CAN/ 11.5.1.2 Re-
feed right to frame the control unit and the POWER, dundant volt-
control unit (D791- component with diag- menu 15 age feed of
1) does not reach nostic menu. Control units
destination. Check the control unit.
253 Incorrect power Functions Check fuse F58-3/1, D791-1/K2:1, CAN/ 11.5.1.4
supply to attach- normally sup- change if needed. K2:9, K2:10 – POWER, Emergency
ment control unit plied emer- Check cabling between F58-3/1:1 menu 15 stop switch
(D791-1). Voltage gency stop the control unit and the voltage
under 18 V or over switch volt- component with diag-
32 V. age have no nostic menu.
feed. No at-
tachment
functions
operational.
255 Incorrect 5 V refer- – Check cabling between D791-1/K1:8 CAN/ 11.5.1 Power
ence voltage to the control unit and the POWER, supply
pressure sensor. component with diag- menu 16
Voltage under 4.9 V nostic menu.
or over 5.1 V. Check the sensor.
256 Transistor has Central lubri- Check cabling between D791-1/K1:14 OPT, 9.14.1 Pump
been triggered due cation attach- the control unit and the – M693-2/1 menu 2 unit
to short circuit or ment not component with diag-
open circuit in cir- working. nostic menu.
cuit for central unit Check the component.
for central lubrica-
tion (M693-2).
257 Transistor has Work light at- Check bulb. D791-1/K1:1 – LIGHTS, 9.6.12 Work
been triggered due tachment left Check the lamp holder. E404L, menu 13 light
to short circuit or not working. E404UL, attachment
open circuit in cir- Check cabling between
E404LL-3/1
cuit for attachment the control unit and the
work lights, left component with diag-
(E404L-3). nostic menu.
258 Transistor has Work light at- Check bulb. D791-1/K1:15 LIGHTS, 9.6.12 Work
been triggered due tachment Check the lamp holder. – E404R, menu 13 light
to short circuit or right not work- E404UR, attachment
Check cabling between
open circuit in cir- ing. E404LR-3/1
the control unit and the
cuit for attachment
component with diag-
work lights, right
nostic menu.
(E404R-3).
DCF90-100 Warning sig- Check the buzzer. D791-1/K1:28 ATTACH, 7.5.7 Buzzer,
Transistor has nal for auto- Check cabling between – H9003/1 menu 21 automatic
been triggered due matic the control unit and the spreading
to short circuit or spreading not component with diag- 20'-40'
open circuit in cir- working. nostic menu.
cuit for warning sig-
nal, automatic
spreading (H9003).
260 Transistor has Levelling of Check cabling between D791-1/K1:42 ATTACH, 7.8.4 Valve
been triggered due attachment the control unit and the – Y637-1/1, menu 15 block, level-
to short circuit or not working. component with diag- Y637-2/1 ling cylinders
open circuit in cir- nostic menu.
cuit for control Check the solenoid
valve for levelling valve.
clockwise (Y637-1,
Y637-2).
261 DCF360-450CSG Extension left Check cabling between D791-1/K1:2 – ATTACH, 7.3.2 Control
Transistor has in of attach- the control unit and the Y6046-1/1 menu 18 valve
been triggered due ment not component with diag- attachment
to short circuit or working. nostic menu.
open circuit in cir- Check the solenoid
cuit for solenoid valve.
valve, extension left
in (Y6046-1).
DCF90-100 Spreading left Check cabling between D791-1/K1:16 ATTACH, 7.3.2 Control
Transistor has in of attach- the control unit and the – Y6019L/2 menu 18 valve
been triggered due ment not component with diag- attachment
to short circuit or working. nostic menu.
open circuit in cir- Check the solenoid
cuit for solenoid valve.
valve, spreading
left in (Y6019L).
DCF90-100 Spreading left Check cabling between D791-1/K1:16 ATTACH, 7.3.2 Control
Transistor has out of attach- the control unit and the – Y6018L/2 menu 17 valve attach-
been triggered due ment not component with diag- ment
to short circuit or functioning. nostic menu.
open circuit in cir- Check the solenoid
cuit for solenoid valve.
valve, spreading
left out (Y6018L).
263 DCF360-450CSG Extension Check cabling between D791-1/K1:4 – ATTACH, 7.3.2 Control
Transistor has right in of at- the control unit and the Y6046-3/1 menu 20 valve attach-
been triggered due tachment not component with diag- ment
to short circuit or working. nostic menu.
open circuit in cir- Check the solenoid
cuit for solenoid valve.
valve, extension
right in (Y6046-3).
265 DCF360-450CSG Clockwise Check cabling between D791-1/K1:30 ATTACH, 7.8.2 Control
Transistor has levelling of at- the control unit and the – Y6036/1 menu 16 valve attach-
been triggered due tachment not component with diag- ment
to short-circuit or working. nostic menu.
open circuit in cir- Check the solenoid
cuit for control valve.
valve, levelling
clockwise (Y6036).
DCF90-100 Levelling left Check cabling between D791-1/K1:19 ATTACH, 7.8.2 Control
Transistor has of attachment the control unit and the – Y6036/2 menu 13 valve attach-
been triggered due not working. component with diag- ment
to short circuit or nostic menu.
open circuit in cir- Check the solenoid
cuit for levelling, left valve.
(Y6036).
DCF90-100 Levelling right Check cabling between D791-1/K1:19 ATTACH, 7.8.2 Control
Transistor has of attachment the control unit and the – Y6036/2 menu 14 valve
been triggered due not working. component with diag- attachment
to short circuit or nostic menu.
open circuit in cir- Check the solenoid
cuit for solenoid valve.
valve, levelling right
(Y6035).
267 Transistor has Side shift left Check cabling between DCF360- ATTACH, 7.4.2 Control
been triggered due of attachment the control unit and the 450CSG menu 11 valve
to short circuit or not working. component with diag- D791-1/K1:32 attachment
open circuit in cir- nostic menu. – Y6020/1
cuit for solenoid Check the solenoid DCF90-100
valve, side shift left valve.
(Y6020). D791-1/K1:18
– Y6020/2
268 Transistor has Side shift right Check cabling between DCF360- ATTACH, 7.4.2 Control
been triggered due of attachment the control unit and the 450CSG menu 12 valve
to short circuit or not working. component with diag- D791-1/K1:33 attachment
open circuit in cir- nostic menu. – Y6021/1
cuit for solenoid Check the solenoid
valve, side shift DCF90-100
valve.
right (Y6021). D791-1/K1:18
– Y6021/2
269 Transistor has Twistlock/lock Check cabling between D791-1/K1:7 – ATTACH, 7.9.1.2 Con-
been triggered due tongue not the control unit and the Y6040/1 menu 9 trol valve at-
to short circuit or working. component with diag- tachment
open circuit in cir- nostic menu.
cuit for solenoid Check the solenoid
valve, lock twist- valve.
lock/lock tongue
(Y6040).
271 Transistor has Twistlocks Check cabling between D791-1/K1:10 CAN/ 7.9.1.2 Con-
been triggered due and spread- the control unit and the – B769-1/A, POWER, trol valve at-
to short circuit or ing not work- component with diag- B777-1/A, menu 16 tachment
open circuit in cir- ing. nostic menu. B7202L/A,
cuit for voltage feed Check the sensor. B7202R/A,
to attachment posi- B7203L/A,
tion sensor. B7203R/A,
B7204L/A,
B7204R/A,
B7205L/A,
B7205R/A,
Transistor has Sensor on at- Check cabling between D791-1/K1:10 CAN/ 7.9.1.2 Con-
been triggered due tachment not the control unit and the – B769-L/A, POWER, trol valve at-
to short circuit or working. component with diag- B769-R/A, menu 16 tachment
open circuit in cir- nostic menu. B777-L/A,
cuit for voltage feed Check the sensor. B777-R/A,
to attachment sen- B7203L/A,
sor. B7203LL/A,
B7203LU/A,
B7203LU-2/A,
B7203R/A,
B7203RL/A,
B7203RU/A,
B7203RU-2/A,
B7204L/A,
B7204R/A,
B7205LL/A,
B7205LU/A,
B7205RL/A,
B7205RU/A
272 Transistor has Indicator light, Check bulb. D791-1/K1:25 ATTACH, 7.9.1 Twist-
been triggered due open twist- Check the lamp holder. – H562/1 menu 10 locks
to short circuit or lock/lock
open circuit in cir- Check cabling between
tongue not
cuit for indicator the control unit and the
working.
light, twistlock/lock component with diag-
tongue open nostic menu.
(H562).
274 Transistor has Indicator light, Check bulb. D791-1/K1:39 ATTACH, 7.9.1
been triggered due attachment Check the lamp holder. – H564/1 menu 10 Twistlocks
to short circuit or alignment not
Check cabling between
open circuit in cir- working.
the control unit and the
cuit for alignment
component with diag-
indicator light
nostic menu.
(H564).
287 DCF360-450CSG Extension left Check cabling between D791-1/K1:16 ATTACH, 7.3.2 Control
Faulty signal from of attachment the control unit and the – Y6046-1/2, menu 17 valve
solenoid, exten- not working. component with diag- Y6046-2/2 and 18 attachment
sion left in (Y6046- nostic menu.
1) and solenoid Check the solenoid
valve, extension left valve.
out (Y6046-2). Re-
turn current does
not match control
current.
DCF90-100 Spreading left Check cabling between D791-1/K1:16 ATTACH, 7.3.2 Control
Faulty signal from not working. the control unit and the – Y6019L/2, menu 17 valve
solenoid, spreading component with diag- Y6019R/2 and 18 attachment
left in (Y6019L) and nostic menu.
solenoid valve, Check the solenoid
spreading left out valve.
(Y6018L). Return
current does not
match control
current.
289 Faulty signal from Sideshift of Check cabling between D791-1/K1:18 ATTACH, 7.4.2 Control
solenoid valve, side attachment the control unit and the – Y6020/2, menu 11 valve
shift left (Y6020) not working. component with diag- Y6021/2 and 12 attachment
and solenoid valve, nostic menu.
side shift right Check the solenoid
(Y6021). Return valve.
current does not
match control
current.
Faulty signal from Levelling of Check cabling between D791-1/K1:19 ATTACH, 7.5.2 Control
solenoid valve, lev- attachment the control unit and the – Y6035/2, menu 13 valve attach-
elling right (Y6036) not working. component with diag- Y6036/2 and 14 ment
and solenoid valve, nostic menu.
levelling left Check the solenoid
(Y6035). Return valve.
current does not
match control cur-
rent.
291 Transistor has Spreading out Check cabling between D791-1/K1:34 ATTACH, 7.5.2 Control
been triggered due of attachment the control unit and the – Y6018/1 menu 13 valve attach-
to short circuit or not working. component with diag- ment
open circuit in cir- nostic menu.
cuit for solenoid Check the solenoid
valve, spreading valve.
out (Y6018).
Transistor has Indicator light Check bulb. D791-1/K1:34 ATTACH, 7.5.2 Control
been triggered due for upper Check the lamp holder. – H564UL/1 menu 23 valve attach-
to short circuit or alignment not ment
Check cabling between
open circuit in cir- working.
the control unit and the
cuit for indicator
component with diag-
light, upper align-
nostic menu.
ment (H564UL).
292 Transistor has Spreading in Check cabling between D791-1/K1:35 ATTACH, 7.5.2 Control
been triggered due of attachment the control unit and the – Y6019/1 menu 14 valve attach-
to short circuit or not working. component with diag- ment
open circuit in cir- nostic menu.
cuit for solenoid Check the solenoid
valve, spreading in valve.
(Y6019).
298 Twistlock sensor in- Lift and Check that Sensors D791-1/K2:13 ATTACH, 7.9.1.7 Sen-
dicates that left spreading not twistlock are clean and menu 8 sor twistlocks
twistlock is be- working. correctly adjusted.
tween open and Check cabling between
locked position. the control unit and the
component with diag-
nostic menu.
300 Alignment sensor Twistlock not Check that the alignment - ATTACH, 7.9.1.6 Sen-
indicates unreason- working. sensors are clean and menu 7 sor alignment
able distance. correctly adjusted.
Check that alignment pin
runs smoothly.
Check cabling between
the control unit and the
component with diag-
nostic menu.
451 Redundant voltage - Check cabling between D795/K1:7 CAN/ 11.5.1.2 Re-
feed left to KID con- the control unit and the POWER, dundant volt-
trol unit (D795) component with diag- menu 9 age feed of
does not reach nostic menu. control units
destination.
452 Redundant voltage - Check cabling between D795/K1:8 CAN/ 11.5.1.2 Re-
feed right to KID the control unit and the POWER, dundant volt-
control unit (D795) component with diag- menu 9 age feed of
does not reach nostic menu. control units
destination.
460 No messages re- Incorrect val- Use diagnostic menu to D795/K1:10, CAN/ 11.6.2 Re-
ceived on CAN- ues in operat- check CAN-bus K1:11, K1:12, POWER, dundant
buffer 1. ing menus. K1:13 menu 1, 2, CAN-bus
17
461 No messages re- Error codes Use diagnostic menu to D795/K1:5, CAN/ 11.6.2 Re-
ceived on CAN- from other check CAN-bus K1:6 POWER, dundant
buffer 2. Control units menu 1, 2, CAN-bus
cannot be 17
shown.
E Schematics
10 Common hydraulics....................................................................................... 3
Hydraulic diagrams, compilation ............................................................................ 3
Hydraulic diagram DCF 90-100, electric servo ....................................................... 4
11 Common electrics .......................................................................................... 6
Circuit diagram, description ................................................................................... 6
Component designations ........................................................................................ 7
Circuit diagrams, compilation ................................................................................. 8
10 Common hydraulics
mm mm mm mm mm mm
electric servo
26
25
25
28
24
24
23
17
20 22
21
27
16
19
36
6
35
42
18
34
33
4e
32
15
4d
41
14
40
4c
5
43
39
4b
4a
31
38
4
13
7
37
29
30
3
11
10
7
1
11 Common electrics
mm mm mm mm mm mm
Component designations
page
–
Prefix Description
A Unit, sub-unit. Example: amplifier with separate components
B Converter from non-electric to electric signals or vice versa. Example: inductive sensor.
C Capacitor
K Relay, connector.
L Inductance, reactance.
T Transformer.
Z Transformer, network, hybrid, filter, equaliser, limiter. Example: cable balancing network.
Sheet Designation
0.0-1 Crossreference list
Sheet Designation
7.2-2 Circuit, freelift sensors
Sheet Designation
9.6-1 Circuit, work lights 20’-40’
Sheet Designation
11.5-10 Circuit, option, ground
Sheet Designation
0.0_1 Crossreference list
A A
B B
C Kretsar DCF300, DCE300330 C
Wiring DCF 300, DCE300330
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
E E
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Den får ej heller delgivas annan eller annars obe
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F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring DCF370, DCE300330 A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
D7901
K1 1:11:6 /11.5_4.C5 K6 6:1 /9.4_1.B1 LAMP INST. ILLUMINATION PWM K9 9:1 /5.2_1.A2 SWITCHES ARM REST 24V reference
6:2 /9.6_2.B8 SW WLIGHTS CARRIAGE Input 9:2 /5.2_1.C2 LAMP F/R ARM REST 1.5A
K2 2:1 /9.5_1.C1 MOTOR FRONT WIPER 5A 6:3 /9.6_3.B8 SW WORK LIGHTS MAST Input 9:3 /5.2_1.C8 SW REVERSE ARM REST Input
2:2 /9.4_2.C1 MOTOR HEATING FAN PWM 6:4 /9.6_4.C8 SWITCH ROT. BEACON Input 9:4 /5.2_1.B8 SW FORWARD ARM REST Input
2:3 /9.4_2.E1 MOTOR RECIRCULATION 1.5 6:5 /9.6_4.A8 SWITCH MAIN LIGHT Input 9:5 /5.2_1.B8 SW ACT. MICRO STEERING Input
2:4 /9.5_1.D1 MOTOR REAR WIPER 5A 6:6 /9.3_1.B8 SWITCH SEAT HEATER Input
2:5 /9.6_4.E1 MOTOR ROT. BEACON 5A 6:7 /9.1_1.E8 SWITCH S2 OPT. Input 9:6 /5.2_1.D8 POT. MICRO STEERING 0V reference
2:6 /9.6_6.A1 REVERSING LIGHT LEFT 5A 6:8 /9.1_1.D8 SWITCH S3 OPT. Input 9:7 /5.2_1.D2 POT. MICRO STEERING Analog reference 5V
2:7 /9.6_6.B1 REVERSING LIGHT RIGHT 5A 9:8 /5.2_1.D8 POT. MICRO STEERING (P6) Analog Input
2:8 /9.4_2.D8 LOGIC SUPPLY HEAT FAN 6:9 /9.1_1.B8 SWITCH S4 OPT. Input 9:9 /5.2_1.E8 POT. MIC STEER/6TH LEV (P7)Analog Input
6:10 /9.6_1.A8 SW WORK LIGHTS MAST Input 9:10 /5.2_1.A8 SWITCH HORN ARM REST Input
B 6:11 /1.0_1.A8 POT. ACCELERATOR 1 Analog Input B
K4 4:1 /9.4_2.B1 MOTOR WATER VALVE 0.5A
4:2 /9.4_2.B1 MOTOR WATER VALVE 0.5A 6:12 /1.0_1.B8 POT. ACCELERATOR 2 Analog Input
4:3 /9.4_2.A1 MOTOR DRAUGHT VALVE 0.5A 6:13
4:4 /9.4_2.A1 MOTOR DRAUGHT VALVE 0.5A 6:14 /2.0_1.C8 PEDAL DECLUTCHING Input K10 10:1
4:5 /9.4_2.B1 POT. DRAUGHT/WAT. VALVE Analog reference 5V 6:15 10:2
4:6 /9.4_2.B8 POT. DRAUGHT/ WAT VALVE 0V reference 6:16 SEE K11:13 10:3 /7.0_4.B8 SENSOR ALIGNMENT Input
4:7 /9.4_2.B8 POT. DRAUGHT VALVE Analog Input 10:4 /9.4_2.C8 POT. WATER VALVE Analog Input
K7 7:1 /7.0_1.A8 POTENTIOM. EL. SERVO 0V reference 10:5 Input
4:8 /9.4_1.D8 SENSOR TEMP. INDOOR Reostat in 7:2 /7.0_1.A1 POTENTIOM. EL. SERVO Analog reference 5V 10:6 Input
4:9 /9.4_1.F8 SENSOR TEMP. AMBIENT Reostat in 7:3 /7.0_1.A8 POT. LIFT / LOWER (P1) Analog Input 10:7 /9.3_1.C2 RELAY SEAT HEATER 0.5A
4:10 /9.4_1.E8 SENSOR TEMP. FAN AIR Reostat in 7:4 /7.0_1.B8 POT. TILT (P2) Analog Input 10:8 /9.6_1.B1 CONTAINER LIGHT 40 0.5A
4:11 /9.4_1.E8 SENSOR DEICING SENSOR Reostat in 7:5 /7.0_1.C8 POT. SIDE SHIFTING (P3) Analog Input
4:12 /9.4_1.F1 SENSORS AIRCONDITION 0V reference 7:6 /7.0_1.D8 POT. SPREADING (P4) Analog Input 10:9 /9.1_2.B1 HOUR MET/RELAY AIR SEAT 0.5A
4:13 /9.5_1.C8 MOTOR FRONT WIPER Input 7:7 /7.0_1.E8 POT. EXTRA (P5) Analog Input 10:10 /11.5_3.E1 RELAY K3151 0.5A
4:14 /9.5_1.C1 MOTOR FRONT WIPER 24V reference 7:8 /9.6_1.D1 CONTAINER LIGHT 20 0.5A 10:11 /11.5_6.C1 RELAY K30091 0.5A
10:12 /11.5_6.B1 RELAY K30092,K3002,K3007 0.5A
C K5 5:1 /9.1_1.B1 SWITCHES LEFT PANEL 24V reference 7:9 /7.0_2.C1 IND. LOCKED LEVELLING 0.5A 10:13 /9.5_1.E1 MOTOR WASHER 3A C
5:2 7:10 /7.0_5.B1 RELAY ACTIVATE TW 0.5A 10:14 /9.5_1.E1 MOTOR ROOF WIPER 1.5A
5:3 /7.0_4.F2 OVERRIDE ALIGNMENT PWM (NPN) 7:11 /7.0_5.C1 RELAY ACTIVATE SPREAD 0.5A 10:15
5:4 /9.5_1.F8 MOTOR WASH REAR/ROOF PWM (NPN) 7:12 /7.0_2.B1 SWITCHES EL. SERVO Analog Reference 24V 10:16 /11.5_3.F1 RELAY K3152 0.5A
5:5 /9.6_7.B8 SWITCH LAMP HAZARD PWM (PNP) 7:13 /7.5_1.B8 SWITCH SPREADING 2040 Input
5:6 /9.6_7.A8 SWITCH HAZARD Input 7:14 /7.5_1.A8 SWITCH SPREADING 4020 Input K11 11:1 /11.5_3.C8 SWITCH IGNITION Input
5:7 /9.4_1.B8 FAN SPEED Analog Input 7:15 /7.9_1.C8 SWITCH UNLOCK TW Input 11:2 /9.6_8.A8 INTERIOR LIGHT Input
7:16 /7.0_2.C8 SWITCH PISTOL Input 11:3 /9.6_8.B8 SWITCH BREAK CAB DOOR Input
5:8 /9.4_1.C8 TEMPERATURE Analog Input 11:4 /9.6_11.B8 SWITCH STEP IN LIGHT Input
5:9 /9.4_1.C8 DRAUGHT VALVE Analog Input K8 8:1 /7.8_1.E7 SWITCH LOCK LEVELLING Input 11:5
5:10 /9.4_1.D8 POT. FAN / TEMP / DEFROST 0V reference 8:2 /7.0_2.C8 SWITCH LOCK TILT Input 11:6 /9.6_8.D1 LAMP INTERIOR LIGHT 1.5A
5:11 /9.4_1.B1 POT. FAN / TEMP / DVALVE Analog reference 5V 8:3 /8.2_1.B8 SWITCH OVERRIDE Input 11:7 See K13 REDUNDANT POWER Dig out
5:12 /1.0_1.A8 POT. ACCELERATOR 0V reference 8:4 /11.5_6.A8 SW. OPERATING POWER Input
5:13 /1.0_1.A1 POT. ACCELERATOR Analog reference 5V 8:5 /4.0_1.B8 SWITCH PBRAKE OPEN Input 11:8 See K13 REDUNDANT POWER Dig out
5:14 /7.0_4.F8 OVERRIDE ALIGNMENT Input (K10:3) 8:6 /9.3_3.A8 SWITCH REV. SEAT C.W Input 11:9 See K13 REDUNDANT POWER Dig out
8:7 /9.3_3.B8 SWITCH REV. SEAT C.C.W Input 11:10 See K13 REDUNDANT POWER Dig out
D 8:8 /7.0_4.D8 SENSOR LOCK TW Input 11:11 /9.7_1.B2 HORN 3A D
11:12 /9.7_1.D2 SWITCH SEAT 24V reference
8:9 /7.0_4.C8 SENSOR UNLOCK TW Input
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
11:13 /11.5_6.E8 FEEDBACK K2 Input
8:10 /7.5_1.C8 SWITCH 3035 STOP Input 11:14 /9.7_1.D8 SWITCH SEAT Input
8:11 /7.5_3.B7 SWITCH AUT. 2040 Input
8:12 /7.9_1.A8 SWITCH LOCK TW Input K12 12:1 /9.5_1.D1 MOTOR REAR WIPER 24V reference
8:13 /4.0_1.A8 SWITCH PBRAKE LOCKED Input 12:2 /9.5_1.D8 MOTOR REAR WIPER Input
8:14 /9.1_1.A8 SWITCH S1 OPT. Input 12:3 /9.5_1.E1 MOTOR ROOF WIPER 24V reference
8:15 /9.3_3.B1 LIGHT SW. S169/S1010 1.5A 12:4 /9.5_1.E8 MOTOR ROOF WIPER Input
8:16 /7.9_1.C2 SWITCH ELSERVO PANEL 24V reference
K13 13:113:12 /11.6_1.D6 CANBUS
E E
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F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Uppdaterade efter senaste ändring 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Crossreference list A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
D7971
CAN /11.6_1.E8
KDU contact K2
2:13 /10.6_1.A8 SENSOR HYDR. OIL TEMP. Temperature Input
2:16 /1.0_1.E1 D+ D+
C C
D7971
KDU contact K1
KDU contact K1
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
1:13 /4.0_1.D8 PRESSURE SWITCH ACCU. TANK Analog In 05V 1:33 /9.6_6.D1 REAR LIGHTS 1.5A
1:14 /10.6_1.B1 MOTOR COOLING FAN HYDR. OIL 10A 1:34 /4.0_1.E1 VALVE PARKING BRAKE 1.5A
1:15 /9.6_5.C1 HEAD LIGHT 6A 1:35 /10.4_1.D2 PUMP ATTACHMENT 1.5A
1:16 /7.2_1.C8 VALVE LIFT / BLOCK LIFT PWM 1:36 /8.2_3.C1 MAST POSITION 1.5A
1:17 /7.2_1.D8 VALVE LOWER / BLOCK LOWER PWM 1:37 /8.2_3.C8 MAST POSITION Dig In / 1.5A
1:18 /7.7_1.D8 VALVE TILT IN PWM 1:38 0V Ref
1:19 /7.7_1.C8 VALVE TILT OUT PWM 1:39 /10.4_1.C2 VALVE PUMP 2 1.5A
1:20 /9.6_5.E8 PRESSURE SWITCH BRAKE LIGHT Analog In 05V 1:40 /9.4_1.A8 PRESSURE SW. REFRIDGE Dig In / 1.5A
1:41 /4.0_1.C8 PRESSURE SWITCH PBRAKE Analog In 05V
1:42 /9.0_1.C2 CENTRAL LUB. / WORK LIGHT OPT. 6A
E E
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F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Uppdaterade efter senaste ändring 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Crossreference list A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
D7972
Power /11.5_5.D5
CAN /11.6_2C.E3
2:6 Temperature Input
KDU contact K2
B B
2:13 Temperature Input
2:15 Reostat In
2:16 D+
D7972
KDU contact K1
KDU contact K1
1:13 /9.3_3.C8 SWITCH SEAT POS. F Analog In 05V 1:33 /7.5_1.E1 VALVE SPREADING OUT 1.5A
1:14 /11.5_9.A1 OPT. 10A 1:34 /9.3_7.B1 DAMPING TURNABLE SEAT 1.5A
1:15 /9.3_5.B1 LAMP DIPPED LIGHT REAR 6A 1:35 /9.3_7.C1 BRAKE TURNABLE SEAT 1.5A
D 1:16 /5.2_2.B8 VALVE MICRO STEERING PWM 1:36 /9.3_4.C2 LAMP BRAKE LIGHT FORWARD RIGHT 1.5A D
1:17 /7.10_1.B8 VALVE EXTRA FUNCT. PWM 1:37 /9.3_4.B2 LAMP BRAKE LIGHT FORWARD LEFT 1.5A
1:18 /7.4_1.B8 VALVE SIDESHIFT PWM 1:38 0V Ref
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
1:19 /7.5_1.E8 VALVE SPREADING PWM 1:39 /9.3_7.B1 VALVE SEAT ROTATION C.C.W 1.5A
1:20 /9.3_3.D8 SWITCH SEAT POS. R Analog In 05V 1:40 /11.5_11.D1 OPT. Dig In / 1.5A
1:41 /11.5_10.A8 OPT. Analog In 05V
1:42 /11.5_9.D1 OPT. 6A
E E
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hörigen användas. Överträdelse härav beivras med
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F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Uppdaterade efter senaste ändring 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Crossreference list A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
D791
Power /11.5_5.C5
CAN /11.6_2B.C3
B 2:6 Temperature Input B
2:11 /11.5_5.B4 Emergency stop Input
KDU contact K2
2:13 Temperature Input
2:15 Reostat In
2:16 D+
D791
KDU contact K1
KDU contact K1
1:13 /7.9_2.D8 SENSOR ALIGNMENT FRONT LEFT Analog In 05V 1:33 /7.4_2.C2 VALVE SIDESHIFT RIGHT 1.5A
1:14 /9.14_1.D2 PUMP CENTRAL LUBRICATION 10A 1:34 /7.5_2.B2 VALVE SPREADING OUT 1.5A
D 1:15 /9.6_2.D2 WORK LIGHT RIGHT 6A 1:35 /7.5_2.C2 VALVE SPREADING IN 1.5A D
1:16 /7.3_1.B7 PROJECTING LEFT PWM 1:36 /7.10_2.C2 OPT. 1.5A
1:17 /7.3_1.C7 PROJECTING RIGHT PWM 1:37 /7.10_2.D2 OPT. 1.5A
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
1:18 /7.4_2.B7 VALVE SIDESHIFT PWM 1:38 0V Ref
1:19 /7.5_2.B7 VALVE SPREADING PWM 1:39 /7.9_1.D2 LAMP ALIGNMENT 1.5A
1:20 /7.5_2.E7 SENSOR 3035 STOP Analog In 05V 1:40 /7.9_2.A8 SENSOR ALIGNMENT FRONT RIGHT Dig In / 1.5A
1:41 /7.9_2.B8 SENSOR UNLOCKED TW. RIGHT Analog In 05V
1:42 /7.8_1.C2 VALVE UNLOCK LEVELLING 6A
E E
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stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Uppdaterade efter senaste ändring 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Crossreference list A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
S1053 S1051 M693
Choice: opt Choice: opt Central
mast fenders lubrication
Val: opt Val opt Central
KDU stativ skärmar S1993 S1994 smörjning
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
D7971 + X240/ X213
D7972 X249
E E
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Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion / New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Truth table opt. A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
X038f X038f
A 00513B 5 6 00512B A
X6901f X006
B6901 BK 2 2 00611 11 K6:11 Analog Input
D7901
X6901f /0.0_1.B4
3
00513C 1 1 RD 1 2 WH 3 3 00512C
POT. ACCELERATOR 1
ACCELERATOR
X016
24V D7902/2:1 0161 1 K2:1 Input
/ 11.5_3.C7 D7902 X066f X040f X040m X006
/11.5_4.F4 D7901/6:12 1 A0403 3 3 00612A 12 K6:12 Analog Input
/ 9.3_3.D6 D7901
SWITCH STARTER /0.0_1.B4
B POT. ACCELERATOR 2 B
X016 X038f
24V D7902/2:2 0162 2 K2:2 Input 8 00612B
/ 11.5_3.C7 D7902
/11.5_4.F4
SWITCH PREHEAT
/ 1.0_2B1.B1
X210f / 1.0_2C.C2
581/3:1 2101 1 581/3:1
/ 11.5_1.B5 / 1.0_2D.B2
/ 1.0_2B2.B7
2102
/ 1.0_2D.B2
2 CHASSIS
/ 1.0_2E2.B7
C / 1.0_2A.B2 C
/ 1.0_2B1.B1
/ 1.0_2C.C2
2033 30 / 1.0_2D.B2
CAN_J1939_+ 3 CAN_J1939_+
/ 11.6_1.C2 / 1.0_2E1.F1
2034
/ 1.0_2A.B2
/ 1.0_2B1.B1
/ 1.0_2C.C2
/ 1.0_2D.B2
2034 30 / 1.0_2E1.F1
CAN_J1939_ 4 CAN_J1939_
/ 11.6_1.C2 / 2.0_2B1.A2
2033
X210f / 1.0_2A.E2
D 581/4:1 2105A 5 581/4:1 D
/ 11.5_1.C5 / 1.0_2B1.B1
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
/ 1.0_2A.B2
/ 1.0_2B1.C1
/ 1.0_2C.C2
X212 / 1.0_2D.B2
D+ K2:16 16 21216 D+
D7971 / 1.0_2E1.C1
/0.0_2.C4 6
D+
/ 1.0_2B2.B2
/ 1.0_2C.C2
2107A
/ 1.0_2D.B2
582/7:1 7 582/7:1
/ 11.5_1.C8 / 1.0_2E2.B2
E / 1.0_2A.E2 E
/ 1.0_2B1.C1
/ 1.0_2C.D2
2108A
/ 1.0_2D.C2
582/8:1 8 582/8:1
/ 11.5_1.C8 / 1.0_2E1.C1
/ 1.0_2A.C2
X211 X278f / 1.0_2B1.D1
1.5A K1:32 32 21132 2 START
D7971 / 1.0_2E1.E1
/0.0_2.D5
B757
RELAY STARTING KEY XB757 XB757 X212
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Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
2102 7572 2 2 1 1 21215 15 K2:15 Reostat In
D7971
U /0.0_2.C4
F SENSOR FUEL LEVEL F
FUEL LEVEL
X37211A
X37211
Ref. Benämning Produkt/Product Blad/Sheet
Nr Ändring Ändring nr Datum Sign. Datum/Date Huvudnr./Project no.
Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets drivlina motor DCF300,DCE300 1.0_1
CJS 050128 A47137.0100
Name
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring drive train engine A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
D5.2
X279
2791 1
A A
X279
2
X279
X37212 8
X279
9
X279
X210m 2103B 12
CAN_J1939_+ 3 2103A X90017
/ 1.0_1.C6 X279
2104B 13
/1.0_2A.F8
CAN_J1939_ 4 2104A X90018
/ 1.0_1.D6 X279
2108D 14
B D794 B
D+ 6 2106 ENGINE
/ 1.0_1.D6
X22
1 2108E
2 2798
3 2792
Diagnostics engine. 4 2104C
5 2799
6 2103C SWITCH CLOSES WHEN
C COOLANT LEVEL IS TOO LOW C
K315 B759
X278m 2 2 1 1
START 2 2782A 85 86 2782B
/ 1.0_1.F6 COOLANT LEVEL
GY
W224
87A 30 X37212
87
G660 BK
M654 B+
STARTING KEY
30 31 W225 B D+
M G
2
1
ALTERNATOR
D 50 D
X280m
STARTER W
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
1
2
X280f
2105C
X210m
581/4:1 5 2105B
/ 1.0_1.D6
6
E E
20
K312
X23f
2108D 2108F 86 85 2108G 8 3
2108E X90016
582/8:1 8 2108B PREHEATER
/ 1.0_1.E6
/1.0_2A.B8
E800
W6 30 87 W7 1 2
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Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
PREHEATER D794
ENGINE
F D5.1 F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring engine TAD722 A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
XD7941m
1/50
2/50
3/50
4/50
5/50
X210m XD7941f 6/50
581/3:1 1 2101 X90068 2101A 7 7/50
/ 1.0_1.C6
2101B 8 8/50
9/50
CAN_J1939_+ 3 30 2103 10/50
/ 1.0_1.C6
B 11/50 B
12/50
CAN_J1939_ 4 30 2104 13/50
/ 1.0_1.D6
14/50
15/50
581/4:1 5 2105 16/50
/ 1.0_1.D6
2101C 17 17/50
2105A 18 18/50
D+ 6 2106 X90069 19/50
/ 1.0_1.D6
20/50
21/50
582/8:1 8 2108 22/50
/ 1.0_1.E6
C 23/50 C
24/50
25/50
26/50
K360 27/50
X278m 2105B 28 28/50
START 2 2782 85 86 W19F W19A 29 29/50
/ 1.0_1.F6
W19B 30 30/50
87 30 31/50
87A 32/50
33/50
STARTING SOLENOID 34/50
D 35/50 D
36/50
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
37 37/50
36030
38 38/50
W19C 39 39/50
RD W19D 40 40/50
41/50
42/50
G660 43/50
M654 B+
44/50
30 31 I W19
B 45/50
M G X90070 46 46/50
50 W 47/50
E E
48/50
WH 49/50
W19E 50 50/50
W11
D794 /1.0_2B2.D6
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Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring engine Cummins QSM11 A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
SWITCH CLOSES WHEN
B B
COOLANT LEVEL IS TOO LOW
K322
X210m X759f X759m B759 X759m X759f X210m
582/7:1 7 2107 86 85 86 85 2102A 2 2 BK 2 2 1 1 GY 1 1 2102 2 CHASSIS
/ 1.0_1.E6 / 1.0_1.C6
/1.0_2B2.D3
XD7942f XD7942m
C W26 5 5/31 C
W25 6 6/31
K322 7 7/31
30 30 87
87A 87a W25A 19 19/31
/1.0_2B2.B3
COOLANT LEVEL
D794 /1.0_2B1.F6
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
E E
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Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring engine Cummins QSM11 A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
X22
1 221
2 2798
3 2793
Diagnostics engine. 4
5 2797
6
B B
X210m
581/3:1 1 2101
/ 1.0_1.C6
X279f X279m
CAN_J1939_+ 3 2103 30 2103 1 1/8
/ 1.0_1.C6
2104 2 2/8
C CAN_J1939_ 4 2104 2793 3 3/8 C
/ 1.0_1.D6
2101 4 4/8
D+ 6 2106
/ 1.0_1.D6
2795 5 5/8
582/7:1 7 2107 X90082 2107 6 6/8
/ 1.0_1.E6
2797 7 7/8
582/8:1 8 2108A 2798 8 8/8
/ 1.0_1.E6
D794
D D
Only 950 & 1250
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
Volvos harness
XG660D+ W
E L E
1
15
65430 1
BS
DFM
M654
G660 G660
B+ 30 31
M
D+ B
G
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Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
50
ALTERNATOR STARTER
W
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Connection 950,1250 changed 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring engine 950,1240,1250 A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
G660
B+
A 2106 D+ B A
G
ALTERNATOR
W
X210m
581/3:1 1 2101
/ 1.0_1.C6
CHASSIS 2 2102
/ 1.0_1.C6
X279f X279m
CAN_J1939_+ 3 2103 30 2103 1 1/8
/ 1.0_1.C6
2104 2 2/8
B CAN_J1939_ 4 2104 2102 3 3/8 B
/ 1.0_1.D6
2101 4 4/8
D+ 6 2106 2108 5 5/8
/ 1.0_1.D6
2107 6 6/8
582/7:1 7 2107 7/8
/ 1.0_1.E6
8/8
582/8:1 8 2108
/ 1.0_1.E6
XK312Am XK312Af
1 1/2
2 2/2
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
K312 D794
XK312f XK312f
1 86 85 2
Volvo harness
XK31230 30 87 XK31287 UH
PRE HEAT
E8001 E8002
E 1 2 1 2 E
M654
Preheat cylinder Preheat cylinder
31 30 XM65430 31230
M
50
STARTER E8003 E8004
1 2 1 2
31287 XE800
Preheat cylinder Preheat cylinder
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
E8005 E8006
1 2 1 2
F F
Preheat cylinder Preheat cylinder
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Preheat added. 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring engine TAD760 A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
D794
F56
XD7943f XD7943m
A 7941 1 1/4 A
7942 2 2/4
65430-2 B:1 30A 2:1 7943 3 3/4
2:2 7944 4 4/4
XD7942m
1/50
2/50
3/50
4/50
B 5/50 B
F56 6/50
1 7/50
2 Power ECU D794
3 8/50
4 9/50
5 10/50
X37217
6
X210m 11/50
D+ 6 2106 12/50
/ 1.0_1.D6
13/50
582/8:1 8 2108 14/50
/ 1.0_1.E6
15/50
16/50
C 17/50 C
18/50
19/50
ALTERNATOR P 20/50
B WH 21/50
L
G B 22/50
B+ 23/50
G660 24/50
25/50
K312 26/50
F51 E800
65430-1 31230 30 87 31287 1 2 XD7942f 27/50
1 2
125A /1.0_2E1.E5 PREHEATER D79428 79428 28 28/50
/ 1.0_2E2.C7
D RELAY PREHEATER 29/50 D
30/50
M654
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
31/50
30 31 D79432 79432 32 32/50
M / 1.0_2E2.C2
RD 33/50
50 34/50
STARTER
35/50
36/50
K360 37/50
36030 30 87 36087 38/50
/1.0_2E1.E3 2108 39 39/50
RELAY STARTER 31286 40 40/50
E 41/50 E
K312 31285 42 42/50
86 85 43/50
K360 /1.0_2E1.D5 44/50
X278m
START 2 2782 86 85 W19 RELAY PREHEATER 45/50
/ 1.0_1.F6
/1.0_2E1.E3 30 46 46/50
RELAY STARTER 47 47/50
X37217 48/50
49/50
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Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
X210m 50/50
CAN_J1939_+ 3 2103 30
F / 1.0_1.C6 F
CAN_J1939_ 4 2104
/ 1.0_1.D6
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 New page 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 070123 Klass/Class
Wiring engine QSB6,7 A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B SWITCH CLOSES WHEN B
COOLANT LEVEL IS TOO LOW
K322
X210m X759f B759 X759f X210m
582/7:1 7 2107 86 85 86 85 2102A 2 2 1 1 2102 2 CHASSIS
/ 1.0_1.E6 / 1.0_1.C6
D79432 79432 30 30 87
/ 1.0_2E1.D7 R82010
87A 87a 1 2 79428 D79428
/ 1.0_2E1.D7
18,0kOHM
COOLANT LEVEL
1
C C
R82011
1 2
560kOHM
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
E E
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hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Resistors added. 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 070123 Klass/Class
Wiring engine QSB6,7 A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
X017
S162 MULTISWITCH 12 K3:12 Input
D7902
/11.5_4.F4
/9.6_4.D4
GEAR SWITCH REVERSE
R R BK/WH/GN
X017
24V reference K3:10 10 RD 15/1 N N
D7902
/11.5_4.F4
X017
24V REF TO GEAR SWITCH F F BK/GN 11 K3:11 Input
D7902
/11.5_4.F4
GEAR /9.5_1.B4 GEAR SWITCH FORWARD
B B
DECLUTCHING PEDAL DECLUTCHING
XS2203f XS2203f
C 0381B 1 7901:51/24V 7901/6:14 2 0382B C
/ 9.3_3.F2 / 9.3_3.F6
S2202
P
X211
582/5:1 216-1B 1 2 21127 27 K1:27 Analog In 05V
/ 9.6_5.E2 D7971
582/5:1 216-1C /0.0_2.D5
/ 4.0_1.C2 DECLUTCHING
SWITCH DECLUTCHING
X205m
CAN_J1939_+ 30 2035 A CAN_J1939_+
D / 11.6_1.C2 / 2.0_2A1.B2 D
2036
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
CAN_J1939_ 30 2036 B CAN_J1939_
/ 11.6_1.C2 / 2.0_2A1.B2
2035
X201f / 2.0_2A1.C7
2011 1 CHASSIS
/ 2.0_2B1.C7
2012
/ 2.0_2A1.C2
581/5:1 2 581/5:1
/ 11.5_1.C5 / 2.0_2B1.C2
E E
2013
/ 2.0_2A1.C7
3 CHASSIS
/ 2.0_2B1.C7
2014
/ 2.0_2A1.C2
582/6:1 4 582/6:1
X37211B / 11.5_1.B8 / 2.0_2B1.C2
X37211
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hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Extra declutch, XS2203 added. 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring drive train gearbox A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
D793
CAN
X205f X252f
CAN_J1939_ B 252A2 A2 L2 ECU793
/ 2.0_1.D7 CAN L
CAN_J1939_+ A 252B2 B2 M2
/ 2.0_1.D7 CAN H
C
B B
251K3D 0V_ref
/ 2.0_2A2.E2
C C
D793
X201m X251f X251f X201m
581/5:1 2 251A1 A1 A1
ECU793 A3 A3 251A3 1 CHASSIS
/ 2.0_1.E7 PPWR Power Supply GND / 2.0_1.E7
X252f X252f
582/6:1 4 252F2 F2 S2 S3 F3 252F3B 252F3A 3 CHASSIS
/ 2.0_1.E7 SPWR VFSGND / 2.0_1.E7
D CHASSIS 252F3D D
/ 2.0_2A3.E7
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
D793
RS 232
E ECU793 X252f X261m E
N2 C2 252C2 A
R x D
P2 D2 252D2 B
T x D
C
251K3E 0V_ref
/ 2.0_2A2.E2
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hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Kabel 252F3C utgår. 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring gearbox TE32 A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
X251f
RPM B3 B3 251B3
D793
XB752
B752 1 1
A X251f A
2 2 251C3 C3 C3 RPM
D793
DRUM SPEED
X251f
RPM D3 D3 251D3
D793
XB758
B758 1 1 X251f
2 2 251E3 E3 E3 RPM
D793
OUTPUT SPEED
B B
B758/766
XB766 X251f
T T 1 251H3 H3 H3 Analogue Input
D793
2 251G3
+ 3 251F3 X251f
G3 G3 RPM
D793
ENGINE SPEED/GEARBOX TEMPERATURE
X251f
F3 F3 RPM
D793
S221
C XS221 C
251J3B X37Gearbox
1 T 2
TEMP SWITCH COOLER IN
(CONVERTER OUT TEMP)
X251f
251J3A J3 J3 Analogue Input
D793
X252f R8 R7
5V Analogue Ref M1 B1 252B1 1 2 251J3C 1 2
D793
10KOhm 10KOhm
251K3B
X252f
D RPM R2 E2 252E2 D
D793
X251f
K3 Signal GND
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
XB751 K3
D793
B751 1 1
2 2 251K3C
TURBINE SPEED
0V_ref 251K3D 251K3A
/ 2.0_2A1.B7
0V_ref 251K3E
/ 2.0_2A1.E7
E B765
E
P PRESURE FEEDBACK SENSOR
X251f X253f X253f
Rheostat Input A2 A2 251A2 11 15 251K3F
D793
2K2
2K2
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hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring gearbox TE32 A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
Y6069
X251f X253f X253f X251f
Analogue Output D1 D1 251D1 1 1 2 2 251E1 E1 E1 Analogue Output
D793 D793
VFS 2ND/4TH
Y630
X251f X253f X253f X251f
Analogue Output B1 B1 251B1 3 1 2 4 251C1 C1 C1 Analogue Output
B D793 D793 B
VFS FWD
Y6067
X251f X253f X253f X251f
Analogue Output H1 H1 251H1 5 1 2 6 251J1 J1 J1 Analogue Output
D793 D793
VFS 1ST/3RD
C C
Y631
X251f X253f X253f X251f
Analogue Output F1 F1 251F1 7 1 2 8 251G1 G1 G1 Analogue Output
D793 D793
VFS REV
Y6066
X251f X253f X253f X251f
Digital Output K1 K1 251K1 9 1 2 10 251K2 K2 K2 Digital Output
D793 D793
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
DRIVE
Y6074
X251f X253f X253f
Digital Output E2 E2 251E2 12 1 2 14 252F3D CHASSIS
D793 / 2.0_2A1.D2
2/4 SELECT
Y6075
E X251f X253f E
Digital Output F2 F2 251F2 13 1 2
D793
1/3 SELECT
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Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ventil Y602 utgår. 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring gearbox TE32 A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
D793
CAN
X205f X252f
CAN_J1939_ B 30 252A2 30 A2 L2 ECU793
A / 1.0_1.D6 CAN L A
CAN_J1939_+ A 252B2 B2 M2
CAN H
B B
D793
C X201m X251f X251f X201m C
581/5:1 2 251A1 A1 A1
ECU793 A3 A3 251A3 1 CHASSIS
/ 2.0_1.E7 PPWR Power Supply GND / 2.0_1.E7
X201m X252f X252f X201m
582/6:1 4 252F2 F2 S2 S3 F3 252F3B 3 CHASSIS
/ 2.0_1.E7 SPWR VFSGND / 2.0_1.E7
0V_ref 252F3C
/ 2.0_2B2.F7
252F3A
0V_ref 252F3D
/ 2.0_2B3.E8
D D
D793
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
RS 232
ECU793 X252f X261m
N2 C2 252C2 A
R x D
P2 D2 252D2 B
T x D
C
251K3D 0V_ref
/ 2.0_2B2.E1
E E
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Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 New page 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring gearbox TE17 A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
X251f
RPM B3 B3 251B3
D793
A XB752f A
DRUM SPEED B752 1 1 X251f
2 2 251C3 C3 C3 RPM
D793
DRUM SPEED
DRUM SPEED
X251f
RPM D3 D3 251D3
D793
XB758f
OUTPUT SPEED B758 1 1 X251f
2 2 251E3 E3 E3 RPM
D793
OUTPUT SPEED
OUTPUT SPEED
B B
X251f
251H3 H3 H3 Analogue Input
D793
GEARBOX TEMPERATURE
B758/766
XB766f
T T B X251f
C 251G3 G3 G3 RPM
D793
+ A
ENGINE SPEED/GEARBOX TEMPERATURE
C ENGINE SPEED/GEARBOX TEMPERATURE C
X251f
251F3 F3 F3 RPM
D793
S221
XS221
2211 1 2 T 1 ENGINE SPEED
X37GND_GEARBOX
TEMPERATURE SWITCH COOLER IN/CONVERTER OUT
X251f
251J3 J3 J3 Analogue Input
D793
X252f R8208 R8209
5V Analogue Ref M1 B1 252B1 1 2 1 2 251K3B TEMPERATURE SWITCH COOLER IN
D D793 D
10KOhm 10KOhm
TEMPERATURE SWITCH COOLER IN
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
0.6W 0.6W
X252f
RPM R2 E2 252E2
D793
XB751f
TURBINE SPEED B751 1 1 X251f
2 2 251K3C 251K3A K3 K3 Signal GND
D793
TURBINE SPEED
0V_ref 251K3D
/ 2.0_2B1.E7
E E
B765
P PRESSURE FEEDBACK SENSOR
X251f X253f X253f
Rheostat Input A2 A2 251A2 11 1 2 12 252F3C 0V_ref
D793 / 2.0_2B1.D2
2K2
PRESSURE FEEDBACK SENSOR
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Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
1 2
F 2K2
F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 New page 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring gearbox TE17 A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A Y630 A
X251f X253f X253f X251f
Analogue Output B1 B1 251B1 3 1 2 4 251C1 C1 C1 Analogue Output
D793 D793
VFS FWD
Y6067
X251f X253f X253f X251f
Analogue Output H1 H1 251H1 5 1 2 6 251J1 J1 J1 Analogue Output
B D793 D793 B
VFS 1ST/3RD
Y1
X251f X253f X253f X251f
Analogue Output D1 D1 251D1 1 1 2 2 251E1 E1 E1 Analogue Output
D793 D793
C C
VFS 2ND
Y631
X251f X253f X253f X251f
Analogue Output F1 F1 251F1 7 1 2 8 251G1 G1 G1 Analogue Output
D793 D793
VFS REV
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
Y6066
X251f X253f X253f X251f
Digital Output K1 K1 251K1 9 1 2 10 251K2 K2 K2 Digital Output
D793 D793
DRIVE
E E
Y6075
X251f X253f X253f
Digital Output F2 F2 251F2 13 1 2 14 252F3D 0V_ref
D793 / 2.0_2B1.D2
1/3 SELECT
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Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 New page 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring gearbox TE17 A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
X008
+CAB 00813A 13 K8:13 Input
A S107 D7901 A
/0.0_1.D4
24V D7901/8:16 00816H 1
/ 7.5_3.B2 SWITCH PBRAKE LOCKED
0
1 1
24V D7901/8:16 00816J 5 5
/ 8.2_1.B2 7 7 0085
10 10 9 9
CHASSIS37D 0923F 00813B X008
/ 7.5_3.B2 PARKING BRAKE
5 K8:5 Input
D7901
/0.0_1.D4
SWITCH PBRAKE OPEN
B B
S200
P
X211
582/5:1 216-1C 1 2 21141 41 K1:41 Analog In 05V
/ 2.0_1.D2 D7971
/0.0_2.E5
PARKING BRAKE
PRESSURE SWITCH PBRAKE
C C
S204
P
X211
216-1D 1 2 21113 13 K1:13 Analog In 05V
D7971
/0.0_2.D2
PRESSURE ACCUMULATORTANK
PRESSURE SWITCH ACCU. TANK
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
Y642
E X211 E
1.5A K1:34 34 21134 1 1 2 2 642 CHASSIS
D7971 / 7.2_2.F5
/0.0_2.D5
VALVE PARKING BRAKE
PARKING BRAKE
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hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 X211.34 V X211.39. 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring brake system A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B772
XB772f XB772f X212
2 2 T 1 1 2126 6 K2:6 Temperature Input
D7971
U /0.0_2.B4
BRAKE OIL TEMPERATURE SENSOR BRAKE OIL TEMP.
B B
7722
K3774
X211
1.5A K1:3 3 2113 86 85 86 85 W212G CHASSIS
C D7971 / 11.5_3.D7 C
/0.0_2.D2
RELAY COOLING FAN BRAKE OIL
M674
XM674f XM674m XM674m XM674f
581/6:1 377430 30 30 87 87 6741 1 1 1 2 2 2 6742
/ 11.5_1.C5 M
87A
COOLING FAN BRAKE OIL X37202B
COOLING FAN BRAKE OIL
X37202
D Feedback oil cooler brakes D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
XM674Am XM674Af XM674Af XM674Am
1 674A1A 674A1B 1 2 674A2 2
X90101
XB771m
E 674A1C C 24V D7971/1:23 E
/ 7.7_2.C5
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hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Feedback oil cooler added. 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring cooling brake oil A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
+CAB
S1492
1
0 XS1492m XS1492f X009Af X009Am X009
X009 X009Am X009Af XS1492f XS1492m 1 2 2 009910A 10 10 00910 10 K9:10 Input
A 24V reference K9:1 1 0091 1 1 0091A 1 1 5 D7901 A
D7901 /0.0_1.B6
/0.0_1.A6
HORN SWITCH HORN ARM REST
SWITCHES ARM REST
+CAB
S113
1
0 XS113m XS113f X009Af X009Am X009
XS113f XS113m 1 2 2 0095A 5 5 0095 5 K9:5 Input
0091B 1 1 5 D7901
/0.0_1.B6
SW ACT. MICRO STEERING
ACTIVATE LEVER / MICRO STEERING
B B
X009Af X009Am X009
0094A 4 4 0094 4 K9:4 Input
1 = FORWARD D7901
+CAB /0.0_1.B6
S1602 0 = NEUTRAL SW FORWARD ARM REST
1 2 = REVERSE
0
2
1 1 X009Af X009Am X009
0091C 3 3
7 7 0093A 3 3 0093 3 K9:3 Input
D7901
2 /0.0_1.B6
4
8 SW REVERSE ARM REST
X009 X009Am X009Af X009Af X009Am
1.5A K9:2 2 0092 2 2 0092A 10 10 9 9 W11A 11 11 W11
D7901
/0.0_1.A6
FORWARD / REVERSE
LAMP F/R ARM REST
C C
X37D
X825Hm
RD 1
LEVER STEERING (P6)
X825Hm X825Hf X009Af X009Am X009
WH 1 1 0098A 8 8 0098 8 K9:8 Analog Input
D7901
/0.0_1.B6
POT. MICRO STEERING (P6)
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
X009 X009Am X009Af X825Pf X825Pm R8251 X825Pm X825Pf X009Af X009Am X009
Analog reference 5V 3 0V reference
K9:7 7 0097 7 7 0097A 1 1 GN 1 2 BN 2 2 0096A 6 6 0096 6 K9:6
D7901 D7901
/0.0_1.B6 /0.0_1.B6
POT. MICRO STEERING MICRO STEERING (P6) POT. MICRO STEERING
MICRO STEERING (P7)
E E
X018 XB770f XB770m
1.5A K8:1 1 0181 1 1
D7902
/11.5_4.F4
SENSOR STEERING WHEEL
BN
B770 XB770m XB770f X018
BK 2 2 0182 2 K8:2 Input
D7902
/11.5_4.F4
STEERING WHEEL ANGLE
BU SENSOR STEERING WHEEL
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hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F XB770m XB770f X018
3 3 0183 3 K8:3 0V ref F
D7902
SENSOR STEERING WHEEL
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring lever/micro wheel A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
Y6363
X221 X244f X244m X244m X244f X221
1.5A K1:2 2 2212 10 10 24410 1 1 2 2 24412B X90039 24412A 12 12 22116 16 K1:16 PWM
D7972 D7972
/0.0_3.C2 /0.0_3.D2
VALVE MICRO STEERING RIGHT VALVE MICRO STEERING
MICRO/LEVERSTEERING RIGHT
B B
Y6364
X221 X244f X244m
1.5A K1:3 3 2213 11 11 24411 1 1 2 2 24412C
D7972
/0.0_3.C2
VALVE MICRO STEERING LEFT
MICRO/LEVERSTEERING LEFT
C C
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
E E
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hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring lever/micro wheel A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
0902B
0901B
XR8072m XR8072f X090m X090f X007
R8072 RD 0904 0074 Analog Input
3 3 4 4 4 K7:4
D7901
/0.0_1.C4
POT. TILT (P2)
B XR8072f XR8072m B
3
1 1 GN 1 2 YE 2 2
TILT (P2)
Placering spakar från vänster
Placement levers from left
0902C
0901C
P1 XR8073m XR8073f X090m X090f X007
R8073 RD 0905 0075 Analog Input
P2 3 3 5 5 5 K7:5
D7901
/0.0_1.C4
P3 POT. SIDE SHIFTING (P3)
XR8073f XR8073m
P4 3
C 1 1 GN 1 2 YE 2 2 C
P7 opt. FCH
SIDE SHIFTING (P3)
P5
0902D
0901D
XR8074m XR8074f X090m X090f X007
R8074 RD 0906 0076 Analog Input
3 3 6 6 6 K7:6
D7901
/0.0_1.C4
POT. SPREADING (P4)
XR8074f XR8074m
3
1 1 GN 1 2 YE 2 2
D D
SPREADING (P4)
PROJECTION LEFT
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written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
0902E
0901E
EXTRA (P5)
E E
LEVELLING
0902F
0901F
POT 7TH LEVER (P7)
XR80752f XR80752m
3
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hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
1 1 GN 1 2 YE 2 2
F EXTRA (P7) F
PROJECTION RIGHT
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring el. servo levers A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
Lever 815
X007 X091f X091m X815f T11 X815f X091m X091f X007f
Analog Reference 24V K7:12 12 00712 8 8 0918 15 15 14 14 0913 3 3 00714 14 K7:14 Input
D7901 D7901
/0.0_1.C4
SWITCHES EL. SERVO SW. SPREAD IN
T12 X091m X091f X007f
16 16 0914 4 4 00713 13 K7:13 Input
B D7901 B
SW. SPREAD OUT
T2 X091m X091f X007f
20 20 0915 5 5 00715 15 K7:15 Input
D7901
SWITCH UNLOCK TW
T4 X091m X091f X007
19 19 0916 6 6 00716 16 K7:16 Input
D7901
/0.0_1.C4
SWITCH PISTOL
T31 X091m X091f X008
17 17 0919 9 9 0081 1 K8:1 Input
X007 X091f X091m D7901
0.5A K7:9 9 0079 7 7 0917 7 7
D7901
/0.0_1.C4 SWITCH LOCK LEVELLING
IND. LOCKED LEVELLING
C T32 X091m X091f X008 C
18 18 0912 2 2 0082 2 K8:2 Input
D7901
CHASSIS37D 0923H 5 /0.0_1.D4
/ 7.8_1.F7
SWITCH LOCK TILT
6 6
X090m X090f X007f
P1 8 8 0903 3 3 0073 3 K7:3 Analog Input
X007f X090f X090m D7901
Analog Reference 5V K7:2 2 0072 2 2 0902 9 9
D7901
POT. LIFT / LOWER (P1)
POTENTIOM. EL. SERVO
X090m X090f X007f
P2 4 4 0904 4 4 0074 4 K7:4 Analog Input
D7901
POT. TILT (P2)
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
POT. (P3)
POTENTIOM. EL. SERVO
E E
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hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 X007.9 skiftad med X007.12 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring el. servo joystick A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
2028 583/3:1
/ 7.0_5.D2
X207m X207f
B 2075 5 5 2025 Alignment B
/ 7.0_5.E2
X207m X207f
C 2076 6 6 2026 Unlock TW C
/ 7.0_5.E2
X207m X207f
D 2077 7 7 2027 Lock TW D
/ 7.0_5.F2
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
R8205 X207m X207f X070m X070f X069f X069m X008
4 4 0703 3 3 A0693 3 3 0088 8 K8:8 Input
D7901
/0.0_1.D4
820 Ohm
SENSOR LOCK TW
E E
X081f
0053B 3
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hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
OVERRIDE ALIGNMENT OVERRIDE ALIGNMENT
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Flyttad från 9.1_3 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring toplift frame A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
K3005
X007 X069m X069f
0.5A K7:10 10 00710 4 4 A0694A 86 85 A0694B
D7901
/0.0_1.C4
RELAY ACTIVATE TW X070f X070m X202f X202m X208f X208m X208Am
A0707C 30 87 A0706 6 6 0706 1 1 BN_/_1 1 1 BN_/_1 1
VALVE TWISTLOCK
TWISTLOCK
584/5:2
/ 11.5_2.B6
B B
A0707B
K3006
X007 X069m X069f
0.5A K7:11 11 00711 5 5 A0695A 86 85 A0695B
D7901
/0.0_1.C4
RELAY ACTIVATE SPREAD X070f X070m X202f X202m X208f X208m X208Am
30 87 A0707A 7 7 0707 2 2 RD_/_2 2 2 RD_/_2 2
VALVE SPREADING
SPREADING
X37A
C C
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
583/3:1 2028 8 8 GY_/_8 13 13 4A
/ 7.0_4.A7
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Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring toplift frame A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
C C
X302f X302m XB72111f XB72111m
582/5:1 2481C A A 302A A A
/ 7.2_6.E1
BN
B72111 XB72111m XB72111f X302m X302f X248m X248f X211
BK C C 302C C C 2484 4 4 21126 26 K1:26 Dig In / 1.5A
D7971
/0.0_2.D5
AUT. CAB TILT
BU SENSOR CAB TILT
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
E E
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Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring lift height A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
1
1 1
Y6005
X211 XK3007 K3007 XK3007 X235f X235m X235m X235f X211
1.5A K1:4 4 2114A 30 30 87 87 2114B 1 1 2351A X90029 2351B 1 1 2 2 2352 2 2 21116 16 K1:16 PWM
D7971 D7971
/0.0_2.D2 87A /0.0_2.D2
VALVE LIFT / LOWER /11.5_6.B4 VALVE LIFT / BLOCK LIFT
LIFT
C C
1
Y6004
X235m X235f X211
2351C 1 1 2 2 2353 3 3 21117 17 K1:17 PWM
D D7971 D
/0.0_2.D2
VALVE LOWER / BLOCK LOWER
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
LOWER
E E
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hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Moved from 7.2_5 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring lift/lower el. servo A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
CHASSIS 6012
/ 10.4_1.D5
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
CHASSIS 771B
/ 7.7_2.D7
CHASSIS 2482
/ 7.2_6.E7
E E
CHASSIS 2132
/ 9.0_1.C7
CHASSIS 6039
/ 8.2_3.D7
XY6040/6019f
2 6040
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
CHASSIS 642
F / 4.0_1.E7 F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring free lift sensors A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B X236Lm B
582/5:2 A RD XB260 1
/ 7.2_2.B3
BN
B260 X236Lm
BK XB260 2 GY C 24V D7971/1:12
/ 7.2_2.B5
SENSOR CARRIAGE UP
BU
X236Lm
XB260 3 BK B CHASSIS
/ 7.2_2.B5
C C
X236Rm
582/5:2 A
/ 7.2_2.C3
BN
B261 X236Rm
BK C 24V D7971/1:11
/ 7.2_2.C5
SENSOR MAST DOWN
BU
D D
X236Rm
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
B CHASSIS
/ 7.2_2.C5
E E
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Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring free lift sensors A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
Y6052
X236Lm X236Lm
B 24V D7971/1:12 C 236C 1 1 2 2 236B B CHASSIS B
/ 7.2_2.B5 / 7.2_2.B5
REGENERATING LEFT
C C
Y6051
X236Rm X236Rm
24V D7971/1:11 C 236C 1 1 2 2 236B B CHASSIS
/ 7.2_2.C5 / 7.2_2.C5
REGENERATING RIGHT
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
X248f X248m X301f X301m XB72112f XB72112m
582/5:1 2481 1 1 2481A 2481B A A 301A A A
/ 9.6_5.E2
X90076
BN
B72112 XB72112m XB72112f X301m X301f X248m X248f X211
BK C C 301C C C 2483 3 3 21124 24 K1:24 Analog In 05V
E D7971 E
/0.0_2.D5
MAST POSITION/STOP REGENERATING
582/5:1 2481C BU SENSOR MAST POS/REGENERATING
/ 7.0_7.C2
B B 301B B B 2482B 2482A 2 2 2482 CHASSIS
/ 7.2_2.E5
X90075
2482C CHASSIS
/ 7.0_7.D7
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring control valves mast A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
Y60461
X421 XY60461 XY60461 X421
1.5A K1:2 2 4212 1 1 2 2 42116B 42116A 16 K1:16 PWM
D791 D791
/0.0_4.C2 X90050 /0.0_4.D2
PROJECTING LEFT IN PROJECTING LEFT
PROJECTING LEFT IN
B B
Y60462
X421 XY60462 XY60462
1.5A K1:3 3 4213 1 1 2 2 42116C
D791
/0.0_4.C2
PROJECTING LEFT OUT
PROJECTING LEFT OUT
C C
Y60463
X421 XY60463 XY60463 X421
1.5A K1:4 4 4214 1 1 2 2 42117B 42117A 17 K1:17 PWM
D791 D791
/0.0_4.C2 X90051 /0.0_4.D2
PROJECTING RIGHT IN PROJECTING RIGHT
PROJECTING RIGHT IN
Y60464
D X421 XY60464 XY60464 D
1.5A K1:5 5 4215 1 1 2 2 42117C
D791
/0.0_4.C2
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
PROJECTING RIGHT OUT
PROJECTING RIGHT OUT
E E
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Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring projection gantry A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
Y6020
X221 X244f X244m X244m X244f X221
2.5A K1:31 31 22131 1 1 2441 1 1 2 2 2443B X90036 2443A 3 3 22118 18 K1:18 PWM
D7972 D7972
/0.0_3.D5 /0.0_3.D2
VALVE SIDESHIFT LEFT VALVE SIDESHIFT
B B
SIDESHIFT LEFT
Y6021
X221 X244f X244m
2.5A K1:30 30 22130 2 2 2442 1 1 2 2 2443C
D7972
/0.0_3.D5
VALVE SIDESHIFT RIGHT
SIDESHIFT RIGHT
C C
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
E E
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring Sideshift el. servo A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
Y6020
X421 X421
1.5A K1:32 32 42132 1 1 2 2 42118B 42118A 18 K1:18 PWM
D791 D791
/0.0_4.D5 X90052 /0.0_4.D2
VALVE SIDESHIFT LEFT VALVE SIDESHIFT
SIDESHIFT LEFT
B B
Y6021
X421
1.5A K1:33 33 42133 1 1 2 2 42118C
D791
/0.0_4.D5
VALVE SIDESHIFT RIGHT
SIDESHIFT RIGHT
C C
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
E E
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring sideshift gantry A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A 1 = 40'20' A
0 = 0
2 = 20'40' X091m X091f X007
0913 3 3 00714 14 K7:14 Input
+CAB D7901
S1012 /0.0_1.C4
1 SWITCH SPREADING 4020
0
24V D7901/8:16 0921C 2
/ 9.7_4.B2 1 1 X091m X091f X007
24V D7901/8:16 0921D 3 3
/ 7.8_1.E2 7 7 0914 4 4 00713 13 K7:13 Input
D7901
2 /0.0_1.C4
4
8 SWITCH SPREADING 2040
CHASSIS37D 0923F 10 10 9 9
/ 7.9_1.B3
B CHASSIS37D 0923G B
/ 7.8_1.F2 2040
0922B 24V D7901/8:15
/ 7.8_1.E7
/ 9.3_3.B7 0922A
24V D7901/8:15
/ 9.10_1.B7
C C
+CAB
S1004
1 X008
00810A 10 K8:10 Input
24V D7901/8:16 00816D 0 D7901
/ 7.9_1.A2 1 1 /0.0_1.D4
24V D7901/8:16 00816E 5 5
/ 9.1_1.A2 7 SWITCH 3035 STOP
CHASSIS37D 0923B 10 10 9 9 00810B
/ 7.9_1.A2
CHASSIS37D 0923C
/ 9.1_1.A2 3035 STOP
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
Y6018
X221 X244f X244m X244m X244f X221
1.5A K1:33 33 22133 4 4 2444 1 1 2 2 2446B X90037 2446A 6 6 22119 19 K1:19 PWM
D7972 D7972
/0.0_3.D5 /0.0_3.D2
VALVE SPREADING OUT VALVE SPREADING
SPREADING OUT
E E
Y6019
X221 X244f X244m
1.5A K1:32 32 22132 5 5 2445 1 1 2 2 2446C
D7972
/0.0_3.D5
VALVE SPREADING IN
SPREADING IN
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring 2040, 3035 stop A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
Y6018
X421 XY6018 XY6018 X421
1.5A K1:34 34 42134 1 1 2 2 42119B 42119A 19 K1:19 PWM
D791 D791
/0.0_4.D5 X90053 /0.0_4.D2
B B
VALVE SPREADING OUT VALVE SPREADING
SPREADING OUT
Y6019
X421 XY6019 XY6019
1.5A K1:35 35 42135 1 1 2 2 42119C
D791
/0.0_4.D5
VALVE SPREADING IN
C C
SPREADING IN
XB7691f XB7691m
24V D7911/1:10 4041C A A
/ 7.9_2.F3
BN
B7691 XB7691m XB7691f X404Am X404Af X421
BK C C 4047 7 7 42112 12 K1:12 Dig In / 1.5A
D791
/0.0_4.D2
DAMPING 2040
BU SENSOR DAMPING 2040
D XB7691m XB7691f D
B B 4042C CHASSIS
/ 7.9_2.F4
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
XB7771f XB7771m
24V D7911/1:10 4041D A A
/ 7.9_2.F3
BN
B7771 XB7771m XB7771f X404Am X404Af X421
BK C C 4048 8 8 42120 20 K1:20 Analog In 05V
D791
/0.0_4.D2
3035 STOP
BU SENSOR 3035 STOP
XB7771m XB7771f
E B B 4042D CHASSIS E
/ 7.9_2.F4
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring spreading gantry A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
S10122
/ 9.3_3.A2 1 X008
24V D7901/8:16 00816G 00811A 11 K8:11 Input
/ 9.10_1.A2 0 D7901
1 1 /0.0_1.D4
24V D7901/8:16 00816H 5 5
/ 4.0_1.A2 SWITCH AUT. 2040
CHASSIS37D 0923F 10 10 9 9 00811B
/ 4.0_1.B2
B / 9.3_3.B2 AUT. 2040 B
CHASSIS37D 0923E
/ 9.10_1.B2
C C
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
W9003 CHASSIS
/ 9.6_2.F8
E E
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Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Searchlight changed, 0811B T. 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring 2040 opt. A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
1
1 1
Y6010
X211 XK3002 K3002 XK3002 X235f X235m X235m X235f X211
1.5A K1:5 5 2115A 30 30 87 87 2115B 4 4 2354A X90030 2354B 1 1 2 2 2355 5 5 21119 19 K1:19 PWM
D7971 D7971
/0.0_2.D2 87A /0.0_2.E2
VALVE TILT /11.5_6.B4 VALVE TILT OUT
C C
TILT OUT
D D
1
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
Y6011
X235m X235f X211
2354C 1 1 2 2 2356 6 6 21118 18 K1:18 PWM
D7971
/0.0_2.D2
VALVE TILT IN
TILT IN
E E
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Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Moved from 7.2_5 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring tilt el. servo A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
24V D7971/1:23
/ 4.8_1.E6
C C
XB771f XB771m
582/5:1 771A A A
/ 9.6_5.E2
BN
B771 XB771m XB771f X211
BK C C 21123 23 K1:23 Analog In 05V
D7971
/0.0_2.D5
SENSOR TILT ANGLE
BU SENS.TILT ANGLE/FEEDBACK BRK FAN
B B 771B CHASSIS
/ 7.2_2.D5
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
E E
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring tilt indicator A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
Y6035
X421
2.5A K1:31 31 42131 1 1 2 2 6035 CHASSIS
A D791 / 7.9_1.E7 A
/0.0_4.D5
VALVE LEVELLING RIGHT
LEVELLING RIGHT
Y6036
B X421 B
2.5A K1:30 30 42130 1 1 2 2 6036 CHASSIS
D791 / 7.9_1.E7
/0.0_4.D5
VALVE LEVELLING LEFT
LEVELLING LEFT
C Y6371 C
X421
6A K1:42 42 42142A X90071 42142B 1 1 2 2 637-1 CHASSIS
D791 / 7.9_1.E7
/0.0_4.D5
VALVE UNLOCK LEVELLING
UNLOCK LEVELLING
D D
Y6372
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
42142C 1 1 2 2 637-2 CHASSIS
/ 7.9_1.E7
UNLOCK LEVELLING
S1037
E 1 X091m X091f X008 E
0919A 9 9 0081 1 K8:1 Input
0 D7901
1 1 /0.0_1.D4
24V D7901/8:16 0921D 5 5
/ 7.5_1.B2 7 SWITCH LOCK LEVELLING
2 2 0919B
6 6
8 8 0922B 24V D7901/8:15
/ 7.5_1.B7
CHASSIS37D 0923G 10 10 9 9
/ 7.5_1.B2
LOCK LEVELLING
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
0922C
F 0923H CHASSIS37D
F
/ 7.0_2.C2
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring levelling gantry A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
+CAB
S1003
1
A 24V D7901/8:16 00816D 0 A
/ 7.5_1.C2 2
1
00816C 3 3
7 7 00812B
2 2 X008
4 4 00812A 12 K8:12 Input
8 D7901
/0.0_1.D4
CHASSIS37D 0923B 10 10 9 9 00812C
/ 7.5_1.D2 SWITCH LOCK TW
0923A
Twistlock
X092f X092m
0923 3 3 0923F
Vid hydr. servo
CHASSIS37D S1002 When hyd. servo
/ 7.5_1.B2
B X37D XS1002m2 XS1002m1 B
1 RD 2 1 BK 1
24V D7901/8:16 0921B
/ 9.7_4.B2 UNLOCK TW
00816B S1002
1
0
2 XS1002m3 XS1002f3 0915A
X008 X092f X092m XS1002f2 XS1002m2 3 X091m X091f X007
24V reference K8:16 16 00816A 1 1 0921A 2 0915 5 5 00715 15 K7:15 Input
D7901 1 D7901
/0.0_1.E4 /0.0_1.C4
SWITCH ELSERVO PANEL SWITCH UNLOCK TW
UNLOCK TW
C C
H562
X421 X405f X405m XH5621 XH5622
1.5A K1:25 25 42125 1 1 4051 1 1 2 1
D791
/0.0_4.C5
LAMP UNLOCKED TW UNLOCKED TW
H564
X421 X405f X405m XH5641 XH5642
1.5A K1:39 39 42139 2 2 4052 1 1 2 1 4054C
D791
/0.0_4.D5
LAMP ALIGNMENT ALIGNMENT
D D
H563
X421 X405f X405m XH5631 XH5632
1.5A
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
K1:29 29 42129 3 3 4053 1 1 2 1 4054B
D791
/0.0_4.D5
LAMP LOCKED TW LOCKED TW
X405m X405f
4054A 4 4 4054 CHASSIS
/ 9.6_2.C8
6035 CHASSIS
/ 7.8_1.A7
Y6040 6036
X421 CHASSIS
/ 7.8_1.B7
1.5A K1:7 7 4217 1 1 2 2 6040
D791
/0.0_4.D2 637-1 CHASSIS
E / 7.8_1.C7 E
VALVE LOCK TWISTLOCK
LOCK TW 637-2 CHASSIS
/ 7.8_1.D7
Y6039
X421
1.5A K1:9 9 4219 1 1 2 2 6039 W402 CHASSIS
D791 / 11.5_5.B7
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Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
/0.0_4.D2 X90060
VALVE UNLOCK TWISTLOCK
F UNLOCK TW F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Connection S1002 changed. 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring twistlock A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
XB7204Rf XB7204Rm
4031B A A
BN
B7204R XB7204Rm XB7204Rf
BK C C 4032B X403Bm X403Bf X403Af X403Am X421
B B 4034 4 4 4034 4 4 42141 41 K1:41 Analog In 05V
UNLOCKED TWISTLOCK RIGHT D791
BU /0.0_4.D5
SENSOR UNLOCKED TW. RIGHT
XB7205Rf XB7205Rm
B 4031C A A B
BN
B7205R XB7205Rm XB7205Rf
BK C C 4032C X403Bm X403Bf X403Af X403Am X421
B B 4035 5 5 4035 5 5 42124 24 K1:24 Analog In 05V
LOCKED TWISTLOCK RIGHT D791
BU /0.0_4.C5
SENSOR LOCKED TW. RIGHT
XB7203Rf XB7203Rm
4031D A A
BN
B7203R XB7203Rm XB7203Rf
42110B BK C C 4032D X403Bm X403Bf X403Af X403Am X421
B B 4036 6 6 4036 6 6 42126 26 K1:26 Dig In / 1.5A
ALIGNMENT REAR RIGHT D791
BU /0.0_4.C5
SENSOR ALIGNMENT REAR RIGHT
D XB7204Lf XB7204Lm D
4041B A A
BN
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
B7204L XB7204Lm XB7204Lf
BK C C 4042B X404Bm X404Bf X404Am X404Af X421
B B 4044 4 4 4044 4 4 42122 22 K1:22 Analog In 05V
UNLOCKED TWISTLOCK LEFT D791
BU /0.0_4.C5
SENSOR UNLOCKED TW. LEFT
XB7205Lf XB7205Lm
4041C A A
BN
B7205L XB7205Lm XB7205Lf
BK C C 4042C X404Bm X404Bf X404Am X404Af X421
B B 4045 5 5 4045 5 5 42123 23 K1:23 Analog In 05V
LOCKED TWISTLOCK LEFT D791
BU /0.0_4.C5
SENSOR LOCKED TW. LEFT
E XB7203Lf XB7203Lm E
4041D A A
BN
B7203L XB7203Lm XB7203Lf
BK C C 4042D X404Bm X404Bf X404Am X404Af X421
B B 4046 6 6 4046 6 6 42127 27 K1:27 Analog In 05V
ALIGNMENT REAR LEFT D791
BU /0.0_4.D5
SENSOR ALIGNMENT REAR LEFT
4041C 24V D7911/1:10 CHASSIS 4042C
/ 7.5_2.D1 / 7.5_2.D6
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
4041D 24V D7911/1:10 CHASSIS 4042D
F / 7.5_2.D1 / 7.5_2.E6 F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Kabelnr, 2 splicar T. 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring sensors gantry A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
X242m
582/4:1 7 YE_/_4
/ 11.5_10.B4
3 3 OG_/_3 8 CHASSIS
/ 11.5_10.D5
Strömbrytare S1008 klämma / lossa.
Kopplas in på XS1012. 4 4 YE_/_4
5 5
Switch S1008 clamping / releasing. 6 6 BU_/_6 3 D7972/1:22
/ 11.5_10.B5
Connected to XS1012.
7 7 VT_/_7 4 D7972/1:23
/ 11.5_10.C5
+CAB
S1008
B 1 B
0
2
1
3
7
2
4
8 K37681
10 9 86 86 85 85
CLAMPING RELEASING
30 30 87 87
87A
C C
K37682
86 86 85 85
30 30 87 87
87A 87a
D D
B7681
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
1
2
3
4
OPENS AT 150 BAR
CLOSES AT 135 BAR
H50001
B7682
E 1 2 E
PRESSURE CYLINDER UNDER 125 BAR (RED) 1
2
3
4
H50002
1 2
OPENS AT 150 BAR
PRESSURE CYLINDER OVER 125 BAR (GREEN) CLOSES AT 135 BAR
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Connection attachment Avesta changed. 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring attachment Avesta A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
Y6022
X221 X244f X244m X244m X244f X221
1.5A K1:4 4 2214 7 7 2447 1 1 2 2 2449B X90038 2449A 9 9 22117 17 K1:17 PWM
D7972 D7972
/0.0_3.C2 /0.0_3.D2
VALVE EXTRA FUNCT. OUT VALVE EXTRA FUNCT.
5TH FUNCTION OUT
C C
Y6023
X221 X244f X244m
1.5A K1:5 5 2215 8 8 2448 1 1 2 2 2449C
D7972
/0.0_3.C2
VALVE EXTRA FUNCT. IN
5TH FUNCTION IN
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
E E
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring 5th function el. servo A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
X409f X409f
24V D7911/1:10 42110D 1 24V D7911/1:10 CHASSIS 2 7211B CHASSIS
/ 7.9_2.C4 / 7.9_2.C7
X409f X421
24V D7911/1:21 3 42121 21 K1:21 Analog In 05V
X421 X409f D791
Analog Ref 5V K1:8 8 4218 5 /0.0_4.C5
B D791 B
/0.0_4.D2 OPT.
OPT.
X421 X409f
1.5A K1:37 37 42137 8
D791
/0.0_4.D5
OPT.
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
XB7692f XB7692f X421
24V D7911/1:10 42110C A C 42111 11 K1:11 Dig In / 1.5A
E / 7.9_2.C4 D791 E
/0.0_4.D2
SENSOR OPT.
B 769B CHASSIS
/ 7.9_2.C7
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 X409.6 utgår. 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring option gantry A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
+CAB
B S1005 B
1
0 XS1005 X008
XS1005 1 1 0083 3 K8:3 Input
24V D7901/8:16 00816J 5 5 D7901
/ 4.0_1.A2 /0.0_1.D4
24V D7901/8:16 00816K
/ 11.5_6.A2 OVER RIDE SWITCH OVERRIDE
C C
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
E E
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring override A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
C C
B7682 X211
2118C 1 2 2116C 2116A 6 K1:6 0V Ref
P D7971
3 X90064 /0.0_2.D2
U
SENSOR HYDR. SCALE
HYDRAULIC SCALE TILT
X211
21122 22 K1:22 Analog In 05V
D7971
/0.0_2.C5
SENSOR HYDR. SCALE TILT
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
1
E E
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Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Valve blocking tilt removed. 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring overloading system A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
1
C X211 XY6039/6018f XY6039/6018m XB72113f XB72113m C
1.5A K1:36 36 21136 1 1 GY A A
D7971 1
/0.0_2.D5
MAST POSITION BN
B72113 XB72113m XB72113f XY6040/6019m XY6040/6019f X211
BK C C RD 1 1 21137 37 K1:37 Dig In / 1.5A
D7971
/0.0_2.D5
MAST POSITION OLS
BU MAST POSITION
XY6039/6018m XY6039/6018f
B B BK 2 2 6039 CHASSIS
/ 7.2_2.E5
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
E E
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Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Moved from 7.0_6 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring sensor mast OLS A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
08712
A 08713 A
D7952
X087f X087f 0876
13 K1:13 CAN 2 K1:6 6
L+ + X90093
12 K1:12 CAN K1:5 5 0875
L
8 K1:8 K1:4 X90094
+ Shield
RS232
K1:11 K1:3 3 30
R+ TX
K1:10 CAN K1:2 2
R RX
K1:7 K1:1 1
+ GND
0878
0879
0871
0872
0592
0591
X088f
25 0872
TX2
26 0873 X059m
RX2 30 1 CAN+
30 08830 X90091 0871 2
C GND CAN C
0878 3
3 0883 +15
+15 0879 5
13 08813 GND
GND X059f
14 0599
Batt+ 9 9 A0599
28 08828
A911 TX1
0895
MIU 29 08829
RX1
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
30
1
2
3
4
5
6
7
8
9
X089m
E E
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Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 New page 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring RMI A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
E E
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring std. opt. A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
(10102)
+CAB
00816E S1992
24V D7901/8:16 X008
/ 7.5_1.D2 1
00814A 14 K8:14 Input
A 0 D7901 A
/ 9.3_3.A2 1 1 /0.0_1.D4
24V D7901/8:16 00816F 5 5
/ 9.10_1.A2 SWITCH S1 OPT.
10 10 9 9 00814B
CHASSIS37D 0923C
/ 7.5_1.D2
/ 9.3_3.A2 0923D
CHASSIS37D
/ 9.10_1.B2
(1019)
B B
+CAB
S1991
1 X080m X080f X006
X005 X081f X081m 0069A 9 9 0069 9 K6:9 Input
24V reference K5:1 1 0051 1 1 0811A 0 D7901
D7901 1 1 /0.0_1.B4
/0.0_1.C1 0811B 5 5
SWITCH S4 OPT.
SWITCHES LEFT PANEL
0812B 10 10 9 9 0069B
OPTION
7901:51/24V 0811
/ 2.0_1.C2
C C
X081m X081f
0812A 2 2 W08 CHASSIS
/ 9.5_1.B8
CHASSIS 0812L
/ 9.1_2.B7
+CAB
S1993
D 1 X080m X080f X006 D
0808A 8 8 0068 8 K6:8 Input
0811B 0 D7901
/0.0_1.B4
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
1 1
0811C 5 5
SWITCH S3 OPT.
0812B 10 10 9 9 0808B
0812C
OPTION
E E
(123)
+CAB
S1994
1 X080m X080f X006
0807A 7 7 0067 7 K6:7 Input
0811C 0 D7901
1 1 /0.0_1.B4
7901:51/24V 0811D 5 5
/ 9.3_1.B2 SWITCH S2 OPT.
0812C 10 10 9 9 0807B
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
CHASSIS 0812D
/ 9.3_1.B2 OPTION
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring option A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
P708 h
HOUR METER
+
1
2
B B
7901/10:9 A0109B
/ 9.3_2.B2
C C
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
E E
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring hour meter A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
When Isringhausen seat:
Switch S143 replaced by
jumper between 1 and 5.
Switch is placed on the seat.
+CAB
S143
1 X080m X080f X006
7901:51/24V 0811E 0806A 6 6 0066 6 K6:6 Input
/ 9.6_4.A2 0 D7901
1 1 /0.0_1.B4
7901:51/24V 0811D 5 5
/ 9.1_1.F2 SWITCH SEAT HEATER
C C
K383
X010
0.5A K10:7 7 A0107 86 85 86 85 W05
D7901
/0.0_1.C6
RELAY SEAT HEATER SEAT HEATER
A0634B X37B
584/6:1 30 30 87 87
/ 11.5_2.B6
87A
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
A0634
X37D
E CHASSIS 0633A E
/ 9.3_2.C7
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hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 XE803f and XE803m changed place. 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring seat heater A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
K358
584/8:1 A0635B 30 30 87 87
/ 11.5_2.B6
B 87A X37B B
COMPRESSOR AIR SEAT
X063m X063f
0635 5 5 A0635
C S268 C
M670
P COMPRESSOR
XM670m XM670f AIRSUSPENDED SEAT XM670f XM670m
1 1 RD 1 + BK 2 2 0633A CHASSIS
M / 9.3_1.E6
COMPRESSOR
AIR CUSHIONED SEAT
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
E E
Denna ritning får ej utan vårt medgivande kopieras.
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hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring aircushioned seat A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
1 = C.W
0 = 0
+CAB 2 = C.C.W X008
S169 0086 Input
6 K8:6
1 D7901
0 /0.0_1.D4
A 24V D7901/8:16 00816F 2 A
/ 9.1_1.A2 1 1 SWITCH REV. SEAT C.W
24V D7901/8:16 00816G 3 3
/ 7.5_3.B2 7 7 0087
2
4
8
CHASSIS37D 0923D 10 10 9 9 00815B X008
/ 9.1_1.B2
CHASSIS37D 0923E 7 K8:7 Input
/ 7.5_3.B2 REVERSIBLE SEAT D7901
/0.0_1.D4
SWITCH REV. SEAT C.C.W
B B
XS720Ff XS720Fm S720F XS720Fm XS720Ff X245f X245m X243m X243f X221
1 1 BU BN 2 2 2453 3 3 2435 5 5 22113 13 K1:13 Analog In 05V
D7972
BK BK/WH /0.0_3.D2
SWITCH SEAT POS. F
C SEAT POS. FRONT C
2451B
X221 X243f X243m X245m X245f XS720Rf XS720Rm S720R XS720Rm XS720Rf X245f X245m X243m X243f X221
1.5A K1:7 7 2217 4 4 2434 1 1 2451A 1 1 BU BN 2 2 2454 4 4 2436 6 6 22120 20 K1:20 Analog In 05V
D7972 D7972
/0.0_3.C2 BK BK/WH /0.0_3.D2
SWITCHES SEAT POS. F/R SWITCH SEAT POS. R
SEAT POS. REAR
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
X6902f X066m
B6902 BK 2 2 0661 1 D7901/6:12
X066m X6902f / 1.0_1.B5
3
5V 2 0662 1 1 RD 1 2 WH 3 3
/ 1.0_1.A4
ACCELERATOR REAR
X066m
0V 3 0663
/ 1.0_1.A6
E E
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hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
DECLUTCHING REAR
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Extra declutch added S2203. 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring turnable drivers seat A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
H410L
B X221 X247f X247m X270f X270m B
1.5A K1:37 37 22137 1 1 2471 3 3 3 1 1 2 CHASSIS
D7972 / 9.6_7.E8
/0.0_3.D5
LAMP BRAKE LIGHT FORWARD LEFT BRAKE LIGHT FORWARD LEFT
H410R
X221 X247f X247m X271f X271m
1.5A K1:36 36 22136 2 2 2472 3 3 3 1 1 2 CHASSIS
D7972 / 9.6_7.D8
/0.0_3.D5
C C
LAMP BRAKE LIGHT FORWARD RIGHT BRAKE LIGHT FORWARD RIGHT
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
E E
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Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring turnable drivers seat A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
E401R
X221 X243f X243m X2752f X2752m X2732f X2732m
6A K1:15 15 22115 1 1 2431A 1 1 2431B X90034 2431D 2 2 2A 1 2
D7972
/0.0_3.D2
B B
LAMP DIPPED LIGHT REAR DIPPED LIGHT REAR RIGHT
E401L
X2722f X2722m
2431C 2 2 2A 1 2
DIPPED LIGHT REAR LEFT
E402R2
C X221 X243f X243m X2752f X2752m X2732f X2732m C
6A K1:1 1 2211 2 2 2432A 2 2 2432B X90033 2432D 1 1 1A 1 2 6A CHASSIS
D7972 / 9.6_6.E7
/0.0_3.C2
HEAD LIGHT REAR HEAD LIGHT REAR RIGHT
E402L2
X2722f X2722m
2432C 1 1 1A 1 2 6A CHASSIS
/ 9.6_6.D7
HEAD LIGHT REAR LEFT
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
H413R
X221 X243f X243m X2712f X2712m
1.5A K1:25 25 22125 3 3 2433A X90025 2433B 2 2 2A 1 2 CHASSIS
D7972 / 9.6_7.D8
/0.0_3.C5
LAMP REAR LIGHT FRONT REAR LIGHT FRONT RIGHT
H413L
X2702f X2702m
2433C 2 2 2A 1 2 CHASSIS
/ 9.6_7.E8
REAR LIGHT FRONT LEFT
E E
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring turnable drivers seat A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B Y6361 B
X221 X243f X243m
1.5A K1:9 9 2219 10 10 24310 1 1 2 2 24312B
D7972
/0.0_3.D2
VALVE STEERING FORWARD
STEERING FORWARD
Y6362
X221 X243f X243m X243m X243f
1.5A K1:10 10 22110 11 11 24311 1 1 2 2 24312C X90040 24312A 12 12 W243
D7972
C /0.0_3.D2 C
VALVE STEERING REVERSE
STEERING REVERSE X37216
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
CHASSIS 24312D
/ 9.3_7.C6
E E
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Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring turnable drivers seat A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
X066f X066m
584/6:2 A0664 4 4 BN
/ 11.5_2.B6
A A
A798
X221 X243f X243m X246f X246m XA7981m
1.5A K1:29 29 22129 8 8 2438 B B RD 5/10
D7972
/0.0_3.D5
VALVE SEAT ROTATION C.W
XA7982m
BN 6/10 1/1 X066m X066f
BU 5 5 A0665
X221 X243f X243m X246f X246m
1.5A K1:39 39 22139 9 9 2439 C C BK 7/10 2/10
D7972
/0.0_3.D5
B B
VALVE SEAT ROTATION C.C.W X37E
BU 8/10 3/10
10/10
WH
C C
A
B
X37798
XM675f
XM675f
Y676
X221 X243Bf X243Bm XY676f XY676m XY676m XY676f
B
/0.0_3.D5
BRAKE TURNABLE SEAT
BU
BN
TURN SEAT BRAKE M675
31 50
M
TURN SEAT
D D
MOTOR
YE/GN
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
E E
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Cable BN and BU switched in A798. 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring turnable drivers seat A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
S246
P
XS2461 XS2462 X211
582/5:1 246-1 1 1 2 1 21140 40 K1:40 Dig In / 1.5A
A / 9.6_5.E2 D7971 A
/0.0_2.E5
REFRIGERANT
PRESSURE SW. REFRIDGE
S118
X005 X033f X033m 1
Analog reference 5V K5:11 11 00511 5 5 0335 0
D7901 2
/0.0_1.D1 1 1 X033m X033f X005
3 3 0331 1 1 0057 7 K5:7 Analog Input
POT. FAN / TEMP / DVALVE 7 7 D7901
/0.0_1.C1
R8206 2
1 2 4 FAN SPEED
8 X033m X033f
8k Ohm 0337 9 9 10 10 0338 8 8 0338 0363 CHASSIS
/ 9.4_2.E7
B X006 X033f X033m FAN SPEED B
PWM K6:1 1 0061 7 7
D7901
/0.0_1.A4
LAMP INST. ILLUMINATION S139 X37D
1
0335A 0
2
1 1 X033m X033f X005
3 3 0333 3 3 0059 9 K5:9 Analog Input
0339A 7 7 D7901
/0.0_1.D1
2
4 DRAUGHT VALVE
8
0337A 9 9 10 10 0338A
DRAUGHT VALVE
C C
S117
X033m 1
9 0339 0
2
0335B 1 1 X033m X033f X005
3 3 0332 2 2 0058 8 K5:8 Analog Input
0339B 7 7 D7901
/0.0_1.D1
2
4 TEMPERATURE
8
0337B 9 9 10 10 0338B
TEMPERATURE
R8207 X005
1 2 4 4 00510 10 K5:10 0V reference
D7901
/0.0_1.D1
D 8k Ohm D
0,5W POT. FAN / TEMP / DEFROST
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
B7751
X035f X035m X7751 X7751 X035m X035f X004
9 9 WH 1 1 T 2 2 YE 7 7 0048 8 K4:8 Reostat in
D7901
WH U /0.0_1.C1
TEMP. INDOOR SENSOR TEMP. INDOOR
10kOhm
B7752
X7752 X7752 X035m X035f X004
00412C
1 1 T 2 2 BU 8 8 00410 10 K4:10 Reostat in
D7901
U /0.0_1.C1
TEMP. FAN AIR SENSOR TEMP. FAN AIR
E 10kOhm at 25°C E
B7753
X036f X036m X7753 X7753 X036m X036f X004
9 9 WH 1 1 T 2 2 YE 8 8 00411 11 K4:11 Reostat in
D7901
U /0.0_1.C1
DEICING SENSOR SENSOR DEICING SENSOR
10kOhm at 25°C
00412B
B774
X004 X039m X039f X065f X065m X774 X774 X065m X065f X039f X039m X004
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stöd av gällande lag.
0V reference K4:12 12 00412A 7 7 A0397 1 1 0651 1 1 T 2 2 0652 2 2 A0399 9 9 0049 9 K4:9 Reostat in
D7901 D7901
/0.0_1.C1 U /0.0_1.C1
F SENSORS AIRCONDITION TEMP. AMBIENT SENSOR TEMP. AMBIENT F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring climate control A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
24V/12V
X004 X035f X035m R6
0.5A K4:4 4 0044 2 2 BK 1 2
A D7901 A
/0.0_1.B1
2 x 47 Ohm
MOTOR DRAUGHT VALVE
X004 X035f X035m R5 Y672 DRAUGHT VALVE
0.5A K4:3 3 0043 1 1 RD 1 2
D7901 5 M 6
/0.0_1.B1
MOTOR DRAUGHT VALVE
X004 X035f X035m X035m X035f X004
Analog reference 5V K4:5 5 0045A 4 4 GN BN 6 6 0046A 6 K4:6 0V reference
D7901 10 8 D7901
/0.0_1.B1 /0.0_1.B1
9
POT. DRAUGHT/WAT. VALVE POT. DRAUGHT/ WAT VALVE
X035m X035f X004
OG 5 5 0047 7 K4:7 Analog Input
D7901
/0.0_1.B1
0045B
24V / 12V
POT. DRAUGHT VALVE
X004 X034f X034m R4
0.5A K4:2 2 0042 5 5 BK 1 2
B D7901 B
/0.0_1.B1
2 x 220 Ohm
MOTOR WATER VALVE WATER VALVE
0046B
X004 X034f X034m R3 Y673
0.5A K4:1 1 0041 4 4 RD 1 2 5 6
D7901 M
/0.0_1.B1
MOTOR WATER VALVE
X034f X034m X034m X034f
7 7 GN 10 8 BN 9 9
M657
C X039f X039m X034f X034m X657f X657m C
585/3:1 A0396 6 6 0396 1 1 OG 1 1 OG
/ 11.5_2.D6 1
X002 X062f X062m X034f X034m X657f X657m
PWM K2:2 2 A0022 8 8 0628 2 2 BK 2 2 BK
D7901 31
/0.0_1.B1
MOTOR HEATING FAN HEATING FAN
X002
585/3:2 A0028 A0028 8 K2:8
/ 11.5_2.D6 D7901
/0.0_1.B1
24/12v LOGIC SUPPLY HEAT FAN
D D
X039f X039m X036f X036m R1
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
585/4:1 A0395 5 5 0395 1 1 RD 1 2 X612f X612m M612
/ 11.5_2.D6
82 Ohm RD 1 1 RD
+12V
BK 2 2 GY
GND M
BU BU 3 3 BU
Signal
X002 X062f X062m X036f X036m
1.5 A0023 0629 MOTOR, RECIRCULATION
K2:3 3 9 9 2 2
D7901
/0.0_1.B1
MOTOR RECIRCULATION
E E
X036m X036f
M645 BK 3 3 0363 CHASSIS
/ 9.4_1.B7
X211 X278f X278m X645
1.5A K1:25 25 21125A X90013 21125B 1 1 2781 1 2
D7971
/0.0_2.D5 1
COMPRESSOR AIRCONDITION
COMPRESSOR
X211
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stöd av gällande lag.
1.5A K1:29 29 21129
D7971
/0.0_2.D5
F COMPRESSOR AIRCONDITION F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring climate control A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
S162 MULTISWITCH
X017 X017
24V reference K3:5 5 RD 15 53C GY 4 K3:4 Input
A D7902 D7902 A
/11.5_4.F4 /11.5_4.F4
SWITCH MULTIFUNCTION SWITCH FLUSHING
X017
J1 GN 6 K3:6 Input
D7902
/11.5_4.F4
SWITCH WIPER FRONT
X017
J2 BK 7 K3:7 Input
D7902
/11.5_4.F4
SWITCH WIPER FRONT
X017
53 BU 8 K3:8 Input
D7902
/9.7_1.B1 /11.5_4.F4
SWITCH WIPER FRONT
WIPER /9.6_4.E5
B /2.0_1.B5 B
31
XM6501m XM6501f
BK 4 4 W01 W08 CHASSIS
/ 9.1_1.D7
M6501 M
X002 X062f X062m XM6501f XM6501m FRONT WIPER
5A K2:1 1 A0021 7 7 0627 2 2 RD
D7901
/0.0_1.B1
53
X37D
53a
53b
31b
MOTOR FRONT WIPER
X004 XM6501f XM6501m
24V reference K4:14 14 00414 1 1 YE
D7901
/0.0_1.C1
XM6501m XM6501f X004
C MOTOR FRONT WIPER GN 3 3 00413 13 K4:13 Input C
D7901
/0.0_1.C1
MOTOR FRONT WIPER
M6502
X002 X057f X057m XM6502f XM6502m XM6502m XM6502f X057m X057f
5A K2:4 4 A0024 1 1 0571 1 1 YE 53 31 BN 2 2 0574 4 4
D7901 M
/0.0_1.B1
MOTOR REAR WIPER
X012 X057f X057m XM6502f XM6502m 31b XM6502m XM6502f X057m X057f X012
24V reference K12:1 1 A0121 3 3 0573 4 4 BK/GN 53a BK 3 3 0572 2 2 A0122 2 K12:2 Input
D7901 D7901
/0.0_1.D6 REAR WIPER /0.0_1.D6
D MOTOR REAR WIPER MOTOR REAR WIPER D
A0574
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
M6503
X010 X055f X055m XM6503f XM6503m XM6503m XM6503f X055m X055f
1.5A K10:14 14 A01014 1 1 0551 1 1 YE 53 31 BN 2 2 0554 4 4 A0554 X37B
D7901 M
/0.0_1.C6
MOTOR ROOF WIPER
X012 X055f X055m XM6503f XM6503m 31b XM6503m XM6503f X055m X055f X012
24V reference K12:3 3 A0123 3 3 0553 4 4 BK/GN 53a BK 3 3 0552 2 2 A0124 4 K12:4 Input
D7901 D7901
/0.0_1.D6 ROOF WIPER /0.0_1.E6
MOTOR ROOF WIPER MOTOR ROOF WIPER
E M6511 E
WASHER FRONT
X010 X058f X058m XM6511 XM6511 X058m X058f
3A K10:13 13 A01013 1 1 0581 1 + 2 0582 2 2 A0582
D7901 M
/0.0_1.C6
MOTOR WASHER
X37B
M6512
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hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
WASHER REAR & ROOF
X058f X058m XM6512 XM6512 X058m X058f X040f X040m X005
F A01013A 3 3 0583 1 + 2 0584 4 4 A0402 2 2 0054 4 K5:4 PWM (NPN) F
M D7901
/0.0_1.C1
MOTOR WASH REAR/ROOF
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring wiper function A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
S1051
1 X080m X080f X006
00610A 1 1 00610 10 K6:10 Input
0 D7901
1 1 /0.0_1.B4
7901:51/24V 0811I 5 5
/ 9.6_2.B2 SW WORK LIGHTS MAST
A A
CHASSIS 0812J 10 10 9 9 00610B
/ 9.6_2.B2
WORK LIGHTS 2040
K30171
X010
0.5A K10:8 8 A0108 86 86 85 85 W02
D7901
/0.0_1.C6
CONTAINER LIGHT 40
584/7:2 A0545B 30 30 87 87
/ 11.5_2.B6
87A
B CONTAINER LIGHT 40 B
A0565
X37A
A0563
E406L1
X056f X056m XE406L1f XE406L1m XE406L1m XE406L1f
3 3 0563 1 1 GY 1 1 2 2 BK 2 2 0567A
CONTAINER LIGHT 40
C C
E406R1
X056f X056m XE406R1f XE406R1m XE406R1m XE406R1f X056m X056f
5 5 0565 1 1 GY 1 1 2 2 BK 2 2 0567B 7 7 A0567
CONTAINER LIGHT 40 X37E
K30172
X007 X069m X069f
0.5A K7:8 8 0078 1 1 A0691 86 86 85 85 W02A
D7901
D /0.0_1.C4 D
CONTAINER LIGHT 20
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
584/7:2 A0545C 30 30 87 87
/ 11.5_2.B6
87A
CONTAINER LIGHT 20
A0564
A0562 X37C
E406L2
X056f X056m XE406L2f XE406L2m XE406L2m XE406L2f
2 2 0562 1 1 GY 1 1 2 2 BK 2 2 0566A
E E
CONTAINER LIGHT 20
E406R2
X056f X056m XE406R2f XE406R2m XE406R2m XE406R2f X056m X056f
4 4 0564 1 1 GY 1 1 2 2 BK 2 2 0566B 6 6 A0566
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
CONTAINER LIGHT 20 X37E
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring work lights 2040 A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
S1052
1 X080m X080f X006
7901:51/24V 0811H 0062A 2 2 0062 2 K6:2 Input
/ 9.6_3.B2 0 D7901
1 1 /0.0_1.A4
7901:51/24V 0811I 5 5
/ 9.6_1.A2 SW WLIGHTS CARRIAGE
B B
CHASSIS 0812J 10 10 9 9 0062B
/ 9.6_1.A2
CHASSIS 0812I WORK LIGHTS CARRIAGE
/ 9.6_3.B2
1
24V D7911/1:1 CHASSIS
/ 9.6_14.B2 / 9.6_14.B7
C C
E404L3
X421 XE404L3f XE404L3f
6A K1:1 1 4211 1 1 2 2 W4211 4054 CHASSIS
D791 / 7.9_1.E7
/0.0_4.C2
WORK LIGHT LEFT WORK LIGHT CARRIAGE LEFT
1 24V D7911/1:15 CHASSIS
/ 9.6_14.E2 / 9.6_14.E7
E404R3
X421 XE404R3f XE404R3f
6A K1:15 15 42115 1 1 2 2 W42115 W400 CHASSIS
D D791 / 11.5_5.B7 D
/0.0_4.D2 X90061
WORK LIGHT RIGHT
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
WORK LIGHT CARRIAGE RIGHT
W42114 CHASSIS
/ 9.14_1.E7
E E
W9003 CHASSIS
/ 7.5_3.E7
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Extra worklight added. 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring work lights carriage A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B S1053 B
1 X080m X080f X006
7901:51/24V 0811G 0063A 3 3 0063 3 K6:3 Input
/ 9.6_4.C2 0 D7901
1 1 /0.0_1.B4
7901:51/24V 0811H 5 5
/ 9.6_2.B2 SW WORK LIGHTS MAST
CHASSIS 0812I 10 10 9 9 0063B
/ 9.6_2.B2
CHASSIS 0812H WORK LIGHTS MAST
/ 9.6_4.C2
C C
D D
E404L1
X211 X204m X204f X2041f X2041f X204f X204m
6A X90019
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
K1:1 1 2111A 2111B 1 1 2041 1 1 2 2 2043 3 3 W2043
D7971
/0.0_2.C2
LAMPS WORK LIGHT MAST WORK LIGHT MAST
E404R1
X204m X204f X2042f X2042f X204f X204m
2111C 2 2 2042 1 1 2 2 2044 4 4 W2044 W204
X90078
WORK LIGHT MAST X37201A
E X37201 E
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Kablage till 5298 utgår 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring work lights mast A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
S100
1 X080m X080f X006
0065A 5 5 0065 5 K6:5 Input
7901:51/24V 0811E 0 D7901
/ 9.3_1.B2 1 1 /0.0_1.B4
5 5
SWITCH MAIN LIGHT
CHASSIS 0812E 10 10 9 9 0065B
/ 9.3_1.B2
CHASSIS 0812F
/ 9.6_7.A2 MAIN LIGHT
B B
0811F
S110
1 X080m X080f X006
0064A 4 4 0064 4 K6:4 Input
0 D7901
1 1 /0.0_1.B4
7901:51/24V 0811G 5 5
/ 9.6_3.B2 SWITCH ROT. BEACON
CHASSIS 0812G 10 10 9 9 0064B
/ 9.6_7.B2
CHASSIS 0812H
/ 9.6_3.C2 ROT. BEACON
C C
S162 MULTISWITCH
D D
56 56b
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
X017
56a WH 9 K3:9 Input
D7902
/11.5_4.F4
SWITCH MAIN / DIPPED BEAM
/2.0_1.A4
MAIN / DIPPED BEAM /9.5_1.B4
E X002 X056f E
5A K2:5 5 A0025 1
D7901
/0.0_1.B1
MOTOR ROT. BEACON
H428
ROT. BEACON
X054f X054m X4281 X4282 X054m X054f
A0547 7 7 0547 1 + 1 0548 8 8 A0548
M
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F X37B F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring lights A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
DIPPED LIGHT FRONT LEFT
B B
6B CHASSIS
/ 9.6_7.E8
X270/271f X270/271m 271:1 E402R1
X211 X271f / 9.6_13.C1 X271m
6A K1:15 15 21115A X90027 21115B 2 2 21115E 1 1 1 1 1 2 1 6A
D7971
/0.0_2.D2 24VK304287
/ 9.6_13.F5
HEAD LIGHT HEAD LIGHT FRONT RIGHT
C C
6B CHASSIS
/ 9.6_7.D8
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
SIDE POSITION FRONT RIGHT
X37207
2112D 2112
/ 9.6_6.D2
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 X270/271 and ref to 9.6_13 added. 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring lights A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
E405L
X056f X056m
A0543 9 9 0569A 1 1 2 1 0569B
REVERSING LIGHT REAR LEFT
A A
E405L
X002 X054f X054m X054m X054f
5A K2:6 6 A0026 3 3 0543 1 1 2 2 0544 4 4 A0544
D7901
/0.0_1.B1
REVERSING LIGHT LEFT REVERSING LIGHT REAR LEFT
E405R
X056f X056m
A0545 8 8 0568A 1 1 2 1 0568B
REVERSING LIGHT REAR RIGHT
E405R X37C
X002 X054f X054m X054m X054f
5A K2:7 7 A0027 5 5 0545 1 1 2 2 0546 6 6 A0546
B D7901 B
/0.0_1.B1
REVERSING LIGHT RIGHT REVERSING LIGHT REAR RIGHT
X37A
H411L
X211 X275f X275m X272f X272m
1.5A K1:7 7 2117 3 3 2753 3 3 3 1 2
D7971
/0.0_2.D2
BRAKE LIGHT LEFT BRAKE LIGHT REAR LEFT
C H411R C
X211 X275f X275m X273f X273m
1.5A K1:9 9 2119 4 4 2754 3 3 3 1 2
D7971
/0.0_2.D2
BRAKE LIGHT RIGHT BRAKE LIGHT REAR RIGHT
CHASSIS
H412L / 9.6_7.E8
X211 X275f X275m X272f X272m
1.5A K1:33 33 21133 5 5 2755A X90007 2755B 2 2 2 1 2 6B
D7971
/0.0_2.D5
6A CHASSIS
REAR LIGHTS REAR LIGHT LEFT / 9.3_5.D7
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
H4162
X275f X275m X272f X272m X272m X272f X275m X275f
2112 2112D 6 6 2756A X90024 2756B 5 5 5 1 2 6C 6 6 6 2726 8 8 2758
/ 9.6_5.D6
X90049
SIDE POSITION REAR LEFT
CHASSIS
H412R / 9.6_7.D8
X273f X273m
2755C 2 2 2 1 2 6B
E 6A CHASSIS E
REAR LIGHT RIGHT / 9.3_5.C7
H4172
X273f X273m X273m X273f X275m X275f
2756C 5 5 5 1 2 6C 6 6 6 2736 7 7 2757
X90048
SIDE POSITION REAR RIGHT
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
X37204
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Jordning lampor ändrad. 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring lights A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A S109 A
1
0 X081m X081f X005
X039f X039m X081f X081m 1 1 0816 6 6 0056 6 K5:6 Input
584/2:2 A0392 2 2 0392 7 7 0817 5 5 D7901
/ 11.5_2.A6 /0.0_1.C1
CHASSIS 0812F 10 10 9 9 0815 5 5 SWITCH HAZARD
/ 9.6_4.B2
CHASSIS 0812G Hazard
/ 9.6_4.C2 X005
0055 5 K5:5 PWM (PNP)
D7901
/0.0_1.C1
SWITCH LAMP HAZARD
B B
S161
R
0
L X018
1 1 0189 9 K8:9 Input
D7902
0187B 2 2 3 /11.5_4.F4
SWITCH DIRECTION LIGHT RIGHT
X018
1.5A K8:7 7 0187A 5 5 4
D7902 X018
/11.5_4.F4 6 6 0188 8 K8:8 Input
C D7902 C
SWITCH DIRECTION LIGHT /11.5_4.F4
DIRECTION LIGHT SWITCH DIRECTION LIGHT LEFT
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
H427
X275f X275m X273f X273m
21131C 2 2 2752 4 4 4 1 1 2 CHASSIS
/ 9.6_6.E7
Direction Right Rear
H426
X275f X275m X272f X272m
21130C 1 1 2751 4 4 4 1 1 2 CHASSIS
/ 9.6_6.D7
Direction Left Rear
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ref to 9.6_13 added. 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring light director & hazard A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A0668 584/2:1
/ 9.6_11.B1
A A
X060f X060m X060Af X060Am X018 X018 X060Am X060Af X060m X060f X011
584/2:1 A0607 7 7 0607 7 7 0607B 10 K8:10 K8:11 11 0609 9 9 0609 9 9 A0112 2 K11:2 Input
/ 11.5_2.A6 D7902 D7902 D7901
/0.0_1.C6
SWITCH INTERIOR LIGHT SWITCH INTERIOR LIGHT INTERIOR LIGHT
584/2:1 0607A
/ 11.5_3.C2
INTERIOR LIGHT SWITCH DISPLAY
B B
X039f X039m X082f X082m S266LE X082m X082f X039m X039f X011
584/2:1 A0393 3 3 0393A 1 1 0393C 1 1 2 1 0394C 2 2 0394A 4 4 A0113 3 K11:3 Input
/ 11.5_2.A6 D7901
/0.0_1.C6
BRAKING CAB DOOR
SWITCH BREAK CAB DOOR
S266RI
C 0393B 1 1 2 1 0394B C
BRAKING CAB DOOR
E4341
X011 X054f X054m X054m X054f
1.5A K11:6 6 A0116 1 1 0541 1 1 2 1 0542 2 2 A0542A
D7901
/0.0_1.D6
LAMP INTERIOR LIGHT INTERIOR LIGHT
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
X066f X066f
A0541 6 24V D7901/11:6 CHASSIS 7 A0542B
/ 9.6_11.C1 / 9.6_11.C7
E E
E4342
X062f X062m XE4342f XE4342m XE4342m XE4342f X062m X062f
585/6:1 A0624 4 4 0624 1 1 BK 1 2 1 2 BK 2 2 0625 5 5 A0625
/ 11.5_2.E6
MAP LIGHT
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
X37A
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring interior lights A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
E404R4
X213m XE404R4f XE404R4f X213m
24V D7971/1:42 1 2131A X90062 2131B 1 1 2 2 2132B 2132A 2 CHASSIS
/ 9.0_1.C4 / 9.0_1.C6
X90063
WORK LIGHT OPT
C C
E404L4
XE404L4f XE404L4f
2131C 1 1 2 2 2132C
WORK LIGHT OPT
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
E E
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Kablage till 5298 utgår 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring work lights option A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
E404R2
XE404R2f XE404R2f
2491C 1 1 2 2 2492C
C C
WORK LIGHT OPT
E404L2
X249m XE404L2f XE404L2f X249m
D7972/1:42 1 2491A X90042 2491B 1 1 2 2 2492B 2492A 2 CHASSIS
/ 11.5_9.D3 / 11.5_9.D6
X90041
WORK LIGHT OPT
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
E E
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Kablage till 5298 U. X249 v X240. 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring work lights option A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
X066f X066m X276f X276m XS141f XS141m S141 XS141m XS141f X276m X276f X066m X066f X011
584/2:1 A0668 8 8 GY 1 1 GY 1 1 BN 1 2 BK 2 2 BK 2 2 BK 9 9 A0114 4 K11:4 Input
/ 9.6_8.A2 D7901
/0.0_1.D6
STEP LIGHT
SWITCH STEP IN LIGHT
B B
C C
E433
X066m X276f X276m X276m X276f X066m
24V D7901/11:6 6 RD 3 3 GY 1 1 2 1 BK 4 4 BU 7 CHASSIS
/ 9.6_8.D3 / 9.6_8.D6
STEP LIGHT
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
E E
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring step in light A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
E404L5
XE404L3m XE404L5f XE404L5f XE404L3m
Kopplas till kontakt för std belyning. 1 4211A X90085 4211B 1 1 2 2 W4211B X90087 W4211A 2
Kopplas till kontakt för std belyning.
B B
Connected to connector std work light. Connected to connector std work light.
WORK LIGHT CARRIAGE LEFT OPT
XE404L3f XE404L3f
4211C 1
Std belysning 2 W4211C
Std work light
C C
E404R5
XE404R3m XE404R5f XE404R5f XE404R3m
Kopplas till kontakt för std belyning. 1 42115A X90086 42115B 1 1 2 2 W42115B X90088 W42115A 2
Kopplas till kontakt för std belyning.
Connected to connector std work light. Connected to connector std work light.
WORK LIGHT CARRIAGE RIGHT OPT
D XE404R3f XE404R3f D
42115C 1
Std belysning 2 W42115C
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
Std work light
E E
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion / New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring work lights carriage opt A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
X270Am
270:1 1 1 X270Af
/ 9.6_5.B4
A 270:2 2 2 2 2 270:2 A
/ 9.6_5.A3 / 9.6_5.A5
3 3 3 3
270:4 4 4 4 4 270:4
/ 9.6_7.E4 / 9.6_7.E5
270:5 5 5 5 5 270:5
/ 9.6_5.C3 / 9.6_5.C5
270:6 6 6 6A 6 270:6
/ 9.6_5.C8 / 9.6_5.C7
E4047L
1A 1 2 6B
B B
OPT. WORKING LIGHT FRONT LEFT
E4048L
1B 1 2 6C
OPT. WORKING LIGHT FRONT LEFT
C C
X271Am
271:1 1 1 X271Af
/ 9.6_5.C4
271:2 2 2 2 2 271:2
/ 9.6_5.B3 / 9.6_5.B5
3 3 3 3
271:4 4 4 4 4 271:4
/ 9.6_7.D4 / 9.6_7.D5
271:5 5 5 5 5 271:5
/ 9.6_5.D3 / 9.6_5.D5
271:6 6 6 6A 6 271:6
/ 9.6_5.D8 / 9.6_5.D7
D D
E4047R
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
1A 1 2 6B
OPT. WORKING LIGHT FRONT RIGHT
E4048R
1B 1 2 6C
OPT. WORKING LIGHT FRONT RIGHT
E E
K3042
X270/271m
X211:1 1 GY 86 86 85 85 W304-2-85
/ 9.6_5.B3
X270/271f X37200R
581/8:1 W304-2-30A 30 30 87 87 BK 1 24VK304287
/ 11.5_1.C5 / 9.6_5.B3
87A RD 2 24VK304287
/ 9.6_5.C3
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
WORK LIGHTS
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 New page 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring work lights option fenders A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
E404L1
XE404m XE404m
24V D7911/1:1 1 4041A XSP4041 4041B 1 1 2 2 4042B XSP4042 4042A 2 CHASSIS
/ 9.6_2.C4 / 9.6_2.C5
WORK LIGHT CARRIAGE LEFT
E404L2
4041C 1 1 2 2 4042C
WORK LIGHT CARRIAGE EXTRA LEFT
C C
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
E404R1
XE404Rm XE404Rm
24V D7911/1:15 1 4041A XSP4041 4041B 1 1 2 2 4042B XSP4042 4042A 2 CHASSIS
/ 9.6_2.D4 / 9.6_2.D5
WORK LIGHT CARRIAGE RIGHT
E404R2
E 4041C 1 1 2 2 4042C E
WORK LIGHT CARRIAGE EXTRA RIGHT
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
1
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
New drawing 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring work lights option carriage A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
S162 MULTISWITCH
/9.5_1.B4
X017
H BN 2 K3:2 Input
D7902
/11.5_4.F4
SWITCH HORN
HORN
B B
0621 A01111B
/ 9.7_3.B2
0622A CHASSIS
/ 9.7_3.C7
X062f X062m
C 2 2 C
A0622
X37B
X011 X063f X063m X230f X230m S230 X230m X230f X063m X063f X011
24V reference K11:12 12 A01112 1 1 0631 2 2 BU 2 1 RD 1 1 0632 2 2 A01114 14 K11:14 Input
D D7901 D7901 D
/0.0_1.D6 3 GY 3 /0.0_1.D6
SWITCH SEAT SWITCH SEAT
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
SEAT SWITCH
H853
E E
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring alarm, buzzer and horn A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
C C
X37210
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
E E
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring reversing alarm A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
K3016
B X37B B
H8501
COMPRESSOR HORN
K3016 X062f X062m
585/8:1 A0623A 30 30 87 87 A0623B 3 3 0623 1 + 1 0622A CHASSIS
/ 11.5_2.E6 M / 9.7_1.C7
87A
/9.7_3.B4
COMPRESSOR HORN
C C
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
E E
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Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring compressor horn A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
S1493
1
24V D7901/8:16 0921B 0 X091m X091f X009
/ 7.9_1.B2 1 0911 1 1 00910 10 K9:10 Input
24V D7901/8:16 0921C 2 D7901
B / 7.5_1.B2 B
HORN SERVO PANEL OPT. HORN SERVO PANEL OPT.
C C
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
E E
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Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Connection S1493 v 51, now 21 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring horn servo panel A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
X900Af X900Bf
1/8 1/8
2/8 2/8 H902R
X900Bm
3/8 3/8 3 BK/WH +
X055f X055m X900Am
584/5:1 A0555 5 5 0555 4 4/8 4/8 4 BK
/ 11.5_2.B6
5/8 5/8 5 BK/WH
SPEAKER RIGHT
6/8 6/8 6 BK
X055f X055m X900Am
584/3:2 A0559 9 9 0559 7 7/8 7/8
/ 11.5_2.B6
A0557 7 7 0557 8 8/8 8/8
B H902L B
+
SPEAKER LEFT
A900
C C
A0557
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
X37C
E E
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Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring radio A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
+12V RD 12V
/ 11.5_7.D6
CHASSIS BK
/ 11.5_7.D6
5V
XA9092f
X182m X182f XA9092m
KID_RX 1822 2 2 90922 TX
/ 11.6_1.A2
KID_TX 1823 3 3 90923 RX
/ 11.6_1.A2
B A909 B
Printer
C C
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
E E
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Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring printer A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
E802R2
BN 1 2 BU
C C
E802L2
BN 1 2 BU
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
E E
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion / New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring heating mirrors A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
Strömställare val manuell/automatisk hyttippning se S1992.
Switch choice manual/automatic cab tilt see S1992. 1 = UP/RIGHT
0 = 0
A 2 = DOWN/LEFT X008 A
S1010 0086 Input
6 K8:6
24V D7901/8:16 00816F 1 D7901
/ 9.1_1.A2 0
2
1 1 SWITCH CAB TILT UP/RIGHT
24V D7901/8:16 00816G 3 3
/ 7.5_3.B2 7 7
2
4
8 X008
CHASSIS37D 0923D 10 10 9 9 00815B 0087 7 K8:7 Input
/ 9.1_1.B2 D7901
CHASSIS37D 0923E
/ 7.5_3.B2 CAB TILT/SLIDING CAB
SWITCH CAB TILT DOWN/LEFT
Y6080
X221 X243f X243m X243m
1.5A K1:25 25 22125 3 3 GY 1 1 2 2 BK 12
D7972
Endast vid hyttkörning, ej hyttilt. ACT. SLIDING CAB
Only for sliding cab, not cab tilt.
C C
Y6047
X221 X243f X243m
1.5A K1:29 29 22129 8 8 2438 1 1 2 2 24312B
D7972
CAB TILT UP/RIGHT
Y6048
X221 X243f X243m X243m X243f
1.5A K1:39 39 22139 9 9 2439 1 1 2 2 24312C 24312A 12 12 W243
D7972
X90067
D CAB TILT DOWN/LEFT X37216 D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
X221 X243f X243m XB7691f XB7691m
1.5A K1:7 7 2217 4 4 2434A X90066 2434B A A
D7972
BN
B7691 XB7691m XB7691f X243m X243f X221
BK C C 2435 5 5 22113 13 K1:13 Input
D7972
CAB TILT UP
BU
B B 24312D
E E
XB7692f XB7692m
2434C A A
BN
B7692 XB7692m XB7692f X243m X243f X221
BK C C 2436 6 6 22120 20 K1:20 Input
D7972
CAB TILT DOWN
Endast vid hyttilt, ej hyttkörning. BU
B B 24312E
Only for cab tilt, not sliding cab.
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
Givare stativ för automatisk hyttilt se B72111.
Sensor mast when automatic cab tilt see B72111.
Ref. Benämning Produkt/Product Blad/Sheet
Nr Ändring Ändring nr Datum Sign. Datum/Date Huvudnr./Project no.
Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets hyttilt/hyttkörning DCF300,DCE300 9.10_1
CJS 050128 A47137.0100
Name
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Cable 00815C U 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring cab tilt/sliding cab A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
M6931
1
GREY
2
B X213m XM6931 B
24V D7971/1:42 1 1 15
/ 9.0_1.C4 M
31 BLACK
2
CENTRAL LUBRICATION
X213m
2 CHASSIS
/ 9.0_1.C6
C C
M6932
1
D GREY D
2
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
X421 XM6932
10A K1:14 14 42114 1 15
D791 M
/0.0_4.D2 BLACK
2 31
PUMP CENTRAL LUBRICATION
CENTRAL LUBRICATION
E W42114 CHASSIS E
/ 9.6_2.E8
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring central lubrication A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
Y6062
X211
1.5A K1:39 39 21139 1 1 2 2 6062 CHASSIS
D7971 / 7.2_2.E5
/0.0_2.E5
VALVE PUMP 2
INTERRUPTION PUMP 2
(EXTRA PUMP LIFT)EC
C C
1
Y60622
X211 XY6012/6062 XY6012/6062
1.5A K1:35 35 21135 1 1 2 2 6012 CHASSIS
D D7971 / 7.2_2.D5 D
/0.0_2.D5
PUMP ATTACHMENT
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
INTERR PUMP ATT
(ACT. PUMP ATT)EC
E E
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Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Moved from 8.2_2 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring interruption hydr. pump A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B776
XB776f XB776f X212
2 2 T 1 1 21213 13 K2:13 Temperature Input
D7971
U /0.0_2.C4
HYDRAULIC OIL TEMPERATURE SENSOR HYDR. OIL TEMP.
7762
B B
M668
X211 XM668f XM668m XM668m XM668f
10A K1:14 14 21114 1 1 1 2 2 2 6682
D7971 M
/0.0_2.D2
MOTOR COOLING FAN HYDR. OIL
COOLING FAN HYDRAULIC OIL
X37202A
X37202
C C
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
E E
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring cooling hydraulic oil A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
0711 544
MAIN RELAY IGNITION / 11.5_2.C1
/11.5_3.E4
87 30
A K3151 A
W208
21211 582/1:1
/ 11.5_4.A2
F582 2121 582/1:1
1a 1b / 11.5_4.B2
50A /11.5_1.B2 W213 A:1 30 A 1:1 2129 582/1:2
A:1 1:1 / 11.5_4.B2
W214 A:2 A:2 1:2 1:2 21210 582/1:2
/ 11.5_4.B2
W226 B:1 5 A
B:1 2:1
B:2 2:2 2221 582/3:1
/ 11.5_5.D2
C:1 25 A 3:1 2229 582/3:1
2a 2b C:1 3:1 / 11.5_5.D2
F581 C:2 C:2 3:2 3:2 22210 582/3:2
50A / 11.5_5.D2
W223
B W209 A:1 30 A 1:1 0526 581/1:1 D:1 10 A 4:1 W237 582/4:1 B
A:1 1:1 / 11.5_2.A2 D:1 4:1 / 11.5_10.B2
A:2 A:2 1:2 D:2 4:2
B:1 5 A E:1 5 A 5:1 216-246 582/5:1
B:1 2:1 E:1 5:1 / 9.6_5.E2
B:2 2:2 E:2 E:2 5:2 5:2 90012A 582/5:2
3a 3b / 7.2_2.C2
50A W210 C:1 15 A 3:1 2101 581/3:1 F:1 5 A 6:1 2014 582/6:1
C:1 3:1 / 1.0_1.C3 F:1 6:1 / 2.0_1.E2
C:2 C:2 3:2 F:2 F:2 6:2
2105A K3152 2107A
D:1 10 A 4:1 581/4:1 G:1 5 A 7:1 582/7:1
D:1 4:1 / 1.0_1.D3 G:1 7:1 / 1.0_1.E3
D:2 D:2 4:2 4:2 W221 30 87 W222 G:2 7:2
E:1 5 A 5:1 2012 581/5:1 87A H:1 5 A 8:1 2108A 582/8:1
4a 4b E:1 5:1 / 2.0_1.E2 H:1 8:1 / 1.0_1.E3
50A E:2 5:2 /11.5_3.F4 H:2 8:2
W228 377430 RELAY IGNITION
F:1 15A 6:1 581/6:1 /11.5_1.D6 +15
F:1 6:1 / 4.8_1.C2
F:2 6:2
C W214 C
G:1 7:1 F582
G:2 7:2 1 KDU CHASSIS
W304-2-30B H:1 15A 8:1 W304-2-30A 581/8:1 2 NOT USED
H:1 8:1 / 9.6_13.F2 3 KDU OPT. CHASSIS
H:2 8:2
4 OPT.
/11.5_1.D3 +30 5 SWITCHES / SENSORS
6 TRANSMISSION
W207
W206
W211
7 ENGINE
1 CAB 8 ENGINE
2 NOT USED
/11.5_1.C6
3 ENGINE
4 ENGINE
5 TRANSMISSION
6 OPT. COOLING FAN, BRAKES
54/3 7 NOT USED
/ 11.5_6.D2
D 8 Opt. work lights D
/11.5_1.C3
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
GY Batt + W212 CHASSIS
/ 8.2_4.F1 / 11.5_3.E2
37209 CHASSIS
S144 G301 G302 / 7.2_2.E8
2 1 W3 + W2 + W1
X2152A X2152B
12V, 140Ah 12V, 140Ah W219 BU CHASSIS
/ 11.5_5.B7
W5
W220 X37200D
W4
E X37100B E
X37200
X37100
X37200A 0712
M654 G660
B+ X37100C
X37100A X37200
30 31 B D+ X37100 X37100
M G
ALTERNATOR
50 STARTER W X37200B X37200C X0712A
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
X37200 X37200 X0712
Inkoppling startmotor & generator
F se sida motor 1.0_2. F
Connection starter & alternator
see page engine 1.0_2.
Ref. Benämning Produkt/Product Blad/Sheet
Nr Ändring Ändring nr Datum Sign. Datum/Date Huvudnr./Project no.
Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets ström DCF300,DCE300 11.5_1
CJS 050128 A47137.0100
Name
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Cable GY added. 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring power A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A0595
A A
F584
X052m X052f
0526 A0526 A0011 X37A
581/1:1 6 6 A:1 10 A 1:1 584/1:1
/ 11.5_1.B5 A:1 1:1 / 11.5_4.C2
AA2-B1 A:2 A:2 1:2 A0607 584/2:1
/ 9.6_8.A1
B:1 5 A 2:1 A0393 584/2:1 X059f
B:1 2:1 / 9.6_8.B1
B:2 2:2 2:2 A0392 584/2:2 5
/ 9.6_7.A2
A0526A C:1 10 A 3:1 A0594 4
C:1 3:1
AC2-D1 C:2 C:2 3:2 3:2 A0559 584/3:2 3
/ 9.8_1.B2
D:1 10 A 4:1 A0672
D:1 4:1
D:2 4:2
10 A 5:1 A0555 584/5:1
E:1 5:1 / 9.8_1.B2
AE2-F1 E:2 E:2 5:2 5:2 A0707C 584/5:2
/ 7.0_5.B1
B F:1 25 A 6:1 A0634B 584/6:1 X067f B
F:1 6:1 / 9.3_1.D2
A0711B F:2 F:2 6:2 6:2 A0664 584/6:2 2
/ 9.3_7.A1 Dedicated for
15 A 7:1 A0545B 584/7:2 1
G:1 7:1 / 9.6_1.B2
AG2-H1 G:2 G:2 7:2 7:2 A0545C 584/7:2 3 use of customer
/ 9.6_1.D2
H:1 15 A 8:1 A0635B 584/8:1 4
H:1 8:1 / 9.3_2.B2
A0711D H:2 H:2 8:2
/11.5_2.C4 +30/+15 in Cab
F584
X071 1 KCU
544 0711 2 KCU STARTUP A0626A +12V
/ 11.5_1.A4 3 SERVICE
/ 11.5_7.D2
4 OPT. CUSTOMER
C 5 OPT. RADIO C
6 OPT. SEAT HEATER, TURNABLE SEAT.
7 OPT. CONTAINER LIGHT
A0673
8 OPT. AIR SEAT
/11.5_2.C4
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
D:1 5 A 4:1 A0395 585/4:1
D:1 4:1 / 9.4_2.D2
AD2-E1 D:2 D:2 4:2
E:1 10 A 5:1 A0593
E:1 5:1
E:2 5:2 5:2 A0671
A0711C F:1 5 A 6:1 A0624 585/6:1
F:1 6:1 / 9.6_8.E1
AF2-G1 F:2 F:2 6:2
901 X901.1f / 11.5_7.B2
G:1 10 A 7:1 585/7:1
G:1 7:1 / 11.5_8.C3
AG2-H1 G:2 G:2 7:2
H:1 10 A 8:1 A0623A 585/8:1
H:1 8:1 / 9.7_3.C2
H:2 8:2
E /11.5_2.F4 +15 in Cab E
F585
1 KCU
2 KIT
3 ECC, FAN
4 ECC, RECIRCULATION
5 SERVICE / CUSTOMER
6 OPT. MAP LIGHT
7 OPT. CONVERTER 12V
8 OPT. COMP. HORN
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
/11.5_2.E4
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 A0664 moved from 5848:2. 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring power A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
P 1
B S150 B
STARTER SWITCH 3
58
15
30
19
50
17
130
819
317
750a
515/54
0161 24V D7902/2:1
/ 1.0_1.B1
0162A
584/2:1 0607A
/ 9.6_8.B1
0162 24V D7902/2:2
/ 1.0_1.B1
C C
X058m X058f
6 6 A0586
Cable 0586 is connected to X058f:6 and X058f:7
X058m X058f
when no engine preheater is used. 0586 7 7 A0111
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
W212G CHASSIS
/ 4.8_1.C4
W212C CHASSIS
/ 11.5_6.C2
W212D CHASSIS
/ 11.5_6.C2
W212E CHASSIS
CHASSIS W212 X90044 / 11.5_6.D2
/ 11.5_1.D6 W212F CHASSIS
/ 11.5_6.D2
E K3151 E
X010 X052f X052m
0.5A K10:10 10 A01010 3 3 0523 2 86 85 1 W212A
D7901
/0.0_1.C6 /11.5_1.A2
RELAY K3151 MAIN RELAY IGNITION
K3152
X010 X052f X052m
0.5A K10:16 16 A01016 7 7 0527 86 86 85 85 W212B
D7901
/0.0_1.C6 /11.5_1.C5
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
RELAY K3152 RELAY IGNITION
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 K3151 v K1, K3152 v K4 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring power A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A X212 A
582/1:1 21211 11 K2:11 Input
/ 11.5_1.A8 D7971
/0.0_2.B4
Emergency stop
X212 D7971
582/1:1 2121 1 K2:1
/ 11.5_1.A8 Main power
X212 Power supply/Ground X212
582/1:2 2129 9 K2:9 Main power Ground K2:12 12 21212
/ 11.5_1.B8
582/1:2 21210 10 K2:10 Main power Ground K2:14 14 21214
/ 11.5_1.B8
/0.0_2.B4
B B
X37203A
X37203
X001 D7901
C 584/1:1 A0011 1 K1:1 C
/ 11.5_2.A6 24V Battery
X001 X001
585/1:1 A0012 2 K1:2 K1:5 5 A0015
/ 11.5_2.D6 24V Ignition Ground
585/1:2 A0013 3 K1:3 K1:6 6 A0016
/ 11.5_2.D6 24V Ignition Ground
585/1:2 A0014 4 K1:4
/ 11.5_2.D6 24V Ignition
/0.0_1.A1
X37A
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
D7902
F
E D7902 D7902 E
/11.6_1.B3
Keyb.
Keybord
Ind.
Ind. Cluster
X061f X061m X061Am X061Af X015 X015 X061Af X061Am X061m X061f
585/2:1 A0615 5 5 0615 5 5 0615 1 K4:1 K4:5 5 0616 6 6 0616 6 6 A0616
/ 11.5_2.D6 +
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Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
X37A
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring power A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
X422
42211 11 K2:11 Input
D791
/0.0_4.B4
Emergency stop
C C
X222
583/5:1 22211 11 K2:11 Input
/ 11.5_6.E7 D7972
/0.0_3.B4
Emergency stop
X222 D7972
582/3:1 2221 1 K2:1
/ 11.5_1.B8 Main power
D Power supply/Ground X222 D
582/3:1 2229 9 K2:9 Main power Ground K2:12 12 22212
/ 11.5_1.B8
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
582/3:2 22210 10 K2:10 Main power Ground K2:14 14 22214
/ 11.5_1.B8
/0.0_3.B4
X37208
E E
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring power A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
S250
X008
24V D7901/8:16 00816K 1 2 0084 4 K8:4 Input
/ 8.2_1.B2 D7901
/0.0_1.D4
OPERATING SWITCH SW. OPERATING POWER
A A
K3002
XK3002 XK3002
0525C 86 85 86 85
/7.7_1.C3
TILT IN / OUT
K3007
XK3007 XK3007
0525B 86 85 86 85
B /7.2_1.C3
B
LIFT / LOWER
K30092
X010 X052f X052m
0.5A K10:12 12 A01012 5 5 0525 X90045 0525A 2 86 85 1
D7901
/0.0_1.C6 /11.5_6.D3
RELAY K30092,K3002,K3007 RELAY OPERATING SWITCH
K30091
X010 X052f X052m
0.5A K10:11 11 A01011 4 4 0524 2 86 85 1
D7901
/0.0_1.C6 /11.5_6.D2
C RELAY K30091 RELAY OPERATING SWITCH C
CHASSIS W212C
/ 11.5_3.D7
CHASSIS W212D
/ 11.5_3.E7
CHASSIS W212E
/ 11.5_3.E7
CHASSIS W212F
/ 11.5_3.E7
X2151A
RELAY OPERATING SWITCH RELAY OPERATING SWITCH 1681 RD 583/1:1
/11.5_6.C4 /11.5_6.C4 F583 / 11.5_5.B2
D D
54/3 W211 W215 W216A A:1 1:1 W227 X168 X2151B
25 A
/ 11.5_1.D3 30 87 30 87 A:1 1:1
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
A:2 A:2 1:2
K30091 K30092
B:1 5 A
B:1 2:1
B:2 2:2
W216B 5 A 3:1 2024 583/3:1
C:1 3:1 / 7.0_5.D2
C:2 C:2 3:2
D:1 5 A
D:1 4:1
D:2 4:2
E:1 5 A 5:1 22211 583/5:1
E:1 5:1 / 11.5_5.C2
E:2 5:2
F:1 6:1
E F:2 6:2 E
G:1 7:1
G:2 7:2 X051m X051f X011
W218 5 A 8:1 0511 1 1 A01113 13 K11:13 Input
H:1 8:1 D7901
H:2 8:2 /0.0_1.D6
/11.5_6.F5 +15E FEEDBACK K2
F583
1 KDU ATTACHMENT
2 NOT USED
3 FORK ATTACHMENT
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
4 NOT USED
5 KDU OPT. CHASSIS
F 6 NOT USED F
7 NOT USED
8 FEEDBACK K30091
/11.5_6.E4
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 S250 Ä. 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring power operating switch A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
X901.3f W14B
24V COM
X901.2f W14A
GND
X901.4f
585/7:1
/ 11.5_2.E6 12V
24V 12V
A901 X37C
B B
X37C
C C
OPTION ADAPTER
+12V A0626A
/ 11.5_2.C8 XA9091f
804A1A 1 +12V
/ 9.8_2.A2
D 804A2A 2 CHASSIS D
/ 9.8_2.A2
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
W03
E E
X37D
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring 24/12V A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
X901.3f
C W14B X37C C
X072f
BK 2
GY 1 24V
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
E E
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring 24V contact A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
X221 X240f
10A K1:14 14 22114 1
D7972
/0.0_3.D2
OPT.
X240f
B 4 W235D CHASSIS B
/ 11.5_11.A8
X221 X240f
6A K1:28 28 22128 2
D7972
/0.0_3.D5
OPT.
C X221 X240f C
Analog In 05V K1:24 24 22124 3
D7972
/0.0_3.C5
OPT.
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
X221 X249f X249f
6A K1:42 42 22142 1 D7972/1:42 CHASSIS 2 W235F CHASSIS
D7972 / 9.6_10.D2 / 9.6_10.D7 / 11.5_11.B8
/0.0_3.D5
OPT.
E E
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Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 X249 T, X249.1 & 2 V X240.3 & 4 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring option base power A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
X242f X221
D7972/1:23 4 22123 23 K1:23 Analog In 05V
C / 7.9_3.B7 D7972 C
/0.0_3.C5
OPT.
X242f
CHASSIS 8 W235E CHASSIS
/ 7.9_3.A7 / 11.5_11.A8
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
E E
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring option base A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
W235D CHASSIS
/ 11.5_9.B7
W235E CHASSIS
/ 11.5_10.D7
W235F CHASSIS
/ 11.5_9.D7
B B
X221 X241f X241f
Dig In / 1.5A K1:11 11 22111 2 24V D7972/1:11 CHASSIS 1 W235B X90035 W235A
D7972 / 9.9_1.B2 / 9.9_1.B7
/0.0_3.D2
OPT.
X37215
X221 X241f
Dig In / 1.5A K1:12 12 22112 3 24V D7972/1:12
D7972 / 9.9_1.D2
/0.0_3.D2
C C
OPT.
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
X221 X241f
Dig In / 1.5A K1:40 40 22140 5
D7972
/0.0_3.D5
OPT.
E E
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Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring option base A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
R8202 D795
1 2 X020 X020 X060Am X060Af X060m X060f X051f X051m
6 K1:6 CAN 2 K1:13 13 30 0605 5 5 30 0605 5 5 A0512A 30 2 2
+ L+
0606 0606 A0513A
WH
GY
5 K1:5 CAN K1:12 12 6 6 6 6 3 3
L
A K1:4 K1:8 8 0604 4 4 0604 4 4 A
Shield +
GY
X020 RS232
KID_TX 30 1823 3 K1:3 K1:11 11 30 0601A 1 1 30 0601 1 1
/ 9.8_2.B2 TX R+
1822 CAN 0602A 0602
WH
KID_RX 2 K1:2 RX R K1:10 10 2 2 2 2
/ 9.8_2.B2
KID_GND 1825 1 K1:1 K1:7 7 0603 3 3 0603 3 3
/ 9.8_2.B2 GND +
GY
X020 X061Af X061Am X061m X061f
7902/1:14 02014 14 K1:14 BUZZER 0V REF K1:9 9 0613 3 3 0613 3 3
/ 9.7_1.E7
WH
KID
0152
0156
6
5
4
3
2
1
X203m
A0513B
A0512B
D7902
30
30
A0613
6
5
4
3
B /11.5_4.E4 B
X203f
X015 X015
2 K4:2 K4:7 7 0601B
+ + X37A
6 K4:6 CAN CAN K4:8 8 0602B
2034
0521 30 X059f
30
2 30 30 0513
0522 K4:3 Shield Shield K4:4 1 0512
2033
30
X052m X052f
1 1 30 A0481B X048 1 30 A0131
2033 CAN_J1939_+
/ 1.0_1.C3 A B
2036
X052m X052f
30
2034 CAN_J1939_
/ 1.0_1.D3 2 2 30 A0482B X048 2 30 A0132
C C
2035 CAN_J1939_+ A B A0135 30
2035
/ 2.0_1.D2
30
X049m A0134
2036 CAN_J1939_
/ 2.0_1.D2 A 30 A0481A
R8201
B A0482A 1 2
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
/ 11.6_2A.C7 30 4 4 30 A0137 7 K13:7 /0.0_1.E6
/ 11.6_2B.B7 R+
CAN 3 0515 5 5 A0138 8 K13:8 CAN
/ 11.6_2C.B7 R
K13:9
Shield
RED+2 2 0519A X011
/ 11.6_2C.B7 A0117 CANBUS
6 6 7 K11:7
Power 1
8 8 A0118A 8 K11:8
Power 1
/ 11.6_2A.C7 7 7 A0119 9 K11:9
/ 11.6_2B.B7 Power 2
RED+1 1 0518A 9 9 A01110A 10 K11:10
/ 11.6_2C.B7 Power 2
E A0118B E
A01110B X212
0513 5
R
0512 4 K2:5 CAN
X209Af R+
K2:4 CANBUS
RED+1 1 0518B 0517 0517 8
/ 11.6_2C.E7 +
K2:8
/ 11.6_2A.D7 0516 0516 7
+ /0.0_2.B4
/ 11.6_2B.C7 0519B 30 2123 K2:7
RED+2 2 3 D7971
/ 11.6_2C.E7 L
2122 2 K2:3 CAN
L+
/ 11.6_2A.D7 K2:2
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
/ 11.6_2B.C7 2123
CAN 3
/ 11.6_2C.F7
F F
/ 11.6_2A.D7
/ 11.6_2B.C7 2122
CAN+ 4
/ 11.6_2C.E7
Ref. Benämning Produkt/Product Blad/Sheet
Nr Ändring Ändring nr Datum Sign. Datum/Date Huvudnr./Project no.
Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets CANBUS grund DCF300,DCE300 11.6_1
CJS 050128 A47137.0100
Name
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring CANBUS base A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
X209Bf
30 4 CAN+
/ 11.6_1.D2
3 CAN
/ 11.6_1.D2
1 RED+1
C
Opt. chassi / 11.6_1.E2 C
X222
K2:2 2 2222
L+
CAN K2:3 3 2223
D7972 L
K2:7 7 2227
+
X209Bm
K2:8 8 2228 2 RED+2
CANBUS + / 11.6_1.F2
K2:4 4 2224 30 4 CAN+
R+ / 11.6_1.F2
CAN K2:5 5 2225 3 CAN
R / 11.6_1.F2
CAN Shield
K2:6
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
E E
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Ny konstruktion/New design 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring CANBUS KDU opt. chassi A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B X209Cf B
4 CAN+
/ 11.6_1.D2
3 CAN
/ 11.6_1.D2
1 RED+1
/ 11.6_1.E2
Opt. attachment
X422 X401Am X401Af
K2:2 2 4222 30 A A GN 30
L+
CAN K2:3 3 4223 B B YE
C D791 L C
K2:7 7 4227 C C GY
/0.0_4.B4 +
X401Bf X401Bm X209Cm
K2:8 8 4228 C C OG 2 RED+2
+ / 11.6_1.F2
CANBUS K2:4 4 4224 30 A A BN 30 4 CAN+
R+ / 11.6_1.F2
CAN K2:5 5 4225 B B WH 3 CAN
R / 11.6_1.F2
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
E E
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 GY changed with OG 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring CANBUS KDU opt. attachment A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
Opt. attachment
X422 X401Am X401Af X209Cf
K2:2 2 30 1 4222 A A GN 30 4 CAN+
L+ / 11.6_1.D2
CAN K2:3 3 2 4223 B B YE 3 CAN
D791 L / 11.6_1.D2
K2:7 7 3 4227 C C GY 1 RED+1
+ / 11.6_1.E2
X401Bf X401Bm 2 RED+2
/ 11.6_1.E2
K2:8 8 3 4228 C C
+
CANBUS K2:4 4 30 1 4224 A A
R+
B CAN K2:5 5 2 4225 B B B
R
BN
WH
OG
2092
C C
30
2091
D D
4
3
2
1
1
2
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
X209Cm
X214m
1
1
2
2
4
3
X214f
X209Bf
2142
Opt. chassis
X222
2222 30
2141
E K2:2 2 E
L+
CAN K2:3 3 2223
D7972 L X209Bm
K2:7 7 2227 1 RED+1
/0.0_3.B4 + / 11.6_1.E2
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 GY changed with OG 071438 CJS 070923 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 061220 Klass/Class
Wiring CANBUS KDU opt. chassi + attach A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
D791
KDU contact K1
KDU contact K1
1:13 /7.9_4.B8 SENSOR DETECT LEFT UPPER Analog In 05V 1:33 /7.4_1.C1 VALVE SIDESHIFT RIGHT 1.5A
1:14 /9.14_1.B2 CENTRAL LUBRICATION 10A 1:34 /11.5_2.B2 LAMP ALIGNMENT (UPPER) 1.5A
1:15 /9.6_1.B1 WORK LIGHT RIGHT 6A 1:35 1.5A
1:16 /7.5_1.A7 SPREADING LEFT PWM 1:36 /11.5_2.D2 SENSOR ALIGNMENT UPPER RIGHT Dig In / 1.5A
1:17 /7.5_1.D7 SPREADING RIGHT PWM 1:37 /7.5_3.E8 SENSOR 3035 STOP RIGHT Dig In / 1.5A
1:18 /7.4_1.B7 VALVE SIDESHIFT PWM 1:38 0V Ref
1:19 /7.8_1.B7 VALVE LEVELLING PWM 1:39 /11.5_2.C2 LAMP ALIGNMENT (LOWER) 1.5A
1:20 /7.5_3.B8 SENSOR 3035 STOP LEFT Analog In 05V 1:40 /7.5_3.D8 SENSOR DAMPING RIGHT Dig In / 1.5A
D 1:41 /7.9_2.C8 SENSOR UNLOCKED RIGHT Analog In 05V
D
1:42 6A
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
E E
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Changes after prototype. 070572 CJS 070903 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 050916 Klass/Class
Crossreference list A50400.0100 03
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
Y6020
X421 X421
1.5A K1:32 32 42132 1 1 2 2 42118B 42118A 18 K1:18 PWM
B D791 D791 B
/0.0_1.C5 XSP23 /0.0_1.D3
VALVE SIDESHIFT LEFT VALVE SIDESHIFT
SIDESHIFT LEFT
Y6021
X421
1.5A K1:33 33 42133 1 1 2 2 42118C
D791
/0.0_1.D5
VALVE SIDESHIFT RIGHT
C C
SIDESHIFT RIGHT
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
E E
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Changes after prototype. 070572 CJS 070903 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 050916 Klass/Class
Wiring sideshift A50400.0100 03
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
Y6019L
X421 X421
1.5A K1:2 2 4212 1 1 2 2 42116B 42116A 16 K1:16 PWM
D791 D791
/0.0_1.C3 XSP10 /0.0_1.D3
VALVE SPREADING LEFT IN SPREADING LEFT
A A
SPREADING LEFT IN
Y6018L
X421
1.5A K1:3 3 4213 1 1 2 2 42116C
D791
/0.0_1.C3
VALVE SPREADING LEFT OUT
SPREADING LEFT OUT
B B
C C
Y6019R
X421 X421
1.5A K1:4 4 4214 1 1 2 2 42117B 42117A 17 K1:17 PWM
D791 D791
/0.0_1.C3 XSP11 /0.0_1.D3
VALVE SPREADING RIGHT IN SPREADING RIGHT
SPREADING RIGHT IN
D Y6018R D
X421
1.5A
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
K1:5 5 4215 1 1 2 2 42117C
D791
/0.0_1.C3
VALVE SPREADING RIGHT OUT
SPREADING RIGHT OUT
E E
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Changes after prototype. 070572 CJS 070903 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 050916 Klass/Class
Wiring spreading A50400.0100 03
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
X421 XH9003f H9003
6A K1:28 28 42128 1 +
D791
/0.0_1.C5 2
SUMMER AUT. SPREADING
WARNING SIGNAL AUT. SPREADING
C W9003 CHASSIS C
/11.5_2.C8
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
E E
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Changes after prototype. 070572 CJS 070903 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 050916 Klass/Class
Wiring buzzer spreading A50400.0100 03
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
C C
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
B B
XB777Rf XB777Rm
4261C A A
BN
B777R XB777Rm XB777Rf X426f X426m X421
BK C C 4264 4 4 42137 37 K1:37 Dig In / 1.5A
D791
/0.0_1.D5
3035 STOP RIGHT
BU SENSOR 3035 STOP RIGHT
B B 4262B
X426f X426m
4262C XSP16 4262A 2 2 4262 CHASSIS
E /11.5_2.E8 E
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Changes after prototype. 070572 CJS 070903 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 050916 Klass/Class
Wiring sensors spreading A50400.0100 03
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
Y6036
X421 X421
2.5A K1:30 30 42130 1 1 2 2 42119B 42119A 19 K1:19 PWM
D791 D791
/0.0_1.C5 XSP17 /0.0_1.D3
VALVE LEVELLING LEFT VALVE LEVELLING
LEVELLING LEFT, C.W
B B
Y6035
X421
2.5A K1:31 31 42131 1 1 2 2 42119C
D791
/0.0_1.C5
VALVE LEVELLING RIGHT
LEVELLING RIGHT, C.C.W
C C
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
E E
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Changes after prototype. 070572 CJS 070903 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 050916 Klass/Class
Wiring levelling A50400.0100 03
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
Y6040
X421
1.5A K1:7 7 4217 1 1 2 2 W6040 CHASSIS
D791 /11.5_2.C8
/0.0_1.C3
B B
VALVE LOCK CONTAINER
LOCK CONTAINER
Y6039
X421
1.5A K1:9 9 4219 1 1 2 2 W6039 CHASSIS
D791 /11.5_2.D8
/0.0_1.C3
VALVE UNLOCK CONTAINER
C C
UNLOCK CONTAINER
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
E E
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Changes after prototype. 070572 CJS 070903 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 050916 Klass/Class
Wiring unlock/lock A50400.0100 03
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
XB7203LUf /7.9_5A.A3
4041F A D7911:1024V
/7.9_5B.A3
4041E D7911:1024V
/7.9_5B.B1
X404f X404m XB7204Lf XB7204Lm
A D7911:1024V 42110B 1 1 4041A XSP2 4041B A A A
/11.5_2.A5
BN
B7204L XB7204Lm XB7204Lf X404m X404f X421
BK C C 4043 3 3 42122 22 K1:22 Analog In 05V
D791
/0.0_1.C5
UNLOCKED LEFT
BU SENSOR UNLOCKED LEFT
X404m X404f
B B 4042B 4042A 2 2 4042 CHASSIS
/11.5_2.D8
XSP4
4042H CHASSIS
XB7203RUf /9.6_1.E7
/7.9_5A.B3 4042G CHASSIS
4031F A D7911:1024V /9.6_1.E7
/7.9_5B.C3
4031E D7911:1024V XB7203LUf /7.9_5A.B5
B /7.9_5B.C1 4042F B CHASSIS B
/7.9_5B.A5
X403m X403f XB7204Rf XB7204Rm 4042E CHASSIS
/7.9_5B.B7
D7911:1024V 42110C 1 1 4031A XSP3 4031B A A
/11.5_2.A5
BN
B7204R XB7204Rm XB7204Rf X403f X403m X421
BK C C 4033 3 3 42141 41 K1:41 Analog In 05V
D791
/0.0_1.D5
UNLOCKED RIGHT
BU SENSOR UNLOCKED RIGHT
X403f X403m
B B 4032B 4032A 2 2 4032 CHASSIS
/11.5_2.E8
XSP5
4032H
4041C
CHASSIS
/9.6_1.D7
C 4032G CHASSIS C
/9.6_1.D7
XB7203RUf /7.9_5A.C5
4032F B CHASSIS
XB7205LLf XB7205LLm /7.9_5B.C5
4032E CHASSIS
A A /7.9_5B.D7
BN
4031C
B7205LL XB7205LLm XB7205LLf X404m X404f X421
BK C C 4044 4 4 42123 23 K1:23 Analog In 05V
D791
/0.0_1.C5
LOCKED LEFT (LOWER SINGLE)
BU SENSOR LOCKED LEFT (LOWER)
B B 4042C
XB7205RLf XB7205RLm
D A A D
BN
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
B7205RL XB7205RLm XB7205RLf X403f X403m X421
BK C C 4034 4 4 42124 24 K1:24 Analog In 05V
D791
/0.0_1.C5
LOCKED RIGHT (LOWER SINGLE)
BU SENSOR LOCKED RIGHT (LOWER)
4031D
4041D
B B 4032C
BN
E B7205LU XB7205LUm E
BK C D7911:1124V
/11.5_2.D5
LOCKED LEFT (UPPER)
BU
XB7205LUm XSP4CHASSI XB7205LUf
B /7.9_5B.E5 B
XB7205RUf XSP324V XB7205RUm
A /7.9_5B.E4 A
BN
B7205RU XB7205RUm
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
BK C D7911:3624V
/11.5_2.D5
F LOCKED RIGHT (UPPER) F
BU
XSP5CHASSI XB7205RUf
B /7.9_5B.F5 B
HOOK
Ref. Benämning Produkt/Product Blad/Sheet
Nr Ändring Ändring nr Datum Sign. Datum/Date Huvudnr./Project no.
Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets sensorer öppna/låsa DCF8010045E 7.9_2
CJS 050916 A51185.0100
Name
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Changes after prototype. 070572 CJS 070903 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 050916 Klass/Class
Wiring sensors unlock/lock A50400.0100 03
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
H562
X415m
D7911:2524V 1 4151 1 1 2 1 4154B
/11.5_2.B5
UNLOCKED (RED)
B B
H564
X415m X415m
D7911:3924V 2 4152 1 1 2 1 4154C 4154A 4 CHASSIS
/11.5_2.C5 /11.5_2.D8
XSP1
ALIGNMENT (YELLOW)
C C
H563
X415m
D7911:2924V 3 4153 1 1 2 1 4154D
/11.5_2.E5
LOCKED (GREEN)
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
E E
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
TWISTLOCK
Benämning
HOOK
Ref. Sign. Datum/Date Huvudnr./Project no. Produkt/Product Blad/Sheet
Nr Ändring Ändring nr Datum
Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets indikeringslampor DCF8010045E 7.9_3A
CJS 050916 A51185.0100
Name
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Changes after prototype. 070572 CJS 070903 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 050916 Klass/Class
Wiring indicator lights A50400.0100 03
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
H562L
X415m
D7911:2524V 1 4151 1 1 2 1 4154B
/11.5_2.B5
UNLOCKED (RED)
B B
H564UL
X415m
D7911:3424V 5 4155 1 1 2 1 4154E
/11.5_2.B5
ALIGNMENT UPPER (YELLOW)
X415m
C 4154A 4 CHASSIS C
/11.5_2.D8
XSP1
H564LL
X415m
D7911:3924V 2 4152 1 1 2 1 4154C
/11.5_2.C5
ALIGNMENT LOWER (YELLOW)
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
4154D
H563L
X415m
D7911:2924V 3 4153 1 1 2 1
/11.5_2.E5
LOCKED (GREEN)
E E
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
FLAPS
Ref. Benämning Produkt/Product Blad/Sheet
Nr Ändring Ändring nr Datum Sign. Datum/Date Huvudnr./Project no.
Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets indikeringslampor DCF8010045E 7.9_3B
CJS 050916 A51185.0100
Name
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Changes after prototype. 070572 CJS 070903 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 050916 Klass/Class
Wiring indicator lights A50400.0100 03
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
X404f X421
D7911:1324V 6 42113 13 K1:13 Analog In 05V
/7.9_5B.A7 D791
/0.0_1.D3
SENSOR DETECT LEFT UPPER
B B
X403m X421
D7911:2124V 6 42121 21 K1:21 Analog In 05V
/7.9_5B.C7 D791
/0.0_1.C5
SENSOR DETECT RIGHT UPPER
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
/7.9_5A.C7 X403m X421
D7911:2624V 7 42126 26 K1:26 Dig In / 1.5A
/7.9_5B.D7 D791
/0.0_1.C5
SENSOR ALIGNMENT RIGHT (LOWER)
E E
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Changes after prototype. 070572 CJS 070903 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 050916 Klass/Class
Wiring sensors alignment A50400.0100 03
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
XB7203Lm
D7911:1024V A
/7.9_2.A6
BN
B7203L XB7203Lm XB7203Lf X404m
BK C C 4047 7 D7911:2724V
/7.9_4.C3
ALIGNMENT LEFT
BU
B CHASSIS
/7.9_2.B7
B B
XB7203Rm
D7911:1024V A
/7.9_2.B4
BN
B7203R XB7203Rm XB7203Rf X403f
BK C C 4037 7 D7911:2624V
/7.9_4.E3
ALIGNMENT RIGHT
BU
B CHASSIS
/7.9_2.C7
C C
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
E E
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
TWISTLOCK
Ref. Benämning Produkt/Product Blad/Sheet
Nr Ändring Ändring nr Datum Sign. Datum/Date Huvudnr./Project no.
Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets sensorer anliggning DCF8010045E 7.9_5A
CJS 050916 A51185.0100
Name
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Changes after prototype. 070572 CJS 070903 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 050916 Klass/Class
Wiring sensors alignment A50400.0100 03
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
XB7203LUm
A D7911:1024V A A
/7.9_2.A6
BN
B7203LU XB7203LUm XB7203LUf X404m
BK C C 4046 6 D7911:1324V
/7.9_4.B3
DETECT LEFT UPPER
BU B CHASSIS
/7.9_2.B7
XB7203LLf XB7203LLm
D7911:1024V 4041E A A
/7.9_2.A6
BN
B7203LL XB7203LLm XB7203LLf X404m
BK C C 4047 7 D7911:2724V
/7.9_4.C3
ALIGNMENT LEFT LOWER
BU B B 4042E CHASSIS
/7.9_2.B7
B B
XB7203RUm
D7911:1024V A
/7.9_2.B4
BN
B7203RU XB7203RUm XB7203RUf X403f
BK C C 4036 6 D7911:2124V
/7.9_4.D3
C DETECT RIGHT UPPER C
BU B CHASSIS
/7.9_2.C7
XB7203RLf XB7203RLm
D7911:1024V 4031E A A
/7.9_2.B4
BN
B7203RL XB7203RLm XB7203RLf X403f
BK C C 4037 7 D7911:2624V
/7.9_4.E3
ALIGNMENT RIGHT LOWER
BU B B 4032E CHASSIS
/7.9_2.C7
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
XB7203LU2m
XSP224V A
/7.9_2.E3
BN
B7203LU2 XB7203LU2m
BK C D7911:1124V
/11.5_2.D5
ALIGNMENT LEFT UPPER
BU
XB7203LU2m
E B XSP4CHASSI E
/7.9_2.E5
XB7203RU2m
XSP324V A
/7.9_2.E3
BN
B7203RU2 XB7203RU2m
BK C D7911:3624V
/11.5_2.D5
ALIGNMENT RIGHT UPPER
BU
XB7203RU2m
B XSP5CHASSI
/7.9_2.F6
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
FLAPS
F F
HOOK
FLAPS
Ref. Benämning Produkt/Product Blad/Sheet
Nr Ändring Ändring nr Datum Sign. Datum/Date Huvudnr./Project no.
Ruta Sign.
Sq.
No. Design change Change No. Date Ritad/Drawn Krets sensorer anliggning DCF8010045E 7.9_5B
CJS 050916 A51185.0100
Name
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Changes after prototype. 070572 CJS 070903 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 050916 Klass/Class
Wiring sensors alignment A50400.0100 03
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
E404L
X421 XE404L XE404L
6A K1:1 1 4211A XSP8 4211B 1 1 2 2 W404L CHASSIS
D791 /11.5_2.B8
/0.0_1.C3
WORK LIGHT LEFT OPT WORK LIGHT CARRIAGE LEFT (TW)
B B
E404R
X421 XE404R XE404R
6A K1:15 15 42115A XSP9 42115B 1 1 2 2 W404R CHASSIS
D791 /11.5_2.B8
/0.0_1.D3
WORK LIGHT RIGHT OPT WORK LIGHT CARRIAGE RIGHT (TW)
X403m X403f
42115C 8 8 4038A
4211C
C C
std TW
E404UL E404UR
X404f X404m XE404UL XE404UL XE404UR XE404UR
8 8 4048A XSP6 4048B 1 1 2 2 XSP7 4038B 1 1 2 2 4032H CHASSIS
/7.9_2.C7
WORK LIGHT ATTACHMENT UPPER LEFT WORK LIGHT ATTACHMENT UPPER RIGHT
E404LL E404LR
D XE404LL XE404LL XE404LR XE404LR D
4048C 1 1 2 2 4038C 1 1 2 2 4032G CHASSIS
/7.9_2.C7
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
WORK LIGHT ATTACHMENT LOWER LEFT WORK LIGHT ATTACHMENT LOWER RIGHT
std HOOK
FLAPS
4042H CHASSIS
/7.9_2.B7
E 4042G CHASSIS E
/7.9_2.B7
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Changes after prototype. 070572 CJS 070903 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 050916 Klass/Class
Wiring work lights carriage/attachment A50400.0100 03
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
M693
1
B B
GREY
2
X421 XM693f
10A K1:14 14 42114 1 15
D791 M
/0.0_1.D3 BLACK
2 31
CENTRAL LUBRICATION
CENTRAL LUBRICATION
C C
W693 CHASSIS
/11.5_2.C8
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
E E
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Changes after prototype. 070572 CJS 070903 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 050916 Klass/Class
Wiring central lubrication A50400.0100 03
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
X422
42211 11 K2:11 Emergency stop
D791
B B
EMERGENCY STOP
C C
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
E E
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Changes after prototype. 070572 CJS 070903 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 050916 Klass/Class
Wiring power A50400.0100 03
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
42110B D7911:1024V
/7.9_2.A1
42110C D7911:1024V
/7.9_2.B1
42110D D7911:1024V W400-2B1 CHASSIS
/7.5_3.A1 /11.5_1.C7
42110E D7911:1024V
/7.5_3.D1 W400-2B2 CHASSIS
A /11.5_1.C7 A
X421 X4002B
1.5A K1:10 10 42110A XSP12 (0) D7911:1024V
D791
/0.0_1.C3 X4002D X4002A
See wiring chassi
SUPPLY SENSORS
X4002C
B B
W693 CHASSIS
/9.14_1.D7
W400-2D1 XSP21 W6040 CHASSIS
X421 X403m X403f XB7205RUf /7.9_2.F5 /7.9_1.B7
Dig In / 1.5A K1:36 36 42136 5 5 4035 C D7911:3624V
D791 /7.9_5B.E5 W6039 CHASSIS
/0.0_1.D5 /7.9_1.C7
SENSOR ALIGNMENT UPPER RIGHT (1) CHASSIS
SENSOR LOCKED HOOK UPPER RIGHT
(0) CHASSIS
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
X415f /7.9_3A.C7
SENSOR ALIGNMENT UPPER LEFT 4154 4 CHASSIS
SENSOR LOCKED HOOK UPPER LEFT /7.9_3B.C8
4042 CHASSIS
/7.9_2.B7
W400-2D2 XSP22 4032 CHASSIS
/7.9_2.C7
X421 X415f /7.9_3A.D2 4252 CHASSIS
1.5A K1:29 29 42129 3 D7911:2924V /7.5_3.C7
D791 /7.9_3B.E1
/0.0_1.C5 4262 CHASSIS
/7.5_3.E7
LAMP LOCKED
E E
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Changes after prototype. 070572 CJS 070903 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 050916 Klass/Class
Wiring power A50400.0100 03
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
X422 X401Am
K2:2 2 4222 30 A
L+
CAN K2:3 3 4223 B
D791 L
K2:7 7 4227 C
+
C X401Bf C
K2:8 8 4228 C
+
CANBUS K2:4 4 4224 30 A
R+
CAN K2:5 5 4225 B
R
See wiring chassi
D D
This document must not be copied without our
written permission and the contents thereof must
not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be pro
secuted.
E E
Denna ritning får ej utan vårt medgivande kopieras.
Den får ej heller delgivas annan eller annars obe
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F
R
Konstr/Design H.Grp: Ritn.nr./ Drawing No. Utgåva/Issue
E³ DRAWING
1 Changes after prototype. 070572 CJS 070903 6
A=Added/Tillk D=Deleted/Utgår W=Was/Var Godk/Appr CJS 050916 Klass/Class
Wiring CANBUS A50400.0100 03
1 2 3 4 5 6 7 8
E Schema - Komponentförteckning / E Schematics - List of Components 1
232 S Brytkontakt lampa luftanslutning släp Contact, breaking, warning lamp air
connection
233 S Slutkontakt lampa låsning vändskiva Contact, warning, interlocking of turntable
235 S Slutkontakt sidoskjutning stol Contact, making, side shifting of seat
236 S Slutkontakt vattennivå Contact, water level
239 S Brytkontakt termisk Contact, breaking, thermic
240 S Slutkontakt termisk Contact, making, thermic
241 S Brytkontakt lampa luftmatning släp Contact, breaking, warning lamp air supply to
trailer
242 S Slutkontakt lampa oljetryck v-låda Contact, making, warning lamp, oil pressure
gear box
243 S Brytkontakt tryck kylmedia AC Contact, breaking, coolant pressure (air
condition)
244 S Slutkontakt hydraulik aktiverad Contact, making, hydraulics
245 S Slutkontakt hydraultryck styrning Contact, making, hydraulic pressure control
410 H G-lampa broms ljus vä fram Light bulb, brake light, left-hand forward
417 H G-lampa sidomarkering hö fram Light bulb, side position light, right -hand
forward
417 H G-lampa sidomarkering hö bak Light bulb, side position light, right-hand rear
427 H G-lampa körvisare hö bak Light bulb, direction indicator right-hand rear
453 H G-lampa bromsljus/körvisare höger Light bulb, brake light/dir. indicator right-hand
454 H G-lampa bromsljus blackout vänster Light bulb, brake light blackout left-hand
454 H G-lampa bromsljus blackout höger Light bulb, brake light blackout right-hand
456 E G-lampa backljus blackout IR vänster Light bulb, rear light blackout IR left-hand
456 E G-lampa backljus blackout IR höger Light bulb, rear light blackout IR right-hand
457 H G-lampa positionsljus blackout vänster Light bulb, position light blackout left-hand
458 E G-lampa fram blackout vänster Light bulb, roading light blackout left-hand
458 E G-lampa fram blackout höger Light bulb, roading light blackout right-hand
459 E G-lampa fram blackout IR vänster Light bulb, roading light blackout IR left-hand
459 E G-lampa fram blackout IR höger Light bulb, roading light blackout IR right-
hand
460 E G-lampa arb.belysning hytt blackout IR vä Light bulb, working light cab blackout IR left
460 E G-lampa arb.belysning hytt blackout IR hö Light bulb, working light cab blackout IR right
461 E G-lampa arb.bel. bom 20' blackout IR vä Light bulb, working light boom20' b.out IR left
461 E G-lampa arb.bel. bom 20' blackout IR hö Light bulb, working light boom20' b.out IR
right
462 E G-lampa arb.bel. bom 40' blackout IR vä Light bulb, working light boom40' b.out IR left
462 E G-lampa arb.bel. bom 40' blackout IR hö Light bulb, working light boom40' b.out IR
right
463 H G-lampa bak ljus vänster bak, blackout Light bulb, rear light left-hand rear, blackout
463 H G-lampa bak ljus höger bak, blackout Light bulb, rear light right-hand rear, blackout
555 H Varn lampa temp kylvatten mot Warning lamp, temperature coolant engine
1016
1017 S Strömställare diagnostik öka/minska Switch, diagnostics increase/decrease
1018 S Strömställare diagnostik on/off Switch, diagnostics on/off
1019 S Strömställare rastvärme Switch, paus heat
1020 S Strömställare automatisk släpp/kläm Switch automatic release/clamp funktion
funktion
1021 S Strömställare sax Switch extender
1022 S Strömställare vertikalhållning Switch, vertical position
1023 S Strömställare låsning övre arm Switch, lock upper arm
1024 S Strömställare Korta Armen av/på Switch, Short Arm on/off
1025 S Strömställare pappersfunktioner av/på Switch, paper funktions on/off
1026 S Strömställare omkoppling Switch, switch papper/bale clamp
pappers/klämmagregat
1027 S Strömställare lyfthöjdsförval Switch, lift height selection
1028 S Strömställare lyfthöjdsförval öka Switch, lift height selection increase
1029 S Strömställare lyfthöjdsförval minska Switch, lift height selection decrease
3013 K Relä arb.bel. bom 20' vxl std/blackout Relay,working light boom20' shift std/b.out
3014 K Relä arb.bel. bom 40' vxl std/blackout Relay,working light boom40' shift std/b.out
3015 K Relä vxl bromsljus/blinkers vä Relay, shift brake light/direction indicator left
3306 K Relä VBFS, helljus Relay, rotating driver´s seat, main beam
3307 K Relä VBFS, halvljus Relay, rotating driver´s seat, dipped beam
3308 K Relä VBFS, bromsljus Relay, rotating driver´s seat, brake light
3310 K Relä VBFS, körvisare vä Relay, rotating driver´s seat, direction
indicator left
3311 K Relä VBFS, körvisare hö Relay, rotating driver´s seat, direction
indicator right
3330 K Relä, säkerhetsbälte Relay, seat belt
3331 K Relä VBFS, drivning fram Relay, rotating driver´s seat, forward driving
3404 K Relä VBFS, mastljus Relay, rotating driver´s seat, mast light
3412 K Relä bak ljus Relay, rotating driver´s seat, rear light
3768 K Relä oljetryck hydraulik Relay, hydraulic pressure
3769 K Relä, blockering av hyttilt Relay, blocking of cab tilt
3770 K Relä anliggning Relay, alignment
3771 K Relä Krok Relay, Hook
3772 K Relä laddsignal (D+) Relay, charge signal (D+)
3773 K Relä 12V för minne radio Relay 12V for radio memory
3774 Relä kylfläkt olja Relay, cooling fan oil
3775
5000 H Kont lampa tryck lyfttång Indicating lamp, pressure lift tong
5001 H Varn lampa, Over Height ben uppe Warn. Lamp, Over Height leg upper pos
6001 Y M-ventil blockering höger Solenoid valve, blocking right
6002 Y M-ventil blockering vänster Solenoid valve, blocking left
6003 Y M-ventil inkoppling av hydraulik till topplyft Solenoid valve, activation of toplift hydraulics
6027 Y M-ventil höger framhjul styrning höger Solenoid valve, right front wheel, steering
right
6028 Y M-ventil vänster framhjul styrning vänster Solenoid valve, left front wheel, steering left
6029 Y M-ventil vänster framhjul styrning höger Solenoid valve, left front wheel, steering right
6030 Y M-ventil höger bakhjul styrning vänster Solenoid valve, right rear wheel, steering left
6033 Y M-ventil vänster bakhjul styrning höger Solenoid valve, left rear wheel, steering right
F Technical data
Technical data
mm mm mm mm mm mm
Data
Power acc. to ISO 3046 (net power) 180 kW at 2200 rpm 164 kW at 2200 rpm
3 Driveline/axle
Drive axle, type Kessler D81
Kessler D91
4 Brakes
Parking brake Spring brake - Drive wheels
6 Suspension
Dimension, front and rear 14.00x24
Volumes
For oil types see Oils and lubricants, recommendation page 6.
10 Common hydraulics
Hydraulic oil tank, volume 360 litres
recommendation
The service intervals indicated by Kalmar Industries in the mainte-
nance manual only apply if oils are selected according to the table be-
low. The table indicates recommended viscosity for different oil types
and qualities depending on the ambient temperature.
Any deviation from this table must be approved in writing by Kalmar
Industries, and may mean changed service intervals.
Oil type, quality °C -40 -30 -20 -10 0 +10 +20 +30 +40
SAE 75W90
7 Load handling
10 Common hydraulics
DIN 51524 Part 3 HVLP ISO VG 68
ISO VG 46 HV
ISO VG 32
NOTE
Oil filters shall always be changed in connection with oil change.
The change interval for engine oils is conditional on the sulphur
content in the fuel does not exceed 0.5 %.
*) Engine oil that meets both VDS-2 and ACEA E5 may be used.
NOTE! API: CH-4 or CI-4 are approved for markets outside Europe
(Instead of ACEA E5).
Grease
Use a universal grease type EP according to NLGI Grade 2 with 3-5%
molybdenum sulphide content for all grease points except glide plates
where lubrication paste Gleitmo 805 or the equivalent shall be used.
For connectors, use contact grease 923836.0552.
Sealant silicone
Use Loctite 5972 or Loctite 598 (or equivalent). If uncertain, contact
Kalmar Industries.
Coolant
The coolant shall consist of clean water mixed with 40-60 % glycol. If
glycol is not used, then anti-corrosion agent must always be added.
However, anti-corrosion agent does not contain any anti-freeze and
may only be used if the outdoor temperature always is above 0 °C.
NOTE! It is important that the coolant is mixed correctly all year to en-
sure adequate protection against corrosion. The corrosion-protective
properties are reduced with time, and that is why the coolant has to be
changed at stated intervals.
A mixture of 60% water and 40% glycol withstands temperatures down
to -28 °C.
A mixture of 40 % water and 60 % glycol withstands temperatures
down to -54 °C.
Tightening torques,
page
–
recommendations
The tightening torques in the following table are recommendations
when tightening bolts and nuts.
When torquing using a machine, for example, bolt runner, the tighten-
ing torque should be reduced by approx. 5%.
For mild surfaces (hardness below 200 HB), washer shall be used un-
der both bolt head and nut. Alternatively, use flange bolt or flange nut.
Tighten to the prescribed torque without stopping.
Recommended tightening torque may vary depending on surface
treatment. Certain combinations of nut and bolt require lubrication ac-
cording to the table below.
State 1 2 3 1 1
Fine M-thread
M81 27 Nm 24 Nm 30 Nm 39 Nm 46 Nm
M101,25 54 Nm 48 Nm 61 Nm 78 Nm 91 Nm
M-thread
M6 11 Nm 9.8 Nm 12.5 Nm 16 Nm 19 Nm
M8 26 Nm 24 Nm 30 Nm 38 Nm 45 Nm
M10 52 Nm 47 Nm 59 Nm 74 Nm 89 Nm
UNC-thread
3/8 44 Nm 39 Nm 50 Nm 62 Nm 73 Nm
couplings
Pipe and hose coupling
6 1/4 23-25
8 5/16
33-38
10 3/8
12 1/2 51-57
14 -
15 - 80-90
16 5/8
18 3/4
120-130
20 -
22 7/8
150-170
25 1"
28 -
30 - 180-200
32 1"1/4
35 -
200-240
38 1"1/2
17 11/16 23-25
22 13/16 33-38
24 15/16 51-57
36 1 3/8 120-130
41 1 5/8 150-170
Flange coupling
42x2 330
48x2 400
system connections
O-rings, radiator hoses
mm inch inch Nm
The above values are to be considered guidelines and may vary de-
pending on installation.
Unit explanations
page
–
Unit Abbreviation
Newton metre Nm
Kilowatt kW
kilojoule kJ
Calorie ca
Inch in
Feet ft
Yard yd
Mile mile
Centimetre cm
Metre m
Kilometre km
Torque
Power (W = J/s)
Energy (J = Nm)
Horsepower/torque
Temperature
Flow factor
Unit cm m km in ft yd mile
1 mm = 0,1 cm - 1 mm = 0,001 m
Unit g kg t oz lb
Terminology
page
–
Term Description
Accumulator Reservoir that stores (accumulates) pressure for i.e. hydraulic functions.
Anti-corrosion compound Prevents oxidation, in simple terms, rustproofing.
Attachment The part of the machine that grips the load when lifting.
Axle distance Distance between drive axle and steering axle.
Battery disconnect switch Cuts off current from battery.
Buzzer Acoustic alarm to catch the operator’s attention.
Control valve Valves that can be used to control something, e.g. release pressure and thus lower a
boom or a fork. See also control valve.
Daily inspection The actions that should be performed daily to ensure the machine’s functionality.
Decitonne Tenth of a tonne; measure of the machine’s lift capacity.
Display "Window" showing digital information on steering wheel panel in cab.
Drive axle Driving axle that receives the torque from the drivetrain.
Drive line Parts in machine involved in power transmission; engine, torque converter, transmission,
propeller shaft and drive axle with differential and hub reduction.
Dust reservoir The air filter collects the coarsest particles in a dust reservoir, which empties automati-
cally while driving.
ECC Electric Climate Control. Climate control system with thermostat-controlled cooling, de-
humidification and heating.
EHC Electric Heat Control. Heater system with thermostat heating control.
Electrolyte level Fluid level in battery cells.
End position As far out or away as the object can be moved, e.g. end position for tilt cylinders.
Environmental waste Used oils, filters, etc., must be handled according to governing national laws and regu-
lations.
Expansion tank Coolant reservoir, with space for the fluid to change volume due to temperature differ-
ences.
Fixed displacement Pump with fixed pump volume.
Frame member Structural members in the frame.
Hanging load Raised load.
Hub reduction Type of final drive (often next to drive wheel) that reduces rpm and increases torque from
the drivetrain.
Hydraulic oil Oil for hydraulic system. See specifications in operator’s manual.
Hydraulic oil pump Pump in the hydraulic system.
Hydraulic system System that uses oil pressure to transfer power to different functions.
Indicator Mechanical "sensor", for example, shows that a filter is clogged and needs to be
changed.
LC Load centre.
Term Description
Levelling Attachment is tilted, for example, if load stands on uneven ground.
Lifting capacity Indicates machine’s maximal lift capacity.
Lifting carriage Lifts the load, located on the mast.
Lifting point Attaching point for lifting device when lifting an object.
Lock hooks Two hooks that are slide down/in into holes in the container to lock the container in place
when lifting.
Low emission engine Engine with low emissions of hazardous substances. Manufactured in accordance with
regulations.
Machine model Machine type. Indicated, for example: DCE 90-100. See also type designation.
Main fuse Located by battery. Cuts off current to all systems in machine.
Maintenance Periodic maintenance operations so that the machine functions safely and lasts well.
Mast Carrier of lifting carriage, attachment and load.
Operating time Number of hours machine has been in operation, shown on hour meter in cab.
Option Optional equipment for machine.
Pilot oil pressure A low control pressure to, for example, a valve.
Planetary gear Type of gearbox with the gears in constant mesh.
Product alternative One of several alternatives selected for a machine, i.e. engine alternative.
Progressive steering Quick steering wheel movements give greater steering angle.
Proportional valve An electromagnetically controlled valve. If a current is applied, the valve is activated in
proportion to the current’s amplitude. In simple terms, infinitely variable valve, as op-
posed to on/off valve. For example, on the transmission valve housing.
Recirculation Circulate over and over again.
Refrigerant Fluid/gas in the climate control system. Must only be handled by authorised trained per-
sonnel.
Securing machine for transport Actions before transporting machine.
Serial number Unique machine designation. On the machine plate.
Service position How machine should be safely positioned before service may be started.
Servo Power amplifier. A small movement by the user generates great displacement, e.g. pow-
er steering.
Servo pressure A low control pressure to control a higher pressure, for example to a valve.
Side lift Attachment. See attachment.
Side shift Parallel sideways movement of attachment.
Solenoid valve An electro magnetically controlled valve. See also proportional valve.
Spirit Delta Enclosed type of cab.
Spreading Widening of attachment.
Steering axle Wheel axle with steering.
Tilting The mast is tilted forwards or backwards.
Torque converter Hydraulic, stepless clutch.
Transmission oil Oil for gearbox and torque converter. See specifications in operator’s manual.
Term Description
Twistlocks Two lock pins, one in each corner of the attachment, pushed down in corresponding
holes in container and twisted to lock the container when lifting.
Type designation Indicates machine type and capacity. See also machine model.
Valve spool Movable part in valve. Determines oil’s path.
Wet brakes Brake friction plates in an oil bath.
Working hydraulics All load handling functions, i.e. lift and lower, tilt, side shift, spreading and levelling.
Index
page
–
ATTACH, DCF 90-100 with lifting hook attachment 8 Control system 8.4.9
Brakes 4 Brakes 4
Cab structure and suspension 9 Frame, body, cab and accessories 9.10
Conditions A Foreword -
Coolant B Safety -
Copyright A Foreword -
Driveline/axle 3 Driveline/axle 3
Environment B Safety -
Feedback A Foreword -
Foreword A Foreword -
Frame, body, cab and accessories 9 Frame, body, cab and accessories 9
Fresh air and recirculation damper 9 Frame, body, cab and accessories 9.4.2
Gear selector and multi-function lever 9 Frame, body, cab and accessories 9.1.1
General A Foreword -
General B Safety -
General B Safety -
Heating, ventilation and air conditioning 9 Frame, body, cab and accessories 9.4
Instrument and control panels 9 Frame, body, cab and accessories 9.11.1
Noise B Safety -
Oils B Safety -
Refrigerant B Safety -
Safety B Safety -
Sensor temperature outlet fan 9 Frame, body, cab and accessories 9.4.16
Solvents B Safety -
Steering 5 Steering 5
Storage A Foreword -
Suspension 6 Suspension 6
Transmission 2 Transmission 2
Washer motor and reservoir 9 Frame, body, cab and accessories 9.5.4
Vibrations B Safety -
Work lights, front wing 9 Frame, body, cab and accessories 9.6.14