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A Foreword

B Safety

C Preventive maintenance

0 Complete machine

1 Engine
Workshop manual
2 Transmission

3 Driveline/axle

4 Brakes

5 Steering

6 Suspension

7 Load handling

8 Control system

9 Frame, body, cab and accessories

10 Common hydraulics

11 Common electrics

12 Common pneumatics

D Error codes

E Schematics

F Technical data

G Terminology and Index


A Foreword 1

A Foreword

Table of Contents A Foreword


mm mm mm mm mm mm

Foreword......................................................................................................... 3
About the Workshop Manual ...................................................................... 3
General ............................................................................................................. 3
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

Workshop Manual DCF 90-100 VDCF03.01GB


2 A Foreword

VDCF03.01GB Workshop Manual DCF 90-100


A Foreword – Foreword 3

Foreword
mm mm mm mm mm mm

About the Workshop Manual


General
page

Thank you for choosing Kalmar Industries as your machine supplier.


We hope that we'll meet your expectations.

Workshop manual contents


page

The workshop manual contains information for corrective mainte-


nance (replacement of components) and serves to supplement the
maintenance manual. The workshop manual is accompanied by sup-
plier documentation for engine, transmission and drive axle. Wherever
possible, the workshop manual makes refers to the maintenance man-
ual and supplier documentation to avoid double information.
The workshop manual is divided into the following sections.

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.

B Safety Keep in mind for your safety.

C Preventive maintenance Reference to maintenance manual: Preventive maintenance.

0 Complete machine

1 Engine

2 Transmission

3 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.

E Schematics Wiring and hydraulic diagrams.

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.

Workshop Manual DCF 90-100 VDCF03.01GB


4 A Foreword – About the Workshop Manual

References between different information types


page

The maintenance manual and workshop manual are mainly divided


into function groups, see Workshop manual contents page 3. Certain
parts are broken out as separate parts to increase usability, e.g.,
"Technical data".
The basic rule of searching for information is to use function groups to
find different types of information regarding the function or component
in question. As a complement to this, there are references according
to the below.

Function descriptions Hydraulic diagrams


(Technical description) (Section E)

Component descriptions Error codes


(Technical description, usually in Workshop manual) (Section D)

Diagnostics Wiring diagrams


(Group 8.4) (Section E)

• From Function description to Component description, to enable


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

VDCF03.01GB Workshop Manual DCF 90-100


A Foreword – About the Workshop Manual 5

Function group breakdown


page

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

The instructions are based on the use of generally available standard


tools. All lifting devices, such as slings, straps and ratchet blocks, must
meet governing national standards and regulations for lifting devices.
Kalmar Industries will not accept any responsibility for modifications
performed without permission from Kalmar Industries or if other lifting
devices, tools or work methods are used other than those described in
this manual.

Storage
page

NOTE
The workshop manual should be accessible to service personnel.

About the machine version


page

The information in this publication corresponds to the machine's de-


sign and appearance at the time of delivery from Kalmar Industries.
Due to customizations, there may be variations and/or deviations.
Kalmar Industries reserves the right to modify specifications and
equipment without prior notice. All information and data in this manual
are valid at the time of publication.

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.

Workshop Manual DCF 90-100 VDCF03.01GB


6 A Foreword – Reading instructions

Reading instructions
Warning information
page

Warnings inform on potential dangers which can, if the warnings are


not heeded, result in personal injury or product damage.

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

Important information marked with NOTE facilitates the work process,


operation/handling or increases understanding of the information.

NOTE
Information that is important without being safety related.

Read the operator's manual/maintenance


page

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

Read the operator’s manual/maintenance manual

Optional equipment
page

The symbol to the left is used in the manual to indicate that a function
000264

or component is optional equipment. Detailed information on how the


machine is equipped is presented by the machine card enclosed with
Indicates optional equipment the spare parts catalogue.

VDCF03.01GB Workshop Manual DCF 90-100


A Foreword – Reading instructions 7

Function descriptions
page

Function descriptions are schematic overviews that describe how a


function works as well as which components and signals work togeth-
er.
Function descriptions describe the function in a logical flow from input
signal to desired output signal. Most functions require that preset con-
ditions are fulfilled for the function to be activated. In these cases, the
conditions are listed above the illustration.
Function descriptions use symbols to illustrate components such as
valves, sensors, etc.

10

8
3

7 4

6
010689

Example of function description

Workshop Manual DCF 90-100 VDCF03.01GB


8 A Foreword – Reading instructions

1. Flag diagnostics, indicates that the signal can be checked with a


diagnostic test; see group 8.4 Diagnostics
2. Hydraulic force (solid double line)
3. Illustration of function, (lift and lower)
4. Reference to description of component
5. Signal description, reference value for signal out from component
6. Description of component's function
7. Position number, reference to position in illustration
8. Position number in illustration, reference to row in table
9. Flag pressure check connection (Check point), indicates that
there is pressure check connection for checking pressure signal
10. Electric power (solid single line)

VDCF03.01GB Workshop Manual DCF 90-100


A Foreword – Reading instructions 9

Symbol explanation function descriptions


The following symbols are used in function descriptions, the symbols
1 2 are based on standard symbols used in wiring and hydraulic diagrams.
3 4 1. Electric control signal
2. Electric force
3. Hydraulic control signal
5 6
4. Hydraulic force
5. Hydraulic motor
6. Hydraulic oil pump with variable displacement
7 8 M 7. Hydraulic oil pump with fixed displacement
8. Electrical motor
9 10 9. Accumulator
10. Disc brake
11. Filter
11 12
12. Radiator

D790-1 13. Bulb

13 14 14. Control system, two control units with CAN bus


D797-F 15. Restriction
16. Adjustable restriction
15 16
17. Inductive position sensor
17 18 18. Electrically controlled servo valve
19. Thermal bypass valve
19 ˚C 20 ˚C
20. Temperature-controlled switch
˚C Pa 21. Temperature sensor
21 22
22. Pressure sensor
23 Pa 24 23. Pressure-controlled switch
24. Hydraulic cylinder
25 25. Double-acting hydraulic cylinder
26. Spring brake cylinder
27. Valve block
26 27
28. Shuttle valve
29. Non-return valve
28 29
000523

Workshop Manual DCF 90-100 VDCF03.01GB


10 A Foreword – About the documentation

About the documentation


Documentation sections
page

The documentation to the machine comprises the following sections:

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

Documentation is ordered from the dealer.


Always specify the publication number when ordering.

VDCF03.01GB Workshop Manual DCF 90-100


A Foreword – Feedback 11

Feedback
Form for copying
page

Kalmar Industries’ ambition is that you who work with maintenance of


Kalmar machines shall have access to correct information.
Your feedback is important to be able to improve the information.
Copy this form, write down your views and send it to us. Thank you for
your participation!

To: Kalmar Industries AB


Product Support
Torggatan 3
SE-340 10 Lidhult
SWEDEN
Fax: +46 372 263 93

From:
Company / Sender: ..........................................................................................................................................

Telephone: ..........................................................................................................................................................

E-mail: .................................................................................................................................................................

Date: .................................... - .................. - ..................

Manual
informa- Name / Publication number: .............................................................................................................................
tion

Section / page number: ......................................................................................................................................

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

.............................................................................................................................................................................

.............................................................................................................................................................................

.............................................................................................................................................................................

.............................................................................................................................................................................

.............................................................................................................................................................................

Workshop Manual DCF 90-100 VDCF03.01GB


12 A Foreword – Feedback

VDCF03.01GB Workshop Manual DCF 90-100


B Safety 1

B Safety

Table of Contents B Safety


mm mm mm mm mm mm

Safety .............................................................................................................. 3
General safety information ......................................................................... 3
Safety concerns everyone! ................................................................................ 3
A near accident is a warning! ............................................................................ 3
Safety instructions ...................................................................................... 4
General ............................................................................................................. 4
Service position ................................................................................................. 4
Hydraulic and brake systems, 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

Workshop Manual DCF 90-100 VDCF03.01GB


2 B Safety

VDCF03.01GB Workshop Manual DCF 90-100


B Safety – Safety 3

Safety
mm mm mm mm mm mm

General safety information


Safety concerns everyone!
page

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.

A near accident is a warning!


page

A near-accident is an unexpected event where neither persons, ma-


chine or property are injured or damaged. However, a near-accident
indicates that there is an injury risk and actions must be taken to avoid
the risk of injuries.

Workshop Manual DCF 90-100 VDCF03.01GB


4 B Safety – Safety instructions

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

Machine with lifting carriage and attachment in totally


lowered position

VDCF03.01GB Workshop Manual DCF 90-100


B Safety – Safety instructions 5

Hydraulic and brake systems, depressurizing


page

1 Machine in service position, see Service position page 4.


2 Depressurise the hydraulic system by draining servo pressure
from the accumulator.
Turn the main current on, turn the starter key to position I and ac-
tivate the load handling functions several times.
3 Turn the start key to position 0 and turn off the main electric pow-
er.

009798

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


accumulator charging valve.

NOTE
Keep the drain valve open as long as work is in progress.
When closing the drain valve, check that it is fully closed and
tighten the lock ring.
005648

Workshop Manual DCF 90-100 VDCF03.01GB


6 B Safety – Safety instructions

Oils
page

The following safety instructions shall be followed for work when hand-
ling oils.

WARNING
Warm and pressurized oil.

Always depressurise hydraulic and brake systems


completely before starting to work in the systems. Hy-
draulic and brake systems are pressurised and the oil
may cause personal injuries.

Avoid skin contact with the oil, use protective gloves.


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

IMPORTANT
Always clean the area around components and con-
nections before they are loosened. Dirt in oil systems
causes increased wear, resulting in subsequent ma-
terial damages.

Always take action to avoid spills. In places where


drain containers cannot be used, use a pump or hose
for safe handling.

Always check that plugs seal tight before collection


containers are moved.

Handle all oil as environmentally hazardous waste.


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

VDCF03.01GB Workshop Manual DCF 90-100


B Safety – Safety instructions 7

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.

Work on the fuel system shall be avoided when the


engine is warm since fuel can spill on hot surfaces
and may ignite.

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.

Avoid skin contact with fuel, use protective gloves.


Fuel is corrosive to mucous membranes in, e.g., eyes,
skin and throat.

CAUTION
Always clean the area around components and con-
nections before they are loosened. Dirt in the fuel may
cause malfunctions and engine stop in undesirable
situations as well as increase wear, resulting in sub-
sequent material damages.

Workshop Manual DCF 90-100 VDCF03.01GB


8 B Safety – Safety instructions

IMPORTANT
Always take action to avoid spills. In places where
drain containers cannot be used, use a pump or hose
for safe handling.

Always check that plugs and connections seal tight


before moving collection containers.

Handle the fuel as environmentally hazardous waste.


Fuel freely released causes damage to the environ-
ment and may also cause fires. Fuel shall always be
handled by an authorized company.

Clothing, etc.
page

Clothes should be in good condition. Remove loosely hanging clothing


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

Several mechanics on the same machine


page

WARNING
Be extra careful if several mechanics work on the
same 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.

VDCF03.01GB Workshop Manual DCF 90-100


B Safety – Safety instructions 9

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.

Working under machine



page

Working under cab


On machines with a tilting cab, the cab must be in the fully tilted down
position.

Work under chassis


A raised vehicle may not, for any reason, be supported or lifted in parts
that belong to the wheel suspension or steering. Always support under
the frame or wheel axle.

Risks
Mechanical or hydraulic tools and lifting devices 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.

Lifting heavy components


page

WARNING
Careless handling of heavy components can lead to
serious personal injury and material damage.

Use type approved lifting tools or other devices to


move heavy components. Make sure that the device is
stable and intact.

Risks
Unsuitable 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.

Workshop Manual DCF 90-100 VDCF03.01GB


10 B Safety – Safety instructions

A component lifted using an overhead crane may start to swing back


and forth, which can cause severe crushing injuries or material dam-
age.

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.

VDCF03.01GB Workshop Manual DCF 90-100


B Safety – Safety instructions 11

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.

Fire and explosion risks


page

Examples of flammable and explosive substances are oils, gasoline,


diesel fuel oil, organic solvents (lacquer, plastics, cleaning agents),
rustproofing agents, welding gas, gas for heating (acetylene), high
concentration of dust particles consisting of combustible materials.
Rubber tyres are flammable and cause explosive fires.

Risks
Examples of cause of ignition is welding, cutting, smoking, sparks
when working with grinders, contact between hot machine parts and
flammable materials, heat development in rag drenched with oil or
paint (linseed oil) and oxygen. Oxygen cylinders, lines and valves shall
be kept free from oil and grease.
Fumes from, e.g., gasoline are heavier than air and may "run" down
into a sloping plane, or down in a grease pit, where welding flames,
grinding sparks or cigarette embers may cause an explosion. Evapo-
rated gasoline explodes very forcefully.

Workshop Manual DCF 90-100 VDCF03.01GB


12 B Safety – Safety instructions

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.

Fluid or gas under pressure


page

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.

VDCF03.01GB Workshop Manual DCF 90-100


B Safety – Safety instructions 13

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

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


corrosion compound and (when needed) anti-freeze fluid, for example,
ethylene glycol.
Coolant must not be drained into the sewer system or directly onto the
ground.

Risks
The cooling system 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.

Workshop Manual DCF 90-100 VDCF03.01GB


14 B Safety – Safety instructions

Refrigerant
page

Refrigerant is used in the machine’s air conditioning system.


Work on the air conditioning system must be performed by accredited/
authorized and trained personnel according to national legislation and
local regulations.

Risks
The air conditioning operates at high pressure. Escaping refrigerant
can cause frostbite.
Refrigerant that is heated (e.g., when repairing leaking climate/AC
system), generates gases that are very dangerous to inhale.

Safety precautions
• Use special instructions and equipment for refrigerant according
to the manual when working on the air conditioning system. 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.

VDCF03.01GB Workshop Manual DCF 90-100


B Safety – Safety instructions 15

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

Examples of tensioned springs:


1. Torque springs in pedals for example
2. Return spring (cup springs) in parking brake cylinder.
3. Lock rings
4. Gas springs

Risks
If a tensioned spring releases, it is shot out by the spring force and can
also take adjoining parts with it.
Small springs can cause eye injuries.
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.

Workshop Manual DCF 90-100 VDCF03.01GB


16 B Safety – Safety instructions

Rotating components and tools


page

Examples of rotating components and tools:


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

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.

VDCF03.01GB Workshop Manual DCF 90-100


B Safety – Safety instructions 17

Tyre and rim system


page

DANGER
Tyres should be regarded as pressurized containers.
They constitute fatal danger if handled incorrectly.

Parts can be thrown with explosive force and may


cause severe injuries.

Never repair damaged tyres, rims or lock rings. Tyre


changes shall be performed by authorised personnel.

Risks
Dismantling wheels: Tyres, rims or lock rings 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.

Workshop Manual DCF 90-100 VDCF03.01GB


18 B Safety – Environment

Environment
General
page

Ever-increasing industrialisation of our world is having a significant im-


pact on our global environment. Nature, animals and man are subject-
ed daily to risks in connection with various forms of chemical handling.
There are still no environmentally safe chemicals, such as oils and
coolants, available on the market. Therefore, all who handle, perform
service on or repair machines must use the tools, assisting devices
and methods necessary to protect the environment in an environmen-
tally sound manner.
By following the simple rules below, you will contribute to protecting
our environment.

Recycling
Well-thought out recycling of the machine is the cornerstone of ending
its life cycle and being able to reuse materials in new products. Ac-
cording to calculations by Kalmar Industries, the machine can be recy-
cled to more than 90% by weight.

Environmentally hazardous waste


Components such as batteries, plastics, and other materials that may
be considered as environmentally hazardous waste must be handled
in an environmentally correct manner.
Discarded batteries contain substances hazardous to personal health
and the environment. Therefore, handle batteries in an environmental-
ly safe manner and according to national regulations.

Oils and fluids


Oils freely discharged cause environmental damage and can also be
a fire hazard. Therefore, when emptying and draining oils or fuel, take
appropriate action to prevent unnecessary spills.
Waste oils and fluids must always be taken care of by an authorized
disposal company.
Pay close attention to oil leaks and other fluid leaks! Take immediate
action to seal the leaks.

Air conditioning unit


The refrigerant in the air conditioning unit for the cab contributes to the
greenhouse effect and may not be intentionally released into the open
air. Special training is required for all service work on the air condition-
ing unit. Many countries demand certification by a governing authority
for such work.

Working in a contaminated area


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

VDCF03.01GB Workshop Manual DCF 90-100


B Safety – Environment 19

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.

Workshop Manual DCF 90-100 VDCF03.01GB


20 B Safety – Environment

VDCF03.01GB Workshop Manual DCF 90-100


C Preventive maintenance 1

C Preventive maintenance

C Preventive maintenance
mm mm mm mm mm mm

Preventive maintenance
page

See Maintenance manual DCF 90-100, section C Preventive mainte-


nance.

Workshop Manual DCF 90-100 VDCF03.01GB


2 C Preventive maintenance – C Preventive maintenance

VDCF03.01GB Workshop Manual DCF 90-100


0 Complete machine 1

0 Complete machine

Table of Contents 0 Complete machine


mm mm mm mm mm mm

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


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

Workshop Manual DCF 90-100 VDCF03.01GB


2 0 Complete machine

VDCF03.01GB Workshop Manual DCF 90-100


0 Complete machine – Complete machine 3

Complete machine
mm mm mm mm mm mm

Complete machine, description


page

Kalmar DCF90-100 is a forklift truck for handling empty containers.


The machine has a lift capacity of up to 9 – 10 metric tons depending
on version.
The power source is a straight 6-cylinder, 4-stroke turbocharged low-
emission diesel engine with unit injectors and air-to-air intercooler.
The transmission is hydromechanical with gear wheels in constant
mesh. It has up to three gears in each direction, depending on the ver-
sion. The power of the engine is transmitted via a torque converter.
The driveline/axle comprises a propeller shaft and a rigid drive axle
1 2 3 4 9 with hub reduction. Drive is via the front wheels.
5 6 7 8
The service brake is of wet disc type, built together with drive wheel
hubs. The parking brake is a disc brake and acts on the drive axle in-
put shaft.
Steering is via the rear wheels and a double acting hydraulic cylinder.
The steering axle is pendulum-suspended in the frame.
The wheels are mounted on the hubs with nuts and clamps. Twin
wheels are mounted on the drive axle, while the steering axle has sin-
gle wheels.
Load handling is components and functions for handling loads. The
load is lifted with a side lifting attachment fastened to a lifting carriage
that sits on a mast. Load handling is divided into the functions lifting/
009775

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.

Workshop Manual DCF 90-100 VDCF03.01GB


4 0 Complete machine – Complete machine

The machine’s electrical system is based on control units at strategic


locations on the machine. The control units receive signals from sen-
sors and contacts and control components close to the respective con-
trol unit. The control units have redundant voltage feed and
communicate via redundant CAN bus. Engine and transmission have
their own control units from the respective supplier. These control
units communicate via CAN bus with a control unit in the cab.

Troubleshooting, general work


page

instructions
When troubleshooting, it is important that the work is structured and
logical. The point of the troubleshooting described in the maintenance
manual is to exclude components as error source so that the real error
source can be pin-pointed. A suggested structured work method is de-
scribed below.
When troubleshooting, it is important to understand how the machine
functions. Certain malfunctions can be pin-pointed directly using func-
tion descriptions. Sections 0–12 contain descriptions of the various
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).

VDCF03.01GB Workshop Manual DCF 90-100


0 Complete machine – Complete machine 5

Troubleshooting without an error


page

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.

Troubleshooting with error code,


page

example
Error codes are strong indicators of malfunctions detected by the con-
trol system. Many error codes are connected to electrical malfunctions
but there are also error codes that interpret associations between one
or several signals that indicate a non-electrical malfunction. It’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.

Workshop Manual DCF 90-100 VDCF03.01GB


6 0 Complete machine – Complete machine

6 If possible, eliminate component fault by testing the component


individually.
Electric components can sometimes be checked with resistance
measurements using a multimeter.
Hydraulic components are often checked by measuring pressure
(then described in the function group and indicated in the section
C Preventive maintenance). Sometimes valves can be activated
mechanically to determine if the malfunction is electric or
hydraulic.
7 If the component’s measurement values are correct, continue by
troubleshooting electric cables and hydraulic hoses.
For electric cabling, see Troubleshooting cable harness page 7.
For hydraulic hoses, see Troubleshooting hydraulic hoses page
8.
8 If the cable is not defective, then connect the lead to the control
unit.

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.

Table 1. Example of error code information in error code list

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.

VDCF03.01GB Workshop Manual DCF 90-100


0 Complete machine – Complete machine 7

Troubleshooting cable harness


page

NOTE
Perform troubleshooting for all cables in the same way to avoid
damage to control units, components or measuring equipment.

1 Study the circuit diagram in question, check where the suspected


cable is connected and if, and if so where, it is spliced.
2 Turn off the main electric power with the battery disconnect
switch.
3 Unplug the connector at the control unit or component in
question.
4 Check if there is open circuit.

NOTE
Some components cannot be checked without power supply
to the component. In such an event, proceed to point 5.
a. Measure resistance between connections 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.

Workshop Manual DCF 90-100 VDCF03.01GB


8 0 Complete machine – Complete machine

Troubleshooting hydraulic hoses


page

WARNING
Oil under high pressure!

Personal injury!

Always depressurize hydraulic and brake systems


before starting to work on the systems.

1 Depressurise the hydraulic and brake systems; see section B


Safety.
2 Study the relevant hydraulic diagram, check between whichever
components the suspect hose is connected and correspondingly
where it is spliced.
3 Locate the hose on the machine.
Start at one component and follow the hose to the next
component.
4 Inspect the entire hose and splicing points with respect to chafing
damage, pinching damage and leaks.
Change damaged hoses. When removing a hydraulic hose,
change of O-ring is always recommended on the hoses that have
these (ORFS).

VDCF03.01GB Workshop Manual DCF 90-100


1 Engine 1

1 Engine

Table of Contents 1 Engine


mm mm mm mm mm mm

1 Engine ............................................................................................................. 3
1.1 Controls and instruments ......................................................................... 23
1.1.1 Ignition 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

Workshop Manual DCF 90-100 VDCF03.01GB


2 1 Engine

VDCF03.01GB Workshop Manual DCF 90-100


1 Engine – 1 Engine 3

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.

Component supplier documentation


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

Workshop Manual DCF 90-100 VDCF03.01GB


4 1 Engine – 1 Engine

Engine, function description


page

(Volvo TAD760VE engine)


Volvo TAD760VE is a straight 6-cylinder, 4-stroke turbocharged low-
emission diesel engine with unit injectors, common rail technology and
air-to-air intercooler.

Condition Reference value Reference


Disconnected (when cable is in start lock-out is activated). Engine heater, description page 37
Engine heater

˚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

The illustration depicts the function description for Volvo TAD760VE.

Pos Explanation Signal description Reference


1 The ignition switch (S150) sends a U = 24 V Ignition, description page 23
voltage signal to cab control unit D1: Diagnostic menu, see section 8 Control sys-
KCU (D790-1) when the start key is tem, group 8.4.1.5 CAN/POWER, menu 5 and
turned to position 1 or the preheating 8.4.6.4 ENGINE, menu 4
position.

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.

VDCF03.01GB Workshop Manual DCF 90-100


1 Engine – 1 Engine 5

Pos Explanation Signal description Reference


3 If preheating has been activated with U = 24 V See Engine control unit, general page 38
the start key or automatically, then
the engine control unit (D794) feeds
voltage to the preheating relay and
through this also the preheating coils
(E800-1).

4 The preheating coils (E800-1) warm - D4: Diagnostic menu, see section 8 Control sys-
each cylinder with a glow plug. tem, group 8.4.6.5 ENGINE, menu 5

5 The ignition switch (S150) sends a U = 24 V Ignition, description page 23


voltage signal to the KIT control unit D5: Diagnostic menu, see section 8 Control sys-
(D790-2) when the start key is tem, group 8.4.6.4 ENGINE, menu 4
turned to start position.

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.

10 The accelerator pedal (B690) sends U = 0.5–4.5 V Accelerator pedal page 24


the cab control unit (D790-1) a volt- Lower voltage than 0.5 V D10: Diagnostic menu, see section 8 Control
age signal proportional to the down- and higher voltage than system, group 8.4.6.1 ENGINE, menu 1
ward press of the pedal. 4.5 V used to detect mal-
function in cable harness-
es and controls.

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.

Workshop Manual DCF 90-100 VDCF03.01GB


6 1 Engine – 1 Engine

Pos Explanation Signal description Reference


14 The engine control unit (D794) trans- Checked by control sys- Se Engine control unit, general page 38
mits engine data and warning mes- tem, error shown with er- D14: Diagnostic menu, see section 8 Control
sages on the CAN bus. ror code. system, group 8.4.6.6 ENGINE, menu 6, 8.4.6.7
ENGINE, menu 7 and 8.4.6.8 ENGINE, menu 8

15 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.

19 Speed limitation - See Supplier documentation, transmission


The output shaft speed sensor D19: Diagnostic menu, see section 8 Control
(B758) sends the transmission con- system, group 8.4.7.6 TRANSM, menu 2
trol unit (D793) pulses with frequen-
cy proportional to output shaft rpm.

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.

VDCF03.01GB Workshop Manual DCF 90-100


1 Engine – 1 Engine 7

Component locations (Volvo engine)


page

4
3 8
2
1 9

10

11
12
13
14
15
16
17
18

010197
19

Volvo TAD760VE, left side (in machine’s direction of travel)

1. Coolant temperature sensor 11. Coolant pump


2. Solenoid valve EGR 12. Sensor oil pressure
3. Crankcase ventilation 13. Oil filter
4. Injector and preheating (6 pcs.) 14. Sensor fuel pressure
5. Turbo 15. Fuel filter
6. Filling point engine oil 16 Solenoid valve proportional valve high-pressure fuel (MPROP)
7. Connection cab heat 17. Electrical connection, engine control unit (D794)
8. Alternator 18. Sensor camshaft rpm
9. Fuel pump 19. Oil plug
10. Sensor fuel pressure (rail)

Workshop Manual DCF 90-100 VDCF03.01GB


8 1 Engine – 1 Engine

3
2

010198
1

Volvo TAD760VE, right side (in machine’s direction of travel)

1. Oil plug 4. Sensor crankshaft rpm


2. Starter motor (M654) 5. Thermostat housing
3. Drain point coolant

VDCF03.01GB Workshop Manual DCF 90-100


1 Engine – 1 Engine 9

Engine, replacement
page

(Volvo TAD760VE engine)

DANGER
The engine is very heavy.

Risk of pinch injury!

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.

Workshop Manual DCF 90-100 VDCF03.01GB


10 1 Engine – 1 Engine

6 Remove the screws holding the cover plate to the flywheel.

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.

9 Remove the screws between engine and gearbox.


10 Remove the screws in the engine brackets.
11 Withdraw the engine rearwards to separate it from the gearbox.

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.

VDCF03.01GB Workshop Manual DCF 90-100


1 Engine – 1 Engine 11

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

Workshop Manual DCF 90-100 VDCF03.01GB


12 1 Engine – 1 Engine

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.

VDCF03.01GB Workshop Manual DCF 90-100


1 Engine – 1 Engine 13

21 Measure and check that the engine is centred in the frame.


22 Fit the screws in the engine bracket.
Tighten to 169 Nm (oiled screw).
23 Fit the cover washer under the flywheel.
24 Remove the hoisting equipment from the engine.
25 Remove the jack from underneath the gearbox.
26 Connect the required hoses and cables for the engine and trans-
mission. Check and fill fluids as needed.
27 Bleed air from the engine’s fuel system before start.

007973

Workshop Manual DCF 90-100 VDCF03.01GB


14 1 Engine – 1 Engine

Engine, function description


page

(Cummins QSB6.7 engine)


Condition Reference value Reference
Disconnected (when cable is in start lock-out is activated). Engine heater, description page 37
Engine heater

˚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

The illustration depicts the function description for Cummins QSB6.7

Pos Explanation Signal description Reference


1 The ignition switch (S150) sends a U = 24 V Ignition, description page 23
voltage signal to cab control unit D1: Diagnostic menu, see section 8 Control sys-
KCU (D790-1) when the start key is tem, group 8.4.1.5 CAN/POWER, menu 5 and
turned to position 1 or the preheating 8.4.6.4 ENGINE, menu 4
position.

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.

VDCF03.01GB Workshop Manual DCF 90-100


1 Engine – 1 Engine 15

Pos Explanation Signal description Reference


3 If preheating has been activated with U = 24 V Se Engine control unit, general page 38
the start key or automatically, then
the engine control unit (D794) feeds
voltage to the preheating relay and
through this also the preheating coil
(E800).

4 The preheating coil (E800) heats the - D4: Diagnostic menu, see section 8 Control sys-
primary air to the engine. tem, group 8.4.6.5 ENGINE, menu 5

5 The ignition switch (S150) sends a U = 24 V Ignition, description page 23


voltage signal to the KIT control unit D5: Diagnostic menu, see section 8 Control sys-
(D790-2) when the start key is tem, group 8.4.6.4 ENGINE, menu 4
turned to start position.

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.

10 The accelerator pedal (B690) sends U = 0.2–4.8 V Accelerator pedal page 24


the cab control unit (D790-1) a volt- Lower voltage than 0.2 V D10: Diagnostic menu, see section 8 Control
age signal proportional to the down- and higher voltage than system, group 8.4.6.1 ENGINE, menu 1
ward press of the pedal. 4.8 V is used to detect
malfunction in cable har-
nesses and controls.

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.

Workshop Manual DCF 90-100 VDCF03.01GB


16 1 Engine – 1 Engine

Pos Explanation Signal description Reference


14 The engine control unit (D794) trans- Checked by control sys- Se Engine control unit, general page 38
mits engine data and warning mes- tem, error shown with er- D14: Diagnostic menu, see section 8 Control
sages on the CAN bus. ror code. system, group 8.4.6.6 ENGINE, menu 6, 8.4.6.7
ENGINE, menu 7 and 8.4.6.8 ENGINE, menu 8

15 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.

19 Speed limitation - See Supplier documentation, transmission


The output shaft speed sensor D19: Diagnostic menu, see section 8 Control
(B758) sends the transmission con- system, group 8.4.7.6 TRANSM, menu 2
trol unit (D793) pulses with frequen-
cy proportional to output shaft rpm.

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.

VDCF03.01GB Workshop Manual DCF 90-100


1 Engine – 1 Engine 17

Component locations
page

(Cummins engine)
6 7

8
9
10
11

3 12
13
14
2
15

009440
1 16

Cummins QSB 6.7, left side (in machine’s direction of travel)

1 Hole for flex plate 9 Coolant inlet


2 Flywheel 10 Oil cooler
3 Crankcase ventilation 11 Oil filter
4 Injector drainage 12 Turbo inlet
5 Lifting eye 13 Turbo wastegate
6 Oil filling 14 Exhaust manifold
7 Coolant outlet 15 Starter motor
8 Alternator 16 Flywheel housing

Workshop Manual DCF 90-100 VDCF03.01GB


18 1 Engine – 1 Engine

7
6
8

10
5
11
4

12
13
14
15

007396
16

Cummins QSB 6.7, right side (in machine’s direction of travel)

1 Drive belt tensioner 9 Fuel pressure sensor in rail


2 Coolant pump 10 Fuel rail
3 Fan drive 11 Pressure reducing valve in rail
4 Air inlet 12 Fuel filter
5 Coolant temperature sensor 13 Dipstick
6 Turbo air inlet 14 Electronic control unit (D794)
7 Turbo air outlet 15 Crankshaft speed sensor
8 High-pressure fuel lines 16 Vibration damper (rubber)

VDCF03.01GB Workshop Manual DCF 90-100


1 Engine – 1 Engine 19

Engine, replacement
page

(Cummins engine)

DANGER
The engine is very heavy.

Risk of pinch injury!

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

4 Remove the radiator.

5 Use a jack to secure the gearbox.

6 Remove the screws holding the cover plate to the flywheel on the
left side of the engine.
008314

Workshop Manual DCF 90-100 VDCF03.01GB


20 1 Engine – 1 Engine

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.

9 Remove the screws between engine and gearbox.


10 Remove the screws in the engine brackets.
11 Carefully detach the gearbox from the engine.
12 Withdraw the engine rearwards to separate it from the gearbox.

NOTE
008275

Beware of balance before the engine is lifted.

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

VDCF03.01GB Workshop Manual DCF 90-100


1 Engine – 1 Engine 21

16 Insert a stud into one of the nuts on the flexible plate as a guide
when the engine is installed.

007769

Gearbox guide stud


17 Lift the engine into place. Guide the stud through the flywheel and
out through the hole in the flywheel housing.
18 Install the screws which fix the 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 screws for the flex
plate/flywheel.
19 Remove the stud through the hole in the flywheel housing.
008319

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

Workshop Manual DCF 90-100 VDCF03.01GB


22 1 Engine – 1 Engine

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


23 Fit the screws in the engine bracket.
Tighten to 169 Nm (oiled screw).
24 Fit the cover plug in front of the flywheel.
25 Remove the hoisting equipment from the engine.
26 Remove the jack from underneath the gearbox.
27 Connect the required hoses and cables for the engine and trans-
mission. Check and fill fluids as needed.

007796

VDCF03.01GB Workshop Manual DCF 90-100


1 Engine – 1.1 Controls and instruments 23

1.1 Controls and instruments


1.1.1 Ignition switch
Ignition, description
page

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.

Workshop Manual DCF 90-100 VDCF03.01GB


24 1 Engine – 1.1.2 Accelerator pedal

1.1.2 Accelerator pedal


Accelerator pedal, replacement
page

1 Machine in service position, see section B Safety.


2 Pull one edge of the cover away to facilitate access to the accel-
erator pedal.
3 Unplug the cable from the connector.
4 Unscrew the connector from the accelerator pedal.
5 Replace the accelerator pedal.
6 Fit in the reverse order.
7 Calibrate the gas pedal, see the section 8 Control system, group
8.5.2.3 Calibrate DRIVE-TRAIN.

1. Accelerator pedal
2. Brake pedal

Accelerator pedal, calibration


page

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

VDCF03.01GB Workshop Manual DCF 90-100


1 Engine – 1.2 Fuel system 25

1.2 Fuel system


Fuel system, description
page

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.

Risk of personal injury.

Fuel pressure is so high that a jet can injure the skin


resulting in serious injuries. Use protective gloves
and safety glasses. Hold a rag above the connection
to collect the fuel.

1.2.1 Fuel tank


Fuel tank, description
page

The fuel tank is located on the left-hand side of the machine behind the
brake fluid reservoir.

1.2.2 Sensor, fuel level


Sensor, fuel level, description
page

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

1. Fuel filling point


2. Fuel tank
3. Fuel level sensor (behind air filter)

Workshop Manual DCF 90-100 VDCF03.01GB


26 1 Engine – 1.6 Air intake and exhaust outlet

1.6 Air intake and exhaust outlet


1.6.1 Air cleaning system
Air cleaning system, description
page

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.

Air cleaning system, overview


1. Dust reservoir As an option, the machine can be equipped with a high-position air in-
2. Air cleaner let with pre-cleaner. It consist of an extension of the inlet pipe to the air
3. Filter indication filter and a pre-cleaner that filters coarser particles by creating cy-
clones at the air inlet. The pre-cleaner does not have any parts that
need to be replaced. When operating in dirty conditions, this means
that less dusty air is drawn into the air cleaner, extending the service
life of the air filters.

1.6.3 Exhaust system


Exhaust system, description
page

The exhaust system is installed in the chassis. A heat shield is in-


stalled between the engine and the exhaust system to protect wiring,
etc. A flex-pipe between the turbo and muffler absorbs the engine’s
1 movements. On the outside of the machine, there is a heat shield over
the exhaust system.

WARNING
2 3
Hot exhaust system!

Risk of burn injuries!

Never touch the turbo or muffler when the machine is


008041

running or just after it has been turned off!


1. End pipe
2. Silencer
3. Exhaust pipe

VDCF03.01GB Workshop Manual DCF 90-100


1 Engine – 1.6.4 Intercooler 27

1.6.4 Intercooler
Intercooler, description
page

The charge-air is cooled by an air-air intercooler in the upper part of


4 the cooler unit.
Also refer to Cooling system, description page 28.

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)

Workshop Manual DCF 90-100 VDCF03.01GB


28 1 Engine – 1.7 Cooling system

1.7 Cooling system


Cooling system, description
page

The engine is water-cooled and has passages through which the cool-
ant from the radiator flows round a closed system.
Main parts of the cooling system:
• Coolant pump, 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.

VDCF03.01GB Workshop Manual DCF 90-100


1 Engine – 1.7.4 Radiator and expansion tank 29

1.7.4 Radiator and expansion tank


Radiator and expansion tank, description
page

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)

Workshop Manual DCF 90-100 VDCF03.01GB


30 1 Engine – 1.7.5 Cooling fan

1.7.5 Cooling fan


Drive belt, replacement
page

Drive belt, changing (engine alternative Volvo TAD760VE)


1 Machine in service position, see section B Safety.
2 Slacken the belt tensioner and lock it in place with a drift or the
like (position 1).

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

VDCF03.01GB Workshop Manual DCF 90-100


1 Engine – 1.7.7 Coolant 31

Drive belt, replacement (Cummins QSB6.7 engine)


1. Machine in service position, see section B Safety.
2. Lift up the belt tensioner to remove the drive belt.

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.

Workshop Manual DCF 90-100 VDCF03.01GB


32 1 Engine – 1.7.7 Coolant

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.

Cleaning with coolant


6 Fill the cooling system with 15-20 % concentrated coolant mix-
ture. Only use recommended concentrated coolant mixed with
clean water.
7 Drain the cooling system after 1-2 days of operation.

NOTE
To prevent dissolved material from clogging the system
again, drain the system quickly, within 10 minutes, without
the machine’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.

VDCF03.01GB Workshop Manual DCF 90-100


1 Engine – 1.7.7 Coolant 33

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.

Workshop Manual DCF 90-100 VDCF03.01GB


34 1 Engine – 1.7.7 Coolant

Changing coolant and cleaning the cooling system


page

(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.

VDCF03.01GB Workshop Manual DCF 90-100


1 Engine – 1.7.7 Coolant 35

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.

Workshop Manual DCF 90-100 VDCF03.01GB


36 1 Engine – 1.7.7 Coolant

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.

VDCF03.01GB Workshop Manual DCF 90-100


1 Engine – 1.7.8 NO (normally open) switch, coolant level 37

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.

1.7.8 NO (normally open) switch, coolant


level
NO (normally open) switch, coolant level, description
page

The coolant level NO switch is located on the expansion tank.

1.7.10 Engine heater


Engine heater, description
page

See supplier documentation engine.


A start-inhibitor function is available as an option coupled with the en-
gine heater. The function is activated when the heater is running.

Workshop Manual DCF 90-100 VDCF03.01GB


38 1 Engine – 1.9 Control system engine

1.9 Control system engine


1.9.1 Control unit, engine
Engine control unit, general
page

See section 11 Common electrics, group 11.5.3.10 Engine control unit


and supplier documentation, engine.

VDCF03.01GB Workshop Manual DCF 90-100


1 Engine – 1.11 Start/stop 39

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.

Starter motor, description (Cummins 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 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.

1.11.2 Stopping device


Stopping device, description
page

The engines have electrically regulated injectors that stop delivering


fuel when the voltage is cut off, which means that the engine stops.
The engine can only be stopped by turning off the ignition via the igni-
tion switch.

NOTE
The battery disconnect switch must not be used for emergency
stop!
For more information, see supplier documentation, engine.

Start lock-out is available as an option, where a code has to be


entered via the display before the engine can be started.

Automatic engine shutdown is available as an option. This means


that the engine shuts off automatically after 3-10 minutes (depending
on customer setting) if the machine is idling without the operator in the
seat.

Workshop Manual DCF 90-100 VDCF03.01GB


40 1 Engine – 1.11.2 Stopping device

VDCF03.01GB Workshop Manual DCF 90-100


2 Transmission 1

2 Transmission

Table of Contents 2 Transmission


mm mm mm mm mm mm

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

Workshop Manual DCF 90-100 VDCF03.01GB


2 2 Transmission

VDCF03.01GB Workshop Manual DCF 90-100


2 Transmission – 2 Transmission 3

2 Transmission
mm mm mm mm mm mm

Transmission, general
page

Component supplier documentation


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

Workshop Manual DCF 90-100 VDCF03.01GB


4 2 Transmission – 2 Transmission

Transmission, function description


page

Condition Reference value Reference


Sensor operator in Operator in seat Section 9 Frame, body, cab and accessories, group 9.3.14 Operator-in-seat
seat sensor

F
D27 R
22 <˚ 1
27 Pa D1
5
D5
21 6,23,28 2, 7
D794 D790-1 D790-2

D793 D795 D797-1


10,16,18,20,26,29 19 25
D13
D8 D14
D9 D15 D22
9 D20
D12 ˚C D24 Pa
8 12 13 14 15
Pa ˚C 24

4 17

11
3

009864

Pos Explanation Signal description Reference


1 The multi-function lever (S162) Forward, Conn. F: U = 24 Gear and multi-function lever, description page
sends a voltage signal to the KIT V 18
control unit (D790-2). Reverse, Conn. R: U = 24 D1: Diagnostic menu, see section 8 Control
V system , group 8.4.7.2 TRANSM, menu 2

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.

3 The transmission’s oil pump pumps - -


oil when the engine is running.

4 The transmission’s oil filter cleans - -


the oil from impurities.

VDCF03.01GB Workshop Manual DCF 90-100


2 Transmission – 2 Transmission 5

Pos Explanation Signal description Reference


5 The accelerator pedal transmits a U = 0.5-4.5 V See section 1 Engine, group 1.1.2 Accelerator
signal to the cab control unit (D790- pedal
1). D5: Diagnostic menu, see section 8 Control
system , group 8.4.6.1 ENGINE, menu 1

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.

11 Solenoid valves for travel direction Checked by Control unit -


and gear position in valve block transmission, error
transmission control activate gears shown with error code.
in the transmission and the engine’s
power is transmitted to the transmis-
sion’s output shaft.

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.

Workshop Manual DCF 90-100 VDCF03.01GB


6 2 Transmission – 2 Transmission

Pos Explanation Signal description Reference


15 The torque converter temperature Checked by Control unit D15: Diagnostic menu, see section 8 Control
switch (S221) sends the transmis- transmission, error system , group 8.4.7.10 TRANSM, menu 10
sion control unit (D793) a voltage shown with error code.
signal if oil temperature in the torque
converter becomes too high.

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

VDCF03.01GB Workshop Manual DCF 90-100


2 Transmission – 2 Transmission 7

Pos Explanation Signal description Reference


25 The frame control unit (D797-1) Checked by control sys- See section 11 Common electrics , group
transmits disengagement approved tem, error shown with er- 11.5.3.2 Frame control unit (D797-1)
on the CAN bus. ror code.

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.

Workshop Manual DCF 90-100 VDCF03.01GB


8 2 Transmission – 2 Transmission

Shifting transmission, function


page

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

1 Fwd 2:nd Rev 1:st 3:rd

008240
29 20 21 22 23 24

Pos Explanation Signal description Reference


1. Bottom strainer oil sump, separates parti- - -
cles from the oil before the pumps.

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.

3. The oil filter cleans the oil. - -

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.

5. The pressure governor releases pressure to Opening pressure: 2500- -


the torque converter if the pressure be- 2900 kPa
comes too high.

6. The pressure reducer reduces the feed 1200 kPa -


pressure to servo pressure.

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

8. Valve spool neutral position opens or closes - -


to allow control pressure to the transmis-
sion.

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

10. Pressure booster forward increases the 0-2000 kPa -


pressure and pressurizes Drive clutch for-
ward.

VDCF03.01GB Workshop Manual DCF 90-100


2 Transmission – 2 Transmission 9

Pos Explanation Signal description Reference


11. Solenoid valve gear 2 (Y6069) controls 0-1000 mA Diagnostic menu, see section 8 Control
Pressure booster gear 2. system , group 8.4.7.8 TRANSM, menu
8 and 8.4.7.9 TRANSM, menu 9

12. Pressure booster gear 2 increases the pres- 0-3000 kPa -


sure and feeds Valve spool gear selection
2.

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

14. Pressure booster reverse increases the 0-2000 kPa -


pressure and pressurizes Drive clutch re-
verse.

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

16. Pressure booster gear 1/3 increases the 0-2000 kPa -


pressure and feeds Valve spool gear selec-
tion 1/3 as well as.

17. Contact drive sends signal to the control - -


unit to verify that drive clutches for travel di-
rection and gear selection are activated
when solenoid valve neutral position (RSP)
(Y6066) is activated.

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

19. Valve spool gear selection 1/3 pressurizes 0-2000 kPa -


Drive clutch gear 1 or Drive clutch gear 3.

20. Drive clutch forward locks transmission in 0-2000 kPa -


forward drive when the clutch is pressu-
rized.

21. Drive clutch 2nd gear locks transmission in 0-2000 kPa -


2nd gear when the clutch is pressurized.

22. Drive clutch reverse locks transmission in 0-2000 kPa -


reverse drive when the clutch is pressu-
rized.

23. Drive clutch 1st gear locks transmission in 0-2000 kPa -


1st gear when the clutch is pressurized.

24. Drive clutch 3rd gear locks transmission in 0-2000 kPa -


3rd gear when the clutch is pressurized.

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.

Workshop Manual DCF 90-100 VDCF03.01GB


10 2 Transmission – 2 Transmission

Pos Explanation Signal description Reference


26. The torque converter transmits the engine’s - -
power to the transmission.

27. The transmission oil cooler cools the oil. - -

28. The bypass valve torque converter leads Opening pressure: 400 -
the oil past the torque converter if the pres- kPa
sure becomes too high.

29. The oil is distributed to different lubrication - -


points in the transmission.

VDCF03.01GB Workshop Manual DCF 90-100


2 Transmission – 2 Transmission 11

Transmission, component positions


page

3 4
6
2 7

14 13 12

15
8
16
9
17
10

004269
19 18 11

1. Valve block transmission control 11. Oil filter transmission


2. Radiator connection (out from transmission) 12. Radiator inlet
3. Oil pump transmission 13. Radiator outlet
4. Power take-off 14. Transmission oil cooler
5. Radiator core 15. Radiator connection (from radiator to sump)
6. Thermostat 16. Temperature monitor torque converter (S221)
7. Breather filter transmission 17. Turbine speed sensor (B751)
8. Sensor, drum rpm (B752) 18. Sensor rpm output shaft (B758)
9. Engine speed and oil temperature sensor (B758/766) 19 Output shaft
10. Sensor oil pressure

Workshop Manual DCF 90-100 VDCF03.01GB


12 2 Transmission – 2 Transmission

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)

VDCF03.01GB Workshop Manual DCF 90-100


2 Transmission – 2 Transmission 13

Gearbox, replacement
page

DANGER
The gearbox is very heavy.

Risk of pinch injury!

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.

Workshop Manual DCF 90-100 VDCF03.01GB


14 2 Transmission – 2 Transmission

4 Remove the screws holding the cover plate to the flywheel.

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.

VDCF03.01GB Workshop Manual DCF 90-100


2 Transmission – 2 Transmission 15

9 Remove the bolts holding together the transmission and engine.

10 Carefully separate the transmission and engine.

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

Workshop Manual DCF 90-100 VDCF03.01GB


16 2 Transmission – 2 Transmission

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

VDCF03.01GB Workshop Manual DCF 90-100


2 Transmission – 2 Transmission 17

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.

19 Tighten the screws which fix the gearbox and engine.

20 Measure and check that the gearbox is centred in the frame.


21 Screw the gearbox into the gearbox mountings. Tighten to 169
Nm (oiled screw). Refit the cover plate and propeller shaft.
22 Remove the hoisting equipment from the gearbox.
23 Remove the jack from underneath the engine.
24 Attach relevant hoses and cables to the engine. Check fluid lev-
els and top up as necessary.
25 Calibrate the transmission; see Transmission, calibration page
28.
007973

Workshop Manual DCF 90-100 VDCF03.01GB


18 2 Transmission – 2.1 Controls and instruments

2.1 Controls and instruments


2.1.1 Gear selector and multi-function
lever
Gear and multi-function lever, description
page

Travel direction is selected with the gear and multi-function lever.


F
Selection of travel direction:
• F – Forward
• N – Neutral
• R – Reverse
The switch is supplied voltage by and sends signals to the KIT control
unit (D790-2).
002209

The signal can be checked from the diagnostic menu, see section 8
R
Control system , group 8.4.7.2 TRANSM, menu 2.

VDCF03.01GB Workshop Manual DCF 90-100


2 Transmission – 2.2 Torque converter/Clutch system 19

2.2 Torque converter/Clutch


system
2.2.1 Flex plates
Flex plates, changing
page

1 Machine in service position, see section B Safety.


2 Remove the gearbox; see Gearbox, replacement page 13.

3 Remove the bolts holding the flex plate to the transmission.


007774

Fastening the flex plate (TE17312 gearbox with Volvo


TAD760VE engine)

Workshop Manual DCF 90-100 VDCF03.01GB


20 2 Transmission – 2.2.1 Flex plates

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

Fastening the flex plate (other gearbox and engine al-


ternatives)

VDCF03.01GB Workshop Manual DCF 90-100


2 Transmission – 2.6 Lubrication system 21

2.6 Lubrication system


Lubrication system, description
page

The transmission lubricating system has the following function:


• Lubricate gear wheel and bearings
• Apply the clutches in the gearbox
• Cool down the torque converter and gearbox
• Clean the oil of any impurities with the oil filter.
During operation of the engine, the oil pump draws oil from the trans-
mission’s oil sump through a strainer, and it then pumps it through the
oil filter to a control valve.
The control valve supplies oil at the correct pressure to the gearbox
valve housing to activate the clutch plates for FORWARD or RE-
VERSE and gear 1, 2, or 3. The clutch plates require just a small
amount of the oil flow supplied by the pump. The remainder of the oil
is pumped through the torque converter circuit to the oil cooler and re-
turns to the gearbox for lubrication.
See also supplier documentation, transmission.

Transmission oil, changing


page

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.

Draining transmission oil

Workshop Manual DCF 90-100 VDCF03.01GB


22 2 Transmission – 2.6 Lubrication system

6 Remove the transmission dipstick and fill new transmission oil


through the dipstick’s hole to the marking for low level on the dip-
stick.
For volume and grade, see section F Technical data.
7 Turn the main current on and start the engine. Allow the engine
to idle for at least two minutes.
8 Check the transmission oil level with the engine running at idle
and top up to the marking for low level.

A 9 Check that the drain plug seals completely.


B

008054

A. Position of oil filling point and level check


B. Oil filling point and oil dipstick
10 Warm up the transmission until the operating menu indicates an
oil temperature of 60-65 °C.

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

Operating menu oil temperature


a. Transmission oil temperature
b. Hydraulic oil temperature

VDCF03.01GB Workshop Manual DCF 90-100


2 Transmission – 2.6 Lubrication system 23

Transmission oil level check


page

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

Work carefully when filling transmission oil to prevent other


fluids or particles from contaminating the oil, which means
A. Position of oil filling point and level check risk of transmission damage.
B. Oil filling point and oil dipstick

Workshop Manual DCF 90-100 VDCF03.01GB


24 2 Transmission – 2.6.3 Oil cooler

2.6.3 Oil cooler


Oil cooler, description
page

The transmission oil is cooled in the lower section of the cooler unit.
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)

VDCF03.01GB Workshop Manual DCF 90-100


2 Transmission – 2.6.3 Oil cooler 25

Thermostat transmission oil cooler, changing


page

NOTE
Read the safety instructions for oil before working, see section B
Safety.

1 Machine in service position, see section B Safety.


2 Drain the oil from the gearbox; see Transmission oil, changing
page 21.
3 Loosen the cover plug and remove the thermostat.
4 Check the O-ring and the spring in the bottom, change as need-
ed.
5 Install the new thermostat, and the cover plug.

IMPORTANT
007447

It is very important that the thermostat is used with


the temperature bulb facing out as shown.

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.

Workshop Manual DCF 90-100 VDCF03.01GB


26 2 Transmission – 2.6.4 Oil filter

2.6.4 Oil filter


Transmission oil filter, changing
page

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

mission oil before starting the engine.


6 Check for leaks at the transmission oil filter.
Oil filter transmission
7 Check the transmission oil level, see Transmission oil level check
page 23.

VDCF03.01GB Workshop Manual DCF 90-100


2 Transmission – 2.7 Cooling system 27

2.7 Cooling system


2.7.3 Oil cooler
Oil cooler, description
page

See Oil cooler, description page 24.

Workshop Manual DCF 90-100 VDCF03.01GB


28 2 Transmission – 2.8 Transmission control system

2.8 Transmission control system


Transmission, calibration
page

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

2.8.1 Control unit transmission


Transmission control unit, general
page

See section 11 Common electrics , group 11.5.3.9 Transmission con-


trol unit and Supplier documentation.

2.8.2 Normally closed (NC) switch,


disengagement
Normally closed (NC) switch, disengagement,
page

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

1. Brake cooling connection, return from wheel brake


2. Brake cooling connection, return to radiator and
tank
3. Brake cooling connection, to wheel brake
4. Brake cooling connection, from accumulator charg-
ing valve
5. Brake cylinder connection, to wheel brake
6. Brake pressure connection, from brake valve
7. Switch (NC), declutch (S220)
8. NO switch, brake lights (S216)
9. Measurement connection, brake pressure
10. Measuring outlet, brake cooling back pressure

VDCF03.01GB Workshop Manual DCF 90-100


2 Transmission – 2.8.3 Transmission cable harness 29

2.8.3 Transmission cable harness


Transmission cable harness, description
page

See section E Schematics.

Workshop Manual DCF 90-100 VDCF03.01GB


30 2 Transmission – 2.8.3 Transmission cable harness

VDCF03.01GB Workshop Manual DCF 90-100


3 Driveline/Axle 1

3 Driveline/Axle

Table of Contents 3 Driveline/Axle


mm mm mm mm mm mm

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

Workshop Manual DCF 90-100 VDCF03.01Gb


2 3 Driveline/Axle

VDCF03.01Gb Workshop Manual DCF 90-100


3 Driveline/Axle – 3 Driveline/axle 3

3 Driveline/axle
mm mm mm mm mm mm

3.2 Propeller shaft


Propeller shaft, description
page

The propeller shaft transfers engine power from the transmission to


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

Propeller shaft, replacement


page

1 Machine in service position, see section B Safety.


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

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


4 Fit the propeller shaft attaching bolts.
Tightening torque 98 Nm (oiled screw). Retighten the attaching
bolts after 50 hours of operation.
005193

Workshop Manual DCF 90-100 VDCF03.01Gb


4 3 Driveline/Axle – 3.3 Drive axle

3.3 Drive axle


Drive axle, general
page

Component supplier documentation


The Workshop manual only describes components and work descrip-
tions that concern installation in the machine. For descriptions and in-
structions for the drive axle’s components and systems, refer to
supplier documentation.
References to supplier documentation are only used in exceptional
cases. If information about a component is missing, use the supplier
documentation.

Drive axle, replacement


page

DANGER
Drive axle and machine are very heavy.

Risk of pinch injury!

It is not permissible to go under a machine which has


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

1 Remove the mast, see section 7 Load handling , group 7.2 Lifting/
lowering.
2 Park the machine with blocks behind the steering wheels.
3 Depressurize the hydraulic systems, See section B Safety.
4 Turn the start key to position 0 and turn off the main electric pow-
er.

VDCF03.01Gb Workshop Manual DCF 90-100


3 Driveline/Axle – 3.3 Drive axle 5

5 Install wedges between the steering axle and frame.

6 Disconnect hydraulic hoses (position 1) and cabling (position 2)


from the distribution block.

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

3. Casing parking brake

Workshop Manual DCF 90-100 VDCF03.01Gb


6 3 Driveline/Axle – 3.3 Drive axle

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.

Securing propeller shaft.


11 Lift the machine so that the wheels are off the ground.
12 Remove the drive wheels from the drive axle.
13 Block up the drive axle under the hubs.

CAUTION
The drive axle may start to roll.

Crushing injury!

Make sure that the drive axle does not roll away when
not under control.
Lifting machine

VDCF03.01Gb Workshop Manual DCF 90-100


3 Driveline/Axle – 3.3 Drive axle 7

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.

Attaching bolts drive axle

16 Undo the hydraulic hoses on the drive axle.

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.

Workshop Manual DCF 90-100 VDCF03.01Gb


8 3 Driveline/Axle – 3.3 Drive axle

18 Transfer the parking brake union to the new axle.

19 Undo the distribution block bracket and move it to the new axle.
20 Connect the hydraulic hoses from the distribution block to the
drive wheels.

21 Clean the contact surfaces on the drive axle and frame. Also
clean the bolts’ contact surface on the 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.

24 Lower the frame towards the drive axle.

VDCF03.01Gb Workshop Manual DCF 90-100


3 Driveline/Axle – 3.3 Drive axle 9

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.

28 Connect hydraulic hoses (position 1) and cabling (position 2) to


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

Workshop Manual DCF 90-100 VDCF03.01Gb


10 3 Driveline/Axle – 3.3 Drive axle

VDCF03.01Gb Workshop Manual DCF 90-100


4 Brakes 1

4 Brakes

Table of Contents 4 Brakes


mm mm mm mm mm mm

4 Brakes ............................................................................................................. 3
4.1 Controls and instruments ........................................................................... 3
4.1.1 Brake pedal ............................................................................................ 3
4.3 Power-assisted brake system .................................................................... 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

Workshop Manual DCF 90-100 VDCF03.01GB


2 4 Brakes

VDCF03.01GB Workshop Manual DCF 90-100


4 Brakes – 4 Brakes 3

4 Brakes
mm mm mm mm mm mm

4.1 Controls and instruments


4.1.1 Brake pedal
Brake pedal, checking and adjusting
page

1 Clean the floor round the brake pedal and check that nothing is
obstructing the movement of the brake pedal.
2 Check that the brake pedal springs back adequately and that the
clearance between brake pedal and brake valve is 1–1.5 mm. If
needed, adjust the brake pedal’s stop bolt to correct clearance.
3 Check that the pedal moves easily.

Stop screw for adjusting clearance between brake


pedal and brake valve. (The illustration shows a loose
brake pedal).
4 Lubricate the pedal hinge with "EP2" universal grease.
5 Check that the rubber pad on the brake pedal is intact and that
the pattern is not worn away. Replace as necessary.
6 Check the brake valve; see Brake valve, checking page 20.

Lubrication points, brake pedal. (The illustration


shows a loose brake pedal).

Workshop Manual DCF 90-100 VDCF03.01GB


4 4 Brakes – 4.1.1 Brake pedal

Brake pedal, replacement


page

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.

5 Detach the steering valve from the pedal bracket.


Secure the steering valve on the cab’s underside. Remove the
steering valve’s attaching bolts. Pull down the valve slightly so
that the steering axle releases from the steering valve.
6 Detach the steering wheel shaft from the brake pedal.
Undo the bolts and pull the steering wheel shaft up slightly so that
the brake pedal can be removed.
7 Detach the clutch pedal from the brake pedal.
8 Remove the brake pedal.
Remove the brake pedal’s attaching bolt and lift away the brake
pedal.
Mounting of steering wheel shaft and steering valve in 9 Transfer the pedal rubber to the new pedal.
pedal bracket.
10 Fit the new brake pedal.
Fit the pedal and fit the pedal’s attaching bolts.
11 Connect the steering valve to the brake pedal.
12 Connect the brake valve to the brake pedal.
13 Fit the clutch pedal to the brake pedal.

VDCF03.01GB Workshop Manual DCF 90-100


4 Brakes – 4.1.1 Brake pedal 5

14 Close the drain valve on the accumulator charging valve.

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.

Workshop Manual DCF 90-100 VDCF03.01GB


6 4 Brakes – 4.3 Power-assisted brake system

4.3 Power-assisted brake system


Power assisted brake system, function
page

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.

5 The brake valve directs pressure - Brake valve, description page 19


from the accumulators to the brake
cylinders proportional to pressing
of the pedal.

6 The brake cylinders compress the See pressure plate on left Wheel brake, description page 27
discs in the brake unit. frame beam.

VDCF03.01GB Workshop Manual DCF 90-100


4 Brakes – 4.3 Power-assisted brake system 7

Pos Explanation Signal description Reference

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

Brake pressure below


0.2 MPa:
Conn 1, U = 24 V
Conn 2, U = 0 V

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

Brake pressure below


11.5 MPa:
Conn 1, U = 24 V
Conn 2, U = 0 V

10 The frame control unit (D797-1) Controlled by control 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)

Hydraulic diagram, see section E Schematics group 10 Common hy-


draulics, Basic machine

Workshop Manual DCF 90-100 VDCF03.01GB


8 4 Brakes – 4.3 Power-assisted brake system

Power-assisted brake system, component


page

positions

4
1 2
5 6

3 8
9

12

008061
11 10

1. Brake lights (H411L and H411R) 7. NC switch, brake pressure (S204)


2. Control unit KIT (D790-2) 8. Distribution block drive axle
3. Brake valve 9. NO switch, brake lights (S216)
4. Frame control unit (D797-1) 10. Oil filter
5. Wheel brake 11. Hydraulic oil pump
6. Accumulator charging valve 12. Accumulators

VDCF03.01GB Workshop Manual DCF 90-100


4 Brakes – 4.3.1 Hydraulic oil pump 9

4.3.1 Hydraulic oil pump


Hydraulic oil pump, description
page

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

1. Hydraulic oil pump for load handling.


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.

Hydraulic oil pump, checking


page

NOTE
Read the safety instructions for oil before working, see section B
Safety.

Checking pump pressure


1 Operate and warm up the machine so that the oil in the brake sys-
tem reaches operating temperature, at least 50 °C.
2 Machine in service position, see section B Safety.
3 Depressurize the hydraulic systems, See section B Safety.
4 Connect a pressure gauge (0–25 MPa) to the pump pressure
measuring outlet on the accumulator charging valve.
5 Start the engine and run it at idling speed.
008048

Measuring outlet, pump pressure

Workshop Manual DCF 90-100 VDCF03.01GB


10 4 Brakes – 4.3.1 Hydraulic oil pump

6 Close the drain valve on the accumulator charging valve and


check the pump pressure during charging.

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.

Checking accumulator charging


12 Depressurize the hydraulic systems, See section B Safety.
13 Connect a pressure gauge (0–25 MPa) to the measuring outlet
for accumulator pressure on the accumulator charging valve.
14 Start the engine and run it at idling speed.
008050

Measuring outlet, accumulator pressure

VDCF03.01GB Workshop Manual DCF 90-100


4 Brakes – 4.3.2 Oil filter 11

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.
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.

Hydraulic oil pump, replacement


page

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.

4.3.2 Oil filter


Hydraulic oil filter, general
page

See Hydraulic oil filter, description page 39.

Workshop Manual DCF 90-100 VDCF03.01GB


12 4 Brakes – 4.3.3 Accumulator charging valve

4.3.3 Accumulator charging valve


Accumulator charging valve, description
page

The accumulator charging valve distributes oil from 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

• Parking brake NC switch, description page 37

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

VDCF03.01GB Workshop Manual DCF 90-100


4 Brakes – 4.3.3 Accumulator charging valve 13

Accumulator charging, checking and adjustment


page

NOTE
Read the safety instructions for oil before working, see section B
Safety.

1 Machine in service position, see section B Safety.


2 Check accumulator charge; see Hydraulic oil pump, checking
page 9.
3 If necessary, adjust the accumulator charging pressure on the
pressure limiting valve.
Undo the lock nut and adjust the pressure by turning the adjusting
screw.
Clockwise: reduce pressure.
Counter-clockwise: increase pressure.
4 Open the drain valve on the accumulator charging valve so that
the accumulators are drained and the valve switches to charging.
Close the valves and check the max. pressure again.
5 Repeat steps 3 and 4 until the pressure is correct.
008245

Adjusting screw accumulator charging pressure

Workshop Manual DCF 90-100 VDCF03.01GB


14 4 Brakes – 4.3.3 Accumulator charging valve

Accumulator charging valve, 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 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

ance with the marking.

Attaching bolts, accumulator charging valve


NOTE
Check that the O-rings are intact and are fitted correctly.
10 Fit the parking brake valve and parking brake NO switch.
11 Connect the wiring to the accumulator charging valve.
12 Close the drain valve on the accumulator charging valve.

NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
13 Turn on the main electric power and start the engine.
Check that the hydraulic connections are sealed tightly.
14 Check the charging and changing function, see Accumulator
charging, checking and adjustment page 13.
009868

VDCF03.01GB Workshop Manual DCF 90-100


4 Brakes – 4.3.4 Accumulator 15

4.3.4 Accumulator
Accumulator, description
page

The accumulators store pressure so that there is a pressure reserve


in the event of engine or brake system malfunction. The brake system
has two accumulators connected in parallel. These are located along
the frame beam on the left side of the machine.
The accumulators are of the diaphragm type. Each accumulator is di-
vided into two spaces by a diaphragm. One side of the diaphragm is
pressurized by nitrogen gas. The other side is pressurized by the hy-
draulic oil, which compresses the nitrogen gas.
At the top of the accumulator, there is a connection for checking nitro-
gen gas pressure (and for filling nitrogen gas using special filling
equipment).
When the accumulator is filled with hydraulic oil the diaphragm is
pressed up and the pressure of the nitrogen gas rises. When the hy-
draulic system requires supply from the accumulator, the diaphragm
forces the oil back into the system
Pressurised oil from the accumulator is used for the service and park-
009869

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.

1 Machine in service position, see section B Safety.


2 Depressurize the hydraulic systems, See section B Safety.
3 The accumulators can be tested with separate test equipment or
in the machine. Primarily, separate test equipment should be
used since it is faster and more exact.
Test equipment can be ordered from Kalmar Industries AB.
• Test with test equipment: continue with step 4.
• Test in machine: continue with step 6.

Workshop Manual DCF 90-100 VDCF03.01GB


16 4 Brakes – 4.3.4 Accumulator

Checking with test equipment


4 Remove the accumulators and test them with the intended test
equipment.
The accumulators’ gas pressure should match with the pressure
plate.
5 Continue with step 17.
M Pa

009870

Pressure plate, gas pressure brake accumulators


Checking in machine
3
2 6 Loosen one of the accumulators from the distribution block. Plug
1 the connection on the distribution block with a plug that can han-
dle high pressure. Plug the connection on the accumulator to pre-
vent contamination.
009871

7 Connect a pressure gauge (0–25 MPa) to the measuring outlet


for accumulator pressure on the accumulator charging valve.
8 Turn on the main electric power and start the engine.
9 Close the drain valve on the accumulator charging valve and
charge the accumulator until the accumulator charging valve
changes to cooling.

NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
10 Check that the plug seals properly.
11 Stop the engine
004810

VDCF03.01GB Workshop Manual DCF 90-100


4 Brakes – 4.3.4 Accumulator 17

12 Lower the pressure by means of braking carefully several times


while checking the pressure on the pressure gauge.
When the pressure reaches approx. 10 MPa the pressure must
decrease immediately to 0 MPa.
If the pressure drops immediately when the engine is shut off,
then the accumulator does not have any pre-charge pressure.
This indicates internal leakage and the accumulator must be
changed.
If the pressure can be reduced slowly to a pressure below
10 MPa then the precharge pressure is too low and the accumu-
lator must be replaced or given to authorised personnel for main-
tenance.
13 Depressurize the hydraulic systems, See section B Safety.
14 Mark up and disconnect the tested accumulator. Plug the con-
nections. Connect one of the other accumulators to the distribu-
tion block.
15 Repeat steps 8 - 14 until all accumulators have been checked.
16 Depressurize the hydraulic systems, See section B Safety.

Installing and final checking


17 Connect both accumulators to the distribution blocks. If needed,
replace or fill defective accumulators.

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.

Workshop Manual DCF 90-100 VDCF03.01GB


18 4 Brakes – 4.3.4 Accumulator

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

7 Fit the new accumulator.

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

VDCF03.01GB Workshop Manual DCF 90-100


4 Brakes – 4.3.5 Brake valve 19

4.3.5 Brake valve


Brake valve, description
page

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

1. Inlet from accumulators [P]


2. Return connection [T]
3. Outlet to brake cylinders [B]

Workshop Manual DCF 90-100 VDCF03.01GB


20 4 Brakes – 4.3.5 Brake valve

Brake valve, checking


page

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

Check that the accumulator drain valve is fully closed and


tighten the lock ring.

VDCF03.01GB Workshop Manual DCF 90-100


4 Brakes – 4.3.5 Brake valve 21

Brake valve, 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 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.

5 Remove the brake valve attaching bolt.


6 Remove the brake valve.
7 Transfer the connection adapters to the new brake valve.
8 Install the new brake valve.

NOTE
Remember the spacer ring.

9 Connect the hydraulic hoses to the brake valve in accordance


B with the marking.

T
NOTE
P
Check that the O-rings are intact and are fitted correctly.
10 Grease and adjust the brake pedal, see Brake pedal, checking
and adjusting page 3.
004795

Workshop Manual DCF 90-100 VDCF03.01GB


22 4 Brakes – 4.3.5 Brake valve

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.
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

VDCF03.01GB Workshop Manual DCF 90-100


4 Brakes – 4.3.6 Drive axle block 23

4.3.6 Drive axle block


Drive axle block, description
page

The drive axle block distributes oil flow and brake pressure to the right
1
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

1. Brake cooling connection, return from wheel brake


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

Workshop Manual DCF 90-100 VDCF03.01GB


24 4 Brakes – 4.3.7 Brake pressure NC (normally closed) switch

4.3.7 Brake pressure NC (normally closed)


switch
Brake pressure NC switch, description
page

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

Break-contact brake pressure, adjusting


page

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

VDCF03.01GB Workshop Manual DCF 90-100


4 Brakes – 4.3.8 NO (normally open) switch, brake lights 25

10 If necessary, adjust the warning level by turning the adjusting


screw in the rear edge of the sensor, between the contact pins.

NOTE
The setting is very sensitive, turn max. 1/4 turn at a time.
11 Repeat steps 6-10 until the warning lamp 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.

4.3.8 NO (normally open) switch, brake


lights
Switch normally open (NO), brake lights, description
page

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

Brake light NO switch, checking


page

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.

Workshop Manual DCF 90-100 VDCF03.01GB


26 4 Brakes – 4.3.8 NO (normally open) switch, brake lights

5 Connect a pressure gauge (0-25 MPa) to the measuring outlet for


brake pressure on the distribution block.
6 Close the drain valve on the accumulator charging valve.

NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
7 Start the engine.

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


DIAG HYD 4(6) system , group 8.4.5.4 HYD, menu 4.
PRESSURE SWITCHES
BRAKE PRESSURE X BRAKE LIGHT PRESS. indicates status for the brake light con-
BRAKE LIGHT PRESS. X tact. 1 = Activated contact (brakes applied).
000144

DECLUTCH PRESSURE X 9 Press down the brake pedal slowly until the brake light is activat-
ed or the status of the input signal changes. Keep the pedal in this
position and check the pressure on the pressure gauge.
The status 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.

VDCF03.01GB Workshop Manual DCF 90-100


4 Brakes – 4.3.9 Wheel brake 27

4.3.9 Wheel brake


Wheel brake, description
page

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

Wheel hub and brake, cross section


1. Disc assembly
2. Brake cylinder

Workshop Manual DCF 90-100 VDCF03.01GB


28 4 Brakes – 4.3.9 Wheel brake

Wheel brakes, bleeding


page

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.

1 Machine in service position, see section B Safety.


2 Place a ring spanner on the bleed nipple and connect a transpar-
ent hose to the bleed nipple.
Lead the other end of the hose down into a collection container.
3 Start the machine and press down on the brake pedal, keep the
pedal pressed down.
4 Open the bleed nipple and allow oil to run out of it until the oil is
free of air bubbles.

NOTE
The hydraulic hose between the brake pedal and brake is
approx. 7 metres long. Therefore, allow at least two litres of
oil to pass through the air bleeder nipple when bleeding to
ensure that no air pockets remain in the system.
Bleed nipple, brake cylinder, on top of the drive axle at 5 Close the bleed nipple.
the wheel hub's inner short side (left-hand side). 6 Move the spanner and hose and repeat steps 1–4 on the other
side.
7 Check the oil level in the brake system, fill as necessary.

Wheel brake, replacement


page

See supplier documentation, drive axle.

VDCF03.01GB Workshop Manual DCF 90-100


4 Brakes – 4.3.9.1 Disc assembly 29

4.3.9.1 Disc assembly


Disc assembly, description
page

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

4.3.9.2 Brake cylinder


Brake cylinder, description
page

The brake cylinder is integrated in the wheel brake and consists of a


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

Brake cylinder

4.3.10 Pipes and hoses


Piped and hoses, description
page

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

Workshop Manual DCF 90-100 VDCF03.01GB


30 4 Brakes – 4.5 Parking brake system

4.5 Parking brake system


Parking brake system, function description
page

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

VDCF03.01GB Workshop Manual DCF 90-100


4 Brakes – 4.5 Parking brake system 31

Pos Explanation Signal description Reference

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.

Hydraulic diagram, see section E Schematics, group 10 Common hy-


draulics, Basic machine

Workshop Manual DCF 90-100 VDCF03.01GB


32 4 Brakes – 4.5 Parking brake system

Parking brake system, component positions


page

1 4
2 5 6

12

008062
11 10 9 8

1. Control unit cab (D790-1) 7. Switch (NO), parking brake (S200)


2. Control unit KIT (D790-2) 8. Parking brake disc
3. Switch parking brake (S107) 9. Parking brake caliper
4. Frame control unit (D797-1) 10. Oil filter
5. Accumulator charging valve 11. Hydraulic oil pump
6. Solenoid valve parking brake (Y642) 12. Accumulators

VDCF03.01GB Workshop Manual DCF 90-100


4 Brakes – 4.5.1 Hydraulic oil pump 33

4.5.1 Hydraulic oil pump


Hydraulic oil pump, general
page

See Hydraulic oil pump, description page 9.

4.5.2 Oil filter


Hydraulic oil filter, general
page

See Hydraulic oil filter, description page 39.

4.5.3 M-valve parking brake


Solenoid valve parking brake, description
page

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.

Solenoid valve parking brake, checking


page

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

Block the wheels so that the machine cannot start to


roll when the parking brake is released.

1 Start the engine and run the engine at 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.

Workshop Manual DCF 90-100 VDCF03.01GB


34 4 Brakes – 4.5.4 Parking brake unit

4.5.4 Parking brake unit


Parking brake unit, description
page

The parking brake unit keeps the machine stationary when parked.
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

Parking brake unit, checking and adjusting


page

DANGER
The machine may start to roll.

Risk of crushing.

Block the wheels so that the machine cannot start to


roll when the parking brake is released.

1 Start the engine and run 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.

VDCF03.01GB Workshop Manual DCF 90-100


4 Brakes – 4.5.4.1 Parking brake caliper 35

6 Remove the cover from the brake calliper and check for oil inside
the cover. Oil inside the cover indicates internal leakage.

7 Undo the lock nut.


8 Adjust the adjustment screw so that the brakes are applied.
9 Turn back the adjusting screw so that the clearance between pad
and disc is 0.5 ±0.1 mm.
10 Tighten lock nut.

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.

4.5.4.1 Parking brake caliper


Brake calliper, description
page

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

Workshop Manual DCF 90-100 VDCF03.01GB


36 4 Brakes – 4.5.4.2 Parking brake pads

4.5.4.2 Parking brake pads


Brake pads, description
page

The brake pads consist of a metal plate with friction material (lining).

Brake pads, replacement (Kessler drive axle)


page

DANGER
The machine may start to roll.

Risk of crushing.

Block the wheels so that the machine cannot start to


roll when the parking brake is released.

1 Machine in service position and wheels blocked, see section B


Safety.
2 Remove the cover from the brake caliper.

3 Undo the lock nut.


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

VDCF03.01GB Workshop Manual DCF 90-100


4 Brakes – 4.5.4.3 Parking brake disc 37

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.

4.5.4.3 Parking brake disc


Brake disc, description
page

The brake disc is mounted on the drive axle input shaft. The drive ax-
le’s gear ratio amplifies the braking force.

4.5.5 Parking brake NC switch


Parking brake NC switch, description
page

The parking brake NC switch (S200) detects whether the parking


brake is applied or released. The NC switch sits on the accumulator
charging valve, which sits on the lifting beam in front of the gearbox in
the engine compartment; see Accumulator charging valve, description
page 12.
Break-contact parking brake (S200) senses the pressure in the park-
ing brake circuit. When the pressure is so high that the parking brake
is released, the sensor opens an electric circuit. This is used to indi-
cate that the parking brake is released.
The parking brake NC switch (S200) is supplied power by and sends
a voltage signal to the frame control unit (D797-1). When the pressure
increases above the opening pressure, the voltage signal to the frame
control unit (D797-1) is cut off.
The signal can be checked from the diagnostic menu, see section 8
009882

Control system , group 8.4.5.5 HYD, menu 5.

NOTE
Gears cannot be engaged when the parking brake is applied.

4.5.6 Pipes and hoses


Piped and hoses, description
page

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

Workshop Manual DCF 90-100 VDCF03.01GB


38 4 Brakes – 4.8 Temperature control, cleaning and hydraulic oil

4.8 Temperature control,


cleaning and hydraulic oil
Temperature control, cleaning and hydraulic oil,
page

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.

Hydraulic diagram, see section E Schematics, group 10 Common hy-


draulics, Basic machine

Temperature control, cleaning and hydraulic oil,


page

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.

4.8.1 Hydraulic oil tank


Hydraulic oil tank, description
page

See section 10 Common hydraulics , group 10.3.1 Hydraulic oil tank.

VDCF03.01GB Workshop Manual DCF 90-100


4 Brakes – 4.8.3 Hydraulic oil pump 39

4.8.3 Hydraulic oil pump


Hydraulic oil pump, description
page

See Hydraulic oil pump, description page 9.

4.8.4 Accumulator charging valve


Accumulator charging valve, description
page

See Accumulator charging valve, description page 12.

4.8.5 Drive axle block


Drive axle block, description
page

See Drive axle block, description page 23.

4.8.6 Wheel brake


Wheel brake, description
page

See Wheel brake, description page 27and supplier documentation,


drive axle.

4.8.8 Thermal bypass valve


Thermal bypass valve, description
page

See section 10 Common hydraulic , group 10.6.5 Radiator bypass


valve.

4.8.9 Cooling fan


Cooling fan, description
page

See section 10 Common hydraulics , group 10.6.3 Cooling fan.

4.8.10 Sensor hydraulic oil temperature


Sensor hydraulic oil temperature, description
page

See section 10 Common hydraulics , group 10.6.4 Hydraulic oil tem-


perature sensor.

4.8.11 Breather filter hydraulic oil tank


Breather filter hydraulic oil tank, description
page

See section 10 Common hydraulics , group 10.6.6 Breather filter, hy-


draulic oil tank.

4.8.12 Oil filter


Hydraulic oil filter, description
page

See section 10 Common hydraulics , group 10.6.7 Hydraulic oil filter.

4.8.13 Pipes and hoses


Piped and hoses, description
page

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

Workshop Manual DCF 90-100 VDCF03.01GB


40 4 Brakes – 4.8.14 Hydraulic oil

4.8.14 Hydraulic oil


Hydraulic oil, description
page

See section 10 Common hydraulics , group 10.6.8 Hydraulic oil.

VDCF03.01GB Workshop Manual DCF 90-100


5 Steering 1

5 Steering

Table of Contents 5 Steering


mm mm mm mm mm mm

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

Workshop Manual DCF 90-100 VDCF03.01GB


2 5 Steering

VDCF03.01GB Workshop Manual DCF 90-100


5 Steering – 5 Steering 3

5 Steering
mm mm mm mm mm mm

5.2 Power assisted system


Power assisted steering system, function
page

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

Workshop Manual DCF 90-100 VDCF03.01GB


4 5 Steering – 5.2 Power assisted system

Pos Explanation Signal description Reference


5 The steering valve pumps pressurised - Steering valve, description page 8
oil to the steering cylinder and transmits
a load signal to the main pump.

6 The steering cylinder turns the wheels. - Steering cylinder, description page 10

Hydraulic diagram, see section E Schematics group 10 Common hy-


draulics, Basic machine

Power-assisted steering system, component


page

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

VDCF03.01GB Workshop Manual DCF 90-100


5 Steering – 5.2.1 Hydraulic oil pump 5

5.2.1 Hydraulic oil pump


Hydraulic oil pump, general
page

Steering is supplied oil by the hydraulic oil pump for steering and load
handling; see section 10 Common hydraulics , group 10.4 Pumps.

Steering pressure, checking


page

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

Measuring outlet on hydraulic oil pump for steering


and load handling
5 Turn the steering wheel fully and read pump pressure during the
steering wheel movement. Compare this to the steering pressure
on the hydraulics plate.
6 Turn the start key to position 0 and turn off the main electric pow-
er.
7 Remove the pressure gauge and fit the protective cap on the
measuring outlet.
009886

Workshop Manual DCF 90-100 VDCF03.01GB


6 5 Steering – 5.2.2 Priority valve

5.2.2 Priority valve


Priority valve, description
page

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

1. Supply pressure from hydraulic oil pump (P)


2. Pilot pressure (PP), pressure drop to steering valve
3. Pressure to control valve, load handling (EF)
4. Load signal from steering valve (LS)
5. Tank draining (T)
6. Pressure to steering valve (CF)

Priority valve, 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 Depressurise the hydraulic system, see section B Safety.
3 Turn the start key to position 0 and turn off the main electric
power.

VDCF03.01GB Workshop Manual DCF 90-100


5 Steering – 5.2.2 Priority valve 7

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.

3 7 Remove the priority valve.


6 4
5 8 Transfer the connection adapters to the new priority valve.

NOTE
Transfer one connection at a time so that the marking is not
mixed up.
9 Connect the new priority valve to control valve lift and lower.

CAUTION
009884

1. Supply pressure from hydraulic oil pump (P)


2. Pilot pressure (PP), pressure drop to steering valve Do not tighten the hydraulic connection between pri-
3. Pressure to control valve, load handling (EF) ority valve and control valve lift and lower before all
4. Load signal from steering valve (LS) other connections and attaching bolts are fitted.
5. Tank draining (T) Stresses in the priority valve may result in incorrect
6. Pressure to steering valve (CF) function.

10 Fit the priority valve attaching bolts.


11 Connect the hydraulic hoses to the priority valve in accordance
with the marking.
12 Check that control valve lift and lower is not jammed against the
priority valve.
13 Tighten the hydraulic connection between priority valve and col-
lection block.
14 Start the engine and check that the hydraulic connections at the
priority valve are sealed.
15 Check steering pressure; see Steering pressure, checking page
5.

Workshop Manual DCF 90-100 VDCF03.01GB


8 5 Steering – 5.2.3 Steering valve

5.2.3 Steering valve


Steering valve, description
page

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

Steering valve, replacement


page

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

VDCF03.01GB Workshop Manual DCF 90-100


5 Steering – 5.2.3 Steering valve 9

4 Detach the steering valve from the brake pedal.


Remove the steering valve attaching bolts and lower the steering
valve.
5 Mark up and detach the hydraulic hoses from the 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.

Workshop Manual DCF 90-100 VDCF03.01GB


10 5 Steering – 5.2.4 Steering cylinder

5.2.4 Steering cylinder


Steering cylinder, description
page

The steering cylinder acts on the wheels via the link arms. The steer-
1 2 3 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)

Steering cylinder, replacement


page

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.

VDCF03.01GB Workshop Manual DCF 90-100


5 Steering – 5.2.4 Steering cylinder 11

4 Disconnect the link arms from the steering cylinder.


5 Mark up and disconnect the hydraulic hoses from the steering
cylinder.

NOTE
Plug all connections immediately to protect the brake sys-
tem from impurities.

1. Link arm attachment


2. Hydraulic connection
6 Remove the steering cylinder’s attaching bolts.
7 Change the steering cylinder. Lift aside the steering cylinder.

NOTE
The steering cylinder is heavy, use lifting equipment.
8 Support the new steering cylinder so that the holes in the 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

Attaching bolts steering cylinder.

Workshop Manual DCF 90-100 VDCF03.01GB


12 5 Steering – 5.2.5 Steering axle cradle

11 Fit the link arms to the steering cylinder.


12 Connect the hydraulic hoses to the steering cylinder.

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.

1. Link arm attachment


2. Hydraulic connection

Hydraulic cylinders, repairs


page

See section 10 Common hydraulics , group 10.7.1 Hydraulic cylinders.

5.2.5 Steering axle cradle


Steering axle cradle, general
page

See section 6 Wheel suspension, group 6.2.1 Steering axle cradle.

5.2.6 Link arm


Link arm, description
page

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

5.2.7 Wheel spindle


Wheel spindle, general
page

See section 6 Wheel suspension , group 6.2.2 Wheel spindle.

5.2.8 Wheel hub


Wheel hub, general
page

See section 6 Wheel suspension , group 6.2.3 Wheel hub.

VDCF03.01GB Workshop Manual DCF 90-100


5 Steering – 5.2.9 Shuttle valve 13

5.2.9 Shuttle valve


Shuttle valve, description
page

See section 10 Common hydraulics , group 10.5.3 Shuttle valve.

5.2.13 Pipes and hoses


Piped and hoses, description
page

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

Workshop Manual DCF 90-100 VDCF03.01GB


14 5 Steering – 5.2.13 Pipes and hoses

VDCF03.01GB Workshop Manual DCF 90-100


6 Suspension 1

6 Suspension

Table of Contents 6 Suspension


mm mm mm mm mm mm

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

Workshop Manual DCF 90-100 VDCF03.01GB


2 6 Suspension

VDCF03.01GB Workshop Manual DCF 90-100


6 Suspension – 6 Suspension 3

6 Suspension
mm mm mm mm mm mm

6.2 Suspension
Bushing steering axle mounting, changing
page

DANGER
Steering axle and machine are very heavy.

Risk of pinch injury!

It is not permissible to go under a machine which has


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

1 Machine in service position, see section B Safety.


2 Turn the start key to position 0 and turn off the main electric
power.
3 Support under the steering axle so that it cannot fall over.
4 Connect lifting equipment to the rear of the machine and take up
the slack so that the steering axle’s mounts are relieved.

NOTE
Do not lift so much that the wheels are off the ground.
5 Remove the 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

The illustration shows rear mounting

Workshop Manual DCF 90-100 VDCF03.01GB


4 6 Suspension – 6.2.1 Steering axle cradle

9 Remove the washers that hold the bushing in place.


2 10 Press out the bushing.

1 11 Clean the bearing surfaces on the steering axle.


12 Press in the new bushing. Grease the bushing to facilitate
installation.
13 Install the washers that hold the bushing in place.
14 Move the steering axle into place under the frame.
15 Grease and install the pins by the steering axle’s mounts.
3
16 Remove the lifting equipment from the machine.
4

010121

1. Steering axle mounting


2. Rubber bushing
3. Washers
4. Bolt

6.2.1 Steering axle cradle


Steering axle cradle, description
page

The oscillating steering axle has a double-acting steering cylinder. The


1 2 3 4 5 6
design has a minimum of moving parts for fewer service points and
simpler maintenance. Suspension in the chassis is performed with
maintenance-free pads.
008047

Steering axle
1. Wheel hub
2. Wheel spindle
3. Link arm
4. Steering axle cradle
5. Steering cylinder
6. King pin/bearing

Steering axle cradle, replacement


page

DANGER
Steering axle and machine are very heavy.

Risk of pinch injury!

It is not permissible to go under a machine which has


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

VDCF03.01GB Workshop Manual DCF 90-100


6 Suspension – 6.2.1 Steering axle cradle 5

1 Clean the steering axle and its surrounding area.


2 Stop the engine and turn the starter key to position I.
3 Depressurize the hydraulic systems, See section B Safety.
4 Turn the start key to position 0 and turn off the main electric
power.
5 Connect the lifting equipment to the rear section of the machine.
6 Tension the lifting equipment, do not lift so high that the wheels
start to hang.
7 Support the machine’s rear section.
8 Detach the hydraulic hoses from the steering cylinder.

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.

12 Adjust the support so that the machine is secured in the new


position.
13 Lift the steering axle into place underneath the frame.
14 Remove the support under the frame.
15 Lower the rear of the machine.
16 Fit the shafts at the steering axle mountings.
17 Connect the hydraulic hoses to the steering cylinder.

NOTE
Check that the O-rings are intact and that they are fitted
correctly.
18 Remove the lifting equipment from the machine.

Workshop Manual DCF 90-100 VDCF03.01GB


6 6 Suspension – 6.2.2 Wheel spindle

6.2.2 Wheel spindle


Wheel spindle, description
page

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

King pin bearing, replacement


page

1 Machine in service position, see section B Safety.


2 Lift the machine under the steering axle at the wheel in question.
Support the steering axle in a suitable way.
3 Remove the steering wheel in question.
4 Clean the wheel spindle and its surrounding area.
5 Detach the link arm from the wheel spindle.
6 Remove the wheel hub and wheel bearing; see Wheel bearing,
replacement page 8.

VDCF03.01GB Workshop Manual DCF 90-100


6 Suspension – 6.2.2 Wheel spindle 7

7 Remove the six screws holding the bearing cage to the wheel
spindle.

8 Detach the bearing cage by screwing a screw into the removal


hole.
9 Remove the bearing cage and shim from the wheel spindle.
10 Remove the wheel spindle.
11 Remove the three screws on the top of the steering axle cradle.
Press out the outer bearing race of the upper bearing by screwing
three screws (approx. 90 mm long) into the holes.
12 Remove the inner bearing races of the upper and lower bearings
from the wheel spindle.
13 Remove the outer bearing race of the lower bearing from the
bearing cage.
002419

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.

Workshop Manual DCF 90-100 VDCF03.01GB


8 6 Suspension – 6.2.3 Wheel hub

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.

6.2.3 Wheel hub


Wheel hub, description
page

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

Wheel bearing, replacement


page

1 Lift the machine under the steering axle by the wheel in question.
Support securely under the steering axle.
2 Remove the steering wheel in question.

VDCF03.01GB Workshop Manual DCF 90-100


6 Suspension – 6.2.3 Wheel hub 9

3 Clean the hub cover and its surrounding area.


4 Remove the hub cover.
5 Wipe away grease from hub cover and hub nuts. Handle it as en-
vironmentally hazardous waste.

6 Secure the hub with a lifting strap.


Route the lift sling over the hub and around a wheel bolt. Install a
clamp and nut to secure the lift sling. Use manual forklift, pallet
forks or similar to lift the hub.

7 Bend up the 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.

10 Lift out the hub from the spindle.


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

Workshop Manual DCF 90-100 VDCF03.01GB


10 6 Suspension – 6.2.3 Wheel hub

11 Remove the inner bearing from the wheel spindle.

12 Remove the seal from the hub.


13 Remove the bearings’ outer races from the hub.
Use a drift and press out the bearing races.
14 Clean the hub and smear the inside with universal grease "EP2".
15 Fit new bearing races in the hub.
Use a drift and press in the bearing races. Never use directly on
the bearings.

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".

VDCF03.01GB Workshop Manual DCF 90-100


6 Suspension – 6.2.3 Wheel hub 11

18 Fill the empty space in the hub with universal grease "EP2".

19 Fit the hub on the wheel spindle.

20 Install the outer bearing, protecting washer, and bearing nut.


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

22 Torque the bearing nut as follows.


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

Workshop Manual DCF 90-100 VDCF03.01GB


12 6 Suspension – 6.2.3 Wheel hub

23 Grease the lock washer and fit it.


24 Fit the lock nut and tighten to at least 250 Nm (oiled screw) or
as hard as necessary to engage the locking washer in the closest
groove. Lock the bearing nut and lock nut with the locking
washer.

25 Fill the bearing casing with grease and fit it.


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

VDCF03.01GB Workshop Manual DCF 90-100


6 Suspension – 6.3 Tyre and rim system 13

6.3 Tyre and rim system


Tyre and rim system, safety
page

DANGER
Always block the wheels on the side of the axle that is
not going to be worked on before positioning the jack.
Always secure the jack to prevent it from sliding out
of position.

Deflate the tyre before removal. Otherwise the conical


ring and locking clips can loosen and shoot out when
the pressure is changed. With double wheel fitting
both tyres must be deflated!

Do not release air through the valve if the tyre or rim


is damaged. Drill a hole in the tread to release the air.
Damaged tyres may explode.

Never stand directly in front of the wheel when deflat-


ing or inflating. The conical ring and locking clips can
loosen and shoot out when the pressure is changed.

Never install damaged tyres or rims.

It's prohibited to repair rims with welding.

It's prohibited to operate the machine if one of the


tyres is flat.

Wheels, tyres and rims are dimensioned and selected


for each machine type so that maximal wheel loads
and travel speeds are not exceeded. That is why it is
forbidden to change tyre dimension, tyre brand, tyre
type, rim type or rim brand without approval from
Kalmar Industries AB

Workshop Manual DCF 90-100 VDCF03.01GB


14 6 Suspension – 6.3 Tyre and rim system

CAUTION
When removing wheels, the wheel nuts should be left
in place after loosening. If the wheel nuts are removed
immediately, the wheel may release from the hub.

When removing drive wheels, make sure that the


wheels are secured in position when the spacer rings
are removed. If the wheels move they may displace
the spacer rings, with crushing injuries as a result.

When installing drive wheels, ensure that the clamps


clamp straight on the spacer ring.

Wheel nuts should be check-tightened after 4-5 oper-


ating hours.

Always follow the tyre manufacturer’s or other ap-


proved instructions when changing tyres.

Never use a steel hammer to install or remove rim


components. Instead, use a lead, brass or plastic
mallet.

Keep the tyre pressure at the prescribed level. Insuf-


ficient tyre pressure impairs stability and reduces the
machine’s capacity.

Remove penetrating objects, such as crushed glass,


pieces of wood and metal filings.

Check if tyre wear is abnormal. This could indicate a


mechanical fault. Rectify faults immediately and
change damaged tyres.

VDCF03.01GB Workshop Manual DCF 90-100


6 Suspension – 6.3.1 Tyres 15

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!

Leave tyre work to authorised personnel/ tyre


company.

The rims must be checked when tyres are changed. See Maintenance
manual DCF 90-100.

Workshop Manual DCF 90-100 VDCF03.01GB


16 6 Suspension – 6.3.2 Rims

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

VDCF03.01GB Workshop Manual DCF 90-100


6 Suspension – 6.3.3 Nut, washer and clamp 17

6.3.3 Nut, washer and clamp


Nut, washer and clamp, description
page

The rim is attached to the wheel hub with nuts.


1 2 3 4

As an option, the rim can be equipped with nut protection.

5
009899

1. Rims
2. Lock ring
3. Rim flange
4. Rim bead seat taper
5. Wheel nut
6. Wheel bolt

Workshop Manual DCF 90-100 VDCF03.01GB


18 6 Suspension – 6.3.3 Nut, washer and clamp

Wheel bolt, replacing


page

1 Machine in service position, see section B Safety.


2 Raise the machine with a jack positioned under the steering axle.
3 Remove the steering wheel; see Maintenance manual DCF 90-
100.

4 Knock out the bolt with a sledge hammer.


5 Replace the bolt.

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling 1

7 Load handling

Table of Contents 7 Load handling


mm mm mm mm mm mm

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

Workshop Manual DCF 90-100 VDCF03.01GB


2 7 Load handling

7.7.5 Control valve, lift and tilt ....................................................................... 62


7.7.6 Load retention valve ............................................................................. 63
7.7.7 Tilt cylinder ........................................................................................... 63
7.7.8 Mast ...................................................................................................... 64
7.7.9 Pipes and hoses ................................................................................... 64
7.8 Levelling .................................................................................................... 65
7.8.1 Hydraulic oil pump ................................................................................ 67
7.8.2 Control valve attachment ...................................................................... 67
7.8.3 Levelling cylinder .................................................................................. 68
7.8.4 Lifting carriage ...................................................................................... 68
7.8.5 Valve block, main pump relief .............................................................. 68
7.8.6 Pipes and hoses ................................................................................... 68
7.9 Load carrier ............................................................................................... 69
7.9.1 Twistlocks ............................................................................................. 69
7.9.2 Lifting hook ........................................................................................... 80
7.10 Other functions .......................................................................................... 93
7.10.1 Container counter ................................................................................. 93

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7 Load handling 3

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.

Workshop Manual DCF 90-100 VDCF03.01GB


4 7 Load handling – 7 Load handling

Position sensor, adjusting


1 Machine in service position, see section B Safety.
2 Check that the sensor in question is free of damage and dirt.

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

Adjusting position sensor - indicator

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7.1 Controls and instruments 5

7.1 Controls and instruments


7.1.1 Control levers
Control levers for electric servo, description
page

The load handling functions are controlled with fingertip-controlled lin-


ear levers.
The control levers are supplied voltage by and send a signal to the cab
control unit (D790-1).
a. Lift/lower (R8071-P1).
LIFT - pull the lever backwards.
LOWER - push the lever forwards.
The lowering speed can only be varied through lever movement -
engine speed has no impact.
b. Tilt (R8072-P2).
IN - pull the lever backwards.
d OUT - push the lever forwards.
c
b
a c. Side shift (R8073-P3).

e LEFT - move lever forward.


RIGHT - pull the lever backwards.
It is not possible to use side shift on the side lifting attachment if
the attachment is in its max or min position.

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

Workshop Manual DCF 90-100 VDCF03.01GB


6 7 Load handling – 7.1.1 Control levers

Control lever, description


page

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

11 10 When the switch is pressed at position 5, spreading out is activated.


1. Not used When the switch is pressed at position 4, spreading in is activated.
2. Not used See Spreading, function description page 43.
3. Side shift (S815-P3) The signal can be checked from the diagnostic menu, see section 8
4. Spreading in (S815-T1.2) Control system , group 8.4.9.3 ATTACH, menu 3.
5. Spreading out (S815-T1.1)
6. Lock/open twistlocks or lock tongues (S815-T2) at Side shift
full contact
When the potentiometer (position 3) is pressed on the left side, side
7. Not used
shift left is activated. When the right side is pressed, side shift right is
8. Pistol trigger (S815-T4): Changes the function of
activated. See Sideshift, function description page 34.
side shift to levelling (S815-P3) The signal can be checked from the diagnostic menu, see section 8
9. Tilt out Control system , group 8.4.9.1 ATTACH, menu 1.
10. Lift
11. Tilt in Levelling
12. Lower

If the pistol trigger (position 8) is pressed in at the same time as the


potentiometer (position 3) is pressed on the left side, levelling left is ac-
tivating. If the right side is pressed, levelling right is activated. See Ac-
tive levelling, function description page 65.
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.9.1 ATTACH, menu 4.

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.

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7.1.2 Switch, lock twistlock/lock tongue 7

Open twistlocks or lock/open lock tongues


When the switch at position 6 is activated, the twistlocks open or the
lock tongues lock/open every other time if the conditions for such are
fulfilled.
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.9.5 ATTACH, menu 5.

7.1.2 Switch, lock twistlock/lock tongue


Switch, lock twistlock/lock tongue, description
page

Switch (green) for locking twistlock/lock tongue (S1003). The switch


has a return-spring action in position 2.
Position 1 - Twistlock/lock tongue locked automatically when contact
is made with load. Parking brake must be OFF.
Position 0 - Twistlock locking not activated.
Position 2 - Twistlock locked manually. Button has a return-spring
009907

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.

7.1.3 Switch, spreading 20'-40'


Switch, spreading 20’-40’, description
page

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

Position 0 - Spreading not activated.


Position 1 - Spreading out activated. The outer end position of the
spreader is at 40’.
Position 2 - Spreading in activated. The inner end position of the
spreader is at 20’.
The switch is supplied power by and sends a voltage signal to the cab
control unit (D790-1).
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.9.2 ATTACH, menu 3.

Workshop Manual DCF 90-100 VDCF03.01GB


8 7 Load handling – 7.1.4 Switch, stop at 30'

7.1.4 Switch, stop at 30'


Switch, stop at 30’, description
page

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.

7.1.13 Switch, automatic spreading


Switch automatic spreading, description
page

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

Position 0 - Automatic spreading not activated.


Position 1 - Automatic spreading activated. Spreading is activated with
the switch for spreading 20’-40’.
The switch is supplied with voltage from and sends a voltage signal to
the cab control unit (D790-1) when the switch is activated.
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.9.4 ATTACH, menu 3.

WARNING
Risk of pinching and product damage!

Automatic spreading is stopped by activating spread-


ing in the opposite direction or deactivating the func-
tion with the switch.

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7.2 Lifting/lowering 9

7.2 Lifting/lowering
Lift and lower, function description
page

Condition Reference value Reference


Emergency stop Not activated Section 11 Common electrics, group 11.5.1.4 Emergency stop
switch switch voltage

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

Workshop Manual DCF 90-100 VDCF03.01GB


10 7 Load handling – 7.2 Lifting/lowering

Pos Explanation Signal description Reference


1a The lifting/lowering control lever U = 0.5-4.5 V Control levers for electric servo, de-
(R8071-P1) sends the cab control unit Lower: U = <2.5 V scription page 5
(D790-1) a voltage signal proportional to D1: Diagnostic menu, see section 8
Lift: U = >2.5 V
lever movement. Control system , group 8.4.8.1
0.5 V is the fastest lowering ELSERV, menu 1
speed and 4.5 V is the fastest lift
speed. Lower voltages than 0.5
V and higher voltages than 4.5 V
are used to detect malfunctions
in cabling and controls.

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.

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7.2 Lifting/lowering 11

Pos Explanation Signal description Reference


9 The steering shuttle valve sends the - Section 10 Common hydraulics,
load signal on to the steering hydraulic group 10.5.3 Shuttle valve
pump and load handling.

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.

15 Quick-lift UB768-L1/1 = 5 V Sensor hydraulic pressure lift cylin-


The hydraulic pressure sensor, left lift der, description page 17
UB768-L1/2 = 0 V
cylinder (B768-L1) sends the frame con- D15: Diagnostic menu, see section 8
UB768-L1/5 = 0.5-4.5 V
trol unit (D797-1) a voltage signal pro- Control system, group 8.4.5.6 HYD,
portional to oil pressure. menu 3 or group 8.4.10.1 OLS,
menu 1.

16 The frame control unit (D797-1) supplies U = 24 V Section 11 Common electrics,


voltage to the quick-lift solenoid valve group 11.5.3.2 Frame control unit
(Y6062) if the conditions for quick-lift are (D797-1)
fulfilled. D16: Diagnostic menu, see section
Conditions for quick-lift when lifting 8 Control system, group 8.4.5.6
• Pressure in lift cylinders HYD, menu 6.

• Transmission in neutral position


• Engine speed over 1200 rpm
• Damping inactive

17 The quick-lift solenoid valve (Y6062) - Valve block quick-lift, description


conducts a load signal to the hydraulic page 33
oil pump for quick-lift.

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

19 The pressure limiting valve prevents - Section 10 Common hydraulics,


pressure from becoming too high to group 10.2.4 Pressure limiting valve
Control valve lift and lower.

Workshop Manual DCF 90-100 VDCF03.01GB


12 7 Load handling – 7.2.1 Hydraulic oil pump

Pos Explanation Signal description Reference


20 Lift speed increases. - Lift cylinder, description page 17

21 Damping UB771/1 = 5 V Mast position sensor, description


When the mast is approx. 50 cm from its page 28
UB771/2 = 0 V
topmost position, damping is activated. Section 11 Common electrics,
UB771/3 = 0.5-4.5 V
The mast position sensor (B7211-2) group 11.5.3.3 Frame control unit
sends the frame control unit (D797-1) a (D797-1)
voltage signal proportional to the lift D21: Diagnostic menu, see section 8
height. The control unit then transmits a Control system , group 8.4.8.15
damping request on the CAN bus. ELSERV, menu 15.

22 The frame control unit (D797-1) deacti- - Section 11 Common electrics,


vates quick-lift and reduces the control group 11.5.3.2 Frame control unit
current to the lift solenoid valve (Y6005) (D797-1)
or the lower solenoid valve (Y6004). D3: Diagnostic menu, see section 8
Control system, group 8.4.5.6 HYD,
menu 6

23 Lift speed decreases. - Lift cylinder, description page 17

Hydraulic diagram, see section E Schematics 10 Common hydraulics,


Hydraulic diagram DCF 90-100, electric servo

7.2.1 Hydraulic oil pump


Hydraulic oil pump, general
page

See section 10 Common hydraulics , group 10.4.2 Axial piston pump


with variable displacement.

7.2.2 Servo filter


Servo filter, description
page

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

is viscous (cold or incorrect viscosity) or if the filter insert is clogged.

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7.2.3 Pressure reducer 13

7.2.3 Pressure reducer


Pressure reducer, description
page

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

1. Accumulator servo pressure


2. Pressure reducer
3. Measuring outlet
4. Pressure supply from servo filter
5. Return to tank
6. Servo pressure to control valve
7. Adjusting screw, servo pressure

Servo pressure, inspection and adjustment


page

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

Workshop Manual DCF 90-100 VDCF03.01GB


14 7 Load handling – 7.2.4 Accumulator servo circuit

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.

7.2.4 Accumulator servo circuit


Accumulator servo circuit, description
page

The accumulator stores pressurised oil and ensures that there is servo
pressure for activating control valve functions. The accumulator 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

Accumulator servo circuit

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7.2.5 Control valve, lift and tilt 15

Accumulator servo circuit, replacement


page

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.

7.2.5 Control valve, lift and tilt


Control valve, lift and tilt, description
page

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)

Workshop Manual DCF 90-100 VDCF03.01GB


16 7 Load handling – 7.2.5 Control valve, lift and tilt

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.

Lift solenoid valve


The valve is controlled electrically by the lift solenoid valve (Y6005),
which is activated by the frame control unit (D797-1). The servo valve
guides servo pressure to the lift spool. This pressure is proportional to
the control current to the solenoid valve.
The signals can be checked from the diagnostic menu, see section 8
Control system , group 8.4.8.3 ELSERV, menu 3.

Lower solenoid valve


The valve is controlled electrically by the lower solenoid valve
(Y6004), which is activated by the frame control unit (D797-1). The
servo valve guides servo pressure to the lift spool. This pressure is
proportional to the control current to the solenoid valve.
The signals can be checked from the diagnostic menu, see section 8
Control system , group 8.4.8.4 ELSERV, menu 4.

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7.2.6 Shuttle valve 17

7.2.6 Shuttle valve


Shuttle valve, description
page

See section 10 Common hydraulics , group 10.5.3 Shuttle valve.

7.2.7 Lift cylinder


Lift cylinder, description
page

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

Hydraulic cylinders, repairs


page

See section 10 Common hydraulics , group 10.7.1 Hydraulic cylinders.

7.2.8 Sensor hydraulic pressure lift


cylinder
Sensor hydraulic pressure lift cylinder, description
page

The lift cylinder hydraulic pressure sensor (B768-L1) measures the


pressure in the lift cylinders and is located on the left lift cylinder.
Pressure is measured to determined whether quick-lift can be ena-
bled. A sensor measures the pressure on the left lift cylinder.
The sensor is supplied power by and sends a voltage signal propor-
tional to hydraulic oil pressure to the frame control unit (D797-1).
The signal can be checked with the diagnostic menu, see section 8
Control system , group 8.4.5.3 HYD, menu 3 or group 8.4.10.1 OLS,
menu 1.
009917

Sensor hydraulic pressure lift cylinder piston side left


(B768-L1)

Workshop Manual DCF 90-100 VDCF03.01GB


18 7 Load handling – 7.2.8 Sensor hydraulic pressure lift cylinder

Sensor, hydraulic pressure, lift cylinder, replace


page

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

7 Clamp the cable harness as before.


8 Turn on the main electric power and start the engine.

Sensor hydraulic pressure lift cylinder 9 Activate lift carefully.

CAUTION
Air in the hydraulic system may cavitate and result in
product damage.

Activate the functions carefully and operate at the


lowest possible speed a couple of times to avoid cav-
itation.

10 Check that there are no leaks at hydraulic connections and that


lifting/lowering works properly.
11 Check the oil level in the hydraulic oil tank with the attachment ful-
ly lowered and the mast tilted in. The oil level should be at the top
of the level glass. Top up as necessary.

CAUTION
Overfilling of oil.

Leakage and environmental damage.

Check the hydraulic oil level with all hydraulic cylin-


ders fully retracted.

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7.2.9 Mast 19

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.

Workshop Manual DCF 90-100 VDCF03.01GB


20 7 Load handling – 7.2.9 Mast

2 Remove the lifting carriage; see Lifting carriage, removing page


29.
3 Connect the lifting equipment to the lifting lugs at the top of the
mast in a secure manner.
4 Start the engine and tilt the mast forwards as far as possible.
5 Stop the engine
6 Turn the start key to position I and activate the hydraulic functions
to depressurise the hydraulic system.
7 Turn the start key to position 0 and turn off the main electric pow-
er.

009974

8 Mark up and disconnect the hydraulic connections of the lift cyl-


inders.

NOTE
Plug all connections immediately to protect the hydraulic
system from impurities.
9 Mark up and detach the electrical connections of the mast.
009980

10 Mark and detach the mast’s hydraulic connections on the front


panel. Let the oil run out.

NOTE
Plug all connections immediately to protect the hydraulic
system from impurities.
009981

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7.2.9 Mast 21

11 Undo the electrical connectors for the mast.


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

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


crane).
13 Release the tilt cylinder from the mast.
Remove the cylinder shaft. If necessary, use the threaded hole
and a puller to press the shaft out.
Start the engine and retract the cylinder so that it comes loose
from the mounting in the mast. Switch off the engine.
Save the circlips. Refit the shaft in the tilt cylinder.
Lower the cylinder onto a block of wood. Then slacken and re-
move the lifting equipment (overhead crane).
Repeat the procedure for the other cylinder.
009984

14 Undo the nuts and bolts and remove the shafts which fix the mast
to the frame.
009979

Workshop Manual DCF 90-100 VDCF03.01GB


22 7 Load handling – 7.2.9 Mast

15 Release the mast from the chassis.

WARNING
The mast can swing out when it is released from the
machine.

This can cause personal injury!

Stand in the mast!

009983

16 Lift aside the mast.


009985

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

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7.2.9 Mast 23

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

5 Before mast is installed, check shafts and bearing surfaces for


deep cracks or scratches and check that the bearings have no fi-
bres that shoot out from the surface. If the shaft/bearing shows
sign of damage it must be replaced.

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

The shafts and bearings mentioned above must NEVER be


lubricated with oil or grease.
Check that seals are intact and clean.
6 Lift the mast into place. It is important that the lifting equipment is
connected to the mast’s lifting lugs in a secure manner.
009976

Workshop Manual DCF 90-100 VDCF03.01GB


24 7 Load handling – 7.2.9 Mast

7 Suspend the mast vertically. Align the mast and position the
shafts in the mast mountings.

009978

8 Fasten the shafts with bolts and lock nuts.


9 Start the engine and tilt the mast forwards as far as possible.
10 Stop the engine
11 Turn the start key to position I and activate the hydraulic functions
to depressurise the hydraulic system.
12 Turn the start key to position 0 and turn off the main electric pow-
er.
009979

13 Lift the tilt cylinders with lifting equipment (overhead crane) and
align the tilt cylinders with the mast.
009982

14 Connect the tilt cylinders to the mast.


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

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7.2.9 Mast 25

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

Flanges on outer and inner mast beam


page

Flanges on outer and inner mast beam, description


The mast and its constituent parts are made of high-strength material
and are tested under extreme operating conditions and environments
to ensure a long and problem-free life.
Despite these efforts, problems can arise due to neglected mainte-
nance, improper handling, malfunction or damage to a mast wheel,
mast or lifting carriage.
For example, lamination or pitting could occur on the mast beam
flange. This most often occurs on the inner mast, but could also occur
on the outer mast.

Workshop Manual DCF 90-100 VDCF03.01GB


26 7 Load handling – 7.2.9 Mast

Flanges on outer and inner mast beam, repair


If the surface of flanges has started to break down in small flakes, this
can be remedied so as to keep the mast in use. This is remedied by
first grinding down the affected areas and then "running in" the surface
layer.

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

Check the internal measurement between the beam’s front and


rear flange. If the measurement exceeds 252 mm for a beam that
is supposed to be 250 mm, contact Kalmar Industries.
010127C

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.

Slide plates in inner mast, adjusting


page

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.

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7.2.9 Mast 27

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

Workshop Manual DCF 90-100 VDCF03.01GB


28 7 Load handling – 7.2.10 Mast position sensor

Mast wheel, adjusting


page

1 Use a drift to tap out the spring pin (position 4).


1
NOTE
Check that the cover washer (position 3) is centred on the clamp-
2
ing screw.
3
2 Screw in the clamping screw (position 5) so that the wheel is
completely locked.

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

7.2.10 Mast position sensor


Mast position sensor, description
page

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.

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7.2.11 Lifting carriage 29

7.2.11 Lifting carriage


Lifting carriage, description
page

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°.

• Active levelling - the attachment can be levelled ± 3°.


The lifting carriage also houses the control valve for the hydraulic func-
tions of the lifting carriage and side lifting attachment.
See also Side shift cylinder, description page 40 and Levelling cylin-
der, description page 68.
009919

1. Side shift cylinder


2. Control valve attachment
3. Slide plates
4. Mast wheels
5. Levelling cylinders

Lifting carriage, removing


page

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

Workshop Manual DCF 90-100 VDCF03.01GB


30 7 Load handling – 7.2.11 Lifting carriage

5 Mark up and disconnect the carriage’s hydraulic connections. Let


the oil run out.

NOTE
Plug all connections immediately to protect the hydraulic
system from impurities.
6 Raise the carriage with the lifting equipment (overhead crane) to
slacken the chains.

009987

7 Undo the nuts and remove the chain tensioners.


8 Start the engine and tilt the mast rearwards.
9 Raise the mast enough for the carriage to release from the mast.
10 Lower the mast again.
11 Lift aside the lifting carriage. Put it on blocks and supports to pre-
vent damage to the cylinders.
12 Undo the lifting equipment (travelling crane).
009986

Lifting carriage, installing


page

NOTE
Read the safety instructions for oil before working, see section B
Safety.
1 Park the machine with the mast vertical.
2 Raise the mast high enough to position the carriage in the inner
mast and lift it into place.
3 Lower the mast so that the carriage fastens in the inner mast.
Stop the mast in a position where the chains can be fastened to
the carriage. Fit the chain tensioners and adjust and fasten with
the nuts.
4 Lower the carriage as far as possible.
5 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.

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7.2.11 Lifting carriage 31

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

Workshop Manual DCF 90-100 VDCF03.01GB


32 7 Load handling – 7.2.11 Lifting carriage

Slide plates in lifting carriage, adjusting and, if


page

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

Measure the interior width of the inner mast (A and B)


4 Use a sliding calliper to measure the external measurements be-
tween the lifting carriage slide plates.

D
010124

Measure the exterior measurements between the lift-


ing carriage slide plates (C and D).

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7.2.12 Valve block quick-lift 33

5 Adjust lifting carriage clearance by removing the screws (position


1) and adding or removing shims (position 2).
2 a) If the width at A and B is the same:

1 Adjust C and D to be equal to or max. 0.5 mm more than A.


b) If A is greater than B:
Adjust C to be equal to or max. 0.5 mm more than A.
Adjust D to be equal to or max. 0.5 mm more than B.
c) If A is less than B:
Adjust C to be equal to or max. 0.5 mm more than A.
Adjust D to be equal to or max. 0.5 mm less than B.

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.

Mast wheel, adjusting


page

For mast wheel adjustment, see Mast wheel, adjusting page 28.

7.2.12 Valve block quick-lift


Valve block quick-lift, description
page

The quick-lift valve block regulates engagement of the quick-lift hy-


draulic oil pump, see section 10 Common hydraulics, group 10.4.2 Ax-
ial piston pump with variable displacement. When the solenoid valve
for quick-lift connection (Y6062) is connected, the valve block guides
a load signal to the quick-lift hydraulic oil pump, which supplies extra
oil to the lift and tilt control valve. The valve block sits on the hydraulic
plate in front of the transmission.
The solenoid valve for quick-lift connection (Y6062) is supplied voltage
from the frame control unit (D797-1) upon activation.
009922

The signal can be checked from the diagnostic menu, see section 8
Control system, group 8.4.5.7 HYD, menu 7.

Valve block quick-lift

7.2.13 Pipes and hoses


Piped and hoses, description
page

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

Workshop Manual DCF 90-100 VDCF03.01GB


34 7 Load handling – 7.4 Side shift

7.4 Side shift


Sideshift, function description
page

Condition Reference Reference


value
Emergency stop Not activated Section 11 Common electrics, group 11.5.1.4 Emergency stop switch voltage
switch

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

Pos Explanation Signal description Reference


1a The side shift control lever (R8073- U = 0.5-4.5 V Control levers for electric servo, description
P3) sends the cab control unit (D790- Left: U = <2.5 V page 5
1) a voltage signal proportional to le- D1: Diagnostic menu, see section 8 Control
Right: U >2.5 V
ver movement. system , group 8.4.9.1 ATTACH, menu 1
0.5 V is the highest speed
for side shift left and 4.5 V is
the highest speed for side
shift right. Voltage lower
than 0.5 V and higher than
4.5 V is used to detect de-
fects in cable harnesses
and controls.

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7.4 Side shift 35

Pos Explanation Signal description Reference


1b The control lever (S815-P3) sends US815-P3 = 0.5-4.5 V Control lever, description page 6
the cab control unit (D790-1) a volt- Right: US815-P3 = <2.5 V D1: Diagnostic menu, see section 8 Control
age signal proportional to lever system, group 8.4.9.1 ATTACH, menu 1
movement. Left: US815-P3 = >2.5 V

0.5 V is the highest speed


for side shift right and 4.5 V
is the highest speed for side
shift left. Voltage lower than
0.5 V and higher than 4.5 V
is used to detect defects in
cable harnesses and con-
trols.

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.

5 The attachment shuttle valve sends - Section 10 Common hydraulics, group


the load signal on to the hydraulic oil 10.5.3 Shuttle valve
pump for load handling or the cab tilt
shuttle valve.

6 The cab tilt shuttle valve sends the - Section 10 Common hydraulics, 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

8 The attachment control unit (D791-1) U = 24 V Section 11 Common electrics, group


activates the solenoid valve for side 11.5.3.5 Attachment control unit (D791-1)
shift left (Y6020) or the solenoid valve D8: Diagnostic menu, see section 8 Control
for side shift right (Y6021). system , group 8.4.9.11 ATTACH, menu 11
and group 8.4.9.12 ATTACH, menu 12

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.

Workshop Manual DCF 90-100 VDCF03.01GB


36 7 Load handling – 7.4.1 Hydraulic oil pump

Pos Explanation Signal description Reference


10 The control valve’s side shift spool - Control valve attachment, description page
changes position and pressurizes the 36
side shift cylinders.

11 The side shift cylinders push in the - Side shift cylinder, description page 40
main beam sideways in relation to the
lifting carriage.

Hydraulic diagram, see section E Schematics 10 Common hydraulics,


Hydraulic diagram DCF 90-100, electric servo

7.4.1 Hydraulic oil pump


Hydraulic oil pump, general
page

See section 10 Common hydraulics , group 10.4.2 Axial piston pump


with variable displacement.

7.4.2 Control valve attachment


Control valve attachment, description
page

1
2 6
4
5
7
8
10 9
11
13
14
12

15
009936

16 17

10 Solenoid valve, lock twistlock/lock tongue (Y6040)


1 Solenoid valve, levelling left (Y6036)
11 Solenoid valve, open twistlock/lock tongue (Y6039)
2 Solenoid valve, levelling right (Y6035)
12 Connection to lock cylinders
3 Connection to levelling cylinders
4 Solenoid valve spreading in right (Y6019R) 13 Solenoid valve, sideshift left (Y6020)
5 Solenoid valve spreading out right (Y6018R) 14 Solenoid valve, side shift right (Y6021)
6 Connection to spreading cylinder right 15 Connection to sideshift cylinder
7 Solenoid valve spreading in left (Y6019L) 16 Connection return to tank (T)

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7.4.2 Control valve attachment 37

8 Solenoid valve spreading out left (Y6018L) 17 Connection, feed from hydraulic oil pump (P)
9 Connection to spreading cylinder left

The attachment control valves controls hydraulic functions on the at-


tachment. The control valve is located at the top of the lifting carriage.
Electric solenoid valves control the flow from the valve.
The control valve is an electro-hydraulically controlled, proportional
and pressure-compensated directional valve. Electrically controlled
solenoid valves convert current to servo pressure. The servo pressure
controls the spring-centred valve spools, which control pressure and
flow for the function in question. The valve spools have a flow limit so
that several functions can be used simultaneously. This enables them
to control main flow.
The control valve has built-in supply of pilot pressure. This means that
the valve has a built-in pressure reduction which converts feed pres-
sure to servo pressure for the various functions. Supply of pilot pres-
sure is common for all functions. This reduces pressure variations due
to long hoses and reduces the number of hoses to the valve.
The control valve has the following sections:

• Levelling
• Spreading right extension beam
• Spreading left extension beam
• Twistlocks/lock tongues
• Side shift

Side shift spool


The valve spool controls side shift direction and speed.
The valve spool is controlled by a solenoid valve for side shift right and
a solenoid valve for side shift left.

Solenoid valve, side shift left


The solenoid valve for side shift left controls pressure to the side shift
spool so that the side shift spool opens and pressurises the side shift
cylinder.
The solenoid valve for side shift lift (Y6020) 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 8.4.9.11 ATTACH, menu 11.

Solenoid valve, side shift right


The solenoid valve for side shift right controls pressure to the side shift
spool so that the side shift spool opens and pressurises the side shift
cylinder.

Workshop Manual DCF 90-100 VDCF03.01GB


38 7 Load handling – 7.4.2 Control valve attachment

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.

Control valve attachment, 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 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

7 Mark up the solenoid valves on the new control valve.


8 Lift the valve into place and fit the attaching bolts.
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 Turn on the main electric power and start the engine.
12 Check that the valve's hydraulic connections are sealed.

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7.4.2 Control valve attachment 39

13 Check that the attachment is working.

CAUTION
Air in the hydraulic system may cavitate and result in
product damage.

Activate the functions carefully and operate at the


lowest possible speed a couple of times to avoid
cavitation.

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.

Leakage and environmental damage.

Check the hydraulic oil level with all hydraulic pistons


fully retracted.

Control valve attachment, checking hydraulic


page

pressure

NOTE
Read the safety instructions for oil before working, see section B
Safety.

1 Operate and warm up the machine so that the hydraulic oil is at


operating temperature, at least 50 °C. As an alternative, operate
until the cooling fan is activated.
˚C 2 Stop the engine
3 Machine in service position, see section B Safety.
˚C
000475

Operating menu hydraulic oil temperature

Workshop Manual DCF 90-100 VDCF03.01GB


40 7 Load handling – 7.4.3 Side shift cylinder

4 Connect a pressure gauge to pressure check connection LS on


the attachment control valve.
5 Start the engine and let it idle. Check the pressures in the attach-
ment’s different functions by letting each function go to its end-
position, then read off the pressure gauge.
The pressures should be:

Function Pressure

Side shift 13.0 MPa

Spreading right extension 13.0 MPa


beam
009950
Spreading left extension 13.0 MPa
beam

20.0 MPa
Pressure check connection control valve attachment Levelling

Twistlocks/lock tongues Same as feed pressure.

6 Remove the pressure gauge and fit the protective cap on the
measuring outlet.

7.4.3 Side shift cylinder


Side shift cylinder, description
page

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

1. Side shift cylinder

Hydraulic cylinders, repairs


page

See section 10 Common hydraulics , group 10.7.1 Hydraulic cylinders.

7.4.4 Shuttle valve


Shuttle valve, description
page

See section 10 Common hydraulics , group 10.5.3 Shuttle valve.

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7.4.5 Lifting carriage 41

7.4.5 Lifting carriage


Lifting carriage, description
page

See Lifting carriage, description page 29.

Slide plates in lifting carriage, adjusting/replacing


page

1 Park the machine with the attachment lowered as far as possible


and spreading run all the way in.
2 Turn off the engine and the main electrical power.
3 Take the strain off the glide plate in question.
The pressure can be relieved from the slide plates by raising the
outer edge of the side lifting attachment or inserting wedges to al-
ter the position of the side lifting attachment in the lifting beam.
4 Remove the attaching bolts for the glide plate’s bracket.
1 5 Remove the guide plate’s guide pin.
6 Pull out the glide plate with spacer plate and bracket.
7 Measure the thickness of the slide plate. Replace if necessary.

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

Do not add too many shims as this increases slide plate


wear.
The illustration depicts slide and roller plates on a lift-
ing carriage with mechanical levelling. NOTE
1. Slide and roller plates
Check that the attaching bolts for all glide plates are
2. Attaching bolts and steering screws for slide and
tightened.
roller plates
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 side lifting attachment.
12 Start the machine and check the function of the side lifting attach-
ment. Try lifting a container and then recheck the side lifting at-
tachment’s clearance in the lifting carriage.

Workshop Manual DCF 90-100 VDCF03.01GB


42 7 Load handling – 7.4.6 Valve block, main pump relief

7.4.6 Valve block, main pump relief


Valve block, main pump relief, description
page

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.

7.4.7 Attachment relief valve


Attachment relief valve, description
page

The attachment relief valve opens the connection between the attach-
ment’s pressure supply and the tank. This is used to drain the pressure
in the attachment hoses prior to work on the hydraulic system. The re-
lief valve sits on the spacer block at the hydraulic oil pump for load
handling.
009961

The illustration depicts an open valve

7.4.8 Pipes and hoses


Piped and hoses, description
page

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

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7.5 Spreading 43

7.5 Spreading
Spreading, function description
page

Condition Reference value Reference


Emergency stop switch Not activated Section 11 Common electrics, group 11.5.1.4 Emergency stop switch
voltage

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

D797-1 D791-1 8,9,17,18


3
D8 D9

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

Pos Explanation Signal description Reference


1a The switch for spreading 20’-40’ U = 24 V Switch, spreading 20’-40’, description page 7
(S1012) sends a voltage signal to D1: Diagnostic menu, see section 8 Control
the cab control unit (D790-1). system , group 8.4.9.3 ATTACH, menu 3

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

In: US815-T1.1 = 24V

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.

Workshop Manual DCF 90-100 VDCF03.01GB


44 7 Load handling – 7.5 Spreading

Pos Explanation Signal description Reference


3 The frame control unit (D797-1) ac- U = 24 V Section 11 Common electrics, group 11.5.3.3
tivates the solenoid valve for main Frame control unit
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 - 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.

13 Left spreader cylinder pushes left - Spreading cylinder, description page 51


spreader beam in or out in the at-
tachment

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7.5 Spreading 45

Pos Explanation Signal description Reference


14 Right spreader cylinder pushes right - Spreading cylinder, description page 51
spreader beam in or out in the at-
tachment

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.

22 Spreader speed decreases. - Position sensor spreading, description page 58

Hydraulic diagram, see section E Schematics 10 Common hydraulics,


Hydraulic diagram DCF 90-100, electric servo

Workshop Manual DCF 90-100 VDCF03.01GB


46 7 Load handling – 7.5 Spreading

30-foot stop, function description


page

Condition Reference val- Reference


ue
Emergency stop switch Not activated Section 11 Common electrics, group 11.5.1.4 Emergency stop switch
voltage

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

Pos Explanation Signal description Reference


1 The switch for stop at 30’ (S1004) Switch in on position: Switch, stop at 30’, description page 8
sends a voltage signal to the cab con- Conn. 1: U = 0 V D1: Diagnostic menu, see section 8 Control
trol unit (D790-1). system, group 8.4.9.2 ATTACH, menu 3
Conn 5: U = 24 V
Switch in off position:
Conn 1: U = 24 V
Conn 5: U = 24 V

2a The switch for spreading 20’-40’ U = 24 V DC Switch, spreading 20’-40’, description 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

In: US815-T1.1 = 24V

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7.5 Spreading 47

Pos Explanation Signal description Reference


3 The cab control unit (D790-1) transmits Checked by control sys- Section 11 Common electrics, group
spreading 30’ on the CAN bus. tem, error shown with er- 11.5.3.1 Cab control unit (D790-1)
ror code.

4 Spreading is activated in the same way - Spreading, function description page 43


as the normal spreading steps 3–14.

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).

7 The attachment control unit (D791-1) - Spreading, function description page 43


dampens the speed the same way as in
steps 17–22 of normal spreading.

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).

Hydraulic diagram, see section E Schematics 10 Common hydraulics,


Hydraulic diagram DCF 90-100, electric servo

Workshop Manual DCF 90-100 VDCF03.01GB


48 7 Load handling – 7.5 Spreading

Automatic spreading 20-40 foot, function


page

description

Condition Reference value Reference


Emergency stop switch Not activated Section 11 Common electrics, group 11.5.1.4 Emergency stop switch
voltage

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

Pos Explanation Signal description Reference


1a. The switch for spreading 20’-40’ U = 24 V DC Switch, spreading 20’-40’, description page 7
(S1012) sends a voltage signal to D2: Diagnostic menu, see section 8 Control
the cab control unit (D790-1). system , group 8.4.9.3 ATTACH, menu 3

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

In: US815/T1.1 = 24V

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

Switch in off position:


US199-2/2 = 24 V

US199-2/5 = 24 V

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7.5 Spreading 49

Pos Explanation Signal description Reference


3 The cab control unit (D790-1) trans- Checked by control sys- Section 11 Common electrics, group 11.5.3.1
mits "automatic spreading out" or tem, error shown with error Cab control unit (D790-1)
"automatic spreading in" on the CAN code.
bus.

4 The attachment control unit (D791- - Spreading, function description page 43


1) activates spreading the same way
as in steps 3-14 of normal
spreading.

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.

7 When automatic spreading is active, - Section 11 Common electrics, group 11.5.3.12


the KID control unit (D795) activates KID control unit (D795)
the Automatic Spreading event
menu.

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)

Workshop Manual DCF 90-100 VDCF03.01GB


50 7 Load handling – 7.5.1 Hydraulic oil pump

Pos Explanation Signal description Reference


11 The attachment control unit (D791- I = 0 mA Section 11 Common electrics, group 11.5.3.5
1) cuts off the current to the solenoid Attachment control unit (D791-1)
valve for spreading out left (Y6018L) D11: Diagnostic menu, see section 8 Control
or the solenoid valve for spreading in system, group 8.4.9.17 ATTACH, menu 17
left (Y6019L). and 8.4.9.18 ATTACH, menu 18

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

Hydraulic diagram, see section E Schematics 10 Common hydraulics,


Hydraulic diagram DCF 90-100, electric servo

7.5.1 Hydraulic oil pump


Hydraulic oil pump, general
page

See section 10 Common hydraulics , group 10.4.2 Axial piston pump


with variable displacement.

7.5.2 Control valve attachment


Control valve attachment, description
page

Spreading is regulated by a separate section in the attachment’s con-


trol valve. For a more detailed description of the valve and component
locations, see Control valve attachment, description page 36.

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.

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7.5.3 Spreading cylinder 51

Solenoid valve for spreading out


The solenoid valve for spreading out controls pressure to the spreader
spool so that it opens and pressurises the spreader cylinder.
The servo valve is controlled electrically by the solenoid valve for
spreading out left (Y6018L) or the solenoid valve for spreading out
right (Y6018R) which are activated by the attachment control unit
(D791-1). The servo valve routes servo pressure to the spreader spool
in proportion to the control current to the solenoid valve.
The signal can be checked with diagnostic menu.
• Left: section 8 Control system, group 8.4.9.13 ATTACH, menu 17
• Right: section 8 Control system, group 8.4.9.15 ATTACH, menu
19

Solenoid valve for spreading in


The solenoid valve for spreading in controls pressure to the spreader
spool so that it opens and pressurises the spreader cylinder.
The servo valve is controlled electrically by the solenoid valve for
spreading in left (Y6019L) or the solenoid valve for spreading in right
(Y6019R) which are activated by the attachment control unit (D791-1).
The servo valve routes servo pressure to the spreader spool in propor-
tion to the control current to the solenoid valve.
The signal can be checked with diagnostic menu.
• Left: section 8 Control system, group 8.4.9.14 ATTACH, menu 18
• Right: section 8 Control system, group 8.4.9.16 ATTACH, menu
20

Control valve attachment, replacement


page

See Control valve attachment, replacement page 38.

7.5.3 Spreading cylinder


Spreading cylinder, description
page

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

Workshop Manual DCF 90-100 VDCF03.01GB


52 7 Load handling – 7.5.4 Spreader beam

7.5.4 Spreader beam


Spreader beam, description
page

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

Spreader beam slide plates, adjusting/replacing


page

1 Park the machine with the attachment lowered as far as possible


and spreading run all the way in.
2 Turn off the engine and the main electrical power.
3 Take the strain off the glide plate in question.
1
The pressure can be relieved from the slide plates by raising the
outer edge of the spreader beam or inserting wedges to alter the
position of the spreader beam in the attachment’s main beam.
4 Remove the attaching bolts for the glide plate’s bracket.
5 Remove the guide plate’s guide pin.
6 Pull out the glide plate with spacer plate and bracket.
7 Measure the thickness of the slide plate. Replace if necessary.

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.

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7.5.5 Main beam, side lifting attachment 53

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.

7.5.5 Main beam, side lifting attachment


Side lifting attachment’s main beam, description
page

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

Side lifting attachment, removing


page

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

Workshop Manual DCF 90-100 VDCF03.01GB


54 7 Load handling – 7.5.5 Main beam, side lifting attachment

3 Connect lifting equipment (overhead crane) to the attachment in


a secure manner.
4 Start the engine and lift slightly with the lifting equipment (over-
head crane). Let the machine run with the ignition on for a little bit.
5 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

7 Fasten the side shift cylinder.


8 Turn the start key to position I and activate the hydraulic functions
to depressurise the hydraulic system.
9 Turn the start key to position 0 and turn off the main electric
power.
009997

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

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7.5.5 Main beam, side lifting attachment 55

11 Detach the cable harness of the attachment from the attachment


control unit.
Undo the connectors and protect the terminals by greasing them
with contact grease. Then loosely insert the connectors.
Remove the cable harness clamping ring.

12 Detach the front panels’ upper mounting in the lifting carriage.


Use a lifting device to lower them forward and release the side lift-
ing attachment.
009953

13 Lift aside the side lifting attachment. Position it so that the twist-
locks/lock tongues are not damaged.
009999

Workshop Manual DCF 90-100 VDCF03.01GB


56 7 Load handling – 7.5.5 Main beam, side lifting attachment

Side lifting attachment, installing


page

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

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7.5.5 Main beam, side lifting attachment 57

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

Workshop Manual DCF 90-100 VDCF03.01GB


58 7 Load handling – 7.5.6 Position sensor positioning

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.

Leakage and environmental damage.

Check the hydraulic oil level with all hydraulic cylin-


ders fully retracted.

7.5.6 Position sensor positioning


Position sensor spreading, description
page

The spreading position sensors indicates the position of the spreader


3 4 5
2 beams. The position sensors are used to control spreading so that the
1 twistlocks/lifting hooks fit the container. The position sensors are locat-
ed under the protective plate on the back of the attachment’s main
beam.
The sensor for end position 20’ and 40’ (B769R and B769L) indicate
the end position for a 20-foot and 40-foot container. The sensor de-
2 tects the end positions of the spreader beams through two indicator
plates on the top of the spreader beam. The sensor is used to activate
1
009928

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.

Position sensor, checking and adjustment


page

See Position sensor, adjusting page 4.

7.5.7 Buzzer, automatic spread 20'-40'


Buzzer automatic spreading 20’-40’, description
page

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.

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7.5.8 Pipes and hoses 59

7.5.8 Pipes and hoses


Piped and hoses, description
page

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

Workshop Manual DCF 90-100 VDCF03.01GB


60 7 Load handling – 7.7 Tilt

7.7 Tilt
Tilt, function description
page

Condition Reference value Reference


Emergency stop switch Not activated Section 11 Common electrics, group 11.5.1.4 Emergency stop switch
voltage

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

Pos Explanation Signal description Reference


1 The hydraulic oil pumps pump oil from See pressure plate on left Section 10 Common hydraulics, group
the hydraulic oil tank. frame beam. 10.4.2 Axial piston pump with variable
displacement

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.

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7.7 Tilt 61

Pos Explanation Signal description Reference


5a The tilt control lever (R8072-P2) sends U = 0.5-4.5 V Control levers for electric servo, description
the cab control unit (D790-1) a voltage Out: U = <2.5 V page 5
signal proportional to lever movement. D5: Diagnostic menu, see section 8 Control
In: U = >2.5 V
system , group 8.4.8.1 ELSERV, menu 1
0.5 V is the fastest speed
for tilt out and 4.5 V is the
fastest speed for tilt in.
Voltages lower than 0.5 V
and voltages higher than
4.5 V are used to detect
malfunctions in cables
and controls.

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

0.5 V is the highest speed


for tilt in and 4.5 V is the
highest speed for tilt out.
Voltage lower than 0.5 V
and voltage higher than
4.5 V is used to detect de-
fects in cables and con-
trols.

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

Hydraulic diagram, see section E Schematics 10 Common hydraulics,


Hydraulic diagram DCF 90-100, electric servo

Workshop Manual DCF 90-100 VDCF03.01GB


62 7 Load handling – 7.7.1 Hydraulic oil pump

7.7.1 Hydraulic oil pump


Hydraulic oil pump, general
page

See section 10 Common hydraulics , group 10.4.2 Axial piston pump


with variable displacement.

7.7.2 Accumulator
Accumulator, description
page

See section 10 Common Hydraulics , group 10.3.2 Accumulator.

7.7.3 Pressure reducer


Pressure reducer, description
page

See Pressure reducer, description page 13.

7.7.4 Servo filter


Servo filter, description
page

See Servo filter, description page 12.

7.7.5 Control valve, lift and tilt


Control valve, lift and tilt, 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.

Solenoid valve, tilt out


On machines with electric servo, the solenoid valve for tilt out is con-
trolled electrically by the solenoid valve for tilt out (Y6010), which is ac-
tivated by the frame control unit, option (ECU D797-1). The solenoid
valve directs the servo pressure to the tilt spool. This pressure is pro-
portional to the control current to the solenoid valve.
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.8.6 ELSERV, menu 6.

Solenoid valve, tilt in


On machines with electric servo, the solenoid valve for tilt in is control-
led electrically by the solenoid valve for tilt in (Y6011), which is activat-
ed by the frame control unit, option (ECU D797-1). The solenoid valve
directs the servo pressure to the tilt spool. This pressure is proportion-
al to the control current to the solenoid valve.
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.8.5 ELSERV, menu 5.

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7.7.6 Load retention valve 63

7.7.6 Load retention valve


Load holding valve, description
page

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

Load retention valve

7.7.7 Tilt cylinder


Tilt cylinder, description
page

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

Workshop Manual DCF 90-100 VDCF03.01GB


64 7 Load handling – 7.7.8 Mast

Hydraulic cylinders, repairs


page

See section 10 Common hydraulics , group 10.7.1 Hydraulic cylinders.

7.7.8 Mast
Lift masts, description
page

See Lift masts, description page 19.

7.7.9 Pipes and hoses


Piped and hoses, description
page

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

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7.8 Levelling 65

7.8 Levelling
Mechanical levelling, function description
page

Mechanical levelling is possible because the attachment’s main beam


is movably suspended over the slide plates in the main beam. A lateral
clearance allows for mechanical levelling ±3°. Mechanical levelling
means that the attachment is in a float position and adapts to the angle
of the container to be lifted.

Active levelling, function description


page

Condition Reference Reference


value
Emergency stop Not activated Section 11 Common electrics, group 11.5.1.4 Emergency stop switch voltage
switch

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

Pos Explanation Signal description Reference


1a The levelling control lever (R8075-1- U = 0.5-4.5 V Control levers for electric servo, description
P5) sends a voltage signal to the cab Left: U = <2.5 V page 5
control unit (D790-1). D1: Diagnostic menu, see section 8 Control
Right: U >2.5 V
system , group 8.4.9.2 ATTACH, menu 2

Workshop Manual DCF 90-100 VDCF03.01GB


66 7 Load handling – 7.8 Levelling

Pos Explanation Signal description Reference


1b Control lever S815-P3 transmits a US815-P3 = 0.5-4.5 V Control lever, description page 6
voltage signal proportional to lever Left: US815-P3 <2.5 V D1: Diagnostic menu, see section 8 Control
movement while control lever S815- system , group 8.4.9.1 ELSERV, menu 1
P4 sends voltage to the cab control Right: US815-P3 = >2.5 V
unit (D790-1). US815-T4 = 24 V

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.

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7.8.1 Hydraulic oil pump 67

Hydraulic diagram, see section E Schematics 10 Common hydraulics,


Hydraulic diagram DCF 90-100, electric servo

7.8.1 Hydraulic oil pump


Hydraulic oil pump, general
page

See section 10 Common hydraulics , group 10.4.2 Axial piston pump


with variable displacement.

7.8.2 Control valve attachment


Control valve attachment, description
page

Levelling is regulated by a separate section in the attachment control


valve. For a general description of the valve and component locations,
see Control valve attachment, description page 36.

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).

Solenoid valve, levelling right


The solenoid valve for levelling right controls pressure to the levelling
spool so that it opens and pressurises the levelling cylinders.
The solenoid valve for levelling right is regulated electrically by the so-
lenoid valve for levelling right (Y6035), which is activated by the at-
tachment control unit (D791-1). The solenoid valve directs servo
pressure to the levelling spool.
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.9.16 ATTACH, menu 16.

Solenoid valve, levelling left


The solenoid valve for levelling left controls pressure to the levelling
spool so that it opens and pressurises the levelling cylinders.
The solenoid valve for levelling left is regulated electrically by the so-
lenoid valve for levelling left (Y6036), which is activated by the attach-
ment control unit (D791-1). The solenoid valve directs servo pressure
to the levelling spool.
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.9.16 ATTACH, menu 16.

Control valve attachment, replacement


page

See Control valve attachment, replacement page 38.

Workshop Manual DCF 90-100 VDCF03.01GB


68 7 Load handling – 7.8.3 Levelling cylinder

7.8.3 Levelling cylinder


Levelling cylinder, description
page

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

Hydraulic cylinders, repairs


page

See section 10 Common hydraulics , group 10.7.1 Hydraulic cylinders.

7.8.4 Lifting carriage


Lifting carriage, description
page

Se Lifting carriage, description page 29

7.8.5 Valve block, main pump relief


Valve block, main pump relief, description
page

Se Valve block, main pump relief, description page 42

7.8.6 Pipes and hoses


Pipes and hoses, description
page

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

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7.9 Load carrier 69

7.9 Load carrier


7.9.1 Twistlocks
Twistlocks, description
page

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.

Workshop Manual DCF 90-100 VDCF03.01GB


70 7 Load handling – 7.9.1 Twistlocks

Twistlocks, function description


page

Condition Reference value Reference


Emergency stop Not activated Section 11 Common electrics , group 11.5.1.4 Emergency stop
switch switch voltage

Alignment Full contact or bypass activated Twistlocks, description page 75


Section 8 Control system , group 8.2.2 Bypassing

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

Pos Explanation Signal description Reference


1 The switch for locking the twistlocks U = 24 V Switch, lock twistlock/lock tongue, descrip-
(S1003) (automatic mode) sends a volt- tion page 7
age signal to the cab control unit (D790- D1: Diagnostic menu, see section 8 Control
1). system , group 8.4.9.5 ATTACH, menu 5

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7.9.1 Twistlocks 71

Pos Explanation Signal description Reference


2a The switch for opening the twistlocks U = 24 V Switch, lock twistlock/lock tongue, descrip-
(S1002) sends a voltage signal to the tion page 7
cab control unit (D790-1) for twistlock D2: Diagnostic menu, see section 8 Control
opening. system , group 8.4.9.5 ATTACH, menu 5
If the "lock twistlocks" switch (S1003) is
in the manual position, a signal from the
"open twistlocks" switch (S1002) is not
needed to open the twistlocks.

2b The control lever (S815-T2) sends a US815/T2 = 24 V Control lever, description page 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.

Workshop Manual DCF 90-100 VDCF03.01GB


72 7 Load handling – 7.9.1 Twistlocks

Pos Explanation Signal description Reference


12 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.

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

14 The attachment control unit (D791-1) U = 24 V Section 11 Common electrics, group


activates the "open twistlocks" solenoid 11.5.3.5 Attachment control unit (D791-1)
valve (Y6039) or the "lock twistlocks" so- D14: Diagnostic menu, see section 8 Control
lenoid valve (Y6040). system , group 8.4.9.9 ATTACH, menu 9

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.

17 The overcentre valve prevents the un- -


controlled opening or closing of the
twistlocks.

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)

Hydraulic diagram, see section E Schematics 10 Common hydraulics,


Hydraulic diagram DCF 90-100, electric servo

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7.9.1.1 Hydraulic oil pump 73

7.9.1.1 Hydraulic oil pump


Hydraulic oil pump, general
page

See section 10 Common hydraulics , group 10.4.2 Axial piston pump


with variable displacement.

7.9.1.2 Control valve attachment


Control valve attachment, description
page

Twistlocks are regulated by a separate section in the attachment’s


control valve. For a general description of the valve and component lo-
cations, see Control valve attachment, description page 36.

Twistlock spool, description


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

"Lock twistlocks" solenoid valve, description


The "lock twistlocks" solenoid valve directs pressure to the twistlock
spool so that the spool opens and pressurises the lock cylinders.
The "lock twistlocks" solenoid valve is regulated electrically with the
"lock twistlocks" solenoid valve (Y6040), which is activated by the at-
tachment control unit (D791-1). The solenoid valve then directs servo
pressure to the twistlock spool.
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.9.9 ATTACH, menu 9.

"Open twistlocks" solenoid valve, description


The "open twistlocks" solenoid valve directs pressure to the twistlock
spool so that the spool opens and pressurises the lock cylinders.
The "open twistlocks" solenoid valve is regulated electrically with the
"open twistlocks" solenoid valve (Y6039), which is activated by the at-
tachment control unit (D791-1). The solenoid valve then directs servo
pressure to the twistlock spool.
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.9.9 ATTACH, menu 9.

Control valve attachment, replacement


page

See Control valve attachment, replacement page 38.

Workshop Manual DCF 90-100 VDCF03.01GB


74 7 Load handling – 7.9.1.3 Twistlock overcentre valve

7.9.1.3 Twistlock overcentre valve


Twistlock overcentre valve, description
page

The overcentre valve prevents the uncontrolled opening or closing of


the twistlocks. The valve sits to the left of the attachment control valve
on the lifting carriage.

009931

7.9.1.4 Lock cylinder


Lock cylinder, description
page

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

Hydraulic cylinders, repairs


page

See section 10 Common hydraulics , group 10.7.1 Hydraulic cylinders.

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7.9.1.5 Lock mechanism 75

7.9.1.5 Lock mechanism


Lock mechanism, description
page

The lock mechanism transfers the force of the lock cylinders to the
twistlocks. Two lock mechanisms - one in the right and one in the left
spreader beam - actuate the twistlocks. The lock mechanism operates
in the 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!

Twistlocks hold the load during load handling and


therefore it is very important that twistlocks are
checked according to instructions and are replaced at
the slightest sign of damage or wear.
009774

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.

Workshop Manual DCF 90-100 VDCF03.01GB


76 7 Load handling – 7.9.1.6 Twistlocks

Twistlock, replacement
page

1 Machine in service position, see section B Safety.


2 Depressurize the hydraulic systems, See section B Safety.
3 Clean the twistlocks and the surrounding area.
4 Slacken the screws of the clamp holding the twistlocks in place.
5 Hold the twistlock while removing the clamp halves.

WARNING
Twistlocks are heavy. Risk of crushing, product dam-
age.

6 Remove the clamp halves and lift away the twistlock.


009958

7 Fit a new twistlock and secure it with the clamp halves.

NOTE
Remember the washer.
8 Check the positions of the parts and that the 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

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7.9.1.7 Sensor alignment 77

7.9.1.7 Sensor alignment


Sensor alignment, description
page

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

Alignment sensor, checking and adjusting


page

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

Workshop Manual DCF 90-100 VDCF03.01GB


78 7 Load handling – 7.9.1.8 Sensor twistlocks

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

7.9.1.8 Sensor twistlocks


Sensor twistlocks, description
page

The twistlocks sensors (B7204L, B7204R, B7205L and B7205R) de-


tect when the twistlocks are locked/unlocked. Four inductive position
sensors - two on each spreader beam - detect the position of the lock
mechanism.
Both sides function the same way independently of one another. An
indicator plate sits on the lock mechanism at the lock cylinder. When
the lock mechanism is in the position that locks the twistlocks, one of
the sensors sends a signal to the attachment control unit (D791-1).
When the lock mechanism is in the position that unlocks the twistlocks,
the other sensor sends a signal to the attachment control unit (D791-
1). No signals are sent if the lock mechanism stops midway.
The sensors are supplied power and send a 24 V signal to the attach-
ment control unit (D791-1) when the indicator plate is in front of the
sensor.
1 The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.9.8 ATTACH, menu 8.

2
009934

1. "Locked twistlock" sensor


2. "Unlocked twistlock" sensor

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7.9.1.9 Valve block, main pump relief 79

Twistlocks sensor, checking and adjusting


page

1 Check that the sensors are free of damage and dirt.


2 Turn the start key to position I and check that the LED on the "un-
locked twistlock" sensor is lit.
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
±1 mm.
3 Check that the "twistlocks open" indicator light is lit.
4 Lower the attachment over a container and lock the twistlocks.
5 Check that the LED on the "locked twistlock" sensor is lit.

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

7.9.1.9 Valve block, main pump relief


Valve block, main pump relief, description
page

Se Valve block, main pump relief, description page 42

7.9.1.10 Pipes and hoses


Piped and hoses, description
page

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

Workshop Manual DCF 90-100 VDCF03.01GB


80 7 Load handling – 7.9.2 Lifting hook

7.9.2 Lifting hook


Lifting hook, description
page

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.

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7.9.2 Lifting hook 81

Lifting hook, function description


page

Condition Reference value Reference


Emergency stop Not activated Section 11 Common electrics , group 11.5.1.4 Emergency stop
switch switch voltage

Alignment Full contact or bypass activated Lifting hook, description page 89


Section 8 Control system , group 8.2.2 Bypassing

2b 1
D1

2a
8,23 21
D2 9
6
D790-1 D790-2 D795

D4 D21
D797-1 D791-1
5,7,15,22
10
D15 4

D10 16 D20 D3 19 3

P1 A

18 20
11 B
T1

17
12 19 3
C 4
14 13

009959

Pos Explanation Signal description Reference


1 The switch for locking the lock tongue U = 24 V Switch, lock twistlock/lock tongue, descrip-
(S1003) (automatic mode) sends a volt- tion page 7
age signal to the cab control unit (D790- D1: Diagnostic menu, see section 8 Control
1). system , group 8.4.9.5 ATTACH, menu 5

Workshop Manual DCF 90-100 VDCF03.01GB


82 7 Load handling – 7.9.2 Lifting hook

Pos Explanation Signal description Reference


2a The switch for opening the lock tongue U = 24 V Switch, lock twistlock/lock tongue, descrip-
(S1002) sends a voltage signal to the tion page 7
cab control unit (D790-1) for lock tongue D2: Diagnostic menu, see section 8 Control
opening. system , group 8.4.9.5 ATTACH, menu 5
If the switch for locking the lock tongue
(S1003) is in the manual position, a sig-
nal from the "open lock tongue" switch
(S1002) is not needed to open the lock
tongues.

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.

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7.9.2 Lifting hook 83

Pos Explanation Signal description Reference


10 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). D10: Diagnostic menu, see section 8 Control
system , group 8.4.5.6 HYD, menu 6

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

15 The attachment control unit (D791-1) U = 24 V Section 11 Common electrics, group


activates the "open lock tongue" sole- 11.5.3.5 Attachment control unit (D791-1)
noid valve (Y6039) or the "lock lock D15: Diagnostic menu, see section 8 Control
tongue" solenoid valve (Y6040). system , group 8.4.9.9 ATTACH, menu 9

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.

18 Pilot-controlled non-return valves pre- - Pilot-controlled non-return valve for lock


vent the uncontrolled opening or closing tongue, description page 86
of the lock tongues.

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).

Workshop Manual DCF 90-100 VDCF03.01GB


84 7 Load handling – 7.9.2 Lifting hook

Pos Explanation Signal description Reference


21 The attachment control unit (D791-1) U = 24 V D21: Diagnostic menu, see section 8 Control
supplies voltage to the "unlocked lock system , group 8.4.9.10 ATTACH, menu 10
tongues" indicator light (H562) or the
"locked lock tongues" indicator light
(H563) on the mast light panel.

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.

Hydraulic diagram, see section E Schematics 10 Common hydraulics,


Hydraulic diagram DCF 90-100, electric servo

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7.9.2.1 Hydraulic oil pump 85

7.9.2.1 Hydraulic oil pump


Hydraulic oil pump, general
page

See section 10 Common hydraulics , group 10.4.2 Axial piston pump


with variable displacement.

7.9.2.2 Control valve attachment


Control valve attachment, description
page

The lock tongues are regulated by a separate section in the attach-


ment’s control valve. For a general description of the valve and com-
ponent locations, see Control valve attachment, description page 36.

Lock tongue spool, description


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

"Lock lock tongue" solenoid valve, description


The "lock lock tongue" solenoid valve directs pressure to the lock
tongue spool so that the spool opens and pressurises the lock
cylinders.
The valve spool is regulated electrically by the "lock lock tongues" so-
lenoid valve (Y6040), which is activated by the attachment control unit
(D791-1). The solenoid valve then directs servo pressure to the lock
tongue spool.
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.9.9 ATTACH, menu 9.

"Open lock tongue" solenoid valve, description


The solenoid valve for lock tongue opening controls pressure to the
lock tongue spool so that it opens and pressurises the lock cylinders.
The valve spool is regulated electrically by the "open lock tongues" so-
lenoid valve (Y6039), which is activated by the attachment control unit
(D791-1). The solenoid valve then directs servo pressure to the lock
tongue spool.
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.9.9 ATTACH, menu 9.

Control valve attachment, replacement


page

See Control valve attachment, replacement page 38.

Workshop Manual DCF 90-100 VDCF03.01GB


86 7 Load handling – 7.9.2.3 Pilot-controlled non-return valve for lock tongue

7.9.2.3 Pilot-controlled non-return valve for


lock tongue
Pilot-controlled non-return valve for lock tongue,
page

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

7.9.2.4 Lock cylinder


Lock cylinder, description
page

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

Hydraulic cylinders, repairs


page

See section 10 Common hydraulics , group 10.7.1 Hydraulic cylinders.

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7.9.2.5 Lock mechanism 87

7.9.2.5 Lock mechanism


Lock mechanism, description
page

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

1. Lock cylinder mounting


2. Lock cylinder
3. Shaft bolt
3. Lock tongue

7.9.2.6 Lock tongue


Lock tongue, description
page

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)

Workshop Manual DCF 90-100 VDCF03.01GB


88 7 Load handling – 7.9.2.6 Lock tongue

Lock tongue, replacement


page

1 Machine in service position, see section B Safety.


2 Depressurize the hydraulic systems, See section B Safety.
3 Clean the lock tongues and the area surrounding them.
4 Detach the lock cylinder mounting in the lock tongue (position 1).
5 Remove the shaft bolt (position 1), which acts like the lock
tongue’s hinge.
6 Hold the lock tongue while removing the shaft bolt.
2

1
009942
WARNING
Lock tongues are heavy. Risk of crushing, product
1. Lock cylinder mounting damage.
2. Shaft bolt for lock tongue

7 Remove the lock tongue.


8 Fit a new lock tongue. Apply lubricating grease to the shaft bolt.
9 Fit the shaft bolt with a new lock nut.
10 Fit the screw of the lock cylinder’s mounting in the 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.

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7.9.2.7 Lifting hook 89

7.9.2.7 Lifting hook


Lifting hook, description
page

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)

Lifting hook, replacing


page

1 Machine in service position, see section B Safety.


2 Depressurize the hydraulic systems, See section B Safety.
3 Clean the lifting hooks and the area surrounding them.
4 Remove the lifting hook’s shaft bolt.
5 Hold the lift hook while removing the shaft bolt.

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.

Workshop Manual DCF 90-100 VDCF03.01GB


90 7 Load handling – 7.9.2.8 Alignment and detection sensor

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.

7.9.2.8 Alignment and detection sensor


Alignment and detection sensor, description
page

Two detection sensors (B7203LU/RU) - one at each lifting hook - use


ultrasound to detect distance (and inform the system) if one or two
containers are to be lifted.
1 At each lifting hook, there is one sensor that indicates contact with the
lower container (B7203LL/RL) and one sensor that indicates contact
2 with the upper container (B7203LU-2/RU-2).
The alignment sensors sense 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
3 sensors stop sending signals when the attachment is lifted.
The sensors are supplied power and send a 24 V signal to the attach-
4 ment control unit (D791-1) when the indicator pin is pressed in.
009949

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

Alignment sensor, checking and adjusting


page

1 Check the alignment sensors and adjust as necessary. Check


A
the left side and right side the same way.
2 With an unactuated contact pin, the measurement (A) across the
contact pin for the upper container should be approx. 39 mm.
3 When the measurement (A) is reduced to 22 mm, the light (B1)
B for contact with the upper container should come on.
4 Adjusting:
Fix the contact pin so that the measurement (A) is 22 mm. Then
move the sensor along the oval retaining hole and screw it into
009374

the exact position that makes the light (B1) come on.

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7.9.2.8 Alignment and detection sensor 91

5 With an unactuated contact pin, the measurement (B) across the


contact pin for the lower container should be approx. 30 mm.
B1 6 When the measurement (B) is reduced to 18 mm, the light (B2)
A C for contact with the lower container should 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

B1 Orange light Alignment (upper container)

B2 Orange light Alignment (lower container)

C Red light Lock tongues released

Detection sensor, upper container, checking


page

The sensors for upper container detection use ultrasound to detect


whether one or two containers will be handled. The sensors are acti-
vated when the attachment is 30-50 cm from the container. At that
time, the alignment event menu lights up on the display.
1 Drive the machine toward two containers and check that the
alignment event menu lights up on the display no later than when
the attachment is 30 cm from the container.
2 If the event menu for upper container alignment does not light up:
• Use a piece of paper or the like to determine which of the
sensors is not activated.
• Clean the sensor.
• Check the sensor and wiring for damage.
3 Repeat the check from step 1 above. If the alignment event menu
remains unlit, replace the sensor.
009830

Workshop Manual DCF 90-100 VDCF03.01GB


92 7 Load handling – 7.9.2.9 Lock tongue sensor

7.9.2.9 Lock tongue sensor


Lock tongue sensor, description
page

The lock tongue sensors (B7204L, B7204R, B7205LL and B7205RL)


detect when the lock tongues are locked/unlocked. Four inductive po-
sition sensors - two on each spreader beam - detect the position of the
lock mechanism.
Both sides function the same way independently of one another. An
1
indicator plate sits on the lock tongue at the lock cylinder. When the
2 lock mechanism is in the position that locks the lock tongues, one of
the sensors sends a signal to the attachment control unit (D791-1).
When the lock mechanism is in the position that unlocks the lock
tongues, the other sensor sends a signal to the attachment control unit
(D791-1). No signals are sent if the lock mechanism stops midway.
The sensors are supplied power and send a 24 V signal to the attach-
009377

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

Lock tongue sensor, checking and adjusting


page

1 Check that the sensors are free of damage and dirt.


2 Turn the start key to position I and check that the LED on the "un-
locked lock tongues" sensor is lit.
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
±1 mm.
3 Check that the "lock tongue open" indicator light is lit.
4 Insert the lifting hooks in the container and lock the lock tongues.
5 Check that the LED on the "locked lock tongues" sensor is lit.
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
±1 mm.
6 Check that the indicator light for locked lock tongues is lit.
7 Check that the lock tongues lock correctly. Adjust the lock cylin-
ders if necessary.

7.9.2.9 Valve block, main pump relief


Valve block, main pump relief, description
page

Se Valve block, main pump relief, description page 42

7.9.2.10 Pipes and hoses


Piped and hoses, description
page

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

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7.10 Other functions 93

7.10 Other functions


7.10.1 Container counter
Container counter, description
page

The container counter counts the number of lifted containers. The


counter has two counter units that can be reset separately. With the
side lifting attachment equipped with lifting hooks, the system detects
whether one or two containers are being handled and adds the corre-
sponding number to the counter.
The container counter uses the alignment sensor and "locked twist-
locks/lock tongues" sensor to determine when a container is lifted. The
container counter counts a lift when alignment disappears with locked
twistlocks/lock tongue and the twistlocks/lock tongue are not reopened
within eight seconds.

Container counter, function description


page

Condition Reference value Reference


Emergency stop Not activated Section 11 Common electrics , group 11.5.1.4 Emergency stop
switch switch voltage

D1
1, 4, 7
10
D790-1 D795

D797-1 D791-1
3,6,9 D5
D2
2,8 5 009956

Pos Explanation Signal description Reference


1 The attachment is positioned over a - Lift and lower, function description page 9
container with the functions 7.2 Lifting/ Sideshift, function description page 34
lowering , 7.4 Side shift, 7.5 Spreading
Spreading, function description page 43
and 7.5 Levelling.
Active levelling, function description page 65
D1: Diagnostic menu, see section 8 Control
system , group 8.4.8.1 ELSERV, menu 1 and
8.4.8.1 ELSERV, menu 2.

Workshop Manual DCF 90-100 VDCF03.01GB


94 7 Load handling – 7.10.1 Container counter

Pos Explanation Signal description Reference


2 If the side lifting attachment is Sensor directly opposite Sensor alignment, description page 77 or
equipped with twistlocks, the left and indicator plate: U = 24 V Alignment and detection sensor, description
right alignment sensors (B7203L and page 90
B7203R) send a voltage signal to the at- D2: Diagnostic menu, see section 8 Control
tachment control unit (D791-1). system , group 8.4.9.7 ATTACH, menu 7
If the side lifting attachment is equipped
with lifting hooks, the left lower, left up-
per, right lower and right upper align-
ment sensors (B7203LL, B7203LU-2,
B7203RL and B7203RU-2) send a volt-
age signal to the attachment control unit
(D791-1).

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.

4 Twistlocks/Lock tongues are turned to - Twistlocks, function description page 70 or


the locked position and closed with the Lifting hook, function description page 81
function 7.9.1 Twistlocks/7.9.2 Lifting
hook.

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.

8 If the side lifting attachment is U=0V Sensor alignment, description page 77 or


equipped with twistlocks, the left and Alignment and detection sensor, description
right alignment sensors (B7203L and page 90
B7203R) stop sending a voltage signal D2: Diagnostic menu, see section 8 Control
to the attachment control unit (D791-1). system , group 8.4.9.7 ATTACH, menu 7
If the side lifting attachment is equipped
with lifting hooks, the left lower, left up-
per, right lower and right upper align-
ment sensors (B7203LL, B7203LU-2,
B7203RL and B7203RU-2) stop send-
ing a voltage signal to the attachment
control unit (D791-1).

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.

VDCF03.01GB Workshop Manual DCF 90-100


7 Load handling – 7.10.1 Container counter 95

Pos Explanation Signal description Reference


10 If the twistlocks/lock tongue remains - Section 11 Common electrics, group 11.5.3.1
locked for 8 seconds, the cab control Cab control unit (D790-1)
unit (D790-1) adds one lift to the con-
tainer counter.

Workshop Manual DCF 90-100 VDCF03.01GB


96 7 Load handling – 7.10.1 Container counter

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system 1

8 Control system

Table of Contents 8 Control system


mm mm mm mm mm mm

8 Control system ............................................................................................... 3


8.1 Controls and instruments ........................................................................... 4
8.1.10 Error code menu .................................................................................... 4
8.2 Monitoring ................................................................................................... 7
8.2.1 Overload protection ............................................................................... 7
8.2.2 Bypass ................................................................................................... 7
8.2.3 Speed limitation ..................................................................................... 7
8.2.4 Service indicator .................................................................................... 8
8.4 Diagnostics ................................................................................................. 9
8.4.1 CAN/POWER ....................................................................................... 11
8.4.2 LIGHTS ................................................................................................ 26
8.4.3 CAB ..................................................................................................... 37
8.4.4 CLIMATE ............................................................................................. 45
8.4.5 HYD ..................................................................................................... 51
8.4.6 ENGINE ............................................................................................... 58
8.4.7 TRANSM .............................................................................................. 65
8.4.8 ELSERV ............................................................................................... 76
8.4.9 ATTACH, DCF360-450CSG ................................................................ 90
8.4.9 ATTACH, DCF 90-100 with lifting hook attachment .......................... 107
8.4.9 ATTACH, DCF 90-100 with twistlock attachment .............................. 123
8.4.10 OLS .................................................................................................... 137
8.4.11 EXTRA ............................................................................................... 139
8.5 Settings .................................................................................................. 171
8.5.1 Initiation ............................................................................................. 171
8.5.2 Calibration .......................................................................................... 208

Workshop Manual DCF 90-100 VDCF03.01GB


2 8 Control system

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8 Control system 3

8 Control system
mm mm mm mm mm mm

Control system, general


page

The machine’s functions are electrically controlled in many cases. The


signals which control the machine are monitored to warn the operator
or limit the machine’s functions in certain dangerous situations or if
faults arise in the machine.
The control system function is divided into the following functions:
• Monitoring
• Error codes
• Diagnostics
• Settings
• Software
Monitoring functions describes the machine’s monitoring functions
that warn the operator or limit the machine’s functions in the event of
any dangerous situations.
Error codes notify operators and mechanics when malfunctions have
been detected.
Diagnostic test is tool for performing service and troubleshooting with
menus in the machine’s display.
Settings is the tool for setting and adapting the machine’s functions.
The software creates the functions in the control system.

Workshop Manual DCF 90-100 VDCF03.01GB


4 8 Control system – 8.1 Controls and instruments

8.1 Controls and instruments


8.1.10 Error code menu
Error code menu, description
page

The control system’s display is divided into four fields that show infor-
C mation (see figure to the left).

D E • Field B: Error code level shown with a symbol.


• Field C: Indicates error code.
B
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.

Field B: Error code level


The control system gives error code information in three levels which
are indicated with a symbol in the lower left corner (B) on the display
unit.
• Stop
C Indicates a serious malfunction that may affect operator safety or
cause machine breakdown. The error code must be taken care of
D E
immediately. Stop working with the machine and contact service
immediately.
000350

The error code is shown automatically on the display.

• Warning
C Indicates machine malfunction that should be taken care of as
soon as possible. After finished work shift with the machine, con-
D E
tact service as soon as possible.
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

menu for service.

Field C: Error code number


The control system gives error codes from three sub-systems:
• Machine:
C
Shown with error code number XXX on display.
D E

B
000389

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.1.10 Error code menu 5

• 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

Field D: Type of error


1. Too high/too low temperature.
1 2 3
2. Incorrect signal to solenoid valve.
3. Incorrect hydraulic pressure.
4. Incorrect sensor signal.

4 5 6 5. Incorrect signal from control.


6. Incorrect signal from battery.
7. Incorrect signal from spool.
8. Level too high/low
7 8 9 9. Incorrect signal to bulb.
10. Incorrect signal, for example, open circuit.
11. Incorrect signal to engine.

10 11
002058

Workshop Manual DCF 90-100 VDCF03.01GB


6 8 Control system – 8.1.10 Error code menu

Field E: Affected function


1. Attachment
1 2 3
2. Rotation of attachment
3. Side shift of attachment
4. Length adjustment attachment
4 5 6
5. Leveling attachment
6. Twistlocks
7. Forks up/down
7 8 9 8. Tilt forks
9. Side shift forks
10. Spreading forks

10 11 12 11. Rotation forks


12. Overload protection
13. Hydraulic functions
14. Brake system
13 14 15
15. Steering
16. Engine
17. Transmission
16 17 18
18. Central lubrication
19. Control unit
20. Hardware-related error
19 20 21 21. Cab
22. Air conditioning system
23. Fuel system
22 23 24 24. Headlights
25. Windshield wipers
26. Battery voltage
25 26 27 27. Bulb for lighting
010153

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.2 Monitoring 7

8.2 Monitoring
8.2.1 Overload protection
Overload protection, description
page

Not used.

8.2.2 Bypass
Bypassing, description
page

Bypassing is activated with the bypass switch.


Bypassing the safety system makes the following possible:
• locking and opening twistlocks without full alignment
• spread 20’-40’ with locked twistlocks
• lowering a load with alignment on top lift.
• manual control of the recirculation damper for ECC or EHC.
• release of parking brake in the event of parking brake switch
malfunction
• output signal to solenoid valves with active error codes.
• engagement of a gear without the operator in the driver’s seat -
the machine can only move at reduced speed.

DANGER
Bypassing the safety systems results in a risk of tip-
ping. Use at your own risk.

8.2.3 Speed limitation


Speed limitation, description
page

Speed limitation prevents the machine’s speed from exceeding pre-


set value by limiting gear position and engine rpm.
Machine speed is limited when:
• the control switch is activated.
• the cab is tilted.
• load is not in transport position during transport. Maximum speed
is 5 km/h.
• the reversible driver’s seat is not in position.
• constant speed limitation is set.
Speed limitation is set via the initiation menu; see section 8 Control
system , group 8.5.1.4 INIT DRIVE-TRAIN, menu 9.

Workshop Manual DCF 90-100 VDCF03.01GB


8 8 Control system – 8.2.4 Service indicator

8.2.4 Service indicator


Service indicator, resetting
page

1 Machine in service position, see section B Safety.


2 First navigate to the service menu and press Enter.

000056

3 Enter the code for service indicator reset.


Code is obtained from Kalmar Industries Support.
1 23
4 5 NOTE
000060

The code determines which service menu shall be activated


(Service, Diagnostics, Initiation or Calibration).
4 Reset the service indicator by pressing Enter. NEXT SERVICE is
SERVICE INTERVALL changed to indicated interval.
NEXT SERVICE XXXXh
SERVICE INTERVALL To change duration of the service interval, set the desired interval
STORED XXXXh with the plus or minus key.
004908

PRESENT XXXXh

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4 Diagnostics 9

8.4 Diagnostics
Diagnostic test, general
page

The machine has built-in functions for troubleshooting called diagnos-


DIAGNOSIS tic test. The diagnostic test consists of several menus shown on the
CAN/POWER LIGHTS CAB display. The menus are grouped for faster access. The following pag-
CLIMATE HYD ENGINE
es describe the menu figures content and which functions that can be
TRANSM ELSERV ATTACH
controlled.

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

Workshop Manual DCF 90-100 VDCF03.01GB


10 8 Control system – 8.4 Diagnostics

Diagnostic menu, description


page

Diagnostic tests show how the control units interpret input signals as
1 2 3 4
well as which signals that the control units send.

7 DIAG CAB 2(X)


FRONT WIPER
SWITCH (1-3) 2
6 OUTPUT 11 5

008873
FEEDBACK 0

1. DIAG = Diagnostic menus


2. Menu group
3. Menu number
4. Total number of menus in the loop. The number of
menus depends on machine configuration, so the
number of menus is specified as (X) in this manual.
5. Signal value
6. Variable
7. Menu heading
DIAG Indicates that diagnostic tests are selected.

CAB Indicates which menu group is selected, these groups are:


CAN/POWER, description page 11.
LIGHTS, description page 26.
CAB, description page 37.
CLIMATE, description page 45.
HYD, description page 51.
ENGINE, description page 58.
TRANSM, description page 65.
ELSERV, description page 76.
ATTACH, description page 90.
OLS, description page 137.
EXTRA, description page 139.

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.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.1 CAN/POWER 11

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

8.4.1.1 CAN/POWER, menu 1


PRESENT REDCAN STATUS, COMMUNICATION MODE
page

Description: Indicates communications status for the redundant CAN-


DIAG CAN/POWER 1(X) bus.
PRESENT REDCAN STATUS
COMMUNICATION MODE X Circuit diagram: 11.6-1
NUMBERS OF UNITS X Connection: -
005266

SEGMENT ERROR X
Function: 11.6.2 Redundant CAN-bus
Signal value:

3 Ok.

2 Segment check

0 Error.

Workshop Manual DCF 90-100 VDCF03.01GB


12 8 Control system – 8.4.1.1 CAN/POWER, menu 1

PRESENT REDCAN STATUS, NUMBER OF UNITS


page

Description: Indicates number of control units, excluding cab KCU


control unit (D790-1), which should be present on the machine in
question. The number depends on the options present.
Circuit diagram: Circuit 11.6-1
Connection: -
Function: 11.6.2 Redundant CAN-bus
Signal value:

X Number of nodes that should be in the machine. Number of


nodes dependent on installed options.

PRESENT REDCAN STATUS, SEGMENT ERROR


page

Description: Indicates if there is open circuit on the redundant CAN


bus. And if there is, where the first open circuit is. If there is open cir-
cuit, it is indicated with a number that corresponds to the incorrect seg-
ment on the redundant CAN bus.
Circuit diagram: Circuit 11.6-1
Connection: -
Function: 11.6.2 Redundant CAN-bus
Signal value:

0 No open circuit.

>0 If X is separated from 0, the first segment is indicated


as missing contact. A 1 means that the first segment is
incorrect, that is, that contact between first and second
control unit is cut off.
To see which control units are installed on the machine
along with their order, use diagnostic menu CAN/POW-
ER, menu 2, see PRESENT REDCAN STATUS, CON-
NECTED CITIES page 13.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.1.2 CAN/POWER, menu 2 13

8.4.1.2 CAN/POWER, menu 2


PRESENT REDCAN STATUS, CONNECTED CITIES
page

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:

1 Communication with the node is OK.

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

8.4.1.3 CAN/POWER, menu 3


PRESENT OPTION KDU
page

Description: Indicates which optional control units should be present


DIAG CAN/POWER 3(X) on the machine and if they have working communication with the cab
PRESENT OPTION KDU KCU control unit (D790-1).

KDU D797-2 XY Circuit diagram: Circuit 11.6-1


007183

KDU D791-1 XY Connection: -


Function: 11.6.2 Redundant CAN-bus
Signal value:

00 The control unit is not installed on the machine.

10 The control unit is installed on the machine but there is no


communication with the cab control unit (D790-1).

11 The control unit is installed on the machine and there is com-


munication with the cab control unit (D790-1).

8.4.1.4 CAN/POWER, menu 4


PRESENT DRIVE-TRAIN CAN BUS STATUS, ENGINE
page

Description: Indicates status for engine in drivetrain’s CAN bus.


DIAG CAN/POWER 4(X) Circuit diagram: Engine circuit group 1.0, CAN bus circuit group 11.6
PRESENT DRIVE-TRAIN
CAN BUS STATUS Connection:
ENGINE X
Volvo TAD760VE: CAN J1939 from D790-1/K13:1 and K13:2 to
005269

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

Workshop Manual DCF 90-100 VDCF03.01GB


14 8 Control system – 8.4.1.4 CAN/POWER, menu 4

Cummins QSM11: CAN J1939 from D790-1/K13:1 and K13:2 to


D794/46 and 37
Cummins QSB6.7: CAN J1939 from D790-1/K13:1 and K13:2 to
D794/46 and 37
Function: 11.6.3 Communication
Signal value:

1 Communication with the node is OK.

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

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.

PRESENT DRIVE-TRAIN CAN BUS STATUS,


page

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:

1 Communication with the node is OK.

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

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.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.1.5 CAN/POWER, menu 5 15

8.4.1.5 CAN/POWER, menu 5


IGNITION, KEY IN
page

Description: Indicates if ignition is on (key in ignition).


DIAG CAN/POWER 5(X)
Circuit diagram: Circuit 11.5-3
IGNITION
KEY IN X Connection: signal from S150/15 to digital in D790-1/K11:1
RELAY K315-1 XY
Function: 11.5.1.3 Ignition voltage

007126
RELAY K315-2 XY
Signal value:

1 Input signal active.

0 No signal.

IGNITION, RELAY K315-1


page

Description: Control current to Relay ignition voltage (K315-1), 15-


voltage.
Circuit diagram: Circuit 11.5-3
Connection: output signal from D790-1/K10:10 to K315-1
Function: 11.5.1.3 Ignition voltage (15)
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

IGNITION, RELAY K315-2


page

Description: Control current to Relay ignition voltage (K315-2), 15-


voltage.
Circuit diagram: Circuit 11.5-3
Connection: output signal from D790-1/K10:16 to K315-2
Function: 11.5.1.3 Ignition voltage (15)
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

Workshop Manual DCF 90-100 VDCF03.01GB


16 8 Control system – 8.4.1.6 CAN/POWER, menu 6

8.4.1.6 CAN/POWER, menu 6


EMERGENCY STOP, SW
page

Description: Indicates if switch, control switch, is activated.


DIAG CAN/POWER 6(X)
Circuit diagram: sheet 11.5-6
EMERGENCY STOP, SW X
RELAY K3009-1 XY Connection: signal from S250/2 to digital in D790-1/K8:4
FEEDBACK X
Function: 11.5.1.4 Control switch voltage (15E)

007127
RELAY K3009-2 XY
Signal value:

1 Input signal active.

0 No signal.

EMERGENCY STOP, RELAY K3009-1


page

Description: Status for control current to relay K3009-1, for emergency


stop switch voltage, 15E voltage.
Circuit diagram: sheet 11.5-6
Connection: signal from D790-1/K10:11 to K3009-1/86
Function: 11.5.1.4 Control switch voltage (15E)
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

EMERGENCY STOP, FEEDBACK


page

Description: Feedback signal from emergency stop switch voltage re-


lay (K3009-1); indicates that relay is working normally.
Circuit diagram: sheet 11.5-6
Connection: signal from K3009-1/87 via F58-3/8 to digital in D790-1/
K11:13
Function: 11.5.1.4 Control switch voltage (15E)
Signal value:

1 Input signal active.

0 No signal.

EMERGENCY STOP, RELAY K3009-2


page

Description: Status of control current to emergency stop switch


voltage relay (K3009-2), 15E-voltage.
Circuit diagram: sheet 11.5-6
Connection: signal from D790-1/K10:12 to K3009-2/86

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.1.7 CAN/POWER, menu 7 17

Function: 11.5.1.4 Control switch voltage (15E)


Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

8.4.1.7 CAN/POWER, menu 7


790-1 CAB, POWER
page

Description: Ignition voltage (15) to cab control unit (D790-1).


DIAG CAN/POWER 7(X)
Circuit diagram: sheet 11.5-4
790-1 CAB
POWER XX.XXV Connection: 15-voltage from K315-1/87 via F54/4 and F58-5/1 to
5V REF X.XXV D790-1/K1:2, D790-1/K1:3 and D790-1/K1:4
005271

Function: 11.5.1 Voltage feed


Signal value: XX.XXV = voltage on the connection. The signal value
should be 22-30 V (battery voltage).

790-1 CAB, 5V REF


page

Description: Reference voltage 5 V to controls in cab.


Circuit diagram: Circuits 9.4-1, 9.4-2 and 9.3-3 (contact 1, 2), Circuit
1.0-1 (contact 3), Circuit 7.0-1 (contact 4), Circuit 5.2-1 (contact 5)
Connection:
1. signal from digital out D790-1/K4:5 to Y672/10 and Y673/10
2. signal from digital out D790-1/K5:11 to S118/1, S 139/1 and
S117/1
3. signal from digital out D790-1/K5:13 till B690-1/1 and B690-2/1
4. signal from digital out D790-1/K7:2 to R8071/1, R8072/1, R8073/
1, R8074/1, R8075-1/1 and R8075-2/1
5. signal from digital out D790-1/K9:7 to R825-1/1 and R825-2/1
Function: 9.4 Heating, ventilation and air conditioning (contact 1 and
2); 1 Engine and 2 Transmission (contact 3); 7 Load handling (contact
4); 5 Steering (contact 5)
Signal value: X.XXV = 5.00 V, Important that the signal value is stable
(not varying).

Workshop Manual DCF 90-100 VDCF03.01GB


18 8 Control system – 8.4.1.8 CAN/POWER, menu 8

8.4.1.8 CAN/POWER, menu 8


790-1 CAB, 24V SENSOR SUPPLY
page

Description: 24 V voltage feed to components in cab.


DIAG CAN/POWER 8(X)
Circuit diagram:
790-1 CAB
24V SENSOR SUPPLY XY 1. Circuit 9.5-1
24V SUPPLY,RPM>500 XY
2. Circuits 2.0-1, 9.1-1, 9.3-1, 9.6-1, 9.6-2, 9.6-3, 9.6-4 and 9.5-1

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

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.1.9 CAN/POWER, menu 9 19

Signal value:

01 No output signal. Error detection only possible when output


signal is active.

10 Output signal active, short-circuiting or open circuit.

11 Output signal active, circuit OK or open circuit.

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


page

Description: Voltage feed at engine speed higher than 500 rpm.


Circuit diagram: Circuit 9.1-2
Connection: signal from digital out D790-1/K10:9 to P708/+ and K358/
86
Function: 9.3.6 Compressor air-suspension seat, 11.1.1 Hour meter
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

8.4.1.9 CAN/POWER, menu 9


795 DISPLAY, RED. POWER
page

Description: Redundant voltage to KID control unit (D795).


DIAG CAN/POWER 9(X)
Circuit diagram: Circuit 11.6-1
795 DISPLAY
Connection:
RED.POWER LE X RI X
Le: redundant feed to D790/K1:8
005276

Ri: redundant feed to D790/K1:7


Function: 11.5.1.2 Redundant voltage feed of control units
Signal value:

1 Feed active.

0 No feed.

Workshop Manual DCF 90-100 VDCF03.01GB


20 8 Control system – 8.4.1.10 CAN/POWER, menu 10

8.4.1.10 CAN/POWER, menu 10


797-1 FRAME, POWER
page

Description: Ignition voltage (15) to frame control unit (D797-1).


DIAG CAN/POWER 10(X)
Circuit diagram: Circuit 11.5-4
797-1 FRAME
POWER XX.XXV Connection: 15 voltage from K315-1/87 via F54/4 and F58-2/1 to
RED.POWER LE X RI X D797-1/K2:1, D797-1/K2:9 and D797-1/K2:10

005277
POWER 2 X
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).

797-1 FRAME, RED. POWER


page

Description: Redundant voltage to frame control unit (D797-1).


Circuit diagram: Circuit 11.6-1
Connection:
• Le: redundant feed to D797-1/K2:7
• Ri: redundant feed to D797-1/K2:8
Function: 11.5.1.2 Redundant voltage feed of control units
Signal value:

1 Feed active.

0 No feed.

797-1 FRAME, POWER 2


page

Description: Battery voltage to frame control unit (D797-1).


Circuit diagram: Circuit 11.5-4
Connection: 15-voltage from K315-1/87 via F54/4 and F58-2/1 to
D797-1/K2:11
Function: 11.5.1.3 Ignition voltage (15)
Signal value:

1 Feed active.

0 No feed.

8.4.1.11 CAN/POWER, menu 11


797-1 FRAME, 5V REF
page

Description: Reference voltage 5 v to sensors connected to frame con-


DIAG CAN/POWER 11(X) trol unit (D797-1) (voltage feed to pressure sensors).
797-1 FRAME
Circuit diagram: Circuit 8.2-2
5V REF X.XXV Connection: digital out from 797-1/K1:8 to B768-1/1 and B768-2/1
005278

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).

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.1.12 CAN/POWER, menu 12 21

8.4.1.12 CAN/POWER, menu 12


793 TRANSMISSION, POWER
page

Description: Battery voltage (30) to transmission control unit (D793).


DIAG CAN/POWER 12(X)
Circuit diagram: Circuit 2.0-2A1
793 TRANSMISSION
POWER XX.XXV Connection: 30-voltage from F54/2 via F58-1/5 to D793/A1
IGNITION POWER XX.XXV
Function: 11.5.1.1 Battery voltage (30)

005279
SENSOR SUPPLY XX.XXV
Signal value: XX.XXV = voltage on the connection. The signal value
should be 22-30 V (battery voltage).

793 TRANSMISSION, IGNITION POWER


page

Description: Ignition voltage (15) to transmission control unit (D793).


Circuit diagram: Circuit 2.0-2A1
Connection: 15-voltage from K315/87 via F54/4 and F58-2/6 to D793/
S2
Function: 11.5.1.3 Ignition voltage (15)
Signal value: XX.XXV = voltage on the connection. The signal value
should be 22-30 V (battery voltage).

793 TRANSMISSION, SENSOR SUPPLY


page

Description: Voltage feed to sensors on transmission, reference volt-


age of 5 V.
Circuit diagram: Circuits 2.0-2A2, 2.0-2A3
Connection: 5V analogue Ref from D793/M1 to S221/1
Function: 2.8 Control system, transmission
Signal value: XX.XXV = voltage on connection. The signal value
should be 8 V, stable (not vary).

8.4.1.13 CAN/POWER, menu 13


797-2 FRAME (OPT), POWER
page

DIAG CAN/POWER 13(X)


797-2 FRAME (OPT) Description: Ignition voltage (15) to frame control unit, option (D797-
POWER XX.XXV 2).
RED.POWER LE X RI X
Circuit diagram: Circuit 11.5-5
005280

EME STOP POWER X


Connection: 15-voltage from K315-1/87 via F54/4 and F58-2/3 to
D797-2/K2:1, D797-2/K2:9 and D797-2/K2:10
Function: 11.5.1.3 Ignition voltage (15)
Signal value: XX.XXV = voltage on the connection. The signal value
should be 22-30 V (battery voltage).

Workshop Manual DCF 90-100 VDCF03.01GB


22 8 Control system – 8.4.1.13 CAN/POWER, menu 13

797-2 FRAME (OPT), RED. POWER


page

Description: Redundant voltage to frame control unit, option (D797-2).


Circuit diagram: Circuit 11.6-2A
Connection:
• Le: redundant feed to D797-2/K2:7
• Ri: redundant feed to D797-2/K2:8
Function: 11.5.1.2 Redundant voltage feed of control units
Signal value:

1 Feed active.

0 No feed.

797-2 FRAME (OPT), EME STOP POWER


page

Description: Emergency stop switch voltage to frame control unit, op-


tion (D797-2).
Circuit diagram: Circuit 11.5-5
Connection: 15E-voltage from K3009-1/87 via K3009-2/87 and F58-3/
5 to D797-2/K2:11
Function: 11.5.1.4 Control switch voltage (15E)
Signal value:

1 Feed active.

0 No feed.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.1.14 CAN/POWER, menu 14 23

8.4.1.14 CAN/POWER, menu 14


797-2 FRAME (OPT), 24V SENSOR SUPPLY
page

DIAG CAN/POWER 14(17)


797-2 FRAME (OPT) Description: Voltage feed 24 V to sensors connected to the frame con-
24V SENSOR SUPPLY XY trol unit, option (D797-2).
5V REF X.XXV
Circuit diagram: Circuit 9.3-3

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:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is
active.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

797-2 FRAME (OPT), 5V REF


page

Not used.

8.4.1.15 CAN/POWER, menu 15


791-1 ATTACHMENT, EME POWER
page

Description: Voltage feed to attachment control unit (D791-1).


DIAG CAN/POWER 15(X)
Circuit diagram: Circuit 11.5-5
791-1 ATTACHMENT(OPT)
EME POWER XX.XXV Connection: 15E voltage from K3009-1/87 via K3009-2/87, F58-3/1 to
RED.POWER LE X RI X D791-1/K2:1, K2:9, K2:10, K2:11
005282

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).

Workshop Manual DCF 90-100 VDCF03.01GB


24 8 Control system – 8.4.1.15 CAN/POWER, menu 15

791-1 ATTACHMENT, RED. POWER


page

Description: Redundant voltage feed to attachment control unit (D791-


1).
Circuit diagram: Circuit 11.5-1, 11.5-6, 11.6-1, 11.6-2B, 11.6-2C
Connection:
Le: redundant voltage feed to D791/K2:7
Ri: redundant voltage feed to D791/K2:8
Function: 11.5.1.2 Redundant voltage feed of control units
Signal value:

1 Feed active.

0 No feed.

791-1 FRAME, EME POWER 2


page

Description: Emergency stop switch voltage (15E) to attachment con-


trol unit (D791-1).
Circuit diagram: Circuit 11.5-5
Connection: 15E voltage from K3009-1/87 via K3009-2/87, F58-3/1 to
D791-1/K2:11
Function: 11.5.1.4 Control switch voltage (15E)
Signal value:

1 Feed active.

0 No feed.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.1.16 CAN/POWER, menu 16 25

8.4.1.16 CAN/POWER, menu 16


791-1 ATTACHMENT (OPT), 24V SENSOR SUPPLY
page

Description: Voltage feed to sensors connected to the attachment con-


DIAG CAN/POWER 16(X) trol unit (D791-1).
791-1 ATTACHMENT (OPT)
24V SENSOR SUPPLY XY Circuit diagram: Circuit 7.5-2, 7.9-2
5V REF X.XXV DCF360-450CSG

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:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

791-1 ATTACHMENT (OPT), 5V REF


page

Not used.

Workshop Manual DCF 90-100 VDCF03.01GB


26 8 Control system – 8.4.1.17 CAN/POWER, menu 17

8.4.1.17 CAN/POWER, menu 17


REDCAN STATUS CHECK
page

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

1 2 3 Function: 11.6.2 Redundant CAN-bus


5 4 Signal value:
CAN R CAN L
008878

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.

D790-1 D797-2 D797-1


CAN L CAN R CAN L CAN R CAN L CAN R

1 2
4 3
CAN R CAN L
008879

D795

DCF 280-330, DCF 370-500


Segment numbering with maximum number of control
units. Control units marked with dashes are optional.

8.4.2 LIGHTS
LIGHTS, description
page

This group covers lighting.


DIAGNOSIS
CAN/POWER LIGHTS CAB Confirm selection with function key for Enter.
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
005285

OLS EXTRA

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.2.1 LIGHTS, menu 1 27

8.4.2.1 LIGHTS, menu 1


MAIN LIGHT, SWITCH
page

Description: Signal from headlights switch.


DIAG LIGHTS 1(X)
Circuit diagram: Circuit 9.6-4
MAIN LIGHT
SWITCH X Connection: signal from S100/1 to digital in D790-1/K6:5
Function: 9.6.1 Headlights.

005286
Signal value:

1 Input signal active.

0 No signal.

8.4.2.2 LIGHTS, menu 2


PRESENT OUTPUT SIGNAL, SIDE LIGHTS
page

Description: Voltage feed to side running lights.


DIAG LIGHTS 2(X)
Circuit diagram: Circuit 9.6-5 and 9.6-6
PRESENT OUTPUT SIGNAL
Connection: digital out from D797-1/K1:2 to H416-1, H416-2, H417-1
SIDE LIGHTS XY and H417-2
005287

REAR LIGHTS XY
Function: 9.6.2 Running lights
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

PRESENT OUTPUT SIGNAL, REAR LIGHTS


page

Description: Voltage feed to rear lights.


Circuit diagram: Circuit 9.6-6
Connection: digital out from D797-1/K1:33 to H412L and H412R
Function: 9.6.3 Rear lights
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

Workshop Manual DCF 90-100 VDCF03.01GB


28 8 Control system – 8.4.2.3 LIGHTS, menu 3

8.4.2.3 LIGHTS, menu 3


HEADLIGHTS, SWITCH
page

Description: Lighting headlights front, switch.


DIAG LIGHTS 3(X)
Circuit diagram: Circuit 9.6-4
HEAD LIGHTS
SWITCH X Connection: from S162:56A to digital in D790-2/K3:9
HEAD LE/RI XY
Function: 9.6.1 Headlights

005288
DIMMED LE/RI XY
Signal value:

1 Input signal active.

0 No signal.

HEADLIGHTS, HEAD LE/RI


page

Description: Voltage feed to headlights, high beam.


Circuit diagram: Circuit 9.6-5
Connection: digital out from D797-1/K1:15 to E402L-1 and E402R-1
Function: 9.6.1 Headlights
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

HEADLIGHTS, DIMMED LE/RI


page

Description: Voltage feed to headlights, low beams.


Circuit diagram: Circuit 9.6-5
Connection: digital out from D797-1/K1:28 to E400L and E400R
Function: 9.6.1 Headlights
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.2.4 LIGHTS, menu 4 29

8.4.2.4 LIGHTS, menu 4


PRESENT INPUT SIGNAL, HAZARD SWITCH
page

Description: Signal from switch flashing hazard lights (Hazard).


DIAG LIGHTS 4(X)
Circuit diagram: Circuit 9.6-7
PRESENT INPUT SIGNAL
HAZARD SWITCH X Connection: signal from S109/1 to digital in D790-1/K5:6
FLASH.SW. LE X RI X
Function: 9.7 Signal system

005289
Signal value:

1 Input signal active.

0 No signal.

PRESENT INPUT SIGNAL, FLASH.SW.


page

Description: Signal from switch direction indicators.


Circuit diagram: Circuit 9.6-7
Connection:
• LE: signal from S161/6 to digital in D790-2/K8:8
• RI: signal from S161/1 to digital in D790-2/K8:9
Function: 9.6 Lighting system
Signal value:

1 Input signal active.

0 No signal.

8.4.2.5 LIGHTS, menu 5


PRESENT OUTPUT SIGNAL HAZARD/FLASHER, LEFT F/R
page

Description: Voltage feed to direction indicator, left-hand side.


DIAG LIGHTS 5(X)
Circuit diagram: Circuit 9.6-7
PRESENT OUTPUT SIGNAL
HAZARD/FLASHER Connection: digital out from D797-1/K1:30 to H422 and H426
LEFT F/R XY
Function: 9.6.6 Direction indicators, 9.6.7 Flashing hazard lights
005290

RIGHT F/R XY
( Hazard)
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

Workshop Manual DCF 90-100 VDCF03.01GB


30 8 Control system – 8.4.2.6 LIGHTS, menu 6

PRESENT OUTPUT SIGNAL HAZARD/FLASHER, RIGHT F/


page

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:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

8.4.2.6 LIGHTS, menu 6


ROTATING BEACON, SWITCH
page

Description: Signal from switch rotating beacon.


DIAG LIGHTS 6(X)
Circuit diagram: Circuit 9.6-4
ROTATION BEACON
SWITCH X Connection: from S110/1 to digital in D790-1/K6:4
OUTPUT XY
Function: 9.6.8 Rotating beacon
005291

Signal value:

1 Input signal active.

0 No signal.

ROTATING BEACON, OUTPUT


page

Description: Voltage feed to rotating beacon.


Circuit diagram: Circuit 9.6-4
Connection: digital out from D790-1/K2:5 to H428
Function: 9.6.8 Rotating beacon
Signal value:

01 No output signal. Error detection only possible when output


signal is active.

10 Output signal active, short-circuiting or open circuit.

11 Output signal active, circuit OK.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.2.7 LIGHTS, menu 7 31

8.4.2.7 LIGHTS, menu 7


PRESENT INPUT SIGNAL, BRAKE LIGHT SWITCH
page

Description: Signal from make-contact brake lights.


DIAG LIGHTS 7(X)
Circuit diagram: Circuit 9.6-5
PRESENT INPUT SIGNAL
BRAKE LGT SWITCH X Connection: from S216/2 to digital in D797-1/K1:20
REVERSE LGT SIGNAL X
Function: 4.3.8 Make-contact brake lights

005292
Signal value:

1 Input signal active.

0 No signal.

PRESENT INPUT SIGNAL, REVERSE LIGHT SIGNAL


page

Description: Signal from transmission control unit (D793) when re-


verse gear is activated.
Circuit diagram: Circuit Lighting group 9.6
Connection: -
Function: 9.6.5 Back-up light
Signal value:

1 Input signal active. Output signal "reverse gear active" from


transmission control unit (D793).

0 No signal.

8.4.2.8 LIGHTS, menu 8


PRESENT OUTPUT SIGNAL, BRAKE LGT
page

Description: Voltage feed to brake lights.


DIAG LIGHTS 8(X)
Circuit diagram: Circuit 9.6-6
PRESENT OUTPUT SIGNAL
BRAKE LGT LE XY RI XY Connection:
REV. LGT LE XY RI XY
• LE: digital out from D797-1/K1:7 to H411L
005293

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

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

Workshop Manual DCF 90-100 VDCF03.01GB


32 8 Control system – 8.4.2.9 LIGHTS, menu 9

PRESENT OUTPUT SIGNAL, REV LGT


page

Description: Voltage feed to reversing lights.


Circuit diagram: Circuit 9.6-6
Connection:
• LE: digital out from D790-1/K2:6 to E405L
• RI: digital out from D790-1/K2:7 to E405R
Function: 9.6.5 Back-up light
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

PRESENT OUTPUT SIGNAL, BACK-UP (REVERSE)


page

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:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

8.4.2.9 LIGHTS, menu 9


CAB LIGHT, MANUAL SWITCH
page

Description: Signal from switch lighting cab.


DIAG LIGHTS 9(X)
Circuit diagram: Circuit 9.6-8
CAB LIGHT
MANUAL SWITCH X Connection: signal from D790-2/K8:11 to digital in D790-1/K11:2
DOOR SWITCH X
Function: 9.6 Lighting system
005294

OUTPUT XXX
Signal value:

1 Input signal active.

0 No signal.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.2.10 LIGHTS, menu 10 33

CAB LIGHT, DOOR SWITCH


page

Description: Signal from contact breaking door.


Circuit diagram: Circuit 9.6-8
Connection: signal from S266-LE or S266-RI (connected in parallel) to
digital in D790-1/K11:3
Function: 9.10.2 Doors
Signal value:

1 Input signal active.

0 No signal.

CAB LIGHT, OUTPUT


page

Description: Voltage feed to interior light cab.


Circuit diagram: Circuit 9.6-8
Connection: digital out from D790-1/K11:6 to E434-1
Function: 9.6.11 Interior lighting
Signal value: XXX = 0-255 = 0-24 V (255 means 24 V which corre-
sponds to battery voltage).

8.4.2.10 LIGHTS, menu 10


WORKING LIGHT MAST, SWITCH
page

Description: Signal from switch for working light, mast.


DIAG LIGHTS 10(X)
Circuit diagram: Circuit 9.6-3
WORKING LIGHT MAST
SWITCH X Connection: signal from S105-3/1 to digital in D790-1/K6:3
OUTPUT LE/RI XY
Function: 9.6 Lighting system
005295

Signal value:

1 Input signal active.

0 No signal.

Workshop Manual DCF 90-100 VDCF03.01GB


34 8 Control system – 8.4.2.11 LIGHTS, menu 11

WORKING LIGHT MAST, OUTPUT


page

Description: Voltage feed to working light, mast.


Circuit diagram: Circuit 9.6-3
Connection: digital out from D797-1/K1:1 to E404L-1 and E404R-1
Function: 9.6.9 Working light, mast
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is
active.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

8.4.2.11 LIGHTS, menu 11


WORKING LIGHT EXTRA OUTPUT, D797-1 C1 P42
page

Description: Voltage feed to auxiliary working light.


DIAG LIGHTS 11(X)
Circuit diagram: Circuit 9.6-9
WORKING LIGHT EXTRA
OUTPUT Connection: digital out from D797-1/K1:42 to E404L-4 and E404R-4
D797-1 C1 P42 XY
Function: 9.1.4 Switch for working light, front wing, 9.1.5 Switch for
005296

D797-2 C1 P42 XY
working light, attachment, 9.1.6 Switch for working light, mast
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is
active.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.2.12 LIGHTS, menu 12 35

WORKING LIGHT EXTRA OUTPUT, D797-2 C1 P42


page

Description: Voltage feed to auxiliary working light.


Circuit diagram: Circuit 9.6-10
Connection: digital out from D797-2/K1:42 to E404L-2 and E404R-2
Function: 9.6.9 Working light, mast, 9.6.10 Working light, cab, 9.6.12
Working light, attachment, 9.6.14 Working light, front wing
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is
active.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

8.4.2.12 LIGHTS, menu 12


WORK LIGHT CAB, SWITCH
page

Description: Signal from switch work light cab roof


DIAG LIGHTS 12(X)
Circuit diagram: 9.6-1
WORKING LIGHT CAB
SWITCH X Connection: signal from S105-1/1 to digital in D790-1/K6:10
Function: 9.6 Lighting system
005297

OUTPUT 20' XY 40' XY


Signal value:

1 Input signal active.

0 No signal.

WORK LIGHT CAB, OUTPUT


page

Description: Voltage feed to work light cab roof.


Circuit diagram: 9.6-1
Connection:
• 20’: digital out from D790-1/K7:8 to E406L-2 and E406R-2
• 40’: digital out from D790-1/K10:8 to E406L-1 and E406R-1
Function: 9.6.10 Work light cab
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is
active.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

Workshop Manual DCF 90-100 VDCF03.01GB


36 8 Control system – 8.4.2.13 LIGHTS, menu 13

8.4.2.13 LIGHTS, menu 13


WORKING LIGHT ATTACH, SWITCH
page

Description: Signal from switch work light attachment


DIAG LIGHTS 13(X)
Circuit diagram: 9.6-2
WORKING LIGHT ATTACH
SWITCH X Connection: signal from S105-2/1 to digital in D790-1/K6:2
OUTPUT LE XY RI XY
Function: 9.6 Lighting system

008895
Signal value:

1 Input signal active.

0 No signal.

WORK LIGHT ATTACH, OUTPUT


page

Description: Voltage feed to working light, attachment.


Circuit diagram: Circuit 9.6-2
Connection:
• LE: digital out from D791-1/K1:1 to E404L-3
• RI: digital out from D791-1/K1:15 to E404R-3
Function: 9.6.12 Work light attachment
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is
active.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

8.4.2.14 LIGHTS, menu 14


SWITCH LIGHTS, OUTPUT
page

Description: Voltage feed to background lights in switches, panels and


DIAG LIGHTS 14(X) keys.
SWITCH LIGHTS Circuit diagram: Circuits 4.0-1, 5.2-1, 7.5-1, 7.9-1, 9.1-1, 9.3-1, 9.3-3,
9.4-1, 9.6-2, 9.6-3, 9.6-4, 9.6-1
OUTPUT XXX
005300

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

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.2.15 LIGHTS, menu 15 37

output signal from D790-1/K6:8 to S199-3


output signal from D790-1/K6:9 to S199-1
output signal from D790-1/K6:10 to S105-1
output signal from D790-1/K8:10 to S1004
output signal from D790-1/K8:12 to S1003
output signal from D790-1/K8:13 to S107
output signal from D790-1/K8:14 to S199-2
output signal from D790-1/K8:15 to S169, S1010
output signal from D790-1/K9:2 to S160-2
Function: 9.6.11 Interior lighting
Signal value:

50 Means 4-5 V.

170 Means 15-16 V.

8.4.2.15 LIGHTS, menu 15


STEP LIGHT, SWITCH
page

Description: Signal from entry lighting switch.


DIAG LIGHTS 15(X)
Circuit diagram: Circuit 9.6-11
STEP LIGHT
SWITCH X Connection: signal from S141/2 to digital in D790-1/K11:4
OUTPUT XXX
Function: 9.6.13 Entry lighting
008897

Signal value:

1 Input signal active.

0 No signal.

STEP LIGHT, OUTPUT


page

Description: Voltage feed to entry lighting.


Circuit diagram: Circuit 9.6-11
Connection: digital out from D790-1/K11:6 to E433
Function: 9.6.13 Entry lighting
Signal value: XXX = 0-255 = 0-24 V (255 means 24 V which corre-
sponds to battery voltage).

8.4.3 CAB
CAB, description
page

This group covers functions in the cab.


DIAGNOSIS
CAN/POWER LIGHTS CAB Confirm selection with function key for Enter.
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
005301

OLS EXTRA

Workshop Manual DCF 90-100 VDCF03.01GB


38 8 Control system – 8.4.3.1 CAB, menu 1

8.4.3.1 CAB, menu 1


WASHER, SWITCH
page

Description: Signal from gear and multi-function lever switch washer.


DIAG CAB 1(X) Circuit diagram: Circuit 9.5-1
WASHER
SWITCH X Connection: signal from S162/53C to digital in D790-2/K3:4
OUTPUT FRONT XY
Function: 9.5 Wiper/washer system

005541
OUTPUT REAR ROOF XY
Signal value:

1 Input signal active.

0 No signal.

WASHER FRONT, OUTPUT


page

Description: Voltage feed to windscreen washer motor


Circuit diagram: Circuit 9.5-1
Connection: digital out from D790-1/K10:13 to M651-1
Function: 9.5.4 Washer motor and reservoir
Signal value:

01 No output signal. Error detection only possible when output


signal is active.

10 Output signal active, short-circuiting or open circuit.

11 Output signal active, circuit OK.

WASHER REAR ROOF, OUTPUT


page

Description: Grounding of motor washer roof and rear window. The


motor is supplied with voltage parallel with Motor windshield washing,
activation is controlled by controlling grounding of the motor. The mo-
tor is grounded at windshield washing if the wiper motor roof or rear
window is activated.
Circuit diagram: Circuit 9.5-1
Connection: PWM out D790-1/K5:4 to M651-2
Function: 9.5.4 Washer motor and reservoir
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is
active.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.3.2 CAB, menu 2 39

8.4.3.2 CAB, menu 2


FRONT WIPER, SWITCH (1-3)
page

Description: Signal from multi-function lever switch wiper function.


DIAG CAB 2(X)
Circuit diagram: Circuit 9.5-1
FRONT WIPER
SWITCH (1-3) X Connection:
OUTPUT XY
X = 1 Interval slow: signal from S162/J1 to digital in D790-2/K3:6

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.

FRONT WIPER, OUTPUT


page

Description: Voltage feed to wiper front.


Circuit diagram: Circuit 9.5-1
Connection: digital out from D790-1/K2:1 to M650-1/53
Function: 9.5.5 Wiper motor front
Signal value:

01 No output signal. Error detection only possible when output


signal is active.

10 Output signal active, short-circuiting or open circuit.

11 Output signal active, circuit OK.

FRONT WIPER, FEEDBACK


page

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:

1 Input signal active (wiper sweep).

0 No signal (resting position).

Workshop Manual DCF 90-100 VDCF03.01GB


40 8 Control system – 8.4.3.3 CAB, menu 3

8.4.3.3 CAB, menu 3


REAR WIPER, SWITCH
page

Description: Status of rear window wiper switch on KIT control unit


DIAG CAB 3(X) (D790-2).
REAR WIPER
SWITCH X Circuit diagram: -
OUTPUT XY Connection: -

005543
FEEDBACK X
Function: 9.5 Wiper/washer system
Signal value:

1 Input signal active. Key for continuous/interval pressed down.

0 No signal.

REAR WIPER, OUTPUT


page

Description: Voltage feed to direction windshield wiper rear.


Circuit diagram: Circuit 9.5-1
Connection: digital out from D790-1/K2:4 to M650-2/53
Function: 9.5.7 Wiper motor rear
Signal value:

01 No output signal. Error detection only possible when output


signal is active.

10 Output signal active, short-circuiting or open circuit.

11 Output signal active, circuit OK.

REAR WIPER, FEEDBACK


page

Description: Signal from motor windshield wiper rear, indicates when


wiper motion is completed.
Circuit diagram: Circuit 9.5-1
Connection: signal from M650-2/31b to digital in D790-1/K12:2
Function: 9.5.7 Wiper motor rear
Signal value:

1 Input signal active (wiper sweep).

0 No signal (resting position).

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.3.4 CAB, menu 4 41

8.4.3.4 CAB, menu 4


ROOF WIPER, SWITCH
page

Description: Signal from switch wiper roof.


DIAG CAB 4(X)
Circuit diagram: -
ROOF WIPER
SWITCH X Connection: -
OUTPUT XY
Function: 9.5 Wiper/washer system

005544
FEEDBACK X
Signal value:

1 Input signal active. Key for continuous/interval pressed down.

0 No signal.

ROOF WIPER, OUTPUT


page

Description: Voltage feed to wiper roof.


Circuit diagram: Circuit 9.5-1
Connection: digital out from D790-1/K10:14 to wiper motor M650-3/53
Function: 9.5.6 Wiper motor roof
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is
active.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

ROOF WIPER, FEEDBACK


page

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:

1 Input signal active (wiper sweep).

0 No signal (resting position).

Workshop Manual DCF 90-100 VDCF03.01GB


42 8 Control system – 8.4.3.5 CAB, menu 5

8.4.3.5 CAB, menu 5


HORN, SWITCH
page

Description: Signal from switch horn.


DIAG CAB 5(X)
Circuit diagram: Circuit 9.7-1
HORN
SWITCH X Connection: signal from S162/H to digital in D790-2/K3:2
SWITCH 2 X
Function: 9.7 Signal system

005545
OUTPUT XY
Signal value:

1 Input signal active.

0 No signal.

HORN, SWITCH 2
page

Description: Signal from horn switch on hydraulic control panel.


Circuit diagram: Circuit 9.7-4
Connection: signal from S149-3 to digital in D790-1/K9:10
Function: 9.7 Signal system
Signal value:

1 Input signal active.

0 No signal.

HORN, OUTPUT
page

Description: Voltage feed to horn.


Circuit diagram: Circuits 9.7-1 and 9.7-3

Connection: digital out D790-1/K11:11 to H850 ( for compressor


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

01 No output signal. Error detection only possible when output


signal is active.

10 Output signal active, short-circuiting or open circuit.

11 Output signal active, circuit OK.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.3.6 CAB, menu 6 43

8.4.3.6 CAB, menu 6


BUZZER
page

Description: Voltage feed to buzzer for alarm indication panel, feed.


DIAG CAB 6(X)
Circuit diagram: Circuit 9.7-1
BUZZER XY
SWITCH SEAT X Connection: digital out from D790-2/K8:4 to H853/1
ALARM X
Function: 9.3 Seats, 1 Engine, 8.2.1 Overload protection

005546
OP X
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is
active.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

SWITCH SEAT
page

Description: Signal from sensor operator in seat.


Circuit diagram: Circuit 9.7-1
Connection: signal from S230/1 to D790-1/K11:14
Function: 9.3.14 Sensor operator in seat

1 Input signal active. Operator in seat.

0 No signal. No operator in seat.

ALARM
page

Description: Status for alarm indication panel, warning from control


system.
Circuit diagram: -
Connection: -
Function: 8.1.2 Information display

1 Conditions for activation of buzzer from seat switch and park-


ing brake are fulfilled.

0 Conditions for activation of buzzer are not fulfilled.

Workshop Manual DCF 90-100 VDCF03.01GB


44 8 Control system – 8.4.3.7 CAB, menu 7

OP
page

Description: Status for overload protection warning from control


system.
Circuit diagram: Circuit 8.2_2
Connection: -
Function: 8.2.1 Overload protection
Signal value:

1 Conditions for activation of buzzer fulfilled, that is, overload


system is indicating.

0 Conditions for activation of buzzer are not fulfilled.

8.4.3.7 CAB, menu 7


FUEL, SENSOR VALUE
page

Description: Signal from sensor fuel level.


DIAG CAB 7(X)
Circuit diagram: Circuit 1.0-1
FUEL
SENSOR VALUE XXXohm Connection: analogue rheostat signal from B757 to D797-1/K2:15
PROC XXX
Function: 1.2.2 Sensor fuel level
009182

Signal value: XXXOHM = Current resistance value from sensor fuel


level in ohm.

FUEL, PROC
page

Description: Control system’s interpretation of signal from fuel tank


sensor.
Circuit diagram: -
Connection: -
Function: 1.2.2 Sensor fuel level
Signal value: XXX = 0-100 = 0-100 % = Fuel volume in tank.

8.4.3.8 CAB, menu 8


SEAT HEATER, SWITCH
page

Description: Signal from seat heater switch.


DIAG CAB 8(X)
Circuit diagram: Circuit 9.3-1
SEAT HEATER
SWITCH X Connection: signal from S143/1 to digital in D790-1/K6:6
OUTPUT XY
Function: 9.3 Seats
005548

Signal value:

1 Input signal active.

0 No signal.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.4 CLIMATE 45

SEAT HEATER, OUTPUT


page

Description: Voltage feed to seat heating relay.


Circuit diagram: Circuit 9.3-1
Connection: digital out from D790-1/K10:7 to K383/86
Function: 9.3.3 Heating coil
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is
active.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

8.4.4 CLIMATE
CLIMATE, description
page

This group covers the cab’s climate control system.


DIAGNOSIS
CAN/POWER LIGHTS CAB Confirm selection with function key for Enter.
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
005302

OLS EXTRA

8.4.4.1 CLIMATE, menu 1


PRESENT INPUT SIGNAL, REQUIRED TEMP
page

Description: Set value for desired temperature.


DIAG CLIMATE 1(X)
Circuit diagram: Circuit 9.4-1
PRESENT INPUT SIGNAL
REQUIRED TEMP XXX Connection: signal from S117/3 to analogue in D790-1/K5:8
PRESENT TEMP XXX
Function: 9.4 Heating, ventilation and air conditioning
005549

WATER VALVE FEEDB. XXX


Signal value: XXX = 160-280 = 16-28 °C Preset temperature shown in
tenths of degrees and adjusted in increments of half degrees (200 =
20 °C). Test by increasing or decreasing temperature with the temper-
ature switch on the panel.

PRESENT INPUT SIGNAL, PRESENT TEMP


page

Description: Signal from sensor cab temperature.


Circuit diagram: Circuit 9.4-1
Connection: signal from B775-1/2 to input D790-1/K4:8
Function: 9.4.17 Sensor cab temperature
Signal value: XXX = Cab’s interior temperature in tenths of degrees
(200 = 20 °C).

Workshop Manual DCF 90-100 VDCF03.01GB


46 8 Control system – 8.4.4.2 CLIMATE, menu 2

PRESENT INPUT SIGNAL, WATER VALVE FEEDB.


page

Description: Water valve’s position (opening in percent).


Circuit diagram: Circuit 9.4-2
Connection: signal from Y673/9 to analogue in D790-1/K10:4
Function: 9.4.5 Water valve
Signal value: XXX = 0-100 = 0-100% = Water valve’s opening in %. 0
= Closed. 100 = Fully open.

8.4.4.2 CLIMATE, menu 2


TEMP COIL
page

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 DE-ICE XXX


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

TEMP COOLANT
page

Description: Coolant temperature (temperature of the engine’s cool-


ant). Signal is retrieved from the engine via CAN bus drivetrain.
Circuit diagram: Circuits 9.4-1, 9.4-2
Connection: from engine via CAN bus, see PRESENT INPUT SIG-
NAL, COOLANT TEMP page 63.
Function: 1.7.9 Sensor coolant temperature
Signal value: XXX = Engine temperature in tenths of degrees (200 =
20 °C).

TEMP AMBIENT
page

Description: Outdoor temperature. Heat radiation from engine and sun


may affect the value since the sensor is located on the rear of the cab
roof.
Circuit diagram: Circuit 9.4-1
Connection: signal from B774/2 to input D790-1/K4:9
Function: 9.4.18 Sensor ambient temperature
Signal value: XXX = Outdoor temperature in tenths of degrees (200 =
20 °C).

TEMP DE-ICE
page

Description: Temperature in refrigerant circuit.


Circuit diagram: Circuit 9.4-1
Connection: signal from B775-3/2 to input D790-1/K4:11
Function: 9.4.12 Sensor temperature refrigerant
Signal value: XXX = Refrigerant temperature in tenths of degrees (200
= 20 °C).

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.4.3 CLIMATE, menu 3 47

8.4.4.3 CLIMATE, menu 3


PRESENT INPUT SIGNAL, PRESSURE SWITCH
page

Description: Signal from refrigerant pressure switch.


DIAG CLIMATE 3(X)
Circuit diagram: Circuit 9.4-1
PRESENT INPUT SIGNAL
PRESSURE SWITCH X Connection: signal from S246/2 to digital in D797-1/K1:40
Function: 9.4.10 Pressure switch

005551
Signal value:

1 Input signal active. Press Ok.

0 No signal, too high or too low pressure.

8.4.4.4 CLIMATE, menu 4


PRESENT INPUT SIGNAL, WATER VALVE
page

Description: Signal from water valve, the voltage is a measure of the


DIAG CLIMATE 4(X) position.
PRESENT INPUT SIGNAL
WATER VALVE XX.XXV Circuit diagram: Circuit 9.4-2
DRAUGHT VALVE XX.XXV Connection: signal from Y673/9 to analogue in D790-1/K10:4
005552

Function: 9.4.5 Water valve


Signal value: XX.XXV = 0.50 - 4.50 V

PRESENT INPUT SIGNAL, DRAUGHT VALVE


page

Description: Signal from the engine to the air distributor. Voltage is a


measure of the valve’s position.
Circuit diagram: Circuit 9.4-2
Connection: signal from Y672/9 to analogue in D790-1/K4:7
Function: 9.4.14 Air distributor
Signal value: XX.XXV = 0.50 - 4.50 V

8.4.4.5 CLIMATE, menu 5


PRESENT INPUT SIGNAL, REQUIRED TEMP
page

Description: Signal from switch temperature. Voltage when switch is


DIAG CLIMATE 5(X) pressed in voltage level indicates increase or decrease of the
PRESENT INPUT SIGNAL temperature.
REQUIRED TEMP XX.XXV
REQ. DRAUGHT XX.XXV Circuit diagram: Circuit 9.4-1
005553

REQ. FAN SPEED XX.XXV Connection: signal from S117/3 to analogue in D790-1/K5:8
Function: 9.4 Heating, ventilation and air conditioning
Signal value: XX.XXV ∼ 2.4 / 0 / 5.0 V = Increase / - / decrease

Workshop Manual DCF 90-100 VDCF03.01GB


48 8 Control system – 8.4.4.6 CLIMATE, menu 6

PRESENT INPUT SIGNAL, REQ. DRAUGHT


page

Description: Signal from switch air distribution, voltage when switch is


pressed in. The voltage level indicates change of air control against
windshield (up) or floor (down). The valve’s position changes in steps
between windshield - floor.
Circuit diagram: Circuit 9.4-1
Connection: signal from S139/3 to analogue in D790-1/K5:9
Function: 9.4 Heating, ventilation and air conditioning
Signal value: XX.XXV ∼ 2.4 / 0 / 5.0 V = Up / - / down.

PRESENT INPUT SIGNAL, FAN SPEED


page

Description: Signal from switch fan speed, switch controls increase or


decrease of fan speed. Speed is endless adjustable. The voltage level
indicates if the speed should be increased or decreased.
Circuit diagram: Circuit 9.4-1
Connection: signal from S118/3 to analogue in D790-1/K5:7
Function: 9.4 Heating, ventilation and climate control unit
Signal value: XX.XXV ∼ 2.4 / 0 / 5.0 V = Increase / - / decrease.

8.4.4.6 CLIMATE, menu 6


PRESENT OUTPUT SIGNAL, FAN SPEED
page

Description: Current control of fan motor, speed is controlled with


DIAG CLIMATE 6(X) PWM-control of grounding (of fan motor).
PRESENT OUTPUT SIGNAL
FAN SPEED XXX Circuit diagram: Circuit 9.4-2
RECIRKULATION XY Connection: analogue out from D790-1/K2:2 to M657/31
005554

COMPRESSOR XY
Function: 9.4.3 cab fan
Signal value: XXX = 0-255 = Fan speed (255 = max. fan speed).

PRESENT OUTPUT SIGNAL, RECIRCULATION


page

Description: Voltage feed to motor for fresh air and recirculation


damper.
Circuit diagram: Circuit 9.4-2
Connection: digital out from D790-1/K2:3 to M612
Function: 9.4.2 Fresh air and recirculation damper
Signal value:

01 No output signal. Error detection only possible when output


signal is active.

10 Output signal active, short-circuiting or open circuit.

11 Output signal active, circuit OK.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.4.7 CLIMATE, menu 7 49

PRESENT OUTPUT SIGNAL, COMPRESSOR


page

Description: Voltage feed AC compressor’s electromagnetic clutch.


Controls cut-in and cut-out of the compressor. Two outputs are con-
nected in parallel to handle the current.
Circuit diagram: Circuit 9.4-2
Connection: digital out from D797-1/K1:25 and D797-1/K1:29 to M645
Function: 9.4.7 Compressor
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is
active.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

8.4.4.7 CLIMATE, menu 7


OUTPUT WATER VALVE, CLOCKWISE
page

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

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


005555

0V circuiting can only be detected when the output signal is


H-bridge active.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

Workshop Manual DCF 90-100 VDCF03.01GB


50 8 Control system – 8.4.4.8 CLIMATE, menu 8

OUTPUT WATER VALVE, COUNTER-CLOCKWISE


page

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

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is
active.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

8.4.4.8 CLIMATE, menu 8


OUTPUT DRAUGHT VALVE, CLOCKWISE
page

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

00 No output signal, open circuit in circuit.

M 01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is
active.

10 Output signal active, short-circuiting.


005556

0V 11 Output signal active, circuit OK or open circuit. Open circuit


H-bridge can only be detected when the output signal is active.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.5 HYD 51

OUTPUT DRAUGHT VALVE, COUNTER-CLOCKWISE


page

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

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is
active.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

8.4.5 HYD
HYD, description
page

This group covers the hydraulic functions.


DIAGNOSIS
CAN/POWER LIGHTS CAB Confirm selection with function key for Enter.
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
005303

OLS EXTRA

8.4.5.1 HYD, menu 1


HYDRAULIC OIL, TEMP
page

Description: Signal from sensor hydraulic oil temperature.


DIAG HYDRAULIC 1(X)
Circuit diagram: Circuit 10.6-1
HYDRAULIC OIL
TEMP XXX Connection: signal from B776/1 to temperature in D797-1/K2:13
FAN XY
Function: 10.6.4 Sensor hydraulic oil temperature
010070

SET OUTPUT + - X
Signal value: XXX = Temperature in tenths of degrees (200 = 20 °C).

HYDRAULIC OIL, FAN


page

Description: Voltage feed cooling fan hydraulic oil.


Circuit diagram: Circuit 10.6-1
Connection: digital out from D797-1/K1:14 to M668/1
Function: 10.6.3 Cooling fan
Signal value:

Workshop Manual DCF 90-100 VDCF03.01GB


52 8 Control system – 8.4.5.2 HYD, menu 2

HYDRAULIC OIL, SET OUTPUT +/-


page

Description: Functionality test of hydraulic oil cooling fan.


Circuit diagram: Circuit 10.6-1
Connection: digital out from D797-1/K1:14 to M668/1 is activated or
deactivated with +/-
Function: 10.6.3 Cooling fan
Signal value:

01 No output signal. Error detection only possible when output


signal is active.

10 Output signal active, short-circuiting or open circuit.

11 Output signal active, circuit OK.

8.4.5.2 HYD, menu 2


BRAKE COOLANT OIL, TEMP
page

DIAG HYDRAULIC 2(X)


BRAKE COOLANT OIL
TEMP XXX
FAN XY FEEDBACK X
010071

SET OUTPUT + - X

Menu for DCF360-450CSG


Description: Signal from sensor brake oil temperature.
DIAG HYDRAULIC 2(X)
Circuit diagram: Circuit 4.8-1
BRAKE COOLANT OIL
TEMP XXX Connection: signal from B772/1 to temperature in D797-1/K2:6
FAN XY
Function: DCF360-450CSG 4.8.10 Brake oil temperature sensor, DCF
010072

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).

BRAKE COOLANT OIL, FAN


page

Description: Voltage feed to cooling fan brake oil.


Circuit diagram: Circuit 4.8-1
Connection: digital out from D797-1/K1:3 via K3774/86 to M674/1
Function: 4.8.9 Cooling fan
Signal value:

BRAKE COOLANT OIL, FEEDBACK


page

Description: Signal from the brake oil cooling fan.


Circuit diagram: Circuit 4.8-1
Connection: signal from M674/1 to D797-1/K1:3 via K3774/86
Function: 4.8.9 Cooling fan
Signal value:

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.5.3 HYD, menu 3 53

BRAKE COOLANT OIL, SET OUTPUT +/-


page

Description: Voltage feed to cooling fan brake oil.


Circuit diagram: Circuit 4.8-1
Connection: digital out from D797-1/K1:3 via K3774/86 to M674/1 is
activated or deactivated with +/-
Function: 4.8.9 Cooling fan
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is
active.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

8.4.5.3 HYD, menu 3


HYDRAULIC PRESSURE, LIFT CYLINDER
page

Description: Pressure on lift cylinders’ piston side (C+). For voltage


DIAG HYDRAULIC 3(X) value, see PRESENT INPUT SIGNAL, LIFT CYLINDER page 137.
HYDRAULIC PRESSURE
Circuit diagram: Circuit 8.2-2
LIFT CYLINDER XXX Connection: signal from B768-1/3 to analogue in D797-1/K1:21
TILT CYLINDER XXX
Function: 7.2.8 Sensor hydraulic pressure lift cylinder
Signal value: XXX = 0-250 = Hydraulic pressure 0 - 25 MPa. (255 =
C- incorrect signal.)

C+
007239

HYDRAULIC PRESSURE, TILT CYLINDER


page

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.)

Workshop Manual DCF 90-100 VDCF03.01GB


54 8 Control system – 8.4.5.4 HYD, menu 4

8.4.5.4 HYD, menu 4


PRESSURE SWITCHES, BRAKE PRESSURE
page

Description: Signal from normally closed (NC) switch, brake pressure.


DIAG HYDRAULIC 4(X)
Circuit diagram: Circuit 4.0-1
PRESSURE SWITCHES
BRAKE PRESSURE X Connection: signal from S204/2 to analogue in D797-1/K1:13
BRAKE LIGHT PRESS. X
Function: 4.3.7 Normally open (NO) switch, brake pressure

007240
DECLUTCH PRESSURE X
Signal value:

1 Input signal active.

0 No signal.

PRESSURE SWITCHES, BRAKE LIGHT PRESSURE


page

Description: Signal from make-contact brake lights.


Circuit diagram: Circuit 9.6-5
Connection: signal from S216/2 to digital in D797-1/K1:20
Function: 4.3.8 Make-contact brake lights
Signal value:

1 Input signal active.

0 No signal.

PRESSURE SWITCHES, DECLUTCH PRESSURE


page

Description: Signal from normally closed (NC) switch, disengagement.


Circuit diagram: Circuit 2.0-1
Connection: signal from S220-2/2 to analogue in D797-1/K1:27
Function: 2.8.2 Normally closed (NC) switch, disengagement
Signal value:

1 Input signal active.

0 No signal.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.5.5 HYD, menu 5 55

8.4.5.5 HYD, menu 5


P-BRAKE, SWITCH
page

Description: Signals from switch parking brake. Two signals, one for
DIAG HYDRAULIC 5(X) released parking brake and one for applied parking brake. Both sig-
P-BRAKE nals must be valid to enable release of parking brake.
SWITCH X/Y
FEEDBACK SWITCH X Circuit diagram: Circuit 4.0-1

007241
VALVE XY Connection: signal from S107/1 to digital in D790-1/K8:13 and from
S107/7 to digital in D790-1/K8:5
Function: 4.5 Parking brake system
Signal value:

1/0 Open, parking brake released.

0/1 On, parking brake applied.

P-BRAKE, FEEDBACK SWITCH


page

Description: Signal from break-contact parking brake.


Circuit diagram: Circuit 4.0-1
Connection: signal from S200 to analogue in D797-1/K1:41
Function: 4.5.5 Normally open (NO) switch, parking brake
Signal value:

1 Input signal active.

0 No signal.

P-BRAKE, VALVE
page

Description: Voltage feed to Solenoid valve parking brake.


Circuit diagram: Circuit 4.0-1
Connection: digital out from D797-1/K1:34 to solenoid valve Y642/1
Function: 4.5.3 Solenoid valve parking brake
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is
active.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

Workshop Manual DCF 90-100 VDCF03.01GB


56 8 Control system – 8.4.5.6 HYD, menu 6

8.4.5.6 HYD, menu 6


CUT OFF HYDRAULIC PUMPS, PUMP 2
page

Description: Voltage feed to solenoid valve for disconnection of the hy-


DIAG HYDRAULIC 6(X) draulic pump
CUT OFF HYDRAULIC
PUMPS Circuit diagram: Circuit 10.4-1
PUMP 2 XY Connection: digital out from D797-1/K1:39 to solenoid valve Y6062

007242
PUMP ATTACHMENT XY
Function: 10.4.3 Vane pump with fixed displacement
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is
active.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

CUT OFF HYDRAULIC PUMPS, PUMP ATTACHMENT


page

Description: Voltage feed to solenoid valve for disconnection of the hy-


draulic pump for the attachment.
Circuit diagram: Circuit 10.4-1
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:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is
active.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.5.7 HYD, menu 7 57

8.4.5.7 HYD, menu 7


PRESENT OUTPUT SIGNAL EXTRA HYD PUMP, VALVE
page

Only applies to DCF 90-100


DIAG HYDRAULIC 7(X)
Description: Voltage feed to solenoid valve for quick-lift pump.
PRESENT OUTPUT SIGNAL
EXTRA HYD PUMP Circuit diagram: 10.4-1
VALVE XY
Connection: digital out from D797-1/K1:39 to solenoid valve Y6062

010073
SET OUTPUT + - X
Function: 10.4.2 Axial piston pump with variable displacement
Signal value:

1 Output signal active.

0 No output signal.

PRESENT OUTPUT SIGNAL EXTRA HYD PUMP, SET


page

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:

1 Output signal active.

0 No output signal.

8.4.5.8 HYD, menu 8


PRESENT OUTPUT SIGNAL, PRESSURE TO ATTACHM.
page

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:

1 Output signal active.

0 No output signal.

Workshop Manual DCF 90-100 VDCF03.01GB


58 8 Control system – 8.4.6 ENGINE

PRESENT OUTPUT SIGNAL, PRESSURE TO ATTACHM,


page

SET OUTPUT +/-


Description: Begin sending or cut off hydraulic pressure to the attach-
ment.
Circuit diagram: 10.4-1
Connection: digital out from D797-1/K1:35 to solenoid valve Y6062-2
is activated or deactivated with +/-
Function: 10.4.2 Axial piston pump with variable displacement
Signal value:

1 Output signal active.

0 No output signal.

8.4.6 ENGINE
ENGINE, description
page

This group covers engine functions.


DIAGNOSIS
CAN/POWER LIGHTS CAB Confirm selection with function key for Enter.
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
005306

OLS EXTRA

8.4.6.1 ENGINE, menu 1


PRESENT INPUT SIGNAL, ACCELERATOR
page

Description: Signal from accelerator pedal.


DIAG ENGINE 1(X)
Circuit diagram: Circuit 1.0-1
PRESENT INPUT SIGNAL
ACCELERATOR X.XXV Connection: signal from B690-1/2 to analogue in D790-1/K6:11
REQUIRED SPD PROC XXX
Function: 1 Engine
008898

REQUIRED SPD RPM XXXX


Signal value: X.XXV = 0.50 - 4.50 V

PRESENT INPUT SIGNAL, REQUIRED SPD PROC


page

Description: Required engine speed (in percent) which is sent from 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%

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.6.2 ENGINE, menu 2 59

PRESENT INPUT SIGNAL, REQUIRED SPD RPM


page

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

8.4.6.2 ENGINE, menu 2


RESENT INPUT SIGNAL, ENGINE SPEED EDC
page

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.

PRESENT INPUT SIGNAL, ENGINE SPEED TCU


page

Description: Engine speed from transmission control unit (D793) to the


cab control unit (D790-1) via the CAN bus drivetrain. The actual value
for engine speed.
Circuit diagram: -
Connection: -
Function: 2.2.5 Sensor engine rpm and oil temperature transmission
Signal value: XXXX = active speed in rpm.

8.4.6.3 ENGINE, menu 3


PRESENT INPUT SIGNAL, PRESENT TORQUE
page

Description: Actual torque from engine control unit (D794). Percent-


DIAG ENGINE 3(X) age torque use of engine’s capacity.
PRESENT INPUT SIGNAL
PRESENT TORQUE XXX Circuit diagram: -
REQUIRED TORQUE XXX Connection: -
005309

PRES TORQUE @ RPM XXX


Function: 1.9 Control system, engine
Signal value: XXXX = 0 - 100%

PRESENT INPUT SIGNAL, REQUIRED TORQUE


page

Description: Requested torque from cab control unit (D790-1) to en-


gine control unit (D794).
Circuit diagram: -
Connection: -
Function: 1.9 Control system, engine
Signal value: XXXX = 0-100%

Workshop Manual DCF 90-100 VDCF03.01GB


60 8 Control system – 8.4.6.4 ENGINE, menu 4

PRESENT INPUT SIGNAL, PRES TORQUE @ RPM


page

Description: Available torque at current engine speed.


Circuit diagram: -
Connection: -
Function: 1.9 Control system, engine
Signal value: XXX = 0-100%

8.4.6.4 ENGINE, menu 4


PRESENT INPUT SIGNAL, PREHEAT SWITCH
page

DIAG ENGINE 4(X)


PRESENT INPUT SIGNAL Description: Signal from ignition, preheating position. Only used on
PREHEAT SWITCH X machines with Volvo engines.
CRANK ENGINE SWITCH X
Circuit diagram: Circuits 11.5-3, 1.0-1
005310

D+ X
Connection: signal from S150/19 to digital in D790-2/K2:2
Function: 1 Engine, 1.10.1 Preheating
Signal value:

1 Input signal active.

0 No signal.

PRESENT INPUT SIGNAL, CRANK ENGINE SWITCH


page

Description: Signal from ignition, start position.


Circuit diagram: Circuits 11.5-3, 1.0-1
Connection: signal from S150/50 to digital in D790-2/K2:1
Function: 1.1.1 Ignition switch, 1.11 Start and stop
Signal value:

1 Input signal active.

0 No signal.

PRESENT INPUT SIGNAL, D+


page

Description: Signal from alternator, indicates if alternator supplies


current.
Circuit diagram: Circuits 11.5-1, 1.0-2A, 1.0-1
Connection: signal from G660/D+ to digital in D797-1/K2:16
Function: 11.4.1 Alternator
Signal value:

1 Input signal active.

0 No signal.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.6.5 ENGINE, menu 5 61

8.4.6.5 ENGINE, menu 5


PRESENT OUTPUT SIGNAL, PREHEAT
page

Description: Status for preheating of induction air.


DIAG ENGINE 5(X)
Circuit diagram: -
PRESENT OUTPUT SIGNAL
PREHEAT X Connection:
CRANK ENGINE CAN X
Volvo: software signals on CAN-bus drivetrain

007639
CRANK ENGINE WIRE XY
Cummins: controlled by engine’s control system.
Function: 1.10.1 Preheating
Signal value:

1 Output signal active.

0 No output signal.

PRESENT OUTPUT SIGNAL, CRANK ENGINE CAN


page

Description: Voltage feed, starter motor. For Volvo TAD760VE,


TAD950VE, TAD952VE and TAD1250VE.
Circuit diagram: -
Connection: software signals on CAN-bus drivetrain.
Function: 1.11 Start and stop
Signal value:

1 Output signal active.

0 No output signal.

PRESENT OUTPUT SIGNAL, CRANK ENGINE WIRE


page

Description: Voltage feed to starter motor relay. For Cummins QSM11.


Circuit diagram: 1.0-1, 1.0-2B1
Connection: digital out D797-1/K1:32 to K360/86.
Function: 1.11 Start and stop
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is
active.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

Workshop Manual DCF 90-100 VDCF03.01GB


62 8 Control system – 8.4.6.6 ENGINE, menu 6

8.4.6.6 ENGINE, menu 6


PRESENT INPUT SIGNAL, OIL PRESSURE
page

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.

PRESENT INPUT SIGNAL, BOOST PRESSURE


page

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.

PRESENT INPUT SIGNAL, OIL LEVEL


page

Only Volvo TAD950VE, TAD952VE and TAD1250VE engines


Description: Engine oil level. CAN bus message from engine control
unit (D794) to cab control unit (D790-1).
Circuit diagram: See supplier documentation, engine
Connection: Volvo TAD950VE, TAD952VE, TAD1250VE: signal from
"15 Oil level sensor" to engine control (D794) "connector A" sleeve 3
Function: -
Signal value: XXX = 0-100 = 0-100% = Oil level in percent.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.6.7 ENGINE, menu 7 63

8.4.6.7 ENGINE, menu 7


PRESENT INPUT SIGNAL, OIL TEMP
page

Description: Engine oil temperature. CAN bus message from engine


DIAG ENGINE 7(X) control unit (D794) to cab control unit (D790-1).
PRESENT INPUT SIGNAL
OIL TEMP XXX Circuit diagram: see supplier documentation, engine
COOLANT TEMP XXX Connection:

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.

PRESENT INPUT SIGNAL, COOLANT TEMP


page

Description: Coolant temperature. CAN bus message from engine


control unit (D794) to cab control unit (D790-1).
Circuit diagram: see supplier documentation, engine
Connection:
Volvo TAD760VE: signal from "4 coolant temperature sensor" to
engine control unit (D794) "Connector B" sleeve 27
Volvo TAD950VE, TAD952VE, TAD1250VE: signal from "16
Coolant temperature sensor" to engine control (D794) "connector
B" sleeve 27
Cummins QSM11: signal from "Coolant temperature sensor" to
engine control unit (D794) "Sensor connector" sleeve 02
Function: 1.7.9 Sensor coolant temperature
Signal value: XXX = 200 equals 20 °C.

Workshop Manual DCF 90-100 VDCF03.01GB


64 8 Control system – 8.4.6.8 ENGINE, menu 8

PRESENT INPUT SIGNAL, INTAKE MAIN.TEMP


page

Description: Charge air temperature. CAN bus message from engine


control unit (D794) to cab control unit (D790-1).
Circuit diagram: see supplier documentation, engine
Connection:
Volvo TAD760VE: signal from "34 charge air pressure/tempera-
ture sensor" to engine control unit (D794) "connector A" sleeve 47
Volvo TAD950VE, TAD952VE, TAD1250VE: signal from "23
Charge air pressure/temperature sensor" to engine control unit
(D794) "Connector B" sleeve 47
Cummins QSM11: signal from "Intake manifold (boost) tempera-
ture sensor" to engine control unit (D794) "Sensor connector"
sleeve 38
Function: 1.6.6 Sensor charge-air temperature
Signal value: XXX = 200 equals 20 °C.

8.4.6.8 ENGINE, menu 8


PRESENT EDC ERROR, NO. OF ACT ERROR
page

Description: Number of error codes from engine control unit EDC


DIAG ENGINE 8(X) (D794).
PRESENT EDC ERROR
NR OF ACT ERROR XX Circuit diagram: -
SPN XXXX Connection: -
005314

FMI XX
Function: 1.9 Control system
Signal value: XX = number of active error codes.

PRESENT EDC ERROR, SPN


page

Description: SPN number for the first error code from 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.

PRESENT EDC ERROR, FMI


page

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.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.6.9 ENGINE, menu 9 65

8.4.6.9 ENGINE, menu 9


FUEL CONSUMPTION, MOMENTARY l/h
page

Description: Current fuel consumption in litres/hour.


DIAG ENGINE 9(X)
Circuit diagram: -
FUEL CONSUMPTION
MOMENTARY l/h XXX Connection: -
Function: 1.2 Fuel system

005315
Signal value: XXX = fuel consumption in l/h

8.4.7 TRANSM
TRANSM, description
page

This group covers transmission functions.


DIAGNOSIS
CAN/POWER LIGHTS CAB Confirm selection with function key for Enter.
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
005324

OLS EXTRA

8.4.7.1 TRANSM, menu 1


PRESENT INPUT SIGNAL, BRAKE PEDAL
page

Description: Not used.

PRESENT INPUT SIGNAL, DECLUTCH SWITCH


page

Description: Signal from declutch pedal.


DIAG TRANSM. 1(X)
Circuit diagram: Circuit 2.0-1
PRESENT INPUT SIGNAL
BRAKE PEDAL X.XXV Connection: signal from S220-1/2 to digital in D790-1/K6:14
DECLUTCH SWITCH X
Function: 2 Transmission
005325

DECLUTCH PRESS SW. X


Signal value:

1 Input signal active. Declutch pedal pressed down.

0 No signal.

PRESENT INPUT SIGNAL, DECLUTCH PRESS SW.


page

Description: Signal from normally closed (NC) switch, disengagement


(pressure switch).
Circuit diagram: Circuit 2.0-1
Connection: signal from S220-2/2 to digital in D797-1/K1:27
Function: 2.8.2 Normally closed (NC) switch, disengagement
Signal value:

1 Input signal active.

0 No signal.

Workshop Manual DCF 90-100 VDCF03.01GB


66 8 Control system – 8.4.7.2 TRANSM, menu 2

8.4.7.2 TRANSM, menu 2


SWITCHES, FORWARD
page

Description: Signal from gear and multi-function lever (forward).


DIAG TRANSM. 2(X)
Circuit diagram: Circuit 2.0-1
SWITCHES
FORWARD X Connection: signal from S162/F to digital in D790-2/K3:11
REVERSE X
Function: 2 Transmission

005326
SHIFT MODE X
Signal value:

1 Input signal active. Travel direction forward selected.

0 No signal.

SWITCHES, REVERSE
page

Description: Signal from gear and multi-function lever (reverse).


Circuit diagram: Circuit 2.0-1
Connection: signal from S162/R to digital in D790-2/K3:12
Function: 2 Transmission
Signal value:

1 Input signal active. Travel direction reverse selected.

0 No signal.

SWITCHES, SHIFT MODE


page

Description: Signal from shifting program switch. Status on CAN bus


from KIT control unit (D790-2). The switches are integrated in the KIT
control unit (D790-2).
Circuit diagram: -
Connection: -
Function: 2 Transmission
Signal value:

1 Shifting program 1 selected.

2 Shifting program 2 selected.

4 Automatic shifting selected.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.7.3 TRANSM, menu 3 67

8.4.7.3 TRANSM, menu 3


PRESENT VALUE, FORWARD
page

Description: Status for forward direction of travel from transmission


DIAG TRANSM. 3(X) control unit (D793). Indicates if forward drive is activated in the trans-
PRESENT VALUE mission.
FORWARD X
REVERSE X Circuit diagram: -

005327
GEAR X Connection: -
Function: 2.8 Control system, transmission
Signal value:

1 Output signal for travel direction forward active.

0 No output signal.

PRESENT VALUE, REVERSE


page

Description: Status for rearward direction of travel from transmission


control unit (D793). Indicates if rearward drive is activated in the trans-
mission.
Circuit diagram: -
Connection: -
Function: 2.8 Control system, transmission
Signal value:

1 Output signal for travel direction reverse active.

0 No output signal.

PRESENT VALUE, GEAR


page

Description: Current gear, status from transmission control unit


(D793). Shows which gear is activated in the transmission.
Circuit diagram: -
Function: 2.8 Control system, transmission
Connection: -
Signal value: X = current gear.

8.4.7.4 TRANSM, menu 4


OPERATING STATE, AUT/MAN MODE
page

Description: Shows which shifting program is selected automatic or


DIAG TRANSM. 4(X) manual.
OPERATING STATE
AUT/MAN MODE X Circuit diagram: -
WARNING X Connection: -
005328

OPERATING MODE X
Function: 2.8 Control system, transmission
Signal value:

1 Automatic.

0 Manual.

Workshop Manual DCF 90-100 VDCF03.01GB


68 8 Control system – 8.4.7.5 TRANSM, menu 5

OPERATING STATE, WARNING


page

Description: Warning for serious malfunction in transmission from


transmission control unit (D793).
Circuit diagram: -
Connection: -
Function: 2.8 Control system, transmission
Signal value:

1 Active error.

0 No errors.

OPERATING STATE, OPERATING MODE


page

Description: Operating mode status for transmission control unit


(D793); also shown in control unit display.
Circuit diagram: -
Connection: -
Function: 2.8 Control system, transmission
Signal value:

0 Not used.

1 Manual or automatic shifting, standard mode shown during


operation.

2 Not used.

3 Not used.

4 Limp home, reduced capacity due to malfunction in


transmission.

5 Shut down, serious transmission malfunction control unit


shuts down, likely that malfunction cannot be shown as CAN-
bus.

6 Calibration of transmission in progress.

8.4.7.5 TRANSM, menu 5


OPERATING STATE, SHIFT IN PROGRESS
page

Description: Status for transmission function during operation, shifting


DIAG TRANSM. 5(X) in progress. Active during shifting.
OPERATING STATE
SHIFT IN PROGRESS X Circuit diagram: -
FAULT X Connection: -
005329

OLD FAULT X
Function: 2.8 Control system, transmission
Signal value:

1 Shifting in progress.

0 No activity.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.7.6 TRANSM, menu 6 69

OPERATING STATE, FAULT


page

Description: Status for transmission’s function during operation, active


error codes present.
Circuit diagram: -
Connection: -
Function: 2.8 Control system, transmission
Signal value:

1 Active error code.

0 No error codes.

OPERATING STATE, OLD FAULT


page

Description: Status for transmission’s function during operation, there


are inactive error codes that have not been acknowledged.
Circuit diagram: -
Connection: -
Function: 2.8 Control system, transmission
Signal value:

1 There are inactive error codes that have not been acknowl-
edged.

0 No unacknowledged error codes.

8.4.7.6 TRANSM, menu 6


DRUM SPEED
page

Description: Signal from sensor rpm drum (position 1).


DIAG TRANSM. 6(X)
Circuit diagram: Circuit 2.0-2A2
DRUM SPEED XXXXHz
OUTPUT SPEED XXXXHz Connection: signal from B752 till D793/B3 and D793/C3
ENGINE SPEED XXXXHz
Function: 2.3.7 Sensor rpm drum
TURBINE SPEED XXXXHz
Signal value: XXXXHz = frequency, indicates pulses from the sensor
in Hz (pulses /second). To convert to rpm, divide frequency by number
1 2 3
of teeth on drum gear.

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)

Workshop Manual DCF 90-100 VDCF03.01GB


70 8 Control system – 8.4.7.7 TRANSM, menu 7

OUTPUT SPEED
page

Description: Signal from sensor rpm output shaft (propeller shaft)


( position 5).
Circuit diagram: Circuit 2.0-2A2
Connection: signal from B758 till D793/ D3 and D793/ E3
Function: 2.3.9 Sensor rpm output shaft
Signal value: XXXXHz = frequency, indicates pulses from the sensor
in Hz (pulses /second). To convert to rpm, divide frequency by number
of teeth on output shaft’s gear.

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: Signal from sensor rpm turbine transmission (position 4).


Circuit diagram: Circuit 2.0-2A2
Connection: signal from B751 to D793/ R2
Function: 2.3.6 Sensor rpm turbine
Signal value: XXXXHz = frequency, indicates pulses from the sensor
in Hz (pulses /second). To convert to rpm, divide frequency by number
of teeth on turbine’s gear.

8.4.7.7 TRANSM, menu 7


OUTPUT STATUS, RSP DRIVE
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

1/3 VFS SELECTION X


Function: 2.8 Control system, transmission

11 Activated high and low side.

10 High side activated, low side no signal.

01 High side no signal, low side activated.

00 No signal.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.7.8 TRANSM, menu 8 71

OUTPUT STATUS, 2/4 VFS SELECTION


page

Description: Status of feed to solenoid valve VFS 2ND/4TH.


Circuit diagram: Circuit 2.0-2A3
Connection: digital out from D793/ D1 and D793/ E1 to Y6069
Function: 2.8 Control system, transmission
Signal value:

1 Activated.

0 No signal.

OUTPUT STATUS, 1/3 VFS SELECTION


page

Description: Status of feed to solenoid valve VFS 1 ST/3 RD.


Circuit diagram: Circuit 2.0-2A3
Connection: signal from D793/ H1 and D793/ J1 to Y6067
Function: 2.8 Control system, transmission
Signal value:

1 Activated.

0 No signal.

8.4.7.8 TRANSM, menu 8


FWD SUPPLY
page

Description: Status for control current to clutch pack forward.


DIAG TRANSM. 8(X)
Circuit diagram: Circuit 2.0-2A3
FWD SUPPLY X
REV SUPPLY X Connection: signal from D793/B1 to Y630
2/4 SUPPLY X
Function: 2.3.5 Valve block, transmission control, 2.8 Control system,
005332

1/3 SUPPLY X
transmission
Signal value:

1 Activated.

0 No signal.

REV SUPPLY
page

Description: Status for control current to clutch pack reverse.


Circuit diagram: Circuit 2.0-2A3
Connection: signal from D793/F1 to Y631
Function: 2.3.5 Valve block, transmission control, 2.8 Control system,
transmission
Signal value:

1 Activated.

0 No signal.

Workshop Manual DCF 90-100 VDCF03.01GB


72 8 Control system – 8.4.7.9 TRANSM, menu 9

2/4 SUPPLY
page

Description: Status for control current to clutch pack 2/4.


Circuit diagram: Circuit 2.0-2A3
Connection: signal from D793/E2 to Y6074
Function: 2.3.5 Valve block, transmission control, 2.8 Control system,
transmission
Signal value:

1 Activated.

0 No signal.

1/3 SUPPLY
page

Description: Status for control current to clutch pack 1/3.


Circuit diagram: Circuit 2.0-2A3
Connection: signal from D793/F2 to Y6075
Function: 2.3.5 Valve block, transmission control, 2.8 Control system,
transmission
Signal value:

1 Activated.

0 No signal.

8.4.7.9 TRANSM, menu 9


FWD FEEDBACK
page

Description: Present control current to solenoid valve clutch pack


DIAG TRANSM. 9(X) forward.
FWD FEEDBACK XXXXmA
REV FEEDBACK XXXXmA Circuit diagram: Circuit 2.0-2A3
2/4 FEEDBACK XXXXmA Connection: signal from D793/B1 to Y630
005333

1/3 FEEDBACK XXXXmA


Function: 2.3.5 Valve block, transmission control, 2.8 Control system,
transmission
Signal value: XXXX = Measured value in mA.

REV FEEDBACK
page

Description: Present control current to solenoid valve clutch pack


reverse
Circuit diagram: Circuit 2.0-2A3
Connection: signal from D793/F1 to Y631
Function: 2.3.5 Valve block, transmission control, 2.8 Control system,
transmission
Signal value: XXXX = Measured value in mA.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.7.10 TRANSM, menu 10 73

2/4 FEEDBACK
page

Description: Present control current to solenoid valve clutch pack 2/4.


Circuit diagram: Circuit 2.0-2A3
Connection: signal from D793/D1 to Y6069
Function: 2.3.5 Valve block, transmission control, 2.8 Control system,
transmission
Signal value: XXXX = Measured value in mA.

1/3 FEEDBACK
page

Description: Present control current to solenoid valve clutch assembly


1/3.
Circuit diagram: Circuit 2.0-2A3
Connection: signal from D793/H1 to Y6067
Function: 2.3.5 Valve block, transmission control, 2.8 Control system,
transmission
Signal value: XXXX = Measured value in mA.

8.4.7.10 TRANSM, menu 10


PRESENT SENSOR INPUT, PRESS FEEDB.
page

Description: Signal from sensor oil pressure in transmission. The


DIAG TRANSM. 10(X) transmission uses a pressure-sensitive make-contact and two resis-
PRESENT SENSOR INPUT tors in the cable harness to generate different voltage levels.
PRESS FEEDB XXXXohm
TRANSM.TEMP XXXXXmV Circuit diagram: Circuit 2.0-2A2
008900

CONV OUT TEMP XXXXXmV Connection: signal from "pressure feedback sensor" to D793/A2
Function: 2.6.2 Sensor oil pressure
Signal value:

0-1000 mV Short-circuiting to ground.

1500-2500 mV Oil pressure is correct.

2500-4000 mV Oil pressure is low.

4500-8000 mV Open circuit.

Over 8000 mV Short-circuiting to voltage

PRESENT SENSOR INPUT, TRANS.TEMP


page

Description: Signal from sensor transmission oil temperature.


Circuit diagram: Circuit 2.0-2A2
Connection: signal from B758/766 to D793/H3
Function: 2.7.2 Sensor engine rpm and oil temperature transmission
Signal value: XXXX mV = signal voltage in mV (0-5000mV).

PRESENT SENSOR INPUT, CONV. OUT TEMP


page

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.

Workshop Manual DCF 90-100 VDCF03.01GB


74 8 Control system – 8.4.7.11 TRANSM, menu 11

Circuit diagram: Circuit 2.0-2A2


Connection: signal from S221 to D793/J3
Function: 2.7.4 Sensor oil temperature oil cooler
Signal value:

0 mV Transmission oil has operating temperature.

2500 mV Transmission oil temperature is low

8.4.7.11 TRANSM, menu 11


AXLE RATIO
page

Description: Drive axle gear ratio.


DIAG TRANSM. 11(X)
Circuit diagram: -
PRESENT VALUE
AXLE RATIO XXXXX Connection: -
RADIUS XXXX
Function: 2.8 Control system, transmission
005335

Signal value: XXXXX = drive axle’s total gear ratio x 1024.

RADIUS
page

Description: Drive wheels’ radius


Circuit diagram: -
Connection: -
Function: 2.8 Control system, transmission
Signal value: XXXX = Drive wheels’ radius in mm.

8.4.7.12 TRANSM, menu 12


SPEED LIMIT, CAB
page

Description: Speed limitation from D790-1, e.g. emergency stop


DIAG TRANSM. 12(X) switch activated, reversible driver’s seat out of position or constant
SPEED LIMIT speed limitation.
SPD GEAR LOG
CAB XX X XX Circuit diagram: -
005336

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.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.7.13 TRANSM, menu 13 75

SPEED LIMIT, FRAME


page

Description: Speed limitation from D797-1 or D797-2, e.g. cab tilted,


load not in transport position during transport.
Circuit diagram: -
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.

8.4.7.13 TRANSM, menu 13


ACT ERROR AREA
page

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

TIME AGO XXXXX Connection: -


Function: 2.8 Control system, transmission
Signal value: XXX = First part of error code; see section D Error codes

TYPE
page

Description: Indicates type of active error.


Circuit diagram: -
Connection: -
Function: 2.8 Control system, transmission
Signal value: XXX = Second part of error code.

NUMBER OF OCCU.
page

Description: Number of times active errors have occurred.


Circuit diagram: -
Connection: -
Function: 2.8 Control system, transmission
Signal value: XXXXX = Number of times active errors have occurred.

TIME AGO
page

Description: When latest active error occurred.


Circuit diagram: -
Connection: -
Function: 2.8 Control system, transmission
Signal value: XXXXX = Operating time in hours since latest error

Workshop Manual DCF 90-100 VDCF03.01GB


76 8 Control system – 8.4.7.14 TRANSM, menu 14

8.4.7.14 TRANSM, menu 14


CONVERTER STATUS (Nm), TORQUE IMPELLER
page

Description: Torque transmitted by from engine to impeller in torque


DIAG TRANSM. 14(X) converter. The torque absorbed by the transmission.
CONVERTER STATUS (Nm)
TORQUE IMPELLER XXXX Circuit diagram: -
TORQUE TURBINE XXXX Connection: -

007622
Function: 2.8 Control system, transmission
Signal value: XXXX = Torque in Nm.

CONVERTER STATUS (Nm), TORQUE TURBINE


page

Description: Current torque transmitted by torque converter to trans-


mission.
Circuit diagram: -
Connection: -
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

8.4.8.1 ELSERV, menu 1


PRESENT INPUT SIGNALS, P1
page

Description: Signal from control lever P1.


DIAG ELSERVO 1(X)
Circuit diagram: Circuits 7.0-1, 7.0-2
PRESENT INPUT SIGNALS
P1 XX.XXV Connection: signal from R8071/3 (S815/8) to analogue in D790-1/K7:3
P2 XX.XXV
Function: 7.1.1 Control levers
005401

P3 XX.XXV
Signal value: XX.XXV = 0,50 - 4,50 V. 2,5 V in zero position.

PRESENT INPUT SIGNALS, P2


page

Description: Signal from control lever P2.


Circuit diagram: Circuits 7.0-1, 7.0-2
Connection: signal from R8072/3 (S815/4) to analogue in D790-1/K7:4
Function: 7.1.1 Control levers
Signal value: XX.XXV = 0,50 - 4,50 V. 2,5 V in zero position.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.8.2 ELSERV, menu 2 77

PRESENT INPUT SIGNALS, P3


page

Description: Signal from control lever P3.


Circuit diagram: Circuits 7.0-1, 7.0-2
Connection: signal from R8073/3 (S815/11) to analogue in D790-1/
K7:5
Function: 7.1.1 Control levers
Signal value: XX.XXV = 0,50 - 4,50 V. 2,5 V in zero position.

8.4.8.2 ELSERV, menu 2


PRESENT INPUT SIGNALS, P4
page

Description: Signal from control lever P4.


DIAG ELSERVO 2(X)
Circuit diagram: Circuits 7.0-1, 7.0-2
PRESENT INPUT SIGNALS
P4 XX.XXV Connection: signal from R8074/3 (S815/1) to analogue in D790-1/K7:6
P7 XX.XXV
Function: 7.1.1 Control levers
005402

P5 XX.XXV
Signal value: XX.XXV = 0,50 - 4,50 V. 2,5 V in zero position.

PRESENT INPUT SIGNALS, P7


page

Description: Signal from control lever P7.


Circuit diagram: Circuit 7.0-1
Connection: signal from R8075-2/3 to analogue in D790-1/K9:9
Function: 7.1.1 Control levers
Signal value: XX.XXV = 0,50 - 4,50 V. 2,5 V in zero position.

PRESENT INPUT SIGNALS, P5


page

Description: Signal from control lever P5.


Circuit diagram: Circuit 7.0-1
Connection: signal from R8075-1/3 to analogue in D790-1/K7:7
Function: 7.1.1 Control levers
Signal value: XX.XXV = 0,50 - 4,50 V. 2,5 V in zero position.

Workshop Manual DCF 90-100 VDCF03.01GB


78 8 Control system – 8.4.8.3 ELSERV, menu 3

8.4.8.3 ELSERV, menu 3


OUTPUT LIFT, REFERENCE
page

Description: Status for control current to control valve (solenoid valve,


DIAG ELSERVO 3(X) lift mast).
OUTPUT LIFT
REFERENCE XY Circuit diagram: Circuit 7.2-1
REQUIRED VALUE XXXmA Connection: digital out from D797-1/K1:4 to Y6005/1 (Y6005-1/1 on

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:

00 No output signal, PWM off.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.

OUTPUT LIFT, REQUIRED VALUE


page

Description: Reference value for control current to control valve, (so-


lenoid valve, lift mast).
Circuit diagram: Circuit 7.2-1
Connection: output signal, reference value out from D797-1/K1:16 to
Y6005/2 (Y6005-1/2 on 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: XXX = Current value: in mA for control of solenoid valve.

OUTPUT LIFT, FEEDBACK


page

Description: Present control current to control valve (solenoid valve, lift


mast).
Circuit diagram: Circuit 7.2-1
Connection: output signal, actual value out from D797-1/K1:16 to
Y6005/2 (Y6005-1/2 on 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: XXX = Measured current value in mA.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.8.4 ELSERV, menu 4 79

8.4.8.4 ELSERV, menu 4


OUTPUT LOWER, REFERENCE
page

Description: Status for control current to control valve (solenoid valve,


DIAG ELSERVO 4(X) lower mast).
OUTPUT LOWER
REFERENCE XY Circuit diagram: Circuit 7.2-1
REQUIRED VALUE XXXmA Connection: digital out from D797-1/K1:4 to Y6004/1 (Y6004-1/1 on

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:

00 No output signal, PWM off.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.

OUTPUT LOWER, REQUIRED VALUE


page

Description: Reference value for control current to control valve (sole-


noid valve, lower mast)
Circuit diagram: Circuit 7.2-1
Connection: output signal, reference value out from D797-1/K1:17 to
Y6004/2 (Y6004-1/2 on 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: XXX = Current value: in mA for control of solenoid valve.

OUTPUT LOWER, FEEDBACK


page

Description: Present control current to control valve (solenoid valve,


lower mast).
Circuit diagram: Circuit 7.2-1
Connection: output signal, actual value out from D797-1/K1:17 to
Y6004/2 (Y6004-1/2 on 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: XXX = Measured current value in mA.

Workshop Manual DCF 90-100 VDCF03.01GB


80 8 Control system – 8.4.8.5 ELSERV, menu 5

8.4.8.5 ELSERV, menu 5


OUTPUT TILT IN, REFERENCE
page

Description: Status for control current to control valve (solenoid valve,


DIAG ELSERVO 5(X) tilt in).
OUTPUT TILT IN
REFERENCE XY Circuit diagram: Circuit 7.7-1
REQUIRED VALUE XXXmA Connection: digital out from D797-1/K1:5 to Y6011/1

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:

00 No output signal, PWM off.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.

OUTPUT TILT IN, REQUIRED VALUE


page

Description: Reference value for control current to control valve (sole-


noid valve, tilt in).
Circuit diagram: Circuit 7.7-1
Connection: output signal reference value out from D797-1/K1:18 to
Y6011/2
Function: 7.7.5 Control valve, lift and tilt (DCF360-450CSG and DCF
90-100)
7.7.5 Control valve, load handling (DCF280-330, DCF370-500)
Signal value: XXX = Current value: in mA for control of solenoid valve.

OUTPUT TILT IN, FEEDBACK


page

Description: Present for control current to control valve (solenoid


valve, tilt in).
Circuit diagram: Circuit 7.7-1
Connection: output signal, actual value out from D797-1/K1:18 to
Y6011/2
Function: 7.7.5 Control valve, lift and tilt (DCF360-450CSG and DCF
90-100)
7.7.5 Control valve, load handling (DCF280-330, DCF370-500)
Signal value: XXX = Measured current value in mA.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.8.6 ELSERV, menu 6 81

8.4.8.6 ELSERV, menu 6


OUTPUT TILT OUT, REFERENCE
page

Description: Status for control current to control valve (solenoid valve,


DIAG ELSERVO 6(X) tilt out).
OUTPUT TILT OUT
REFERENCE XY Circuit diagram: Circuit 7.7-1
REQUIRED VALUE XXXmA Connection: digital out from D797-1/K1:5 to Y6010/1

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:

00 No output signal, PWM off.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.

OUTPUT TILT OUT, REQUIRED VALUE


page

Description: Reference value for control current to control valve, (so-


lenoid valve, tilt out).
Circuit diagram: Circuit 7.7-1
Connection: output signal, reference value out from D797-1/K1:19, to
solenoid valve Y6010/1
Function: 7.7.5 Control valve, lift and tilt (DCF360-450CSG and DCF
90-100)
7.7.5 Control valve, load handling (DCF280-330, DCF370-500)
Signal value: XXX = Current value: in mA for control of solenoid valve.

OUTPUT TILT OUT, FEEDBACK


page

Description: Present control current to control valve (solenoid valve, tilt


out).
Circuit diagram: Circuit 7.7-1
Connection: output signal, actual value out from D797-1/K1:19 to so-
lenoid valve Y6010/2
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: XXX = Measured current value in mA.

Workshop Manual DCF 90-100 VDCF03.01GB


82 8 Control system – 8.4.8.7 ELSERV, menu 7

8.4.8.7 ELSERV, menu 7


OUTPUT SIDE SHIFT LE, REFERENCE
page

Description: Status for control current to control valve, load handling


DIAG ELSERVO 7(X) (solenoid valve, side shift left).
OUTPUT SIDESHIFT LE
REFERENCE XY Circuit diagram: Circuit 7.4-1
REQUIRED VALUE XXXmA Connection: digital out from D797-2/K1:31 to Y6020/1

005407
FEEDBACK XXXmA
Function: 7.4.5 Control valve, load handling (DCF280-330, DCF370-
500)
Signal value:

00 No output signal, PWM off.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.

OUTPUT SIDE SHIFT LE, REQUIRED VALUE


page

Description: Reference value for control current to control valve for


load handling (solenoid valve, side shift left).
Circuit diagram: Circuit 7.4-1
Connection: output signal, reference value out from D797-2/K1:18 to
Y6020/2
Function: 7.4.5 Control valve, load handling (DCF280-330, DCF370-
500)
Signal value: XXX = Current value: in mA for control of solenoid valve.

OUTPUT SIDE SHIFT LE, FEEDBACK


page

Description: Present control current to control valve, load handling (so-


lenoid valve, side shift left).
Circuit diagram: Circuit 7.4-1
Connection: output signal, actual value out from D797-2/K1:18 to
Y6020/2
Function: 7.4.5 Control valve, load handling (DCF280-330, DCF370-
500)
Signal value: XXX = Measured current value in mA.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.8.8 ELSERV, menu 8 83

8.4.8.8 ELSERV, menu 8


OUTPUT SIDE SHIFT RI, REFERENCE
page

Description: Status for control current to control valve, load handling


DIAG ELSERVO 8(X) (solenoid valve, side shift right).
OUTPUT SIDESHIFT RI
REFERENCE XY Circuit diagram: Circuit 7.4-1
REQUIRED VALUE XXXmA Connection: digital out from D797-2/K1:30 to Y6021/1

005408
FEEDBACK XXXmA
Function: 7.4.5 Control valve, load handling (DCF280-330, DCF370-
500)
Signal value:

00 No output signal, PWM off.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.

OUTPUT SIDE SHIFT RI, REQUIRED VALUE


page

Description: Reference value for control current to control valve for


load handling (solenoid valve, side shift right).
Circuit diagram: Circuit 7.4-1
Connection: output signal, reference value out from D797-2/K1:18 to
Y6021/2
Function: 7.4.5 Control valve, load handling (DCF280-330, DCF370-
500)
Signal value: XXX = Current value: in mA for control of solenoid valve.

OUTPUT SIDE SHIFT RI, FEEDBACK


page

Description: Present control current to control valve, load handling (so-


lenoid valve, side shift right).
Circuit diagram: Circuit 7.4-1
Connection: output signal, actual value out from D797-2/K1:18 to
Y6021/2
Function: 7.4.5 Control valve, load handling (DCF280-330, DCF370-
500)
Signal value: XXX = Measured current value in mA.

Workshop Manual DCF 90-100 VDCF03.01GB


84 8 Control system – 8.4.8.9 ELSERV, menu 9

8.4.8.9 ELSERV, menu 9


OUTPUT SPREADING IN, REFERENCE
page

Description: Status for control current to control valve, load handling


DIAG ELSERVO 9(X) (solenoid valve, spreading left).
OUTPUT SPREADING IN
REFERENCE XY Circuit diagram: Circuit 7.5-1
REQUIRED VALUE XXXmA Connection: digital out from D797-2/K1:32 to Y6019/1

005409
FEEDBACK XXXmA
Function: 7.5.5 Control valve, load handling (DCF280-330, DCF370-
500)
Signal value:

00 No output signal, PWM off.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.

OUTPUT SPREADING IN, REQUIRED VALUE


page

Description: Reference value for control current to control valve, load


handling (solenoid valve, spreading in).
Circuit diagram: Circuit 7.5-1
Connection: output signal, reference value out from D797-2/K1:19 to
Y6019/2
Function: 7.5.5 Control valve, load handling (DCF280-330, DCF370-
500)
Signal value: XXX = Current value: in mA for control of solenoid valve.

OUTPUT SPREADING IN, FEEDBACK


page

Description: Present control current to control valve, load handling (so-


lenoid valve, spreading in).
Circuit diagram: Circuit 7.5-1
Connection: output signal, actual value out from D797-2/K1:19 to
Y6019/2
Function: 7.5.5 Control valve, load handling (DCF280-330, DCF370-
500)
Signal value: XXX = Measured current value in mA.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.8.10 ELSERV, menu 10 85

8.4.8.10 ELSERV, menu 10


OUTPUT SPREADING OUT, REFERENCE
page

Description: Status for control current to control valve, load handling


DIAG ELSERVO 10(X) (solenoid valve, spreading out).
OUTPUT SPREADING OUT
REFERENCE XY Circuit diagram: Circuit 7.5-1
REQUIRED VALUE XXXmA Connection: digital out from D797-2/K1:33 to Y6018/1

005410
FEEDBACK XXXmA
Function: 7.5.5 Control valve, load handling (DCF280-330, DCF370-
500)
Signal value:

00 No output signal, PWM off.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.

OUTPUT SPREADING OUT, REQUIRED VALUE


page

Description: Reference value for control current to control valve, load


handling (solenoid valve, spreading out).
Circuit diagram: Circuit 7.5-1
Connection: output signal, reference value out from D797-2/K1:19 to
Y6018/2
Function: 7.5.5 Control valve, load handling (DCF280-330, DCF370-
500)
Signal value: XXX = Current value: in mA for control of solenoid valve.

OUTPUT SPREADING OUT, FEEDBACK


page

Description: Present control current to control valve, load handling (so-


lenoid valve, spreading out).
Circuit diagram: Circuit 7.5-1
Connection: output signal, actual value out from D797-2/K1:19 to
Y6018/2
Function: 7.5.5 Control valve, load handling (DCF280-330, DCF370-
500)
Signal value: XXX = Measured current value in mA.

Workshop Manual DCF 90-100 VDCF03.01GB


86 8 Control system – 8.4.8.11 ELSERV, menu 11

8.4.8.11 ELSERV, menu 11


OUTPUT LIFT 2, REFERENCE
page

Description: Status for control current to control valve, load handling


DIAG ELSERVO 11(X) (solenoid valve, lift carriage).
OUTPUT LIFT 2
REFERENCE XY Circuit diagram: Circuit 7.10-1
REQUIRED VALUE XXXmA Connection: digital out from D797-2/K1:4 to Y6022/1

005411
FEEDBACK XXXmA
Function: 7.2.6 Control valve, load handling (DCF280-330, DCF370-
500)
Signal value:

00 No output signal, PWM off.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.

OUTPUT LIFT 2, REQUIRED VALUE


page

Description: Reference value for control current to control valve, load


handling (solenoid valve, lift carriage).
Circuit diagram: Circuit 7.10-1
Connection: output signal, reference value out from D797-2/K1:17 to
Y6022/2
Function: 7.2.6 Control valve, load handling (DCF280-330, DCF370-
500)
Signal value: XXX = Current value: in mA for control of solenoid valve.

OUTPUT LIFT 2, FEEDBACK


page

Description: Present control current to control valve, load handling (so-


lenoid valve, lift carriage).
Circuit diagram: Circuit 7.10-1
Connection: output signal, actual value out from D797-2/K1:17 to
Y6022/2
Function: 7.2.6 Control valve, load handling (DCF280-330, DCF370-
500)
Signal value: XXX = Measured current value in mA.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.8.12 ELSERV, menu 12 87

8.4.8.12 ELSERV, menu 12


OUTPUT LOWER 2, REFERENCE
page

Description: Status for control current to control valve, load handling


DIAG ELSERVO 12(X) (solenoid valve, lower carriage).
OUTPUT LOWER 2
REFERENCE XY Circuit diagram: Circuit 7.10-1
REQUIRED VALUE XXXmA Connection: digital out from D797-2/K1:5 to Y6023/1

005412
FEEDBACK XXXmA
Function: 7.2.6 Control valve, load handling (DCF280-330, DCF370-
500)
Signal value:

00 No output signal, PWM off.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.

OUTPUT LOWER 2, REQUIRED VALUE


page

Description: Reference value for control current to control valve, load


handling (solenoid valve, lower carriage).
Circuit diagram: Circuit 7.10-1
Connection: output signal, reference value out from D797-2/K1:17 to
Y6023/2
Function: 7.2.6 Control valve, load handling (DCF280-330, DCF370-
500)
Signal value: XXX = Current value: in mA for control of solenoid valve.

OUTPUT LOWER 2, FEEDBACK


page

Description: Present control current to control valve, load handling (so-


lenoid valve, lower carriage).
Circuit diagram: Circuit 7.10-1
Connection: output signal, actual value out from D797-2/K1:17 to
Y6023/2
Function: 7.2.6 Control valve, load handling (DCF280-330, DCF370-
500)
Signal value: XXX = Measured current value in mA.

Workshop Manual DCF 90-100 VDCF03.01GB


88 8 Control system – 8.4.8.13 ELSERV, menu 13

8.4.8.13 ELSERV, menu 13


PRESENT INPUT SIGNALS, SPREADER
page

Description: Signal from switch for spreading the attachment.


DIAG ELSERVO 13(X) Circuit diagram: Circuit 7.0-2
PRESENT INPUT SIGNALS
SPREADER IN X OUT X Connection:
PISTOL X
IN: Signal from S815/14 to digital in D790-1/K7:14 (spreading in)

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:

1 Input signal active.

0 No signal.

PRESENT INPUT SIGNALS, PISTOL


page

Description: Signals from control lever for pistol trigger.


Circuit diagram: Circuit 7.0-2
Connection: from S815/19 to digital in D790-1/K7:16
Function: 7.1.1 Control lever
Signal value:

1 Input signal active.

0 No signal.

PRESENT INPUT SIGNALS, UNLOCK TW


page

Description: Signal from control lever to unlock twistlock.


Circuit diagram: Circuit 7.0-2
Connection: signal from S815/20 to digital in D790-1/K7:15
Function: 7.1.1 Control lever
Signal value:

1 Input signal active.

0 No signal.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.8.14 ELSERV, menu 14 89

8.4.8.14 ELSERV, menu 14


PRESENT INPUT SIGNALS, OPTION LOCKING
page

Description: Signal from control lever for option locking.


DIAG ELSERVO 14(X)
Circuit diagram: Circuit 7.0-2
PRESENT INPUT SIGNALS
OPTION LOCKING X Connection: signal from S815/18 to digital in D790-1/K8:2
LEVELLING LOCKING X
Function: 7.1.1 Control lever

007129
Signal value:

1 Input signal active.

0 No signal.

PRESENT INPUT SIGNALS, LEVELLING LOCKING


page

Description: Signal from control lever fir levelling locking.


Circuit diagram: Circuit 7.0-2
Connection: signal from S815/17 to digital in D790-1/K8:1
Function: 7.1.1 Control lever
Signal value:

1 Input signal active.

0 No signal.

8.4.8.15 ELSERV, menu 15


REGENERATION STATUS, INPUT DAMPING
page

Description: Signal from position sensor, end position, regeneration.


DIAG ELSERVO 15(X)
Circuit diagram: Circuit 7.2-6
REGENERATION STATUS
INPUT DAMPING X Connection: Signal from B7211-2 to digital in D797-2/K1:24.
OUTPUT LEFT XY
Function: 7.2.10 Mast position sensor (DCF360-450CSG)
005415

OUTPUT RIGHT XY
Signal value:

1 Input signal active.

0 No signal.

Workshop Manual DCF 90-100 VDCF03.01GB


90 8 Control system – 8.4.9 ATTACH, DCF360-450CSG

REGENERATION STATUS, OUTPUT LEFT


page

Description: Power supply to solenoid valve, regeneration, left.


Circuit diagram: Circuit 7.2-6
Connection: Signal from D797-1/K1:12 to Y6052/1
Function: 7.2.6 Valve block, lift cylinder (DCF360-450CSG)
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is
active.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

REGENERATION STATUS, OUTPUT RIGHT


page

Description: Power supply to solenoid valve, regeneration, right.


Circuit diagram: Circuit 7.2-6
Connection: Signal from D797-1/K1:11 to Y6051/1
Function: 7.2.6 Valve block, lift cylinder (DCF360-450CSG)
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is
active.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

8.4.9 ATTACH, DCF360-450CSG


ATTACH, description
page

This group covers attachment functions.


DIAGNOSIS
Confirm selection with function key for Enter.
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
005339

OLS EXTRA

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.9.1 ATTACH, menu 1 91

8.4.9.1 ATTACH, menu 1


PRESENT INPUT SIGNALS, P3
page

Description: Signal from control lever P3.


DIAG ATTACHMENT 1(X)
Circuit diagram: Circuits 7.0-1, 7.0-2
PRESENT INPUT SIGNALS
P3 XX.XXV Connection: signal from R8073/3 (S815/11) to analogue in D790-1/
P4 XX.XXV K7:5

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.

PRESENT INPUT SIGNALS, P4


page

Description: Signal from control lever P4.


Circuit diagram: Circuits 7.0-1, 7.0-2
Connection: signal from R8074/3 (S815/1) to analogue in D790-1/K7:6
Function: 7.1.1 Control levers
Signal value: XX.XXV = 0,50 - 4,50 V. 2,5 V in zero position.

PRESENT INPUT SIGNALS, P7


page

Description: Signal from control lever P7.


Circuit diagram: Circuit 7.0-1
Connection: signal from R8075-2/3 to analogue in D790-1/K9:9
Function: 7.1.1 Control levers
Signal value: XX.XXV = 0,50 - 4,50 V. 2,5 V in zero position.

8.4.9.2 ATTACH, menu 2


PRESENT INPUT SIGNALS, P5
page

Description: Signal from control lever P5.


DIAG ATTACHMENT 2(X)
Circuit diagram: Circuit 7.0-1
PRESENT INPUT SIGNALS
P5 XX.XXV Connection: signal from R8075-1/3 to analogue in D790-1/K7:7
Function: 7.1.1 Control levers
005417

Signal value: XX.XXV = 0,50 - 4,50 V. 2,5 V in zero position.

Workshop Manual DCF 90-100 VDCF03.01GB


92 8 Control system – 8.4.9.3 ATTACH, menu 3

8.4.9.3 ATTACH, menu 3


PRESENT INPUT SIGNALS, SPREADER
page

Description: Signals from switch for spreading the attachment.


DIAG ATTACHMENT 3(X) Circuit diagram: Circuits 7.5-1, 7.0-2
PRESENT INPUT SIGNALS
SPREADER IN X OUT X Connection:
AUTO 20/40 X IN: Signal from S1012/1 (S815/14) to digital in D790-1/K7:14

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:

1 Input signal active.

0 No signal.

PRESENT INPUT SIGNALS, AUTO 20/40


page

Description: Signal from switch automatic spreading 20/40.


Circuit diagram: Circuit 7.5-3
Connection: from S1012-2/1 to digital in D790-1/K8:11
Function: 7.5 Spreading
Signal value:

1 Input signal active.

0 No signal.

PRESENT INPUT SIGNALS, 30/35 STOP


page

Description: Signal from switch for stop at 30’/35’.


Circuit diagram: Circuit 7.5-1
Connection: from S1004/1 to digital in D790-1/K8:10
Function: 7.5 Spreading
Signal value:

1 Input signal active.

0 No signal.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.9.4 ATTACH, menu 4 93

8.4.9.4 ATTACH, menu 4


PRESENT INPUT SIGNALS, PISTOL
page

Description: Signals from control lever for pistol trigger.


DIAG ATTACHMENT 4(X) Circuit diagram: Circuit 7.0-2
PRESENT INPUT SIGNALS
Connection: from S815/19 to digital in D790-1/K7:16
PISTOL X Function: 7.1.1 Control lever

007130
Signal value:

1 Input signal active.

0 No signal.

8.4.9.5 ATTACH, menu 5


PRESENT INPUT SIGNALS, LOCK TWISTLOCK
page

Description: Signal from switch lock twistlock.


DIAG ATTACHMENT 5(X) Circuit diagram: Circuit 7.9-1
PRESENT INPUT SIGNALS
LOCK TWISTLOCK X Connection: signal from S1003/7 and S1007/2 to digital in D790-1/
UNLOCK TWISTLOCK X K8:12
005420

LOCK LEVELLING X
Function: 7.9.1 Twistlocks
Signal value:

1 Input signal active.

0 No signal.

PRESENT INPUT SIGNALS, UNLOCK TWISTLOCK


page

Description: Signal from control lever to unlock twistlock.


Circuit diagram: Circuits 7.9-1, 7.0-2
Connection: signal from S1002/1 (S815/20) to digital in D790-1/K7:15
Function: 7.1.1 Control levers
Signal value:

1 Input signal active.

0 No signal.

PRESENT INPUT SIGNALS, LOCK LEVELLING


page

Description: Signal from switch for levelling lock.


Circuit diagram: Circuits 7.8-1, 7.0-2
Connection: signal from S1037/1 (S815/17) to digital in D790-1/K8:1
Function: 7.8 Levelling, 7.1.1 Control levers
Signal value:

1 Input signal active.

0 No signal.

Workshop Manual DCF 90-100 VDCF03.01GB


94 8 Control system – 8.4.9.6 ATTACH, menu 6

8.4.9.6 ATTACH, menu 6


PRESENT INPUT SIGNALS, LOW SPEED 20/40
page

Description: Signal from spreading position sensor for end position


DIAG ATTACHMENT 6(X) damping 20’/40’.
PRESENT INPUT SIGNALS
Circuit diagram: Circuit 7.5-2
LOW SPEED 20/40 X Connection: from inductive sensor B769-1/C to digital in D791-1/K1:12

008902
30/35 STOP X
Function: 7.5.8 Position sensor spreading
Signal value:

1 Input signal active.

0 No signal.

PRESENT INPUT SIGNALS, 30/35 STOP


page

Description: Signal from spreading position sensor for stop at 30’/35’.


Circuit diagram: Circuit 7.5-2
Connection: from inductive sensor B777-1/C to digital in D791-1/K1:20
Function: 7.5.8 Position sensor spreading
Signal value:

1 Input signal active.

0 No signal.

8.4.9.7 ATTACH, menu 7


PRESENT INPUT SIGNALS, ALIGNMENT LE RI, FRONT
page

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:

1 Input signal active.

0 No signal.

PRESENT INPUT SIGNALS, ALIGNMENT LE RI, REAR


page

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

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.9.8 ATTACH, menu 8 95

Signal value:

1 Input signal active.

0 No signal.

8.4.9.8 ATTACH, menu 8


PRESENT INPUT SIGNAL LE RI, LOCKED TW
page

Description: Signals from sensors locked twistlock right and left.


DIAG ATTACHMENT 8(X)
Circuit diagram: Circuit 7.9-2
PRESENT INPUT SIGNALS
LE RI Connection:
LOCKED TW X X
LE: signal from B7205L/B to digital in D791-1/K1:23
005423

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:

1 Input signal active.

0 No signal.

PRESENT OUTPUT SIGNAL LE RI, UNLOCKED TW


page

Description: Signals from sensors open twistlock right and left.


Circuit diagram: Circuit 7.9-2
Connection:
LE: signal from B7204L/B to digital in D791-1/K1:22
RI: Signal from B7204R/B to digital in D791-1/K1:41
Function: 7.9.1.7 Sensor twistlock
Signal value:

1 Input signal active.

0 No signal.

Workshop Manual DCF 90-100 VDCF03.01GB


96 8 Control system – 8.4.9.9 ATTACH, menu 9

8.4.9.9 ATTACH, menu 9


PRESENT OUTPUT SIGNAL, LOCK TW
page

Description: Voltage feed to attachment control valve, locked twist-


DIAG ATTACHMENT 9(X) lock.
PRESENT OUTPUT SIGNAL
LOCK TW XY Circuit diagram: Circuit 7.9-1
UNLOCK TW XY Connection: digital out from D791-1/K1:7 to /1

005424
Function: 7.9.1.2 Attachment control valve
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is
active.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

PRESENT OUTPUT SIGNAL, UNLOCK TW


page

Description: Voltage feed to control valve attachment, open twistlock.


Circuit diagram: Circuit 7.9-1
Connection: digital out from D791-1/K1:9 to Y6039/1
Function: 7.9.1.2 Attachment control valve
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is
active.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

8.4.9.10 ATTACH, menu 10


PRESENT OUTPUT SIGNAL, IND. LOCKED TW
page

Description: Voltage feed, indicator light for locked twistlock - located


DIAG ATTACHMENT 10(X) on carriage.
PRESENT OUTPUT SIGNAL
IND. LOCKED TW XY Circuit diagram: Circuit 7.9-1
IND. UNLOCKED TW XY Connection: digital out from D791-1/K1:29 to H563/1
005425

IND. ALIGNMENT XY

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.9.10 ATTACH, menu 10 97

Function: 7.9.1 Twistlocks


Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is
active.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

PRESENT OUTPUT SIGNAL, IND. UNLOCKED TW


page

Description: Voltage feed, indicator light for open twistlock - located on


carriage.
Circuit diagram: Circuit 7.9-1
Connection: digital out from D791-1/K1:25 to H562/1
Function: 7.9.1 Twistlocks
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is
active.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

PRESENT OUTPUT SIGNAL, ALIGNMENT


page

Description: Voltage feed, alignment indicator light - located on car-


riage.
Circuit diagram: Circuit 7.9-1
Connection: digital out from D791-1/K1:39 to H564/1
Function: 7.9.1 Twistlocks
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is
active.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

Workshop Manual DCF 90-100 VDCF03.01GB


98 8 Control system – 8.4.9.11 ATTACH, menu 11

8.4.9.11 ATTACH, menu 11


OUTPUT SIDE SHIFT LE, REFERENCE
page

Description: Status for control current to attachment control valve for


DIAG ATTACHMENT 11(X) side shift left.
OUTPUT SIDESHIFT LE
REFERENCE XY Circuit diagram: Circuit 7.4-2
REQUIRED VALUE XXXmA Connection: digital out from D791-1/K1:32 to Y6020/1

005426
FEEDBACK XXXmA
Function: 7.4.2 Control valve attachment
Signal value:

00 No output signal, PWM off.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.

OUTPUT SIDE SHIFT LE, REQUIRED VALUE


page

Description: Reference value for control current to attachment control


valve for output signal, side shift left.
Circuit diagram: Circuit 7.4-2
Connection: output signal reference value out from D791-1/K1:18 to
Y6020/2
Function: 7.4.2 Control valve attachment
Signal value: XXX = Current value: in mA for control of solenoid valve.

OUTPUT SIDE SHIFT LE, FEEDBACK


page

Description: Present control current to attachment control valve for


side shift left.
Circuit diagram: Circuit 7.4-2
Connection: output signal actual value out from D791-1/K1:18 to
Y6020/2
Function: 7.4.2 Control valve attachment
Signal value: XXX = Measured current value in mA.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.9.12 ATTACH, menu 12 99

8.4.9.12 ATTACH, menu 12


OUTPUT SIDE SHIFT RI, REFERENCE
page

Description: Status for control current to attachment control valve for


DIAG ATTACHMENT 12(X) side shift right.
OUTPUT SIDESHIFT RI
REFERENCE XY Circuit diagram: Circuit 7.4-2
REQUIRED VALUE XXXmA Connection: digital out from D791/K1:33 to Y6021/1

005427
FEEDBACK XXXmA
Function: 7.4.2 Control valve attachment
Signal value:

00 No output signal, PWM off.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.

OUTPUT SIDE SHIFT RI, REQUIRED VALUE


page

Description: Reference value for control current to attachment control


valve for output signal, side shift right.
Circuit diagram: Circuit 7.4-2
Connection: output signal reference value out from D791-1/K1:18 to
Y6021/2
Function: 7.4.2 Control valve attachment
Signal value: XXX = Current value: in mA for control of solenoid valve.

OUTPUT SIDE SHIFT RI, FEEDBACK


page

Description: Present control current to attachment control valve for


side shift right.
Circuit diagram: Circuit 7.4-2
Connection: output signal actual value out from D791-1/K1:18 to
Y6019/2
Function: 7.4.2 Control valve attachment
Signal value: XXX = Measured current value in mA.

Workshop Manual DCF 90-100 VDCF03.01GB


100 8 Control system – 8.4.9.13 ATTACH, menu 13

8.4.9.13 ATTACH, menu 13


OUTPUT SPREADER OUT, REFERENCE
page

Description: Status control current to control valve attachment for


DIAG ATTACHMENT 13(X) spreader out 20/40.
OUTPUT SPREADER OUT
REFERENCE XY Circuit diagram: Circuit 7.5-2
REQUIRED VALUE XXXmA Connection: digital out from D791-1/K1:34 to Y6018/1

005428
FEEDBACK XXXmA
Function: 7.5.2 Control valve attachment
Signal value:

00 No output signal, PWM off.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.

OUTPUT SPREADER OUT, REQUIRED VALUE


page

Description: Reference value for control current to attachment control


valve for output signal, spreading out 20/40.
Circuit diagram: Circuit 7.5-2
Connection: output signal reference value out from D791-1/K1:19 to
Y6018/2
Function: 7.5.2 Control valve attachment
Signal value: XXX = Current value: in mA for control of solenoid valve.

OUTPUT SPREADER OUT, FEEDBACK


page

Description: Present control current to control valve attachment for


spreader out 20/40.
Circuit diagram: Circuit 7.5-2
Connection: output signal actual value out from D791-1/K1:19 to
Y6018/2
Function: 7.5.2 Control valve attachment
Signal value: XXX = Measured current value in mA.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.9.14 ATTACH, menu 14 101

8.4.9.14 ATTACH, menu 14


OUTPUT SPREADER IN, REFERENCE
page

Description: Status control current to control valve attachment for


DIAG ATTACHMENT 14(X) spreader in 40/20.
OUTPUT SPREADER IN
REFERENCE XY Circuit diagram: Circuit 7.5-2
REQUIRED VALUE XXXmA Connection: digital out from D791-1/K1:35 to Y6019/1

005429
FEEDBACK XXXmA
Function: 7.5.2 Control valve attachment
Signal value:

00 No output signal, PWM off.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.

OUTPUT SPREADER IN, REQUIRED VALUE


page

Description: Reference value for control current to attachment control


valve for output signal, spreading in 40/20.
Circuit diagram: Circuit 7.5-2
Connection: output signal, reference value out from D791-1/K1:19 to
Y6019/2
Function: 7.5.2 Control valve attachment
Signal value: XXX = Current value: in mA for control of solenoid valve.

OUTPUT SPREADER IN, FEEDBACK


page

Description: Present control current to control valve attachment for


spreader in 40/20.
Circuit diagram: Circuit 7.5-2
Connection: output signal, actual value out from D791-1/K1:19 to
Y6019/2
Function: 7.5.2 Control valve attachment
Signal value: XXX = Measured current value in mA.

Workshop Manual DCF 90-100 VDCF03.01GB


102 8 Control system – 8.4.9.15 ATTACH, menu 15

8.4.9.15 ATTACH, menu 15


PRESENT OUTPUT SIGNAL, UNLOCK LEVELLING
page

Description: Voltage feed to levelling solenoid valve.


DIAG ATTACHMENT 15(X) Circuit diagram: Circuit 7.8-1
PRESENT OUTPUT SIGNAL
UNLOCK LEVELLING XY Connection: digital out from D791-1/K1:42 to Y637-1/1 and Y637-2/1
Function: 7.8.4 Valve block, levelling cylinders

005430
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is
active.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

8.4.9.16 ATTACH, menu 16


OUTPUT LEVELLING, CLOCKWISE
page

Description: Voltage feed to attachment control valve, clockwise


DIAG ATTACHMENT 16(X) levelling.
OUTPUT LEVELLING
CLOCKWISE XY Circuit diagram: Circuit 7.8-1
COUNTERCLOCKWISE XY Connection: digital out from D791-1/K1:30 to Y6036/1
005431

Function: 7.8.2 Control valve attachment


Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is
active.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.9.17 ATTACH, menu 17 103

OUTPUT LEVELLING, COUNTERCLOCKWISE


page

Description: Voltage feed to attachment control valve, counterclock-


wise levelling.
Circuit diagram: Circuit 7.8-1
Connection: digital out from D791-1/K1:31 to Y6035/1
Function: 7.8.2 Control valve attachment
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

8.4.9.17 ATTACH, menu 17


OUTPUT PROJECT LE OUT, REFERENCE
page

Description: Status for control current to attachment control valve for


DIAG ATTACHMENT 17(X) extension, left side, out.
OUTPUT PROJECT LE OUT
REFERENCE XY Circuit diagram: Circuit 7.3-1
REQUIRED VALUE XXXmA Connection: digital out from D791-1/K1:3 to Y6046-2/1
005432

FEEDBACK XXXmA
Function: 7.3.2 Control valve attachment
Signal value:

00 No output signal, PWM off.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.

OUTPUT PROJECT LE OUT, REQUIRED VALUE


page

Description: Reference value for control current to attachment control


valve for output signal, extension, left side out
Circuit diagram: Circuit 7.3-1
Connection: output signal reference value out from D791-1/K1:16 to
Y6046-2/2
Function: 7.3.2 Control valve attachment
Signal value: XXX = Current value: in mA for control of solenoid valve.

Workshop Manual DCF 90-100 VDCF03.01GB


104 8 Control system – 8.4.9.18 ATTACH, menu 18

OUTPUT PROJECT LE OUT, FEEDBACK


page

Description: Present control current to attachment control valve for ex-


tension, left side out.
Circuit diagram: Circuit 7.3-1
Connection: output signal actual value out from D791-1/K1:16 to
Y6046-2/2
Function: 7.3.2 Control valve attachment
Signal value: XXX = Measured current value in mA.

8.4.9.18 ATTACH, menu 18


OUTPUT PROJECT LE IN, REFERENCE
page

Description: Status for control current to attachment control valve for


DIAG ATTACHMENT 18(X) extension, left side in.
OUTPUT PROJECT LE IN
REFERENCE XY Circuit diagram: Circuit 7.3-1
REQUIRED VALUE XXXmA Connection: digital out from D791-1/K1:2 to Y6046-1/1
005433

FEEDBACK XXXmA
Function: 7.3.2 Control valve attachment
Signal value:

00 No output signal, PWM off.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.

OUTPUT PROJECT LE IN, REQUIRED VALUE


page

Description: Reference value for control current to attachment control


valve for output signal, extension, left side in.
Circuit diagram: Circuit 7.3-1
Connection: output signal reference value out from D791-1/K1:16 to
Y6046-1/2
Function: 7.3.2 Control valve attachment
Signal value: XXX = Current value: in mA for control of solenoid valve.

OUTPUT PROJECT LE IN, FEEDBACK


page

Description: Present control current to attachment control valve for ex-


tension, left side in.
Circuit diagram: Circuit 7.3-1
Connection: output signal actual value out from D791-1/K1:16 to
Y6046-1/2
Function: 7.3.2 Control valve attachment
Signal value: XXX = Measured current value in mA.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.9.19 ATTACH, menu 19 105

8.4.9.19 ATTACH, menu 19


OUTPUT PROJECT RI OUT, REFERENCE
page

Description: Status for control current to attachment control valve for


DIAG ATTACHMENT 19(X) extension, right side out.
OUTPUT PROJECT RI OUT
REFERENCE XY Circuit diagram: Circuit 7.3-1
REQUIRED VALUE XXXmA Connection: digital out from D791-1/K1:5 to Y6046-4/1

005434
FEEDBACK XXXmA
Function: 7.3.2 Control valve attachment
Signal value:

00 No output signal, PWM off.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.

OUTPUT PROJECT RI OUT, REQUIRED VALUE


page

Description: Reference value for control current to attachment control


valve for output signal, extension, right side out
Circuit diagram: Circuit 7.3-1
Connection: output signal, reference value out from D791-1/K1:17 to
Y6046-4/2
Function: 7.3.2 Control valve attachment
Signal value: XXX = Current value: in mA for control of solenoid valve.

OUTPUT PROJECT RI OUT, FEEDBACK


page

Description: Present control current to attachment control valve for ex-


tension, right side out.
Circuit diagram: Circuit 7.3-1
Connection: output signal, actual value out from D791-1/K1:17 to
Y6046-4/2
Function: 7.3.2 Control valve attachment
Signal value: XXX = Measured current value in mA.

Workshop Manual DCF 90-100 VDCF03.01GB


106 8 Control system – 8.4.9.20 ATTACH, menu 20

8.4.9.20 ATTACH, menu 20


OUTPUT PROJECT RI IN, REFERENCE
page

Description: Status for control current to attachment control valve for


DIAG ATTACHMENT 20(X) extension, right side in.
OUTPUT PROJECT RI IN
REFERENCE XY Circuit diagram: Circuit 7.3-1
REQUIRED VALUE XXXmA Connection: digital out from D791-1/K1:4 to Y6046-3/1

005435
FEEDBACK XXXmA
Function: 7.3.2 Control valve attachment
Signal value:

00 No output signal, PWM off.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.

OUTPUT PROJECT RI IN, REQUIRED VALUE


page

Description: Reference value for control current to attachment control


valve for output signal, extension, right side in.
Circuit diagram: Circuit 7.3-1
Connection: output signal, reference value out from D791-1/K1:17 to
Y6046-3/2
Function: 7.3.2 Control valve attachment
Signal value: XXX = Current value: in mA for control of solenoid valve.

OUTPUT PROJECT RI IN, FEEDBACK


page

Description: Present control current to attachment control valve for ex-


tension, right side in.
Circuit diagram: Circuit 7.3-1
Connection: output signal, actual value out from D791-1/K1:17 to
Y6046-3/2
Function: 7.3.2 Control valve attachment
Signal value: XXX = Measured current value in mA.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.9.21 ATTACH, menu 21 107

8.4.9.21 ATTACH, menu 21


PRESENT OUTPUT SIGNAL, BUZZER AUTO 20-40
page

DIAG ATTACHMENT 21(X)


PRESENT OUTPUT SIGNAL Description: Voltage feed to buzzer automatic spreading 20’-40’.
Circuit diagram: Circuit 7.5.3
BUZZER AUTO 20-40 XY

009181
Connection: digital out from D791-1/K1:28 to H9003/1
Function: 7.5 Spreading
Signal value:

01 No output signal. Error detection only possible when output


signal is active.

10 Output signal active, short-circuiting or open circuit.

11 Output signal active, circuit OK.

8.4.9 ATTACH, DCF 90-100 with lifting hook


attachment
ATTACH, description
page

This group covers attachment functions.


DIAGNOSIS
Confirm selection with function key for Enter.
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
005339

OLS EXTRA

8.4.9.1 ATTACH, menu 1


PRESENT INPUT SIGNALS, P3
page

Description: Signal from control lever P3.


DIAG ATTACHMENT 1(X)
Circuit diagram: Circuits 7.0-1, 7.0-2
PRESENT INPUT SIGNALS
P3 XX.XXV Connection: signal from R8073/3 (S815/11) to analogue in D790-1/
P4 XX.XXV K7:5
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.

PRESENT INPUT SIGNALS, P4


page

Description: Signal from control lever P4.


Circuit diagram: Circuits 7.0-1, 7.0-2
Connection: signal from R8074/3 (S815/1) to analogue in D790-1/K7:6
Function: 7.1.1 Control levers
Signal value: XX.XXV = 0,50 - 4,50 V. 2,5 V in zero position.

Workshop Manual DCF 90-100 VDCF03.01GB


108 8 Control system – 8.4.9.2 ATTACH, menu 2

PRESENT INPUT SIGNALS, P7


page

Description: Signal from control lever P7.


Circuit diagram: Circuit 7.0-1
Connection: signal from R8075-2/3 to analogue in D790-1/K9:9
Function: 7.1.1 Control levers
Signal value: XX.XXV = 0,50 - 4,50 V. 2,5 V in zero position.

8.4.9.2 ATTACH, menu 2


PRESENT INPUT SIGNALS, P5
page

Description: Signal from control lever P5.


DIAG ATTACHMENT 2(X)
Circuit diagram: Circuit 7.0-1
PRESENT INPUT SIGNALS
P5 XX.XXV Connection: signal from R8075-1/3 to analogue in D790-1/K7:7
Function: 7.1.1 Control levers
005417

Signal value: XX.XXV = 0,50 - 4,50 V. 2,5 V in zero position.

8.4.9.3 ATTACH, menu 3


PRESENT INPUT SIGNALS, SPREADER
page

Description: Signals from switch for spreading the attachment.


DIAG ATTACHMENT 3(X) Circuit diagram: Circuits 7.5-1, 7.0-2
PRESENT INPUT SIGNALS
SPREADER IN X OUT X Connection:
AUTO 20/40 X IN: Signal from S1012/1 (S815/14) to digital in D790/K7:14
005418

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:

1 Input signal active.

0 No signal.

PRESENT INPUT SIGNALS, AUTO 20/40


page

Description: Signal from switch automatic spreading 20/40.


Circuit diagram: Circuit 7.5-3
Connection: from S1012-2/1 to digital in D790-1/K8:11
Function: 7.5 Spreading
Signal value:

1 Input signal active.

0 No signal.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.9.4 ATTACH, menu 4 109

PRESENT INPUT SIGNALS, 30/35 STOP


page

Description: Signal from switch for stop at 30’/35’.


Circuit diagram: Circuit 7.5-1
Connection: from S1004/1 to digital in D790-1/K8:10
Function: 7.5 Spreading
Signal value:

1 Input signal active.

0 No signal.

8.4.9.4 ATTACH, menu 4


PRESENT INPUT SIGNALS, PISTOL
page

Description: Signals from control lever for pistol trigger.


DIAG ATTACHMENT 4(X) Circuit diagram: Circuit 7.0-2
PRESENT INPUT SIGNALS
Connection: from S815/19 to digital in D790-1/K7:16
PISTOL X Function: 7.1.1 Control lever
007130

Signal value:

1 Input signal active.

0 No signal.

8.4.9.5 ATTACH, menu 5


PRESENT INPUT SIGNALS, LOCK CONT
page

Description: Signal from switch, lock lock tongue.


DIAG ATTACHMENT 5(X) Circuit diagram: Circuit 7.9-1
PRESENT INPUT SIGNALS
LOCK CONT X Connection: signal from S1003 to digital in D790-1/K8:12
UNLOCK CONT X
Function: 7.9.2 Lifting hook
010079

Signal value:

1 Input signal active.

0 No signal.

PRESENT INPUT SIGNALS, UNLOCK CONT


page

Description: Signal from control lever to open lock tongue.


Circuit diagram: Circuit 7.9-1
Connection: signal from S1002 to digital in D790-1/K7:15
Function: 7.1.1 Control levers
Signal value:

1 Input signal active.

0 No signal.

Workshop Manual DCF 90-100 VDCF03.01GB


110 8 Control system – 8.4.9.6 ATTACH, menu 6

8.4.9.6 ATTACH, menu 6


PRESENT INPUT SIGNALS, LOW SPEED 20/40
page

Description: Signal from spreading position sensor for end position


DIAG ATTACHMENT 6(X) damping 20’/40’ right or left.
PRESENT INPUT SIGNALS
LE RI Circuit diagram: Circuit 5
LOW SPEED 20/40 X X Connection: from inductive sensor B769L to digital in D791/K1:12 or

010080
30/35 STOP X X from inductive sensor B769R to digital in D791/K1:40
Function: 7.5.6 Position sensor spreading
Signal value:

1 Input signal active.

0 No signal.

PRESENT INPUT SIGNALS, 30/35 STOP


page

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:

1 Input signal active.

0 No signal.

8.4.9.7 ATTACH, menu 7


PRESENT INPUT SIGNALS, ALIGNMENT LE RI, UPPER
page

Description: Signals from sensors alignment right upper and left


DIAG ATTACHMENT 7(X) upper.
PRESENT INPUT SIGNALS
ALIGNMENT LE RI Circuit diagram: Circuit 11B
UPPER X X Connection:
010081

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:

1 Input signal active.

0 No signal.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.9.8 ATTACH, menu 8 111

PRESENT INPUT SIGNALS, ALIGNMENT LE RI, LOWER


page

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:

1 Input signal active.

0 No signal.

8.4.9.8 ATTACH, menu 8


PRESENT INPUT SIGNAL LE RI, LOCKED CONT
page

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:

1 Input signal active.

0 No signal.

PRESENT OUTPUT SIGNAL LE RI, UNLOCKED CONT


page

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:

1 Input signal active.

0 No signal.

Workshop Manual DCF 90-100 VDCF03.01GB


112 8 Control system – 8.4.9.9 ATTACH, menu 9

8.4.9.9 ATTACH, menu 9


PRESENT OUTPUT SIGNAL, LOCK CONT
page

Description: Voltage feed to attachment control valve, locked lock


DIAG ATTACHMENT 9(X) tongues.
PRESENT OUTPUT SIGNAL
LOCK CONT XY Circuit diagram: Circuit 8
UNLOCK CONT XY Connection: digital out from D791/K1:7 to Y6040

010083
Function: 7.4.2 Control valve attachment
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

PRESENT OUTPUT SIGNAL, UNLOCK CONT


page

Description: Voltage feed to attachment control valve, open lock


tongues.
Circuit diagram: Circuit 8
Connection: digital out from D791/K1:9 to Y6039
Function: 7.4.2 Control valve attachment
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.9.10 ATTACH, menu 10 113

8.4.9.10 ATTACH, menu 10


PRESENT OUTPUT SIGNAL, IND. LOCKED CONT
page

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:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

PRESENT OUTPUT SIGNAL, IND. UNLOCKED CONT


page

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:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

Workshop Manual DCF 90-100 VDCF03.01GB


114 8 Control system – 8.4.9.11 ATTACH, menu 11

PRESENT OUTPUT SIGNAL, ALIGNMENT


page

Description: Voltage feed, alignment indicator light - located on


carriage.
Circuit diagram: Circuit 10A
Connection: digital out from D791/K1:39 to H564
Function: 7.9.2 Lifting hook
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

8.4.9.11 ATTACH, menu 11


OUTPUT SIDE SHIFT LE, REFERENCE
page

Description: Status for control current to attachment control valve for


DIAG ATTACHMENT 11(X) side shift left.
OUTPUT SIDESHIFT LE
REFERENCE XY Circuit diagram: Circuit 7.4-2
REQUIRED VALUE XXX Connection: digital out from D791-1/K1:32 to Y6020/1
010088

FEEDBACK XXX
Function: 7.4.2 Control valve attachment
Signal value:

00 No output signal, PWM off.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.

OUTPUT SIDE SHIFT LE, REQUIRED VALUE


page

Description: Reference value for control current to attachment control


valve for output signal, side shift left.
Circuit diagram: Circuit 7.4-2
Connection: output signal reference value out from D791-1/K1:18 to
Y6020/2
Function: 7.4.2 Control valve attachment
Signal value: XXX = Current value: in mA for control of solenoid valve.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.9.12 ATTACH, menu 12 115

OUTPUT SIDE SHIFT LE, FEEDBACK


page

Description: Present control current to attachment control valve for


side shift left.
Circuit diagram: Circuit 7.4-2
Connection: output signal actual value out from D791-1/K1:18 to
Y6020/2
Function: 7.4.2 Control valve attachment
Signal value: XXX = Measured current value in mA.

8.4.9.12 ATTACH, menu 12


OUTPUT SIDE SHIFT RI, REFERENCE
page

Description: Status for control current to attachment control valve for


DIAG ATTACHMENT 12(X) side shift right.
OUTPUT SIDESHIFT RI
REFERENCE XY Circuit diagram: Circuit 7.4-2
REQUIRED VALUE XXX Connection: digital out from D791/K1:33 to Y6021/1
010089

FEEDBACK XXX
Function: 7.4.2 Control valve attachment
Signal value:

00 No output signal, PWM off.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.

OUTPUT SIDE SHIFT RI, REQUIRED VALUE


page

Description: Reference value for control current to attachment control


valve for output signal, side shift right.
Circuit diagram: Circuit 7.4-2
Connection: output signal reference value out from D791-1/K1:18 to
Y6021/2
Function: 7.4.2 Control valve attachment
Signal value: XXX = Current value: in mA for control of solenoid valve.

OUTPUT SIDE SHIFT RI, FEEDBACK


page

Description: Present control current to attachment control valve for


side shift right.
Circuit diagram: Circuit 7.4-2
Connection: output signal actual value out from D791-1/K1:18 to
Y6019/2
Function: 7.4.2 Control valve attachment
Signal value: XXX = Measured current value in mA.

Workshop Manual DCF 90-100 VDCF03.01GB


116 8 Control system – 8.4.9.13 ATTACH, menu 13

8.4.9.13 ATTACH, menu 13


OUTPUT LEVELLING CW, REFERENCE
page

Description: Status control current to control valve attachment for lev-


DIAG ATTACHMENT 13(X) eling right.
OUTPUT LEVELLING CW
REFERENCE XY Circuit diagram: Circuit 6
REQUIRED VALUE XXX Connection: digital out from D791/K1:31 to Y6035

010085
FEEDBACK XXX
Function: 7.8.2 Control valve attachment
Signal value:

00 No output signal, PWM off.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.

OUTPUT LEVELLING CW, REQUIRED VALUE


page

Description: Reference value for control current to attachment control


valve for output signal, levelling right.
Circuit diagram: Circuit 6
Connection: output signal reference value out from D791/K1:19 to
Y6035
Function: 7.8.2 Control valve attachment
Signal value: XXX = Current value: in mA for control of solenoid valve.

OUTPUT LEVELLING CW, FEEDBACK


page

Description: Present control current to control valve attachment for


leveling right.
Circuit diagram: Circuit 6
Connection: output signal, actual value out from D791/K1:19 to Y6035
Function: 7.8.2 Control valve attachment
Signal value: XXX = Measured current value in mA.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.9.14 ATTACH, menu 14 117

8.4.9.14 ATTACH, menu 14


OUTPUT LEVELLING CCW, REFERENCE
page

Description: Status control current to control valve attachment for lev-


DIAG ATTACHMENT 14(X) eling left.
OUTPUT LEVELLING CW
REFERENCE XY Circuit diagram: Circuit 6
REQUIRED VALUE XXX Connection: digital out from D791/K1:30 to Y6036

010086
FEEDBACK XXX
Function: 7.8.2 Control valve attachment
Signal value:

00 No output signal, PWM off.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.

OUTPUT LEVELLING CCW, REQUIRED VALUE


page

Description: Reference value for control current to attachment control


valve for output signal, levelling left.
Circuit diagram: Circuit 6
Connection: output signal, reference value out from D791/K1:19 to
Y6036
Function: 7.8.2 Control valve attachment
Signal value: XXX = Current value: in mA for control of solenoid valve.

OUTPUT LEVELLING CCW, FEEDBACK


page

Description: Present control current to control valve attachment for


leveling left.
Circuit diagram: Circuit 6
Connection: output signal, actual value out from D791/K1:19 to Y6036
Function: 7.8.2 Control valve attachment
Signal value: XXX = Measured current value in mA.

Workshop Manual DCF 90-100 VDCF03.01GB


118 8 Control system – 8.4.9.15 ATTACH, menu 15

8.4.9.15 ATTACH, menu 15


Not used.
page

DIAG ATTACHMENT 15(X)


NOT USED

010077
8.4.9.16 ATTACH, menu 16
Not used.
page

DIAG ATTACHMENT 16(X)


NOT USED
010078

8.4.9.17 ATTACH, menu 17


OUTPUT SPREAD LE OUT, REFERENCE
page

Description: Status for control current to attachment control valve for


DIAG ATTACHMENT 17(X) spreading, left side out.
OUTPUT SPREAD LE OUT
REFERENCE XY Circuit diagram: Circuit 4
REQUIRED VALUE XXX Connection: digital out from D791/K1:3 to Y6018L
010087

FEEDBACK XXX
Function: 7.5.2 Control valve attachment
Signal value:

00 No output signal, PWM off.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.

OUTPUT SPREAD LE OUT, REQUIRED VALUE


page

Description: Reference value for control current to attachment control


valve for output signal, spreading, left side out
Circuit diagram: Circuit 4
Connection: output signal, reference value out from D791/K1:16 to
Y6018L
Function: 7.5.2 Control valve attachment
Signal value: XXX = Current value: in mA for control of solenoid valve.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.9.18 ATTACH, menu 18 119

OUTPUT SPREAD LE OUT, FEEDBACK


page

Description: Present control current to attachment control valve for


spreading, left side out
Circuit diagram: Circuit 4
Connection: output signal, actual value out from D791/K1:16 to
Y6018L
Function: 7.5.2 Control valve attachment
Signal value: XXX = Measured current value in mA.

8.4.9.18 ATTACH, menu 18


OUTPUT SPREADER LE IN, REFERENCE
page

Description: Status for control current to attachment control valve for


DIAG ATTACHMENT 18(X) spreading, left side in.
OUTPUT SPREADER LE IN
REFERENCE XY Circuit diagram: Circuit 4
REQUIRED VALUE XXX Connection: digital out from D791/K1:2 to Y6019L
010090

FEEDBACK XXX
Function: 7.5.2 Control valve attachment
Signal value:

00 No output signal, PWM off.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.

OUTPUT SPREADER LE IN, REQUIRED VALUE


page

Description: Reference value for control current to attachment control


valve for output signal, spreading, left side in
Circuit diagram: Circuit 4
Connection: output signal, reference value out from D791/K1:16 to
Y6019L
Function: 7.5.2 Control valve attachment
Signal value: XXX = Current value: in mA for control of solenoid valve.

OUTPUT SPREADER LE IN, FEEDBACK


page

Description: Present control current to attachment control valve for


spreading, left side in.
Circuit diagram: Circuit 4
Connection: output signal, actual value out from D791/K1:16 to
Y6019L
Function: 7.5.2 Control valve attachment
Signal value: XXX = Measured current value in mA.

Workshop Manual DCF 90-100 VDCF03.01GB


120 8 Control system – 8.4.9.19 ATTACH, menu 19

8.4.9.19 ATTACH, menu 19


OUTPUT SPREAD RI OUT, REFERENCE
page

Description: Status for control current to attachment control valve for


DIAG ATTACHMENT 19(X) spreading, right side out.
OUTPUT SPREAD RI OUT
Circuit diagram: Circuit 4
REFERENCE XY
REQUIRED VALUE XXX Connection: digital out from D791/K1:5 to Y6018R

010091
FEEDBACK XXX
Function: 7.5.2 Control valve attachment
Signal value:

00 No output signal, PWM off.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.

OUTPUT SPREAD RI OUT, REQUIRED VALUE


page

Description: Reference value for control current to attachment control


valve for output signal, spreading, right side out
Circuit diagram: Circuit 4
Connection: output signal, reference value out from D791/K1:17 to
Y6018R
Function: 7.5.2 Control valve attachment
Signal value: XXX = Current value: in mA for control of solenoid valve.

OUTPUT SPREAD RI OUT, FEEDBACK


page

Description: Present control current to attachment control valve for


spreading, right side out.
Circuit diagram: Circuit 4
Connection: output signal, actual value out from D791/K1:17 to
Y6018R
Function: 7.5.2 Control valve attachment
Signal value: XXX = Measured current value in mA.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.9.20 ATTACH, menu 20 121

8.4.9.20 ATTACH, menu 20


OUTPUT SPREADER RI IN, REFERENCE
page

Description: Status for control current to attachment control valve for


DIAG ATTACHMENT 20(X) spreading, right side in.
OUTPUT SPREADER RI IN
REFERENCE XY Circuit diagram: Circuit 4
REQUIRED VALUE XXX Connection: digital out from D791/K1:4 to Y6019R

010092
FEEDBACK XXX
Function: 7.5.2 Control valve attachment
Signal value:

00 No output signal, PWM off.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.

OUTPUT SPREADER RI IN, REQUIRED VALUE


page

Description: Reference value for control current to attachment control


valve for output signal, spreading, right side in.
Circuit diagram: Circuit 4
Connection: output signal, reference value out from D791/K1:17 to
Y6019R
Function: 7.5.2 Control valve attachment
Signal value: XXX = Current value: in mA for control of solenoid valve.

OUTPUT SPREADER RI IN, FEEDBACK


page

Description: Present control current to attachment control valve for


spreading, right side in.
Circuit diagram: Circuit 4
Connection: output signal, actual value out from D791/K1:17 to
Y6019R
Function: 7.5.2 Control valve attachment
Signal value: XXX = Measured current value in mA.

Workshop Manual DCF 90-100 VDCF03.01GB


122 8 Control system – 8.4.9.21 ATTACH, menu 21

8.4.9.21 ATTACH, menu 21


PRESENT OUTPUT SIGNAL, BUZZER AUTO 20-40
page

DIAG ATTACHMENT 21(X)


PRESENT OUTPUT SIGNAL Description: Voltage feed to buzzer automatic spreading 20’-40’.
Circuit diagram: Circuit 3
BUZZER AUTO 20-40 XY

009181
Connection: digital out from D791/K1:28 to H9003
Function: 7.5 Spreading
Signal value:

01 No output signal. Error detection only possible when output


signal is active.

10 Output signal active, short-circuiting or open circuit.

11 Output signal active, circuit OK.

8.4.9.22 ATTACH, menu 22


PRESENT INPUT SIGNALS, DETECT UPPER CONT.
page

Description: Signals from detection sensor for upper container right


DIAG ATTACHMENT 22(X) (B7203 RU) and detection sensor for upper container left (B7203LU).
PRESENT INPUT SIGNALS
DETECT UPPER CONT. Circuit diagram: Circuit 11B
LE RI LE: signal from B7203LU to digital in D791-1/K1:13
010075

X X
RI: Signal from B7203RU to digital in D791-1/K1:21
Function: 7.9.2.8 Alignment and detection sensor
Signal value:

1 Input signal active.

0 No signal.

8.4.9.23 ATTACH, menu 23


PRESENT OUTPUT SIGNAL, IND. UPPER ALIGNMENT
page

Description: Signals from alignment sensor right upper (B7203RU-2)


DIAG ATTACHMENT 23(X) and left upper (B7203LU-2).
PRESENT OUTPUT SIGNAL
IND. UPPER Circuit diagram: Circuit 11B
ALIGNMENT XY Connection:
010076

LE: signal from B7203LU-2 to digital in D791-1/K1:11


RI: Signal from B7203RU-2 to digital in D791-1/K1:36
Function: 7.9.2.8 Alignment and detection sensor
Signal value:

1 Input signal active.

0 No signal.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.9 ATTACH, DCF 90-100 with twistlock attachment 123

8.4.9 ATTACH, DCF 90-100 with twistlock


attachment
ATTACH, description
page

This group covers attachment functions.


DIAGNOSIS
Confirm selection with function key for Enter.
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH

005339
OLS EXTRA

8.4.9.1 ATTACH, menu 1


PRESENT INPUT SIGNALS, P3
page

Description: Signal from control lever P3.


DIAG ATTACHMENT 1(X)
Circuit diagram: Circuits 7.0-1, 7.0-2
PRESENT INPUT SIGNALS
P3 XX.XXV Connection: signal from R8073/3 (S815/11) to analogue in D790-1/
P4 XX.XXV K7:5
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.

PRESENT INPUT SIGNALS, P4


page

Description: Signal from control lever P4.


Circuit diagram: Circuits 7.0-1, 7.0-2
Connection: signal from R8074/3 (S815/1) to analogue in D790-1/K7:6
Function: 7.1.1 Control levers
Signal value: XX.XXV = 0,50 - 4,50 V. 2,5 V in zero position.

PRESENT INPUT SIGNALS, P7


page

Description: Signal from control lever P7.


Circuit diagram: Circuit 7.0-1
Connection: signal from R8075-2/3 to analogue in D790-1/K9:9
Function: 7.1.1 Control levers
Signal value: XX.XXV = 0,50 - 4,50 V. 2,5 V in zero position.

8.4.9.2 ATTACH, menu 2


PRESENT INPUT SIGNALS, P5
page

Description: Signal from control lever P5.


DIAG ATTACHMENT 2(X)
Circuit diagram: Circuit 7.0-1
PRESENT INPUT SIGNALS
P5 XX.XXV Connection: signal from R8075-1/3 to analogue in D790-1/K7:7
Function: 7.1.1 Control levers
005417

Signal value: XX.XXV = 0,50 - 4,50 V. 2,5 V in zero position.

Workshop Manual DCF 90-100 VDCF03.01GB


124 8 Control system – 8.4.9.3 ATTACH, menu 3

8.4.9.3 ATTACH, menu 3


PRESENT INPUT SIGNALS, SPREADER
page

Description: Signals from switch for spreading the attachment.


DIAG ATTACHMENT 3(X) Circuit diagram: Circuits 7.5-1, 7.0-2
PRESENT INPUT SIGNALS
SPREADER IN X OUT X Connection:
AUTO 20/40 X IN: Signal from S1012/1 (S815/14) to digital in D790-1/K7:14

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:

1 Input signal active.

0 No signal.

PRESENT INPUT SIGNALS, AUTO 20/40


page

Description: Signal from switch automatic spreading 20/40.


Circuit diagram: Circuit 7.5-3
Connection: from S1012-2/1 to digital in D790-1/K8:11
Function: 7.5 Spreading
Signal value:

1 Input signal active.

0 No signal.

PRESENT INPUT SIGNALS, 30/35 STOP


page

Description: Signal from switch for stop at 30’/35’.


Circuit diagram: Circuit 7.5-1
Connection: from S1004/1 to digital in D790-1/K8:10
Function: 7.5 Spreading
Signal value:

1 Input signal active.

0 No signal.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.9.4 ATTACH, menu 4 125

8.4.9.4 ATTACH, menu 4


PRESENT INPUT SIGNALS, PISTOL
page

Description: Signals from control lever for pistol trigger.


DIAG ATTACHMENT 4(X) Circuit diagram: Circuit 7.0-2
PRESENT INPUT SIGNALS
Connection: from S815/19 to digital in D790-1/K7:16
PISTOL X Function: 7.1.1 Control lever

007130
Signal value:

1 Input signal active.

0 No signal.

8.4.9.5 ATTACH, menu 5


PRESENT INPUT SIGNALS, LOCK CONT
page

Description: Signal from switch for locking twistlocks.


DIAG ATTACHMENT 5(X) Circuit diagram: Circuit 7.9-1
PRESENT INPUT SIGNALS
LOCK CONT X Connection: signal from S1003 to digital in D790-1/K8:12
UNLOCK CONT X
Function: 7.9.1 Twistlocks
010079

Signal value:

1 Input signal active.

0 No signal.

PRESENT INPUT SIGNALS, UNLOCK CONT


page

Description: Signal from control lever to open twistlocks.


Circuit diagram: Circuit 7.9-1
Connection: signal from S1002 to digital in D790-1/K7:15
Function: 7.1.1 Control levers
Signal value:

1 Input signal active.

0 No signal.

Workshop Manual DCF 90-100 VDCF03.01GB


126 8 Control system – 8.4.9.6 ATTACH, menu 6

8.4.9.6 ATTACH, menu 6


PRESENT INPUT SIGNALS, LOW SPEED 20/40
page

Description: Signal from spreading position sensor for end position


DIAG ATTACHMENT 6(X) damping 20’/40’ right or left.
PRESENT INPUT SIGNALS
LE RI Circuit diagram: Circuit 5
LOW SPEED 20/40 X X Connection: from inductive sensor B769L to digital in D791/K1:12 or

010080
30/35 STOP X X from inductive sensor B769R to digital in D791/K1:40
Function: 7.5.6 Position sensor spreading
Signal value:

1 Input signal active.

0 No signal.

PRESENT INPUT SIGNALS, 30/35 STOP


page

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:

1 Input signal active.

0 No signal.

8.4.9.7 ATTACH, menu 7


PRESENT INPUT SIGNALS, ALIGNMENT LE RI
page

Description: Signals from right and left alignment sensors.


DIAG ATTACHMENT 7(X)
Circuit diagram: Circuit 11A
PRESENT INPUT SIGNALS
ALIGNMENT LE RI Connection:
X X
LE: signal from B7203R to digital in D791/K1:26
010093

RI: signal from B7203L to digital in D791/K1:27


Function: 7.9.1.7 Alignment sensor
Signal value:

1 Input signal active.

0 No signal.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.9.8 ATTACH, menu 8 127

8.4.9.8 ATTACH, menu 8


PRESENT INPUT SIGNAL LE RI, LOCKED CONT
page

Description: Signals from sensors locked twistlock 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: 7.9.1.8 Twistlocks sensor
Signal value:

1 Input signal active.

0 No signal.

PRESENT OUTPUT SIGNAL LE RI, UNLOCKED CONT


page

Description: Signals from sensors open twistlock 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: 7.9.1.8 Twistlocks sensor
Signal value:

1 Input signal active.

0 No signal.

8.4.9.9 ATTACH, menu 9


PRESENT OUTPUT SIGNAL, LOCK CONT
page

Description: Voltage feed to attachment control valve, locked twist-


DIAG ATTACHMENT 9(X) locks.
PRESENT OUTPUT SIGNAL
LOCK CONT XY Circuit diagram: Circuit 8
UNLOCK CONT XY Connection: digital out from D791/K1:7 to Y6040
010083

Function: 7.4.2 Control valve attachment


Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

Workshop Manual DCF 90-100 VDCF03.01GB


128 8 Control system – 8.4.9.10 ATTACH, menu 10

PRESENT OUTPUT SIGNAL, UNLOCK CONT


page

Description: Voltage feed to attachment control valve, open twistlocks.


Circuit diagram: Circuit 8
Connection: digital out from D791/K1:9 to Y6039
Function: 7.4.2 Control valve attachment
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

8.4.9.10 ATTACH, menu 10


PRESENT OUTPUT SIGNAL, IND. LOCKED CONT
page

Description: Voltage feed, indicator light for locked twistlocks - located


DIAG ATTACHMENT 10(X) 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: 7.9.1 Twistlocks
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

PRESENT OUTPUT SIGNAL, IND. UNLOCKED CONT


page

Description: Voltage feed, indicator light for unlocked twistlocks - lo-


cated on carriage.
Circuit diagram: Circuit 10A
Connection: digital out from D791/K1:25 to H562

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.9.11 ATTACH, menu 11 129

Function: 7.9.1 Twistlocks


Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

PRESENT OUTPUT SIGNAL, ALIGNMENT


page

Description: Voltage feed, alignment indicator light - located on car-


riage.
Circuit diagram: Circuit 10A
Connection: digital out from D791/K1:39 to H564
Function: 7.9.1 Twistlocks
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

8.4.9.11 ATTACH, menu 11


OUTPUT SIDE SHIFT LE, REFERENCE
page

Description: Status for control current to attachment control valve for


DIAG ATTACHMENT 11(X) side shift left.
OUTPUT SIDESHIFT LE
REFERENCE XY Circuit diagram: Circuit 7.4-2
REQUIRED VALUE XXX Connection: digital out from D791-1/K1:32 to Y6020/1
010088

FEEDBACK XXX
Function: 7.4.2 Control valve attachment
Signal value:

00 No output signal, PWM off.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.

Workshop Manual DCF 90-100 VDCF03.01GB


130 8 Control system – 8.4.9.12 ATTACH, menu 12

OUTPUT SIDE SHIFT LE, REQUIRED VALUE


page

Description: Reference value for control current to attachment control


valve for output signal, side shift left.
Circuit diagram: Circuit 7.4-2
Connection: output signal reference value out from D791-1/K1:18 to
Y6020/2
Function: 7.4.2 Control valve attachment
Signal value: XXX = Current value: in mA for control of solenoid valve.

OUTPUT SIDE SHIFT LE, FEEDBACK


page

Description: Present control current to attachment control valve for


side shift left.
Circuit diagram: Circuit 7.4-2
Connection: output signal actual value out from D791-1/K1:18 to
Y6020/2
Function: 7.4.2 Control valve attachment
Signal value: XXX = Measured current value in mA.

8.4.9.12 ATTACH, menu 12


OUTPUT SIDE SHIFT RI, REFERENCE
page

Description: Status for control current to attachment control valve for


DIAG ATTACHMENT 12(X) side shift right.
OUTPUT SIDESHIFT RI
REFERENCE XY Circuit diagram: Circuit 7.4-2
REQUIRED VALUE XXX Connection: digital out from D791/K1:33 to Y6021/1
010089

FEEDBACK XXX
Function: 7.4.2 Control valve attachment
Signal value:

00 No output signal, PWM off.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.

OUTPUT SIDE SHIFT RI, REQUIRED VALUE


page

Description: Reference value for control current to attachment control


valve for output signal, side shift right.
Circuit diagram: Circuit 7.4-2
Connection: output signal reference value out from D791-1/K1:18 to
Y6021/2
Function: 7.4.2 Control valve attachment
Signal value: XXX = Current value: in mA for control of solenoid valve.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.9.13 ATTACH, menu 13 131

OUTPUT SIDE SHIFT RI, FEEDBACK


page

Description: Present control current to attachment control valve for


side shift right.
Circuit diagram: Circuit 7.4-2
Connection: output signal actual value out from D791-1/K1:18 to
Y6019/2
Function: 7.4.2 Control valve attachment
Signal value: XXX = Measured current value in mA.

8.4.9.13 ATTACH, menu 13


OUTPUT LEVELLING CW, REFERENCE
page

Description: Status control current to control valve attachment for lev-


DIAG ATTACHMENT 13(X) eling right.
OUTPUT LEVELLING CW
REFERENCE XY Circuit diagram: Circuit 6
REQUIRED VALUE XXX Connection: digital out from D791/K1:31 to Y6035
010085

FEEDBACK XXX
Function: 7.8.2 Control valve attachment
Signal value:

00 No output signal, PWM off.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.

OUTPUT LEVELLING CW, REQUIRED VALUE


page

Description: Reference value for control current to attachment control


valve for output signal, levelling right.
Circuit diagram: Circuit 6
Connection: output signal reference value out from D791/K1:19 to
Y6035
Function: 7.8.2 Control valve attachment
Signal value: XXX = Current value: in mA for control of solenoid valve.

OUTPUT LEVELLING CW, FEEDBACK


page

Description: Present control current to control valve attachment for


leveling right.
Circuit diagram: Circuit 6
Connection: output signal, actual value out from D791/K1:19 to Y6035
Function: 7.8.2 Control valve attachment
Signal value: XXX = Measured current value in mA.

Workshop Manual DCF 90-100 VDCF03.01GB


132 8 Control system – 8.4.9.14 ATTACH, menu 14

8.4.9.14 ATTACH, menu 14


OUTPUT LEVELLING CCW, REFERENCE
page

Description: Status control current to control valve attachment for lev-


DIAG ATTACHMENT 14(X) eling left.
OUTPUT LEVELLING CW
REFERENCE XY Circuit diagram: Circuit 6
REQUIRED VALUE XXX Connection: digital out from D791/K1:30 to Y6036

010086
FEEDBACK XXX
Function: 7.8.2 Control valve attachment
Signal value:

00 No output signal, PWM off.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.

OUTPUT LEVELLING CCW, REQUIRED VALUE


page

Description: Reference value for control current to attachment control


valve for output signal, levelling left.
Circuit diagram: Circuit 6
Connection: output signal, reference value out from D791/K1:19 to
Y6036
Function: 7.8.2 Control valve attachment
Signal value: XXX = Current value: in mA for control of solenoid valve.

OUTPUT LEVELLING CCW, FEEDBACK


page

Description: Present control current to control valve attachment for


leveling left.
Circuit diagram: Circuit 6
Connection: output signal, actual value out from D791/K1:19 to Y6036
Function: 7.8.2 Control valve attachment
Signal value: XXX = Measured current value in mA.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.9.15 ATTACH, menu 15 133

8.4.9.15 ATTACH, menu 15


Not used.
page

DIAG ATTACHMENT 15(X)


NOT USED

010077
8.4.9.16 ATTACH, menu 16
Not used.
page

DIAG ATTACHMENT 16(X)


NOT USED
010078

8.4.9.17 ATTACH, menu 17


OUTPUT SPREAD LE OUT, REFERENCE
page

Description: Status for control current to attachment control valve for


DIAG ATTACHMENT 17(X) spreading, left side out.
OUTPUT SPREAD LE OUT
REFERENCE XY Circuit diagram: Circuit 4
REQUIRED VALUE XXX Connection: digital out from D791/K1:3 to Y6018L
010087

FEEDBACK XXX
Function: 7.5.2 Control valve attachment
Signal value:

00 No output signal, PWM off.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.

OUTPUT SPREAD LE OUT, REQUIRED VALUE


page

Description: Reference value for control current to attachment control


valve for output signal, spreading, left side out
Circuit diagram: Circuit 4
Connection: output signal, reference value out from D791/K1:16 to
Y6018L
Function: 7.5.2 Control valve attachment
Signal value: XXX = Current value: in mA for control of solenoid valve.

Workshop Manual DCF 90-100 VDCF03.01GB


134 8 Control system – 8.4.9.18 ATTACH, menu 18

OUTPUT SPREAD LE OUT, FEEDBACK


page

Description: Present control current to attachment control valve for


spreading, left side out
Circuit diagram: Circuit 4
Connection: output signal, actual value out from D791/K1:16 to
Y6018L
Function: 7.5.2 Control valve attachment
Signal value: XXX = Measured current value in mA.

8.4.9.18 ATTACH, menu 18


OUTPUT SPREADER LE IN, REFERENCE
page

Description: Status for control current to attachment control valve for


DIAG ATTACHMENT 18(X) spreading, left side in.
OUTPUT SPREADER LE IN
REFERENCE XY Circuit diagram: Circuit 4
REQUIRED VALUE XXX Connection: digital out from D791/K1:2 to Y6019L
010090

FEEDBACK XXX
Function: 7.5.2 Control valve attachment
Signal value:

00 No output signal, PWM off.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.

OUTPUT SPREADER LE IN, REQUIRED VALUE


page

Description: Reference value for control current to attachment control


valve for output signal, spreading, left side in
Circuit diagram: Circuit 4
Connection: output signal, reference value out from D791/K1:16 to
Y6019L
Function: 7.5.2 Control valve attachment
Signal value: XXX = Current value: in mA for control of solenoid valve.

OUTPUT SPREADER LE IN, FEEDBACK


page

Description: Present control current to attachment control valve for


spreading, left side in.
Circuit diagram: Circuit 4
Connection: output signal, actual value out from D791/K1:16 to
Y6019L
Function: 7.5.2 Control valve attachment
Signal value: XXX = Measured current value in mA.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.9.19 ATTACH, menu 19 135

8.4.9.19 ATTACH, menu 19


OUTPUT SPREAD RI OUT, REFERENCE
page

Description: Status for control current to attachment control valve for


DIAG ATTACHMENT 19(X) spreading, right side out.
OUTPUT SPREAD RI OUT
Circuit diagram: Circuit 4
REFERENCE XY
REQUIRED VALUE XXX Connection: digital out from D791/K1:5 to Y6018R

010091
FEEDBACK XXX
Function: 7.5.2 Control valve attachment
Signal value:

00 No output signal, PWM off.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.

OUTPUT SPREAD RI OUT, REQUIRED VALUE


page

Description: Reference value for control current to attachment control


valve for output signal, spreading, right side out
Circuit diagram: Circuit 4
Connection: output signal, reference value out from D791/K1:17 to
Y6018R
Function: 7.5.2 Control valve attachment
Signal value: XXX = Current value: in mA for control of solenoid valve.

OUTPUT SPREAD RI OUT, FEEDBACK


page

Description: Present control current to attachment control valve for


spreading, right side out.
Circuit diagram: Circuit 4
Connection: output signal, actual value out from D791/K1:17 to
Y6018R
Function: 7.5.2 Control valve attachment
Signal value: XXX = Measured current value in mA.

8.4.9.20 ATTACH, menu 20


OUTPUT SPREADER RI IN, REFERENCE
page

Description: Status for control current to attachment control valve for


DIAG ATTACHMENT 20(X) spreading, right side in.
OUTPUT SPREADER RI IN
REFERENCE XY
REQUIRED VALUE XXX
010092

FEEDBACK XXX

Workshop Manual DCF 90-100 VDCF03.01GB


136 8 Control system – 8.4.9.21 ATTACH, menu 21

Circuit diagram: Circuit 4


Connection: digital out from D791/K1:4 to Y6019R
Function: 7.5.2 Control valve attachment
Signal value:

00 No output signal, PWM off.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.

OUTPUT SPREADER RI IN, REQUIRED VALUE


page

Description: Reference value for control current to attachment control


valve for output signal, spreading, right side in.
Circuit diagram: Circuit 4
Connection: output signal, reference value out from D791/K1:17 to
Y6019R
Function: 7.5.2 Control valve attachment
Signal value: XXX = Current value: in mA for control of solenoid valve.

OUTPUT SPREADER RI IN, FEEDBACK


page

Description: Present control current to attachment control valve for


spreading, right side in.
Circuit diagram: Circuit 4
Connection: output signal, actual value out from D791/K1:17 to
Y6019R
Function: 7.5.2 Control valve attachment
Signal value: XXX = Measured current value in mA.

8.4.9.21 ATTACH, menu 21


PRESENT OUTPUT SIGNAL, BUZZER AUTO 20-40
page

DIAG ATTACHMENT 21(X)


PRESENT OUTPUT SIGNAL Description: Voltage feed to buzzer automatic spreading 20’-40’.
Circuit diagram: Circuit 3
BUZZER AUTO 20-40 XY
009181

Connection: digital out from D791/K1:28 to H9003


Function: 7.5 Spreading
Signal value:

01 No output signal. Error detection only possible when output


signal is active.

10 Output signal active, short-circuiting or open circuit.

11 Output signal active, circuit OK.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.10 OLS 137

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

8.4.10.1 OLS, menu 1


PRESENT INPUT SIGNAL, LIFT CYLINDER
page

Description: Signal from hydraulic pressure sensor, lift cylinder. See


DIAG OLS 1(X) also HYDRAULIC PRESSURE, LIFT CYLINDER page 53 for pressure
PRESENT INPUT SIGNAL information.

LIFT CYLINDER X.XXV Circuit diagram: Circuit 8.2-2


005437

TILT CYLINDER X.XXV Connection: signal from B768-1/3 to analogue in D797-1/K1:21


Function: 7.2.8 Sensor hydraulic pressure lift cylinder
Signal value: X.XXV = 0.50-4.50 V = Hydraulic oil pressure, 0.50 V
corresponds to 0 MPa, 4.50 V corresponds to 25 MPa.

PRESENT INPUT SIGNAL, TILT CYLINDER


page

Description: Signal from hydraulic pressure sensor, lift cylinder (C+


piston side). See also HYDRAULIC PRESSURE, TILT CYLINDER
page 53 for pressure information.
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: X.XXV = 0.50-4.50 V = Hydraulic oil pressure, 0.50 V
corresponds to 0 MPa, 4.50 V corresponds to 25 MPa.

8.4.10.2 OLS, menu 2


PRESENT INPUT SIGNAL, BYPASS
page

Description: Signal from bypass switch.


DIAG OLS 2(X)
Circuit diagram: Circuit 8.2-1
PRESENT INPUT SIGNAL
Connection: signal from S1005/1 to digital in D790-1/K8:3
BY-PASS X
Function: 8.1.3 Bypass switch
005438

Signal value:

1 Input signal active. Signal is only active for max. 60 seconds.

0 No signal.

Workshop Manual DCF 90-100 VDCF03.01GB


138 8 Control system – 8.4.10.3 OLS, menu 3

8.4.10.3 OLS, menu 3


VD VALUE
page

Description: Permitted load at load centre in question as per Vehicle


DIAG OLS 3(X) Data.
VD VALUE XXXXXkg
PRESENT LOAD XXXXXkg Circuit diagram: -
Connection: -

008903
MAST POS SENSOR X
Function: 8.2.1 Overload protection
Signal value: XXXXX = Weight, kg

PRESENT LOAD
page

Description: Calculated load.


Circuit diagram: -
Connection: -
Function: 8.2.1 Overload protection
Signal value: XXXXX = Weight, kg

MAST POS SENSOR


page

Applies to DCF360-450CSG with 14000 mm lift height.


Description: Signal from sensor for limiting lift over 13,000 mm for
loads over 30 metric tons.
Circuit diagram: 8.2-3
Connection: signal from B7211-3/C to digital in D797-1/K1:37
Function: 8.2.1 Overload protection
Signal value:

1 Input signal active.

0 No signal.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.11 EXTRA 139

8.4.11 EXTRA
EXTRA, description
page

This menu consists of optional functions:


DIAGNOSIS
CAN/POWER LIGHTS CAB • Reversible driver’s seat, VBFS
CLIMATE HYD ENGINE • Lever steering or mini-wheel, EL-STEERING
TRANSM ELSERV ATTACH
• External attachment, EXT-ATTACH

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

PRESENT INPUT SIGNAL REVERSIBLE SEAT, SWITCH


CW

DIAG VBFS 1(X)


PRESENT INPUT SIGNAL Description: Signal from switch, reversible driver’s seat, clockwise ro-
REVERSIBLE SEAT tation.
SWITCH CW X
Circuit diagram: Circuit 9.3-3
005561

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:

1 Input signal active.

0 No signal.

Workshop Manual DCF 90-100 VDCF03.01GB


140 8 Control system – 8.4.11.1 VBFS

PRESENT INPUT SIGNAL REVERSIBLE SEAT, SWITCH


CCW

Description: Signal from switch, reversible driver’s seat, counterclock-


wise rotation.
Circuit diagram: Circuit 9.3-3
Connection: signal from S169/7 to digital in D790-1/K8:7
Function: 9.3.9 Reversible driver’s seat
Signal value:

1 Input signal active.

0 No signal.

VBFS, menu 2
page

PRESENT OUTPUT SIGNAL REVERSIBLE SEAT, SEAT


CW

DIAG VBFS 2(X)


PRESENT OUTPUT SIGNAL Description: Voltage feed to seat reversal control unit (clockwise
REVERSIBLE SEAT rotation).
SEAT CW XY
Circuit diagram: Circuit 9.3-7
007131

SEAT CCW XY
Connection: digital out from D797-2/K1:29 to A798/6
Function: 9.3.9 Reversible driver’s seat
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.11.1 VBFS 141

PRESENT OUTPUT SIGNAL REVERSIBLE SEAT, SEAT


CCW

Description: Voltage feed to seat reversal control unit (counterclock-


wise rotation).
Circuit diagram: Circuit 9.3-7
Connection: digital out from D797-2/K1:39 to A798/7
Function: 9.3.9 Reversible driver’s seat
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

VBFS, menu 3
page

PRESENT INPUT SIGNAL SEAT SENSORS, SEAT POS


FRONT

DIAG VBFS 3(X)


PRESENT INPUT SIGNAL Description: Signal from sensor, reversible driver’s seat, forward.
SEAT SENSORS Circuit diagram: Circuit 9.3-3
SEAT POS FRONT X
005563

SEAT POS REAR X Connection: signal from S720-F/2 to digital in D790-1/K1:13


Function: 9.3.13 Sensor, reversible driver’s seat
Signal value:

1 Input signal active.

0 No signal.

PRESENT INPUT SIGNAL SEAT SENSORS, SEAT POS


REAR

Description: Signal from sensor, reversible driver’s seat, rearward.


Circuit diagram: Circuit 9.3-3
Connection: signal from S720-R/2 to digital in D790-1/K1:20
Function: 9.3.13 Sensor, reversible driver’s seat
Signal value:

1 Input signal active.

0 No signal.

Workshop Manual DCF 90-100 VDCF03.01GB


142 8 Control system – 8.4.11.1 VBFS

VBFS, menu 4
page

PRESENT INPUT SIGNAL, ACCELERATOR 2

DIAG VBFS 4(X)


PRESENT INPUT SIGNAL Description: Signal from switch for auxiliary accelerator pedal
ACCELERATOR 2 X.XXV ( reverse).
REQUIRED SPD PROC XXX
Circuit diagram: Circuit 9.3-3

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

PRESENT INPUT SIGNAL, REQUIRED SPD PROC

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%

PRESENT INPUT SIGNAL, REQUIRED SPD RPM

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

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.11.1 VBFS 143

VBFS, menu 5
page

PRESENT OUTPUT SIGNAL STEERING VALVE, VALVE


CAB FRONT

DIAG VBFS 5(X)


PRESENT OUTPUT SIGNAL Description: Voltage feed to directional control valve, reversible driv-
STEERING VALVE er’s seat (forward).
VALVE CAB FRONT XY
Circuit diagram: Circuit 9.3-6

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:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

PRESENT OUTPUT SIGNAL STEERING VALVE, VALVE


CAB REAR

Description: Voltage feed to directional control valve, reversible driv-


er’s seat (rearward).
Circuit diagram: Circuit 9.3-6
Connection: digital out from D797-2/K1:10 to Y636-2/1
Function: 9.3.12 Directional valve, reversible driver’s seat
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

Workshop Manual DCF 90-100 VDCF03.01GB


144 8 Control system – 8.4.11.1 VBFS

VBFS, menu 6
page

HEADLIGHTS REAR, SWITCH

DIAG VBFS 6(X)


HEAD LIGHTS REAR Description: Signal from headlights switch.
SWITCH X Circuit diagram: Circuit 9.6-4
HEAD LE/RI XY

005566
DIMMED LE/RI XY Connection: signal from S100/1 to digital in D790-1/K6:5
Function: 9.6.1 Headlights.
Signal value:

1 Input signal active.

0 No signal.

HEADLIGHTS REAR, HEAD L/R

Description: Voltage feed to high beam rear


Circuit diagram: Circuit 9.3-5
Connection: digital out from D797-2/K1:1 to E402L-2/1 and E402R-2/1
Function: 9.6.1 Headlights
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.11.1 VBFS 145

HEADLIGHTS REAR, DIMMED L/R

Description: Voltage feed to low beam rear.


Circuit diagram: Circuit 9.3-5
Connection: digital out from D797-2/K1:15 to E401L/1 and E401R/1
Function: 9.6.1 Headlights
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

VBFS, menu 7
page

PRESENT OUTPUT SIGNAL, TAIL LIGHT FRONT

DIAG VBFS 7(X)


PRESENT OUTPUT SIGNAL Description: Voltage feed to front tail lights.
TAILLIGHT FRONT Circuit diagram: Circuit 9.3-5
005567

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:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

Workshop Manual DCF 90-100 VDCF03.01GB


146 8 Control system – 8.4.11.1 VBFS

VBFS, menu 8
page

PRESENT OUTPUT SIGNAL, BRAKE LIGHT FRONT

DIAG VBFS 8(X)


PRESENT OUTPUT SIGNAL Description: Voltage feed to front brake lights.
BRAKE LIGHT FRONT Circuit diagram: Circuit 9.3-4

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:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

VBFS, menu 9
page

PRESENT OUTPUT SIGNAL, REVERSIBLE SEAT, RE-


LEASE BRAKE

DIAG VBFS 9(X)


PRESENT OUTPUT SIGNAL Description: Voltage feed to brake solenoid valve, seat reversal. The
REVERSIBLE SEAT brake keeps the seat locked in position. The break is only released
RELEASE BRAKE XY when the stool is rotated.
008918

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

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.11.2 EL-STEERING 147

PRESENT OUTPUT SIGNAL, REVERSIBLE SEAT, DAMP


SPEED

Description: Voltage feed to seat reversal control unit (speed


damping).
Circuit diagram: Circuit 9.3-7
Connection: digital out from D797-2/K1:34 to A798/8
Function: 9.3.9 Reversible driver’s seat

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

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

PRESENT INPUT SIGNAL, SIGNAL 1 P6


Description: Signal from mini-wheel (signal 1) or steering lever.
DIAG STEERING 1(X)
Circuit diagram: Circuit 5.2-1
PRESENT INPUT SIGNAL
SIGNAL 1 P6 X.XXV Connection: signal from R825/H1 to digital in D790-1/K9:8
SIGNAL 2 P7 X.XXV
Function: 5.2 Power-steering system
005443

LOGIC X.XXV
Signal value: XX.XXV = 0.50 - 4.50 V

PRESENT INPUT SIGNAL, SIGNAL 2 P7


Description: Signal from mini-wheel (signal 2). (Only applies to mini-
wheel.)
Circuit diagram: Circuit 5.2-1
Connection: signal from R825/H2 to digital in D790-1/K9:9
Function: 5.2 Power-steering system
Signal value: XX.XXV = 0.50 - 4.50 V

Workshop Manual DCF 90-100 VDCF03.01GB


148 8 Control system – 8.4.11.2 EL-STEERING

PRESENT INPUT SIGNAL, LOGIC


Description: Signal from mini-wheel (signals 1 and 2). Indicates logical
value for mini-wheel. A high value indicates steering to the left. A low
value indicates steering to the right.
Circuit diagram: Circuit 5.2-1
Connection: signal from R825/H1 to digital in D790-1/K9:8 and R825/
H2 to digital in D790-1/K9:9.
Function: 5.2 Power-steering system
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:

1 Input signal active.

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:

1 Input signal active.

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:

1 Input signal active.

0 No signal.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.11.2 EL-STEERING 149

EL-STEERING, menu 3
page

PRESENT INPUT SIGNAL, HORN


Description: Signal from mini-wheel or steering lever (audible signal).
DIAG STEERING 3(X)
Circuit diagram: Circuit 5.2-1
PRESENT INPUT SIGNAL
HORN X Connection: signal from S149-2/1 to digital in D790-1/K9:10
STEER.WHEEL CUT OFF X
Function: 5.2 Power-steering system

007624
Signal value:

1 Input signal active.

0 No signal.

PRESENT INPUT SIGNAL, STEER. WHEEL CUT OFF


Description: Signal from sensor steering angle.
Circuit diagram: Circuit 5.2-1
Connection: Signal from B770/2 to digital in D790-2/K8:2
Function: 5.2.12 Sensor steering angle
Signal value:

1 Input signal active.

0 No signal.

EL-STEERING, menu 4
page

OUTPUT STEERING LEFT, REFERENCE


Description: Status for control current to control valve for mini-wheel/
DIAG STEERING 4(X) lever steering, solenoid valve steering left.
OUTPUT STEERING LEFT
REFERENCE XY Circuit diagram: Circuit 5.2-2
REQUIRED VALUE XXX Connection: output signal, reference value out from D797-2/K1:3 to
005570

FEEDBACK XXX Y636-4/1


Function: 5.2.10 Control valve, mini-wheel/lever steering
Signal value:

00 No output signal, PWM off.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.

Workshop Manual DCF 90-100 VDCF03.01GB


150 8 Control system – 8.4.11.2 EL-STEERING

OUTPUT STEERING LEFT, REQUIRED VALUE


Description: Reference value for control current to control valve for
mini-wheel/lever steering, solenoid valve steering left.
Circuit diagram: Circuit 5.2-2
Connection: output signal, reference value out from D797-2/K1:16 to
Y636-4/2
Function: 5.2.10 Control valve, mini-wheel/lever steering
Signal value: XXX = Current value: in mA for control of solenoid valve.

OUTPUT STEERING LEFT, FEEDBACK


Description: Present control current to control valve for mini-wheel/
lever steering, solenoid valve steering left.
Circuit diagram: Circuit 5.2-2
Connection: output signal, actual value out from D797-2/K1:16 to
Y636-4/2
Function: 5.2.10 Control valve, mini-wheel/lever steering
Signal value: XXX = Measured current value in mA.

EL-STEERING, menu 5
page

OUTPUT STEERING RIGHT, REFERENCE


Description: Status for control current to control valve for mini-wheel/
DIAG STEERING 5(X) lever steering, solenoid valve steering left.
OUTPUT STEERING RIGHT
REFERENCE XY Circuit diagram: Circuit 5.2-2
REQUIRED VALUE XXX Connection: output signal, reference value out from D797-2/K1:2 to
005571

FEEDBACK XXX Y636-3/1


Function: 5.2.10 Control valve, mini-wheel/lever steering
Signal value:

00 No output signal, PWM off.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.

OUTPUT STEERING RIGHT, REQUIRED VALUE


Description: Reference value for control current to control valve for
mini-wheel/lever steering, solenoid valve steering left.
Circuit diagram: Circuit 5.2-2
Connection: output signal, reference value out from D797-2/K1:16 to
Y636-3/2
Function: 5.2.10 Control valve, mini-wheel/lever steering
Signal value: XXX = Current value: in mA for control of solenoid valve.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.11.3 EXT-ATTACH 151

OUTPUT STEERING RIGHT, FEEDBACK


Description: Present control current to control valve for mini-wheel/
lever steering, solenoid valve steering left.
Circuit diagram: Circuit 5.2-2
Connection: output signal, actual value out from D797-2/K1:16 to
Y636-3/2
Function: 5.2.10 Control valve, mini-wheel/lever steering
Signal value: XXX = Measured current value in mA.

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

PRESENT INPUT SIGNAL, EXT-ATTACH ACTIVE


Description: Signal which indicates if external attachment is
DIAG EXT-ATTACH 1(X) connected.
PRESENT INPUT SIGNAL
Circuit diagram: Circuit 7.0-4
EXT-ATTACH ACTIVE X Connection: -
007626

Function: 7.10.5 Separate top lift attachment


Signal value:

1 Input signal active.

0 No signal.

EXT-ATTACH, menu 2
page

PRESENT INPUT SIGNALS, LOCK TW


Description: Signal from switch for locking twistlock.
DIAG EXT-ATTACH 2(X) Circuit diagram: Circuit 7.9-1
PRESENT INPUT SIGNALS
LOCK TW X Connection: signal from S1003/2 to digital in D790-1/K8:12
UNLOCK TW X Function: 7.10.5 Separate top lift attachment.
007627

Signal value:

1 Input signal active.

0 No signal.

Workshop Manual DCF 90-100 VDCF03.01GB


152 8 Control system – 8.4.11.3 EXT-ATTACH

PRESENT INPUT SIGNALS, UNLOCK TW


Description: Signal from switch/control lever for opening the twistlock.
Circuit diagram: Circuits 7.9-1, 7.0-2
Connection: signal from S1002/1 (S815/20) to digital in D790-1/K7:15
Function: 7.1.1 Control lever, 7.10.5 Separate top lift attachment
Signal value:

1 Input signal active.

0 No signal.

EXT-ATTACH, menu 3
page

PRESENT INPUT SIGNALS, SPREADING OUT


Description: Signal from switch for spreading the attachment.
DIAG EXT-ATTACH 3(X) Circuit diagram: Circuits 7.5-1, 7.0-2
PRESENT INPUT SIGNALS
SPREADING OUT X Connection: signal from S1012/7 (S815/16) to digital in D790-1/K7:13
SPREADING IN X Function: 7.5 Spreading, 7.1.1 Control lever
007628

Signal value:

1 Input signal active.

0 No signal.

PRESENT INPUT SIGNALS, SPREADING IN


Description: Signal from switch for spreading the attachment.
Circuit diagram: Circuits 7.5-1, 7.0-2
Connection: signal from S1012/1 (S815/14) to digital in D790-1/K7:14
Function: 7.5 Spreading, 7.1.1 Control lever
Signal value:

1 Input signal active.

0 No signal.

EXT-ATTACH, menu 4
page

PRESENT INPUT SIGNALS, ALIGNMENT


Description: Signal from alignment sensor.
DIAG EXT-ATTACH 4(X)
Circuit diagram: Circuit 7.0-4
PRESENT INPUT SIGNALS
ALIGNMENT X Connection: Signal from B7202L/R and B7203L/R to digital in D790-1/
LOCKED TW X K10:3
007629

UNLOCKED TW X
Function: 7.10.5 Separate top lift attachment
Signal value:

1 Input signal active.

0 No signal.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.11.3 EXT-ATTACH 153

PRESENT INPUT SIGNALS, LOCKED TW


Description: Signal from sensor for locked twistlocks.
Circuit diagram: Circuit 7.0-4
Connection: Signal from B7205L/R to digital in D790-1/K8:8
Function: 7.10.5 Separate top lift attachment
Signal value:

1 Input signal active.

0 No signal.

PRESENT INPUT SIGNALS, UNLOCKED TW


Description: Signal from sensor for open twistlock.
Circuit diagram: Circuit 7.0-4
Connection: Signal from B7204L/R to digital in D790-1/K8:9
Function: 7.10.5 Separate top lift attachment
Signal value:

1 Input signal active.

0 No signal.

EXT-ATTACH, menu 5
page

PRESENT OUTPUT SIGNAL 4TH FUNCTION (HYD), 4TH


OUT
Description: Voltage feed to 4th function out.
DIAG EXT-ATTACH 5(X) Circuit diagram: Circuit 7.0-6
PRESENT OUTPUT SIGNAL
4:E FUNCTION (HYD) Connection: digital out from D797-1/K1:36 to Y6039/6018/1
4:E OUT XY Function: 7.10.5 Separate top lift attachment
007630

4:E IN XY
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

Workshop Manual DCF 90-100 VDCF03.01GB


154 8 Control system – 8.4.11.3 EXT-ATTACH

PRESENT OUTPUT SIGNAL 4TH FUNCTION (HYD), 4TH IN


Description: Voltage feed to 4th function in.
Circuit diagram: Circuit 7.0-6
Connection: digital out from D797-1/K1:37 to Y6040/6019/1
Function: 7.10.5 Separate top lift attachment
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

EXT-ATTACH, menu 6
page

PRESENT OUTPUT SIGNAL 4TH FUNCTION, TW ACTIVE


Description: Voltage feed to relay for activating twistlock.
DIAG EXT-ATTACH 6(X) Circuit diagram: Circuit 7.0-5
PRESENT OUTPUT SIGNAL
4:E FUNCTION Connection: digital out from D790-1/K7:10 to K3005/86
TW ACTIVE XY Function: 7.10.5 Separate top lift attachment
007631

SPREADING ACTIVE XY
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.11.3 EXT-ATTACH 155

PRESENT OUTPUT SIGNAL 4TH FUNCTION, SPREADING


ACTIVE
Description: Voltage feed to relay for activating spreading.
Circuit diagram: Circuit 7.0-5
Connection: digital out from D790-1/K7:11 to K3006/86
Function: 7.10.5 Separate top lift attachment
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

EXT-ATTACH, menu 7
page

OUTPUT SPREADING IN, REFERENCE


Description: Status for control current to load handling control valve
DIAG EXT-ATTACH 7(X) (solenoid valve, spreading in).
OUTPUT SPREADING IN
REFERENCE Circuit diagram: Circuit 7.5-1
XY
REQUIRED VALUE XXX Connection: digital out from D797-2/K1:32 to Y6019/1
007632

FEEDBACK XXX
Function: 7.5.5 Control valve, load handling
Signal value:

00 No output signal, PWM off.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.

OUTPUT SPREADING IN, REQUIRED VALUE


Description: Reference value for control current to load handling con-
trol valve (solenoid valve, spreading in).
Circuit diagram: Circuit 7.5-1
Connection: output signal, reference value out from D797-2/K1:19 to
Y6019/2
Function: 7.5.5 Control valve, load handling
Signal value: XXX = Current value: in mA for control of solenoid valve.

Workshop Manual DCF 90-100 VDCF03.01GB


156 8 Control system – 8.4.11.3 EXT-ATTACH

OUTPUT SPREADING IN, FEEDBACK


Description: Present control current to load handling control valve (so-
lenoid valve, spreading in).
Circuit diagram: Circuit 7.5-1
Connection: output signal, actual value out from D797-2/K1:19 to
Y6019/2
Function: 7.5.5 Control valve, load handling
Signal value: XXX = Measured current value in mA.

EXT-ATTACH, menu 8
page

OUTPUT SPREADING OUT, REFERENCE


Description: Status for control current to load handling control valve
DIAG EXT-ATTACH 8(X) (solenoid valve, spreading out).
OUTPUT SPREADING OUT
REFERENCE Circuit diagram: Circuit 7.5-1
XY
REQUIRED VALUE XXX Connection: digital out from D797-2/K1:33 to Y6018/1
007633

FEEDBACK XXX
Function: 7.5.5 Control valve, load handling
Signal value:

00 No output signal, PWM off.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.

OUTPUT SPREADING OUT, REQUIRED VALUE


Description: Reference value for control current to load handling con-
trol valve (solenoid valve, spreading out).
Circuit diagram: Circuit 7.5-1
Connection: output signal, reference value out from D797-2/K1:19 to
Y6018/2.
Function: 7.5.5 Control valve, load handling
Signal value: XXX = Current value: in mA for control of solenoid valve.

OUTPUT SPREADING OUT, FEEDBACK


Description: Present control current to load handling control valve (so-
lenoid valve, spreading out).
Circuit diagram: Circuit 7.5-1
Connection: output signal, actual value out from D797-2/K1:19 to
Y6018/2
Function: 7.5.5 Control valve, load handling
Signal value: XXX = Measured current value in mA.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.11.4 FREELIFT 157

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

PRESENT INPUT SIGNAL MAST CARRIAGE, MAST POS


DOWN
Description: Signal from sensor, mast down.
DIAG FREELIFT 1(X) Circuit diagram: Circuit 7.2-3
PRESENT INPUT SIGNAL
MAST CARRIAGE Connection: Signal from B261 to digital in D797-1/K1:11
MAST POS DOWN X Function: 7.2.10 Mast position sensor
007635

LIFT CARRIAGE TOP X


Signal value:

1 Input signal active.

0 No signal.

PRESENT INPUT SIGNAL MAST CARRIAGE, LIFT


CARRIAGE TOP
Description: Signal from sensor, mast up.
Circuit diagram: Circuit 7.2-3
Connection: Signal from B260 to digital in D797-1/K1:12
Function: 7.2.10 Mast position sensor
Signal value:

1 Input signal active.

0 No signal.

Workshop Manual DCF 90-100 VDCF03.01GB


158 8 Control system – 8.4.11.5 MOVE-CAB

FREELIFT, menu 2
page

PRESENT OUTPUT SIGNAL MAST CARRIAGE (HYD)


Description: Voltage feed to freelift shift valve. The four solenoid
DIAG FREELIFT 2(X) valves which change between mast and carriage are activated in pairs
PRESENT OUTPUT SIGNAL depending on the position of the mast.
MAST CARRIAGE (HYD)
Circuit diagram: Circuit 7.2-4
MAST UP XY DOWN XY

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:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

Status for different mast positions.

MAST MAST CARR CARR


UP DOWN UP DOWN

Mast position: down 11 11


Carriage position:
down

Mast position: down 11 11


Carriage position: up

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

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.11.5 MOVE-CAB 159

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:

1 Input signal active.

0 No signal.

INPUT SWITCHES, DOWN


Description: Signal from switch for manual cab tilt, cab down.
Circuit diagram: Circuit 9.10-1
Connection: signal from S1010:/7 to digital in D790-1/K8:7
Function: 9.10.4 Cab tilt
Signal value:

1 Input signal active.

0 No signal.

INPUT SWITCHES, OPEN DOORS


Description: Signal from sensor for opening doors.
Circuit diagram: Circuit 9.6-8
Connection: signal from S266-LE/2 to S266-RI/2 to digital in D790-1/
K11:3
Function: 9.10.2 Doors
Signal value:

1 Input signal active.

0 No signal.

MOVE-CAB, menu 2
page

PRESENT INPUT SIGNAL, AUTO CAB TILT


Description: Signal from switch for automatic/manual cab tilt.
DIAG MOVE-CAB 2(X) Circuit diagram: Circuit 9.1-1
PRESENT INPUT SIGNAL
AUTO CABTILT X Connection: signal from S199-2/1 to digital in D790-1/K8:14
LIFT HEIGHT POS X Function: 9.10.4 Cab tilt
005447

Signal value:

1 Input signal active.

0 No signal.

Workshop Manual DCF 90-100 VDCF03.01GB


160 8 Control system – 8.4.11.5 MOVE-CAB

PRESENT INPUT SIGNAL, LIFT HEIGHT POS


Description: Signal from sensor for automatic cab tilt.
Circuit diagram: Circuit 7.0-7
Connection: signal from B7211-1/C to digital in D797-1/K1:26
Function: 9.10.4 Cab tilt
Signal value:

1 Input signal active.

0 No signal.

MOVE-CAB, menu 3
page

PRESENT INPUT SIGNAL, CAB UPPER POS


Description: Signal from sensor for cab tilt, cab in upper position.
DIAG MOVE-CAB 3(X) Circuit diagram: Circuit 9.10-1
PRESENT INPUT SIGNAL
CAB UPPER POS X Connection: signal from B769-1/C to digital in D797-2/K1:13
CAB LOWER POS X Function: 9.10.4 Cab tilt
005448

Signal value:

1 Input signal active.

0 No signal.

PRESENT INPUT SIGNAL, CAB LOWER POS


Description: Signal from sensor for cab tilt, cab in lower position.
Circuit diagram: Circuit 9.10-1
Connection: signal from B769-2/C to digital in D797-2/K1:20
Function: 9.10.4 Cab tilt
Signal value:

1 Input signal active.

0 No signal.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.11.5 MOVE-CAB 161

MOVE-CAB, menu 4
page

PRESENT OUTPUT SIGNAL, VALVE CAB UP


Description: Voltage feed to cab tilt control valve, cab up.
DIAG MOVE-CAB 4(X)
Circuit diagram: Circuit 9.10-1
PRESENT OUTPUT SIGNAL
VALVE CAB UP XY Connection: digital out from D797-2/K1:29 to Y6047/1
VALVE CAB DOWN XY
Function: 9.10.4 Cab tilt

005449
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

PRESENT OUTPUT SIGNAL, VALVE CAB DOWN


Description: Voltage feed to cab tilt control valve, cab down.
Circuit diagram: Circuit 9.10-1
Connection: digital out from D797-2/K1:39 to Y6048/1
Function: 9.10.4 Cab tilt
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

Workshop Manual DCF 90-100 VDCF03.01GB


162 8 Control system – 8.4.11.5 MOVE-CAB

MOVE-CAB, menu 5
page

PRESENT OUTPUT SIGNAL, ACTIVATE SLID-CAB


Description: Voltage feed to control valve to activate sliding cab.
DIAG MOVE-CAB 5(X) Circuit diagram: Circuit 9.10-1
PRESENT OUTPUT SIGNAL
ACTIVATE SLID-CAB XY Connection: digital out from D797-2/K1:25 to Y6080/1
Function: 9.10.4 Hydraulic sliding cab

007134
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

MOVE-CAB, menu 6
page

OUTPUT RIGHT, REFERENCE


Description: Status for control current to control valve, load handling
DIAG MOVE-CAB 6(X) (solenoid valve, side shift right).
OUTPUT RIGHT
REFERENCE XY Circuit diagram: Circuit 7.4-1
REQUIRED VALUE XXX Connection: digital out from D797-2/K1:30 to Y6021/1
007135

FEEDBACK XXX
Function: 9.10.4 Hydraulic sliding cab
Signal value:

00 No output signal, PWM off.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.

OUTPUT RIGHT, REQUIRED VALUE


Description: Reference value for control current to control valve for
load handling (solenoid valve, side shift right).
Circuit diagram: Circuit 7.4-1
Connection: output signal, reference value out from D797-2/K1:18 to
Y6021/2
Function: 9.10.4 Hydraulic sliding cab
Signal value: XXX = Current value: in mA for control of solenoid valve.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.11.5 MOVE-CAB 163

OUTPUT RIGHT, FEEDBACK


Description: Present control current to control valve, load handling (so-
lenoid valve, side shift right).
Circuit diagram: Circuit 7.4-1
Connection: output signal, actual value out from D797-2/K1:18 to
Y6019/2
Function: 9.10.4 Hydraulic sliding cab
Signal value: XXX = Measured current value in mA.

MOVE-CAB, menu 7
page

OUTPUT LEFT, REFERENCE


Description: Status for control current to control valve, load handling
DIAG MOVE-CAB 6(X) (solenoid valve, side shift left).
OUTPUT LEFT
REFERENCE XY Circuit diagram: Circuit 7.4-1
REQUIRED VALUE XXX Connection: digital out from D797-2/K1:31 to Y6020/1
007136

FEEDBACK XXX
Function: 9.10.4 Hydraulic sliding cab
Signal value:

00 No output signal, PWM off.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK.

NOTE
Depending on different types of PWM connections, the following
is also possible: XY = 01 No output signal, PWM off.

OUTPUT LEFT, REQUIRED VALUE


Description: Reference value for control current to control valve for
load handling (solenoid valve, side shift left).
Circuit diagram: Circuit 7.4-1
Connection: output signal, reference value out from D797-2/K1:18 to
Y6020/2
Function: 9.10.4 Hydraulic sliding cab
Signal value: XXX = Current value: in mA for control of solenoid valve.

OUTPUT LEFT, FEEDBACK


Description: Present control current to control valve, load handling (so-
lenoid valve, side shift left).
Circuit diagram: Circuit 7.4-1
Connection: output signal, actual value out from D797-2/K1:18 to
Y6020/2
Function: 9.10.4 Hydraulic sliding cab
Signal value: XXX = Measured current value in mA.

Workshop Manual DCF 90-100 VDCF03.01GB


164 8 Control system – 8.4.11.6 OPT

8.4.11.6 OPT
OPT, description
page

This group covers a number of options.


DIAGNOSIS EXTRA
VBFS EL-STEERING Confirm selection with function key for Enter.
EXT-ATTACH FREELIFT
MOVE-CAB OPT I/O RMI

008914
OPT, menu 1
page

OPTION SWITCH, S199-1


Description: Signal from switch S199-1.
DIAG OPTION 1(X) Circuit diagram: Circuit 9.1-1
OPTION SWITCH
S199-1 X S199-4 X Connection: signal from S199-1/1 to digital in D790-1/K6:9
S199-2 X Function: -
005488

S199-3 X
Signal value:

1 Input signal active.

0 No signal.

OPTION SWITCH, S199-2


Description: Signal from switch S199-2.
Circuit diagram: Circuit 9.1-1
Connection: signal from S199-2/1 to digital in D790-1/K8:14
Function: -
Signal value:

1 Input signal active.

0 No signal.

OPTION SWITCH, S199-3


Description: Signal from switch S199-3.
Circuit diagram: Circuit 9.1-1
Connection: signal from S199-3/1 to digital in D790-1/K6:8
Function: -
Signal value:

1 Input signal active.

0 No signal.

OPTION SWITCH, S199-4


Description: Signal from switch S199-4.
Circuit diagram: Circuit 9.1-1
Connection: signal from S199-4/1 to digital in D790-1/K6:7

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.11.6 OPT 165

Function: -
Signal value:

1 Input signal active.

0 No signal.

OPT, menu 2
page

PRESENT OUTPUT SIGNAL CENTRAL LUBRICATION,


FRAME
Description: Voltage feed to central lubrication of frame.
DIAG OPTION 2(X)
Circuit diagram: Circuit 9.14-1
PRESENT OUTPUT SIGNAL
CENTRAL LUBRICATION Connection: digital out from D797-1/K1:42 to M693-1/1
FRAME XY
Function: 9.14.1 Pump unit
005489

ATTACHMENT XY
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

PRESENT OUTPUT SIGNAL CENTRAL LUBRICATION,


ATTACHMENT
Description: Voltage feed to central lubrication of attachment.
Circuit diagram: Circuit 9.14-1
Connection: digital out from D791-1/K1:14 to M693-2/1
Function: 9.14.1 Pump unit
Signal value:

01 No output signal. Error detection only possible when output


signal is active.

10 Output signal active, short-circuiting or open circuit.

11 Output signal active, circuit OK.

Workshop Manual DCF 90-100 VDCF03.01GB


166 8 Control system – 8.4.11.6 OPT

OPT, menu 3
page

PRESENT OUTPUT SIGNAL, D797-1/K1:42


Description: Voltage feed from D797-1/K1:42.
DIAG OPTION 3(X)
Circuit diagram: -
PRESENT OUTPUT SIGNAL
D797-1 C1 P42 XY Connection: digital out D797-1/K1:42
Function: -

005490
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

OPT, menu 4
page

PRESENT OUTPUT SIGNAL, D797-2/K1:28


Description: Voltage feed from D797-2/K1:28.
DIAG OPTION 4(X)
Circuit diagram: -
PRESENT OUTPUT SIGNAL
D797-2 C1 P28 XY Connection: digital out from D797-2/K1:28
D797-2 C1 P42 XY
Function: -
005491

Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.11.6 OPT 167

PRESENT OUTPUT SIGNAL, D797-2/K1:42


Description: Voltage feed from D797-2/K1:42.
Circuit diagram: -
Connection: digital out from D797-2/K1:42
Function: -
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

OPT, menu 5
page

PRESENT OUTPUT SIGNAL, D791-1/K1:14


Description: Voltage feed from D791-1/K1:14.
DIAG OPTION 5(X)
Circuit diagram: -
PRESENT OUTPUT SIGNAL
D791-1 C1 P14 XY Connection: digital out from D791-1/K1:14
D791-1 C1 P28 XY
Function: -
005492

Signal value:

01 No output signal. Error detection only possible when output


signal is active.

10 Output signal active, short-circuiting or open circuit.

11 Output signal active, circuit OK.

PRESENT OUTPUT SIGNAL, D791-1/K1:28


Description: Voltage feed from D791-1/K1:28.
Circuit diagram: -
Connection: digital out from D791-1/K1:28
Function: -
Signal value:

00 No output signal, open circuit in circuit.

01 No output signal, circuit OK or short-circuiting. Short-


circuiting can only be detected when the output signal is ac-
tive.

10 Output signal active, short-circuiting.

11 Output signal active, circuit OK or open circuit. Open circuit


can only be detected when the output signal is active.

Workshop Manual DCF 90-100 VDCF03.01GB


168 8 Control system – 8.4.11.7 RMI

8.4.11.7 RMI
RMI, description
page

This group covers RMI (Remote Machine Interface) functions.


DIAGNOSIS EXTRA
VBFS EL-STEERING Confirm selection with function key for Enter.
EXT-ATTACH FREELIFT
MOVE-CAB OPT I/O RMI

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

Signal value: xxxx.xxxx = software number.

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

SIGNAL QUALITY, GSM


Description: Signal strength of GSM signal through receiver in the RMI
DIAG RMI 2(X) interface.
SIGNAL QUALITY
GSM XXX GPRS XXX Circuit diagram: Circuit 8.2-4
WLAN XXX RADIO XXX Connection: -
007659

SMS XXX: UNS.DATA XXX


Function: 11.6.5 RMI (Remote Machine Interface)
Signal value: XXX = 0-100 = Signal strength, 0-100%.

SIGNAL QUALITY, GPRS


Description: Signal strength of GPRS signal through receiver in the
RMI interface.
Circuit diagram: Circuit 8.2-4
Connection: -
Function: 11.6.5 RMI (Remote Machine Interface)
Signal value: XXX = 0-100 = Signal strength, 0-100%.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.4.11.7 RMI 169

SIGNAL QUALITY, WLAN


Description: Signal strength of WLAN signal through receiver in the
RMI interface.
Circuit diagram: Circuit 8.2-4
Connection: -
Function: 11.6.5 RMI (Remote Machine Interface)
Signal value: XXX = 0-100 = Signal strength, 0-100%.

SIGNAL QUALITY, RADIO


Description: Signal strength of RADIO signal through receiver in the
RMI interface.
Circuit diagram: Circuit 8.2-4
Connection: -
Function: 11.6.5 RMI (Remote Machine Interface)
Signal value: XXX = 0-100 = Signal strength, 0-100%.

SIGNAL QUALITY, SMS


Description: Signal strength of SMS signal through receiver in the RMI
interface.
Circuit diagram: Circuit 8.2-4
Connection: -
Function: 11.6.5 RMI (Remote Machine Interface)
Signal value: XXX = 0-100 = Signal strength, 0-100%.

SIGNAL QUALITY, UNS.DATA


Description: Amount of unsent data in line in transmitter part in the RMI
interface.
Circuit diagram: Circuit 8.2-4
Connection: -
Function: 11.6.5 RMI (Remote Machine Interface)
Signal value: XXX = 0-100 = Data amount in percent of transmitter
buffer, 0-100%.

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

Signal value: XX.XX.XX.XX = Error code

Workshop Manual DCF 90-100 VDCF03.01GB


170 8 Control system – 8.4.11.7 RMI

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

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.5 Settings 171

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 VALUE XXXmA

Example of initiation menu, start current for lift NOTE


function.
Initiation does not need to be performed in one process but each
1. Menu group step can be performed separately, independently of other steps.
2. Number of menus. Because the number of menus In order that hydraulic functions shall work satisfactorily and safely,
depends on machine configuration, it is specified as certain values must be set to operate the machine, this is known as
(X) in this manual. initiation.
3. Signal value
Initiation consists of several menus grouped according to functions.
4. Current variable
Each individual menu sets a specific variable. The menus are similar
in construction and use a common terminology explained here:

PRESENT
Displays the stored value when the menu is opened. Adjust the value
with the plus and minus keys. Save the set value with the Enter key.
Go to the next menu with the arrow keys. Go back with the R-key.

STORED
States the stored value for the current variable.

Workshop Manual DCF 90-100 VDCF03.01GB


172 8 Control system – 8.5.1 Initiation

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

INIT DRIVE-TRAIN, menu 11 page


1 Engine, automatic shut-down on idling
203

1 Engine, automatic engine speed increase for lifting INIT DRIVE-TRAIN, menu 13 page
204

2 Transmission, starting gear INIT DRIVE-TRAIN, menu 1 page


200

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

2 Transmission, speed limit declutch INIT DRIVE-TRAIN, menu 6 page


202

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.5.1 Initiation 173

Function Menu
INIT DRIVE-TRAIN, menu 10 page
2 Transmission, speed limitation (gear lock-out)
203

INIT DRIVE-TRAIN, menu 12 page


2 Transmission, automatic engine speed reduction for shift forward - reverse
204

7.2 Lifting/lowering, lift mast INIT ELSERVO, menu 1 page 179


INIT ELSERVO, menu 2 page 180

7.2 Lifting/lowering, lower mast INIT ELSERVO, menu 3 page 180


Note: The current value is for unladen machines. When loaded, the current value is INIT ELSERVO, menu 4 page 180
controlled by the limited lowering speed.

7.3 Extension out INIT ATTACH for DCF360-450CSG


page 186
INIT ATTACH, menu 2 page 187

7.3 Extension in INIT ATTACH, menu 3 page 187


INIT ATTACH, menu 4 page 187

7.4 Side shift INIT ATTACH, menu 5 page 188


INIT ATTACH, menu 6 page 188

7.5 Spreading out INIT ATTACH, menu 9 page 189


INIT ATTACH, menu 10 page 189
INIT ATTACH, menu 11 page 189

7.5 Spreading in INIT ATTACH, menu 12 page 190


INIT ATTACH, menu 13 page 190
INIT ATTACH, menu 14 page 190

7.7 Tilt INIT ELSERVO, menu 5 page 181


INIT ELSERVO, menu 6 page 181

7.8 Levelling INIT ATTACH, menu 7 page 188


INIT ATTACH, menu 8 page 188

Workshop Manual DCF 90-100 VDCF03.01GB


174 8 Control system – 8.5.1 Initiation

Overview, initiations DCF 280-330, DCF 370-500

Function Menu
INIT DRIVE-TRAIN, menu 9 page
1 Engine, speed limitation (limitation of engine speed
203

INIT DRIVE-TRAIN, menu 11 page


1 Engine, automatic shut-down on idling
203

1 Engine, automatic engine speed increase for lifting INIT DRIVE-TRAIN, menu 13 page
204

2 Transmission, starting gear INIT DRIVE-TRAIN, menu 1 page


200

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

2 Transmission, speed limit declutch INIT DRIVE-TRAIN, menu 6 page


202

INIT DRIVE-TRAIN, menu 10 page


2 Transmission, speed limitation (gear lock-out)
203

INIT DRIVE-TRAIN, menu 12 page


2 Transmission, automatic engine speed reduction for shift forward - reverse
204

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

7.2 Lifting/lowering, lift mast INIT ELSERVO, menu 1 page 179


INIT ELSERVO, menu 2 page 180

7.2 Lifting/lowering, lower mast INIT ELSERVO, menu 3 page 180


Note: The current value is for unladen machines. When loaded, the current value is INIT ELSERVO, menu 4 page 180
controlled by the limited lowering speed.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.5.1 Initiation 175

Function Menu
7.2 Lifting/lowering, lift carriage INIT ELSERVO, menu 13 page 183
INIT ELSERVO, menu 14 page 184

7.2 Lifting/lowering, lower carriage INIT ELSERVO, menu 15 page 184


Note: The current value is for unladen machines. When loaded, the current value is INIT ELSERVO, menu 16 page 184
controlled by the limited lowering speed.

7.4 Side shift INIT ELSERVO, menu 9 page 182


INIT ELSERVO, menu 10 page 182

7.5 Spreading INIT ELSERVO, menu 11 page 183


INIT ELSERVO, menu 12 page 183

7.7 Tilt INIT ELSERVO, menu 5 page 181


INIT ELSERVO, menu 6 page 181

9.10.4 Hydraulic sliding cab INIT SLID-CAB, menu 1 page 205


INIT SLID-CAB, menu 2 page 206
INIT SLID-CAB, menu 3 page 206
INIT SLID-CAB, menu 4 page 206
INIT SLID-CAB, menu 5 page 207
INIT SLID-CAB, menu 6 page 207

Workshop Manual DCF 90-100 VDCF03.01GB


176 8 Control system – 8.5.1 Initiation

Overview, initiations DCF 90-100

Function Menu
INIT DRIVE-TRAIN, menu 9 page
1 Engine, speed limitation (limitation of engine speed
203

INIT DRIVE-TRAIN, menu 11 page


1 Engine, automatic shut-down on idling
203

1 Engine, automatic engine speed increase for lifting INIT DRIVE-TRAIN, menu 13 page
204

2 Transmission, starting gear INIT DRIVE-TRAIN, menu 1 page


200

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

2 Transmission, speed limit declutch INIT DRIVE-TRAIN, menu 6 page


202

INIT DRIVE-TRAIN, menu 10 page


2 Transmission, speed limitation (gear lock-out)
203

INIT DRIVE-TRAIN, menu 12 page


2 Transmission, automatic engine speed reduction for shift forward - reverse
204

7.2 Lifting/lowering, lift mast INIT ELSERVO, menu 1 page 179


INIT ELSERVO, menu 2 page 180

7.2 Lifting/lowering, lower mast INIT ELSERVO, menu 3 page 180


Note: The current value is for unladen machines. When loaded, the current value is INIT ELSERVO, menu 4 page 180
controlled by the limited lowering speed.

7.4 Side shift INIT ATTACH, menu 5 page 191


INIT ATTACH, menu 6 page 191

7.5 Spreading out INIT ATTACH, menu 9 page 192


INIT ATTACH, menu 10 page 193
INIT ATTACH, menu 11 page 193

7.5 Spreading in INIT ATTACH, menu 12 page 193


INIT ATTACH, menu 13 page 194
INIT ATTACH, menu 14 page 194

7.7 Tilt INIT ELSERVO, menu 5 page 181


INIT ELSERVO, menu 6 page 181

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.5.1 Initiation 177

Function Menu
7.8 Levelling INIT ATTACH, menu 7 page 188
INIT ATTACH, menu 8 page 188

Workshop Manual DCF 90-100 VDCF03.01GB


178 8 Control system – 8.5.1 Initiation

Initiate hydraulic function, work instruction


page

To select a hydraulic function to initiate, proceed as follows:


All hydraulic functions are initiated the same way.
1 Navigate to the service menu.
2 Press Enter.

000056
3 Enter the code for initiation.
Code is obtained from Kalmar Industries Support.
1 23
4 5 NOTE
000060

The code determines which service menu is activated (Diag-


nostic test, Initiation or Calibration.
4 Select group by scrolling with the arrow keys (1 and 2) and con-
INITIATION firm with Enter.
ELSERVO ATTACHMENT
STEERING DRIVE-TRAIN Each initiation consists of a sequence of a number of menus. The
SLIDING-CAB first menu for the selected initiation opens in the display. Select
007169

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".

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.5.1.1 ELECTRIC SERVO 179

8.5.1.1 ELECTRIC SERVO


INIT ELSERVO
page

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.

INIT ELSERVO, menu 1


page

START CURRENT, LIFT


INIT ELSERVO 1(X)
Description: Start current for activation of solenoid valve, lift mast
START CURRENT
LIFT (Y6005).
STORED VALUE XXXmA PRESENT VALUE: Indicates the current value for the start current.
005494

PRESENT VALUE XXXmA Adjust the value with the plus and minus keys. 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.

Workshop Manual DCF 90-100 VDCF03.01GB


180 8 Control system – 8.5.1.1 ELECTRIC SERVO

INIT ELSERVO, menu 2


page

END CURRENT, LIFT


INIT ELSERVO 2(X)
Description: Control current on full lever actuation for the activation of
END CURRENT
LIFT the solenoid valve for mast lift (Y6005).
STORED VALUE XXXmA PRESENT VALUE: Indicates the current value for max. current. Adjust

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.

INIT ELSERVO, menu 3


page

START CURRENT, LOWER


INIT ELSERVO 3(X)
Description: Start current for the activation of the solenoid valve for
START CURRENT
LOWER mast lowering (Y6004).
STORED VALUE XXXmA PRESENT VALUE: Indicates the current value for the start current.
005496

PRESENT VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE: indicates stored value for start current.
Function: 7.2.5 Control valve, lift and tilt (DCF360-450CSG)
7.2.6 Control valve, load handling (DCF 280-330, DCF 370-500)
Component: Solenoid valve, lower mast(Y6004)
Signal value: XXXmA = 0 - 999 mA.

INIT ELSERVO, menu 4


page

END CURRENT, LOWER


INIT ELSERVO 4(X)
Description: Control current on full lever actuation for the activation of
END CURRENT
LOWER the solenoid valve for mast lowering (Y6004).
STORED VALUE XXXmA PRESENT VALUE: Indicates the current value for max. current. Adjust
005497

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.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.5.1.1 ELECTRIC SERVO 181

INIT ELSERVO, menu 5


page

START CURRENT, TILT IN


INIT ELSERVO 5(X)
Description: Start current for the activation of the solenoid valve for tilt
START CURRENT
TILT IN in (Y6011).
STORED VALUE XXXmA PRESENT VALUE: Indicates the current value for the start current.

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.

INIT ELSERVO, menu 6


page

END CURRENT, TILT IN


INIT ELSERVO 6(X)
Description: Control current on full lever actuation for the activation of
END CURRENT
TILT IN the solenoid valve for tilt in (Y6011).
STORED VALUE XXXmA PRESENT VALUE: Indicates the current value for max. current. Adjust
007140

PRESENT VALUE XXXmA the value with the plus and minus keys. Save the set value with the En-
ter key. Go to the next menu with the arrow keys. Exit initiation with the
R-key.
STORED VALUE indicates stored value for max. current.
Function: 7.7.5 Control valve, lift and tilt (DCF360-450CSG)
7.7.6 Control valve, load handling (DCF 280-330, DCF 370-500)
Component: Solenoid valve, tilt in (Y6011)
Signal value: XXXmA = 0 - 999 mA.

INIT ELSERVO, menu 7


page

START CURRENT, TILT OUT


INIT ELSERVO 7(X)
Description: Start current for the activation of the solenoid valve for tilt
START CURRENT
TILT OUT out (Y6010).
STORED VALUE XXXmA PRESENT VALUE: Indicates the current value for the start current.
007141

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.

Workshop Manual DCF 90-100 VDCF03.01GB


182 8 Control system – 8.5.1.1 ELECTRIC SERVO

INIT ELSERVO, menu 8


page

END CURRENT, TILT OUT


INIT ELSERVO 8(X)
Description: Control current on full lever actuation for the activation of
END CURRENT
TILT OUT the solenoid valve for tilt out (Y6010).
STORED VALUE XXXmA PRESENT VALUE: Indicates the current value for max. current. Adjust

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.

INIT ELSERVO, menu 9


page

START CURRENT, SIDE SHIFT LE/RI


INIT ELSERVO 9(X)
Description: Start current of activation of solenoid valve for side shift
START CURRENT
SIDESHIFT LE/RI left (Y6020) and solenoid valve for side shift right (Y6021).
STORED VALUE XXXmA PRESENT VALUE: Indicates the current value for the start current.
007143

PRESENT VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE: indicates stored value for start current.
Function: 7.4.5 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.

INIT ELSERVO, menu 10


page

END CURRENT, SIDE SHIFT LE/RI


INIT ELSERVO 10(X)
Description: Control current at full lever actuation for activation of so-
END CURRENT
SIDESHIFT LE/RI lenoid valve for side shift left (Y6020) and solenoid valve for side shift
STORED VALUE XXXmA right (Y6021).
007144

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.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.5.1.1 ELECTRIC SERVO 183

INIT ELSERVO, menu 11


page

START CURRENT, SPREADING IN/OUT


INIT ELSERVO 11(X)
Description: Start current for activation of solenoid valve for spreading
START CURRENT
SPREADING IN/OUT in (Y6019) and solenoid valve for spreading out (Y6018).
STORED VALUE XXXmA PRESENT VALUE: Indicates the current value for the start current.

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.

INIT ELSERVO, menu 12


page

END CURRENT, SPREADING IN/OUT


INIT ELSERVO 12(X)
Description: Control current at full lever actuation for activation of so-
END CURRENT
SPREADING IN/OUT lenoid valve for spreading in (Y6019) and solenoid valve for spreading
STORED VALUE XXXmA out (Y6018).
007146

PRESENT VALUE XXXmA PRESENT VALUE: Indicates the current value for max. current. Adjust
the value with the plus and minus keys. Save the set value with the En-
ter key. Go to the next menu with the arrow keys. Exit initiation with the
R-key.
STORED VALUE indicates stored value for max. current.
Function: 7.5.5 Control valve, load handling
Component: Solenoid valve for spreading in (Y6019) and solenoid
valve for spreading out (Y6018)
Signal value: XXXmA = 0 - 999 mA.

INIT ELSERVO, menu 13


page

START CURRENT, LIFT 2


INIT ELSERVO 13(X)
Description: Start current for activation of solenoid valve, lift carriage
START CURRENT
LIFT 2 (Y6022).
STORED VALUE XXXmA PRESENT VALUE: Indicates the current value for the start current.
007147

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.

Workshop Manual DCF 90-100 VDCF03.01GB


184 8 Control system – 8.5.1.1 ELECTRIC SERVO

INIT ELSERVO, menu 14


page

END CURRENT, LIFT 2


INIT ELSERVO 14(X)
Description: Control current on full lever actuation for the activation of
END CURRENT
LIFT 2 the solenoid valve for carriage lift (Y6022).
STORED VALUE XXXmA PRESENT VALUE: Indicates the current value for max. current. Adjust

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.

INIT ELSERVO, menu 15


page

START CURRENT, LOWER 2


INIT ELSERVO 15(X)
Description: Start current for activation of solenoid valve, lower car-
START CURRENT
LOWER 2 riage (Y6023).
STORED VALUE XXXmA PRESENT VALUE: Indicates the current value for the start current.
007149

PRESENT VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE: indicates stored value for start current.
Function 7.2.6 Solenoid valve, load handling
Component: Solenoid valve, lower carriage (Y6023)
Signal value: XXXmA = 0 - 999 mA.

INIT ELSERVO, menu 16


page

END CURRENT, LOWER 2


INIT ELSERVO 16(X)
Description: Control current on full lever actuation for the activation of
END CURRENT
LOWER 2 the solenoid valve for carriage lowering (Y6023).
STORED VALUE XXXmA PRESENT VALUE: Indicates the current value for max. current. Adjust
007150

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.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.5.1.1 ELECTRIC SERVO 185

INIT ELSERVO, menu 17


page

DAMP (PROC), LIFT


INIT ELSERVO 17(X)
Description: Percentage damping of control current to solenoid valve
DAMP (PROC)
LIFT for mast lift (Y6005) when the mast reaches max height.
STORED VALUE XX PRESENT VALUE: Indicates the current value for damping. Adjust the
PRESENT VALUE XX value with the plus and minus keys. Save the set value with the Enter
I [mA] key. Go to the next menu with the arrow keys. Exit initiation with the R-
key.
1
STORED VALUE: indicates stored value in percent.
2 Function: 7.2.5 Control valve, lift and tilt (DCF360-450CSG)
3
007151
7.2.6 Control valve, load handling (DCF 280-330, DCF 370-500)
t [s]
Component: Solenoid valve, lift mast (Y6005)
1. Max. current (END CURRENT)
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

Workshop Manual DCF 90-100 VDCF03.01GB


186 8 Control system – 8.5.1.2 ATTACHMENT

8.5.1.2 ATTACHMENT
INIT ATTACH
page

This function initiates the attachment functions extension, side shift,


INITIATION spreading, rotation and controllable levelling for DCF360-450CSG
ELSERVO ATTACHMENT (see INIT ATTACH for DCF360-450CSG page 186) and side shift,
STEERING DRIVE-TRAIN
spreading and controllable levelling for DCF 90-100 (see INIT AT-
SLIDING-CAB
TACH for DCF 90-100 page 191).

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.

INIT ATTACH for DCF360-450CSG


page

INIT ATTACH, menu 1


START CURRENT, PROJECTION OUT
INIT ATTACH 1(X)
Description: Start current for activation of solenoid valve for extension
START CURRENT
PROJECTION OUT left side out (Y6046-2) and solenoid valve for extension right side out
STORED VALUE XXXmA (Y6046-4).
005509

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

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.5.1.2 ATTACHMENT 187

INIT ATTACH, menu 2


END CURRENT, PROJECTION OUT
INIT ATTACH 2(X)
Description: Start current for activation of solenoid valve for extension
END CURRENT
PROJECTION OUT left side out (Y6046-2) and solenoid valve for extension right side out
STORED VALUE XXXmA (Y6046-4).

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

INIT ATTACH, menu 3


START CURRENT, PROJECTION IN
INIT ATTACH 3(X)
Description: Start current for activation of solenoid valve for extension
START CURRENT
PROJECTION IN left side in (Y6046-1) and solenoid valve for extension right side in
STORED VALUE XXXmA (Y6046-3).
005511

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

INIT ATTACH, menu 4


END CURRENT, PROJECTION IN
INIT ATTACH 4(X)
Description: Control current at full lever angle for activation of solenoid
END CURRENT
PROJECTION IN valve for extension left side in (Y6046-1) and solenoid valve for exten-
STORED VALUE XXXmA sion right side in (Y6046-3).
005512

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

Workshop Manual DCF 90-100 VDCF03.01GB


188 8 Control system – 8.5.1.2 ATTACHMENT

INIT ATTACH, menu 5


START CURRENT, SIDE SHIFT
INIT ATTACH 5(X)
Description: Start current of activation of solenoid valve for side shift
START CURRENT
SIDESHIFT left (Y6020) and solenoid valve for side shift right (Y6021).
STORED VALUE XXXmA PRESENT VALUE: Indicates the current value for the start current.

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

INIT ATTACH, menu 6


END CURRENT, SIDE SHIFT
INIT ATTACH 6(X)
Description: Control current at full lever actuation for activation of so-
END CURRENT
SIDESHIFT lenoid valve for side shift left (Y6020) and solenoid valve for side shift
STORED VALUE XXXmA right (Y6021).
005514

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

INIT ATTACH, menu 7


Not used.

INIT ATTACH, menu 8


Not used.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.5.1.2 ATTACHMENT 189

INIT ATTACH, menu 9


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

INIT ATTACH, menu 10


END CURRENT, SPREADER OUT, 20’-40’
INIT ATTACH 10(X)
Description: Control current at full lever actuation for activation of so-
END CURRENT
SPREADER OUT, 20'-40' lenoid valve for spreading out 20’-40’ (Y6018).
STORED VALUE XXXmA PRESENT VALUE: Indicates the current value for max. current. Adjust
PRESENT VALUE XXXmA the value with the plus and minus keys. Save the set value with the En-
I [mA] ter key. Go to the next menu with the arrow keys. Exit initiation with the
R-key.
1
STORED VALUE indicates stored value for max. current.
2 Function: 7.5.2 Control valve attachment
3
005518

Component: Solenoid valve for spreading out 20’-40’ (Y6018)


t [s]
Signal value: XXXmA = 0 - 999 mA
1. Max. current (END CURRENT)
2. Damping (PROC DAMPING)
3. Start current (START CURRENT)

INIT ATTACH, menu 11


DAMP (PROC), SPREADER OUT, 20’-40’
INIT ATTACH 11(X)
Description: Percentage damping of control current to solenoid valve
DAMP (PROC)
SPREADER OUT, 20'-40' for spreading in 20’-40’ (Y6018) when outward spreader approaches
STORED VALUE XX 40’.
PRESENT VALUE XX PRESENT VALUE: Indicates the current value for damping. Adjust the
I [mA] 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-
1 key.
2 STORED VALUE: indicates stored value in percent.
3 Function: 7.5.2 Control valve attachment
005519

t [s] Component: Solenoid valve for spreading out 20’-40’ (Y6018)


1. Max. current (END CURRENT) Signal value: XXX = 0 - 100%. 100% means no damping, i.e. max. cur-
2. Damping (PROC DAMPING) rent. 0% means full damping, i.e. start current
3. Start current (START CURRENT)

Workshop Manual DCF 90-100 VDCF03.01GB


190 8 Control system – 8.5.1.2 ATTACHMENT

INIT ATTACH, menu 12


START CURRENT, SPREADER IN, 40’-20’
INIT ATTACH 12(X)
Description: Start current for activation of solenoid valve for spreading
START CURRENT
SPREADER IN, 40'-20' in 40’-20’ (Y6019).
STORED VALUE XXXmA PRESENT VALUE: Indicates the current value for the start current.
PRESENT VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
I [mA] the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
1
STORED VALUE: indicates stored value for start current.
2 Function: 7.5.2 Control valve attachment
3 005520
Component: Solenoid valve for spreading in 40’-20’ (Y6019)
t [s]
Signal value: XXXmA = 0 - 999 mA
1. Max. current (END CURRENT)
2. Damping (PROC DAMPING)
3. Start current (START CURRENT)

INIT ATTACH, menu 13


END CURRENT, SPREADER IN, 40’-20’
INIT ATTACH 13(X)
Description: Control current at full lever actuation for activation of so-
END CURRENT
SPREADER IN, 40'-20' lenoid valve for spreading in 40’-20’ (Y6019).
STORED VALUE XXXmA PRESENT VALUE: Indicates the current value for max. current. Adjust
PRESENT VALUE XXXmA the value with the plus and minus keys. Save the set value with the En-
I [mA] ter key. Go to the next menu with the arrow keys. Exit initiation with the
R-key.
1
STORED VALUE indicates stored value for max. current.
2 Function: 7.5.2 Control valve attachment
3
005521

Component: Solenoid valve for spreading in 40’-20’ (Y6019)


t [s]
Signal value: XXXmA = 0 - 999 mA
1. Max. current (END CURRENT)
2. Damping (PROC DAMPING)
3. Start current (START CURRENT)

INIT ATTACH, menu 14


DAMP (PROC), SPREADER IN, 40’-20’
INIT ATTACH 14(X)
Description: Percentage damping of control current to solenoid valve
DAMP (PROC)
SPREADER IN, 40'-20' for spreading in 40’-20’ (Y6019) when inward spreader approaches
STORED VALUE XX 20’
PRESENT VALUE XX PRESENT VALUE: Indicates the current value for damping. Adjust the
I [mA] 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
1 R-key.
2 STORED VALUE: indicates stored value in percent.
3 Function: 7.5.2 Control valve attachment
005522

t [s] Component: Solenoid valve for spreading in 40’-20’ (Y6019)


1. Max. current (END CURRENT) Signal value: XXX = 0 - 100%. 100% means no damping, i.e. max. cur-
2. Damping (PROC DAMPING) rent. 0% means full damping, i.e. start current
3. Start current (START CURRENT)

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.5.1.2 ATTACHMENT 191

INIT ATTACH for DCF 90-100


page

INIT ATTACH, menu 1


Not used.

INIT ATTACH, menu 2


Not used.

INIT ATTACH, menu 3


Not used.

INIT ATTACH, menu 4


Not used.

INIT ATTACH, menu 5


START CURRENT, SIDE SHIFT
INIT ATTACH 5(X)
Description: Start current of activation of solenoid valve for side shift
START CURRENT
SIDESHIFT left (Y6020) and solenoid valve for side shift right (Y6021).
STORED VALUE XXXmA PRESENT VALUE: Indicates the current value for the start current.
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

INIT ATTACH, menu 6


END CURRENT, SIDE SHIFT
INIT ATTACH 6(X)
Description: Control current at full lever actuation for activation of so-
END CURRENT
SIDESHIFT lenoid valve for side shift left (Y6020) and solenoid valve for side shift
STORED VALUE XXXmA right (Y6021).
005514

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

Workshop Manual DCF 90-100 VDCF03.01GB


192 8 Control system – 8.5.1.2 ATTACHMENT

INIT ATTACH, menu 7


START CURRENT, LEVELLING
INIT ATTACH 7(X)
Description: Start current of activation of solenoid valve for levelling
START CURRENT
LEVELLING left (Y6036) and solenoid valve for levelling right (Y6035).
STORED VALUE XXXmA PRESENT VALUE: Indicates the current value for the start current.

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

INIT ATTACH, menu 8


END CURRENT, LEVELLING
INIT ATTACH 7(X)
Description: Control current at full lever actuation for activation of so-
END CURRENT
LEVELLING lenoid valve for levelling left (Y6036) and solenoid valve for levelling
STORED VALUE XXXmA right (Y6035).
010068

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

INIT ATTACH, menu 9


START CURRENT, SPREADER OUT, 20’-40’
INIT ATTACH 9(X)
Description: Start current for activation of solenoid valve for spreading
START CURRENT
SPREADER OUT, 20'-40' out left (Y6018L) and solenoid valve for spreading out right (Y6018R)
STORED VALUE XXXmA PRESENT VALUE: Indicates the current value for the start current.
PRESENT VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
I [mA] the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
1
STORED VALUE: indicates stored value for start current.
2 Function: 7.4.2 Control valve attachment
3
005517

Component: Solenoid valve for spreading out 20’-40’ (Y6018)


t [s]
Signal value: XXXmA = 0 - 999 mA
1. Max. current (END CURRENT)
2. Damping (PROC DAMPING)
3. Start current (START CURRENT)

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.5.1.2 ATTACHMENT 193

INIT ATTACH, menu 10


END CURRENT, SPREADER OUT, 20’-40’
INIT ATTACH 10(X)
Description: Control current at full lever actuation for activation of so-
END CURRENT
SPREADER OUT, 20'-40' lenoid valve for spreading out left (Y6018L) and solenoid valve for
STORED VALUE XXXmA spreading out right (Y6018R)
PRESENT VALUE XXXmA PRESENT VALUE: Indicates the current value for max. current. Adjust
I [mA] 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
1 R-key.
2 STORED VALUE indicates stored value for max. current.
3 Function: 7.4.2 Control valve attachment
t [s] 005518 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: XXXmA = 0 - 999 mA
3. Start current (START CURRENT)

INIT ATTACH, menu 11


DAMP (PROC), SPREADER OUT, 20’-40’
INIT ATTACH 11(X)
Description: Percentage damping of control current to solenoid valve
DAMP (PROC)
SPREADER OUT, 20'-40' for spreading out left (Y6018L) and solenoid valve for spreading out
STORED VALUE XX right (Y6018R) when spreading out approaches 40’.
PRESENT VALUE XX PRESENT VALUE: Indicates the current value for damping. Adjust the
I [mA] 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
1 R-key.
2 STORED VALUE: indicates stored value in percent.
3 Function: 7.4.2 Control valve attachment
005519

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

INIT ATTACH, menu 12


START CURRENT, SPREADER IN, 40’-20’
INIT ATTACH 12(X)
Description: Start current for activation of solenoid valve for spreading
START CURRENT
SPREADER IN, 40'-20' in left (Y6019L) and solenoid valve for spreading in right (Y6019R)
STORED VALUE XXXmA PRESENT VALUE: Indicates the current value for the start current.
PRESENT VALUE XXXmA Adjust the value with the plus and minus keys. Save the set value with
I [mA] the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
1
STORED VALUE: indicates stored value for start current.
2 Function: 7.4.2 Control valve attachment
3
005520

Component: Solenoid valve for spreading in left (Y6019L) and sole-


t [s] noid valve for spreading in right (Y6019R).
1. Max. current (END CURRENT) Signal value: XXXmA = 0 - 999 mA
2. Damping (PROC DAMPING)
3. Start current (START CURRENT)

Workshop Manual DCF 90-100 VDCF03.01GB


194 8 Control system – 8.5.1.2 ATTACHMENT

INIT ATTACH, menu 13


END CURRENT, SPREADER IN, 40’-20’
INIT ATTACH 13(X)
Description: Control current at full lever actuation for activation of so-
END CURRENT
SPREADER IN, 40'-20' lenoid valve for spreading in left (Y6019L) and solenoid valve for
STORED VALUE XXXmA spreading in right (Y6019R)
PRESENT VALUE XXXmA PRESENT VALUE: Indicates the current value for max. current. Adjust
I [mA] 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
1 R-key.
2 STORED VALUE indicates stored value for max. current.
3 005521
Function: 7.4.2 Control valve attachment
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: XXXmA = 0 - 999 mA
3. Start current (START CURRENT)

INIT ATTACH, menu 14


DAMP (PROC), SPREADER IN, 40’-20’
INIT ATTACH 14(X)
Description: Percentage damping of control current to solenoid valve
DAMP (PROC)
SPREADER IN, 40'-20' for spreading in left (Y6019L) and solenoid valve for spreading in right
STORED VALUE XX (Y6019R) when spreading in approaches 20’.
PRESENT VALUE XX PRESENT VALUE: Indicates the current value for damping. Adjust the
I [mA] 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
1 R-key.
2 STORED VALUE: indicates stored value in percent.
3 Function: 7.4.2 Control valve attachment
005522

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

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.5.1.3 STEERING 195

8.5.1.3 STEERING
INIT STEERING
page

This function covers initiation of lever steering or mini-wheel.


INITIATION
ELSERVO ATTACHMENT
STEERING DRIVE-TRAIN
SLIDING-CAB DANGER

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.

INIT STEERING, menu 1


page

CHARACTER OF THE STEERING LEVER


INIT STEERING 1(X)
Description: Indicates the responsiveness of the steering lever in ac-
CHARACTER OF THE
STEERING LEVER, 0-31 cordance with 32 predefined curves (0-31) 0 means that linear wheel
STORED VALUE XX angle is uniform in relation to lever angle during the whole lever move-
PRESENT VALUE XX ment. 31 means that the wheel angle is small at the beginning of the
lever movement and large at the end.
U [V] 0
PRESENT VALUE: indicates current curve. Change curve with the
plus or minus keys. Save the set curve with the Enter key. Go to the
next menu with the arrow keys. Go back from initiation using the R key.
31
STORED VALUE: indicates saved curve.
Function: 5.2 Power-assisted steering system (product option lever
005572

steering or mini-wheel)
X Component: -
Y = Output signal to solenoid valve
Signal value: XX = 0-31.
X = Lever movement

Workshop Manual DCF 90-100 VDCF03.01GB


196 8 Control system – 8.5.1.3 STEERING

INIT STEERING, menu 2


page

BREAK POINT BP1


INIT STEERING 2(X)
Description: Speed for cut-off point 1. Cut-off points are used to adapt
BRAKE POINT BP1
(kph) the steering angle to the machine’s speed. This enables both sensitive
STORED VALUE XX.X steering at low speeds and stable steering at higher speeds.
PRESENT VALUE XX.X PRESENT VALUE: indicates present speed setting for cut-off point 1.
I [mA] Change speed with plus or minus keys. Save set speed with the Enter-
100% key. Go to the next menu with arrow keys. Exit initiation with the R-key.
STORED VALUE: indicates saved speed for break point 1.
% BP2 Function: 5.2 Power-assisted steering system (product option lever
% BP3 steering or mini-wheel)
V [kph] 005573 Component: -
BP1 BP2 BP3
I [mA] = control current to solenoid valve Signal value: XX.X = speed for BP1 in km/h.
V [kph] = machine’s speed in km/h
BP1 = speed setting for break point 1
BP2 = speed setting for break point 2
BP3 = speed setting for break point 3
%BP2 = per cent of control current to solenoid valve at
BP2
%BP2 = per cent of control current to solenoid valve at
BP2

INIT STEERING, menu 3


page

BREAK POINT BP2


INIT STEERING 3(X)
Description: Speed for cut-off point 2. Cut-off points are used to adapt
BRAKE POINT BP2
(kph) the steering angle to the machine’s speed. This enables both sensitive
STORED VALUE XX.X steering at low speeds and stable steering at higher speeds.
PRESENT VALUE XX.X PRESENT VALUE: indicates present speed setting for cut-off point 2.
I [mA] Change speed with plus or minus keys. Save set speed with the Enter-
100% key. Go to the next menu with arrow keys. Exit initiation with the R-key.
STORED VALUE: indicates saved speed for break point 2.
% BP2 Function: 5.2 Power-assisted steering system (product option lever
% BP3 steering or mini-wheel)
005574

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

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.5.1.3 STEERING 197

INIT STEERING, menu 4


page

BREAK POINT BP3


INIT STEERING 4(X)
Description: Speed for cut-off point 3. The cut-off points are used to
BRAKE POINT BP3
(kph) adapt the steering angle in accordance with the machine’s speed. This
STORED VALUE XX.X enables both sensitive steering at low speeds and stable steering at
PRESENT VALUE XX.X higher speeds.

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

INIT STEERING, menu 5


page

PROC REDUCTION, AT PB2


INIT STEERING 5(X)
Description: Percentage reduction of control current to solenoid valve
PROC REDUCTION
AT BP2 for steering right (Y636-3) and solenoid valve for steering left (Y636-4)
STORED VALUE XXX at BP2.
PRESENT VALUE XXX PRESENT VALUE: Indicates the current value for the reduction. Ad-
I [mA] just the value with the plus and minus keys. Save the set value with
100% the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
% BP2 STORED VALUE: indicates stored value for the reduction.
% BP3 Function: 5.2 Power-assisted steering system (product option lever
005576

V [kph] steering or mini-wheel)


BP1 BP2 BP3
Component: -
I [mA] = control current to solenoid valve
V [kph] = machine’s speed in km/h Signal value: XXX = 0 - 100%. 100% means no damping, i.e. max. cur-
BP1 = speed setting for break point 1 rent. 0% means full damping, i.e., start current.
BP2 = speed setting for break point 2
BP3 = speed setting for break point 3
%BP2 = per cent of control current to solenoid valve at
BP2
%BP2 = per cent of control current to solenoid valve at
BP2

Workshop Manual DCF 90-100 VDCF03.01GB


198 8 Control system – 8.5.1.3 STEERING

INIT STEERING, menu 6


page

PROC REDUCTION, AT PB3


INIT STEERING 6(X)
Description: Percentage reduction of control current to solenoid valve
PROC REDUCTION
AT BP3 for steering right (Y636-3) and solenoid valve for steering left (Y636-4)
STORED VALUE XXX at BP3.
PRESENT VALUE XXX PRESENT VALUE: Indicates the current value for the reduction. Ad-
I [mA] just the value with the plus and minus keys. Save the set value with
100% the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
% BP2 STORED VALUE: indicates stored value for the reduction.
% BP3 Function: 5.2 Power-assisted steering system (product option lever
V [kph] 005577 steering or mini-wheel)
BP1 BP2 BP3
Component: -
I [mA] = control current to solenoid valve
V [kph] = machine’s speed in km/h Signal value: XXX = 0 - 100%. 100% means no damping, i.e. max. cur-
BP1 = speed setting for break point 1 rent. 0% means full damping, i.e., start current.
BP2 = speed setting for break point 2
BP3 = speed setting for break point 3
%BP2 = per cent of control current to solenoid valve at
BP2
%BP2 = per cent of control current to solenoid valve at
BP2

INIT STEERING, menu 7


page

START CURRENT, STEERING RIGHT


INIT STEERING 7(X)
Description: Start current to the solenoid valve for steering right (Y636-
START CURRENT
STEERING RIGHT 3).
STORED VALUE XXXmA PRESENT VALUE: Indicates the current value for the start current.
005578

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

INIT STEERING, menu 8


page

END CURRENT, STEERING RIGHT


INIT STEERING 8(X)
Description: Control current to the solenoid valve for steering right
END CURRENT
STEERING RIGHT (Y636-3) at end lever position.
STORED VALUE XXXmA PRESENT VALUE: Indicates the current value for max. current. Adjust
005579

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

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.5.1.3 STEERING 199

INIT STEERING, menu 9


page

START CURRENT, STEERING LEFT


INIT STEERING 9(X)
Description: Start current to the solenoid valve for steering left (Y636-
START CURRENT
STEERING LEFT 4).
STORED VALUE XXXmA PRESENT VALUE: Indicates the current value for the start current.

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

INIT STEERING, menu 10


page

END CURRENT, STEERING LEFT


INIT STEERING 10(X)
Description: Control current to the solenoid valve for steering left
END CURRENT
STEERING LEFT (Y636-4) at end lever position.
STORED VALUE XXXmA PRESENT VALUE: Indicates the current value for max. current. Adjust
005581

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

Workshop Manual DCF 90-100 VDCF03.01GB


200 8 Control system – 8.5.1.4 DRIVETRAIN

8.5.1.4 DRIVETRAIN
INIT DRIVE-TRAIN
page

This function covers engine and transmission initiation.


INITIATION
ELSERVO ATTACHMENT
STEERING DRIVE-TRAIN
SLIDING-CAB DANGER

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.

INIT DRIVE-TRAIN, menu 1


page

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

INIT DRIVE-TRAIN, menu 2


page

VEHICLE SPEED F-R


INIT DRIVE-TRN 2(X)
Description: Setting of highest permitted speed for shifting between
VEHICLE SPEED F-R
forward and reverse.
STORED VALUE XXX PRESENT VALUE: Indicates the current setting. Change the value
005582

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

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.5.1.4 DRIVETRAIN 201

INIT DRIVE-TRAIN, menu 3


page

ENGINE SPEED F-R


INIT DRIVE-TRN 3(X)
Description: Setting of highest permitted engine speed when shifting
ENGINE SPEED F-R
between forward and reverse.
STORED VALUE XXX

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)

INIT DRIVE-TRAIN, menu 4


page

ENGINE SPEED N-DIR


INIT DRIVE-TRN 4(X)
Description: Setting of highest permitted engine speed for shifting from
ENGINE SPEED N-DIR
neutral to gear.
STORED VALUE XXX
005584

PRESENT VALUE XXX NOTE


This setting takes priority over the setting in INIT DRIVE-TRAIN,
menu 3 page 201. If the engine speed is set lower in this menu
that in menu 3, this engine speed will also apply to switching di-
rection of travel. This occurs because the transmission must shift
into neutral when changing direction of travel.
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)

Workshop Manual DCF 90-100 VDCF03.01GB


202 8 Control system – 8.5.1.4 DRIVETRAIN

INIT DRIVE-TRAIN, menu 5


page

ENGINE SPEED, KICKDOWN 1ST


INIT DRIVE-TRN 5(X)
Description: Setting of the lowest engine rpm when conditions for kick-
ENGINE SPEED
KICK DOWN 1:ST down to 1st gear are to be checked.
STORED VALUE XXX

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)

INIT DRIVE-TRAIN, menu 6


page

VEHICLE SPEED, DECLUTCH


INIT DRIVE-TRN 6(X)
Description: Setting of highest permitted speed for disengaging the
VEHICLE SPEED
DECLUTCH transmission.
STORED VALUE XXX PRESENT VALUE: Indicates the current setting. Change the value
005586

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)

INIT DRIVE-TRAIN, menu 7


page

Not used.

INIT DRIVE-TRAIN, menu 8


page

Not used.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.5.1.4 DRIVETRAIN 203

INIT DRIVE-TRAIN, menu 9


page

OPTION SPEED LIMIT


INIT DRIVE-T 9(X)
OPTION SPEED LIMIT
(km/h)
Description: Setting of speed limitation.
STORED VALUE XXX

005587
PRESENT VALUE XXX PRESENT VALUE: Indicates the current setting. Change the value
with the plus and minus keys. Save the set value with the Enter key.
Go to the next menu with the arrow keys. Exit initiation with the R-key.
STORED VALUE: indicates saved setting.
Function: 2 Transmission
Component: -
Signal value: XXX = speed (km/h)

INIT DRIVE-TRAIN, menu 10


page

OPTION HIGHEST GEAR AT SPEED LIMIT


INIT DRIVE-T 10(X)
OPTION HIGHEST GEAR
AT SPEED LIMIT
Description: Setting of highest permissible gear (speed limitation
STORED VALUE XXX
005588

PRESENT VALUE XXX through blocked gears).


PRESENT VALUE: Indicates the current setting. Change the value
with the plus and minus keys. Save the set value with the Enter key.
Go to the next menu with the arrow keys. Exit initiation with the R-key.
STORED VALUE: indicates saved setting.
Function: 2 Transmission
Component: -
Signal value: XXX = gear

INIT DRIVE-TRAIN, menu 11


page

OPTION ENGINE SHUT DOWN


INIT DRIVE-T 11(X)
OPTION ENGINE SHUT
DOWN AT IDLE (sec)
Description: Setting of idle time prior to automatic engine shutdown
STORED VALUE XXX
005589

PRESENT VALUE XXX PRESENT VALUE: Indicates the current setting. Change the value
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.

Workshop Manual DCF 90-100 VDCF03.01GB


204 8 Control system – 8.5.1.4 DRIVETRAIN

INIT DRIVE-TRAIN, menu 12


page

F-R WITHOUT ENGINE SPEED REDUCTION


INIT DRIVE-T 12(X)
Description: Activation or deactivation of automatic engine speed re-
F-R WITHOUT ENGINE
SPEED REDUCTION duction when changing direction of travel forward - reverse. This
STORED VALUE X makes it possible to change direction of travel without releasing the ac-

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

INIT DRIVE-TRAIN, menu 13


page

AUTO ENGINE SPEED AT LIFT


INIT DRIVE-T 13(X)
AUTO ENGINE SPEED AT
LIFT
Description: Activation or deactivation of automatic engine speed in-
STORED VALUE X
005591

PRESENT VALUE X crease during lift.


PRESENT VALUE: Indicates the current setting. Change the value
with the plus and minus keys. Save the set value with the Enter key.
Go to the next menu with the arrow keys. Exit initiation with the R-key.
STORED VALUE: indicates saved setting.
Function: 2 Transmission
Component: -
Signal value:
X = 1, activated
X = 0, deactivated

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.5.1.5 SLIDING-CAB 205

8.5.1.5 SLIDING-CAB
INIT SLIDING-CAB
page

This function handles initiation of the hydraulic sliding cab.


INITIATION
ELSERVO ATTACHMENT The sliding cab is smooth started by means of the control current to
STEERING DRIVE-TRAIN the solenoid valves being increased from a low start value to a max.
SLIDING-CAB level. When the cab reaches an end position the speed is dampened

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.

INIT SLID-CAB, menu 1


page

START CURRENT, RIGHT


INIT SLID-CAB 1(X)
Description: Start current to solenoid valve side shift right (Y6021) at
START CURRENT
RIGHT activation of sliding cab. The control current controls the start speed
STORED VALUE XXXmA for cab sliding to the right.
PRESENT VALUE XXXmA PRESENT VALUE: Indicates the current value for the start current.
I [mA] Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
1 with the R-key.
2 STORED VALUE: indicates stored value for start current.
3 Function: 9.10.4 Hydraulic sliding cab
007162

t [s] Component: Solenoid valve, side shift right (Y6021)


1. Max. current (END CURRENT) Signal value: XXXmA = 0 - 999 mA
2. Damping (PROC DAMPING)
3. Start current (START CURRENT)

Workshop Manual DCF 90-100 VDCF03.01GB


206 8 Control system – 8.5.1.5 SLIDING-CAB

INIT SLID-CAB, menu 2


page

END CURRENT, RIGHT


INIT SLID-CAB 2(X)
Description: Control current to solenoid valve for side shift right
END CURRENT
RIGHT (Y6021) after full ramp time at activation of switch for cab sliding. This
STORED VALUE XXXmA current controls maximum speed cab sliding speed to the right.
PRESENT VALUE XXXmA PRESENT VALUE: Indicates the current value for max. current. Adjust
I [mA] 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
1 R-key.
2 STORED VALUE indicates stored value for max. current.
3 007163 Function: 9.10.4 Hydraulic sliding cab
t [s] Component: Solenoid valve, side shift right (Y6021)
1. Max. current (END CURRENT)
Signal value: XXXmA = 0 - 999 mA
2. Damping (PROC DAMPING)
3. Start current (START CURRENT)

INIT SLID-CAB, menu 3


page

Not used.

INIT SLID-CAB, menu 4


page

START CURRENT, LEFT


INIT SLID-CAB 4(X)
Description: Start current to solenoid valve side shift left (Y6020) at ac-
START CURRENT
LEFT tivation of sliding cab. The control current controls the start speed for
STORED VALUE XXXmA cab sliding to the left.
PRESENT VALUE XXXmA PRESENT VALUE: Indicates the current value for the start current.
I [mA] Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
1 with the R-key.
2 STORED VALUE: indicates stored value for start current.
3 Function: 9.10.4 Hydraulic sliding cab
007165

t [s] Component: Solenoid valve, side shift left (Y6020)


1. Max. current (END CURRENT) Signal value: XXXmA = 0 - 999 mA
2. Damping (PROC DAMPING)
3. Start current (START CURRENT)

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.5.1.5 SLIDING-CAB 207

INIT SLID-CAB, menu 5


page

END CURRENT, LEFT


INIT SLID-CAB 5(X)
Description: Control current to solenoid valve for side shift left (Y6020)
END CURRENT
LEFT after full ramp time at activation of switch for cab sliding. This current
STORED VALUE XXXmA controls maximum speed cab sliding speed to the left.
PRESENT VALUE XXXmA PRESENT VALUE: Indicates the current value for max. current. Adjust
I [mA] 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
1 R-key.
2 STORED VALUE indicates stored value for max. current.
3 Function: 9.10.4 Hydraulic sliding cab
t [s] 007166 Component: Solenoid valve, side shift left (Y6020)
1. Max. current (END CURRENT) Signal value: XXXmA = 0 - 999 mA
2. Damping (PROC DAMPING)
3. Start current (START CURRENT)

INIT SLID-CAB, menu 6


page

Not used.

Workshop Manual DCF 90-100 VDCF03.01GB


208 8 Control system – 8.5.2 Calibration

8.5.2 Calibration
Calibration, description
page

Certain functions require calibration in order to operate correctly. The


control system has integrated calibrations for these functions.

SCALE
This menu handles calibration of sensors 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:

SCALE STEERING Lever steering, calibration page 210


DRIVE-TRAIN RETURN
000074

NOTE
Calibration does not need to be performed in one process but
each step can be performed separately, independently of other
steps.

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

Transmission, calibration page 213

NOTE
Calibration does not need to be performed in one process but
each step can be performed separately, independently of other
steps.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.5.2 Calibration 209

Calibration menu, explanation


The figure shows an example of a menu, here for calibrating the centre
1 2
position of the lever steering control. The table indicates what a de-
scription contains (which follows in the next section):
5 CALIBR STEERING 1(X)
STEERING LEVER CENTER
POSITION Designation: Example Description
4 STORED VALUE X.XXV
3 Variable (position 5): STEERING Name of the affected input

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.

Function: 5.2 Power-steering sys- Name of current function.


tem

Component: Lever steering control Indicates the component


(R825) whose signal is the basis for
calibration.

Calibration, work instructions


page

Calibration consists of a number of menus (the number of menus de-


pends on the function). All menus are similar in construction and there-
fore the descriptions are similar.
To select a function to calibrate, proceed as follows:

1 Navigate to the service menu.


2 Press Enter.
000056

3 State code for calibration.


Code is obtained from Kalmar Industries Support.
1 23
4 5 NOTE
000060

The code determines which service menu is activated (Diag-


nostic test, Initiation or Calibration).
4 Select group by scrolling with the arrow keys (1 and 2) and con-
CALIBRATION firm with Enter.

SCALE STEERING Each calibration consists of a sequence of a number of menus.


DRIVE-TRAIN RETURN The first menu for the selected calibration appears in the display.
000062

Select the next menu with key 1 and 2 (arrow function).

Workshop Manual DCF 90-100 VDCF03.01GB


210 8 Control system – 8.5.2.1 Calibrate SCALE

8.5.2.1 Calibrate SCALE


Fixed scale, calibration
page

1 Park the machine on level ground with the mast vertical and with-
out load.

CALIBR SCALE, menu 1


2 Go into the calibration menus and select CALIBR SCALE, menu
CALIBR SCALE 1(X) 1, see Calibration, work instructions page 209
PRESENT LOAD XXXXXkg
Description: Setting of dead weight (tare).
STORED TARE XXXXXkg 007154
PRESENT LOAD: indicates present load.
PRESENT TARE XXXXXkg
PRESENT TARE: indicates present dead weight (tare).
STORED VALUE: indicates stored dead weight (tare).
3 Move the mast to the position where weighing normally is done.
Lower just a little and wait until the value in present load has sta-
bilised.
4 Store values with function key for Enter.
CALIBR SCALE, menu 2
CALIBR SCALE 2(X)
Description: Diagnostic menu for scale. The values come from the Ve-
PRESENT LOAD XXXXXkg
LIFT PRESSURE XXXbar hicle data file and cannot be adjusted.
GEAR RATIO MAST X PRESENT LOAD: indicates present load.
007155

CYL. AREA XXXXXmm2


LIFT PRESSURE: indicates lift pressure.
GEAR RATIO MAST: indicates gear ratio for the mast.
CYL. AREA: indicates cylinder area.

8.5.2.2 Calibrate STEERING


Lever steering, calibration
page

NOTE
Calibration does not need to be performed in one process but
each step can be performed separately, independently of other
steps.

1 Start key in operating position.

CALIBR STEERING, menu 1


2 Go into the calibration menus and select CALIBR STEERING,
CALIBR STEERING 1(X) menu 1, see Calibration, work instructions page 209
STEERING LEVER CENTER
POSITION STEERING LEVER CENTRE POSITION
STORED VALUE X.XXV Description: Setting the centre position of the lever steering con-
005529

PRESENT VALUE X.XXV trol (R825).


PRESENT VALUE: indicates current signal value from lever
steering control (R825).
STORED VALUE: indicates stored signal value from lever steer-
ing control (R825).

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.5.2.2 Calibrate STEERING 211

Component: Lever steering control (R825)


Function: 5.2 Power-steering system
3 Move steering lever to required centre position.
4 Store the position with function key for Enter.

CALIBR STEERING, menu 2


5 Select CALIBR STEERING, menu 2.
CALIBR STEERING 2(X)
STEERING LEVER LEFT POSITION
STEERING LEVER LEFT
POSITION Description: Setting of position for max. angle left on lever steer-
STORED VALUE X.XXV ing control (R825).
005530
PRESENT VALUE X.XXV
PRESENT VALUE: indicates current signal value from lever
steering control (R825).
STORED VALUE: indicates stored signal value from lever steer-
ing control (R825).
Component: Lever steering control (R825)
Function: 5.2 Power-steering system
6 Move steering lever to required position for max. angle left.
7 Store the position with function key for Enter.

CALIBR STEERING, menu 3


8 STEERING LEVER RIGHT POSITION
CALIBR STEERING 3(X)
Description: Setting of position for max. angle right on lever steer-
STEERING LEVER RIGHT
POSITION ing control (R825).
STORED VALUE X.XXV PRESENT VALUE: indicates current signal value from lever
005531

PRESENT VALUE X.XXV steering control (R825).


STORED VALUE: indicates stored signal value from lever steer-
ing control (R825).
Component: Lever steering control (R825)
Function: 5.2 Power-steering system
9 Move steering lever to required position for max. angle right.
10 Store the position with function key for Enter.

Workshop Manual DCF 90-100 VDCF03.01GB


212 8 Control system – 8.5.2.3 Calibrate DRIVETRAIN

8.5.2.3 Calibrate DRIVETRAIN


Accelerator pedal, calibration
page

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.

1 Start key in operating position, engine switched off.

DRIVE-TRAIN, menu 1
2 Go into the calibration menus and select DRIVE-TRAIN, menu 1,
CALIBR DRIVE-TRN 1(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

PRESENT VALUE X.XXV


STORED VALUE: Indicates current calibrated control value from
accelerator pedal (R690-1).
PRESENT VALUE: Indicates present signal value from Acceler-
ator pedal (B690-1).
Function: 1 Engine
Component: Accelerator pedal (B690-1).
3 Release the accelerator pedal.
4 Store the position with function key for Enter.

DRIVE-TRAIN, menu 2
5 ACCELERATOR, PRESS THE PEDAL TO FLOOR
CALIBR DRIVE-TRN 2(X) Description: Setting of full-throttle position of Accelerator pedal
ACCELERATOR, PRESS (B690-1).
THE PEDAL TO FLOOR
STORED VALUE X.XXV STORED VALUE: Indicates current calibrated control value from
PRESENT VALUE X.XXV accelerator pedal (R690-1).
00

PRESENT VALUE: Indicates present signal value from Acceler-


ator pedal (B690-1).
Function: 1 Engine
Component: Accelerator pedal (B690-1).
6 Press the accelerator pedal down fully and keep it down until the
position is stored.
7 Store the position with function key for Enter.

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.5.2.3 Calibrate DRIVETRAIN 213

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

PRESENT VALUE X.XXV


throttle position for the accelerator pedal (B690-2).
STORED VALUE: Indicates current calibrated control value from
accelerator pedal (R690-2).
PRESENT VALUE: Indicates present signal value from Acceler-
ator pedal (B690-2).
Function: 1 Engine
Component: Accelerator pedal (B690-2).
12 Press the accelerator pedal down fully and keep it down until the
position is stored.
13 Store the position with function key for Enter.

Transmission, calibration
page

DANGER
Do not leave the machine during calibration. The ma-
chine may start to move.

1 Park the machine on level ground, engage neutral position and


apply the parking brake. Run the engine at idling speed.

Workshop Manual DCF 90-100 VDCF03.01GB


214 8 Control system – 8.5.2.3 Calibrate DRIVETRAIN

2 Go into the calibration menus and select DRIVE-TRAIN, menu 4,


CALIBR DRIVE-TRN 4(X) see Calibration, work instructions page 209.
GEARBOX WARM UP
MODE X 3 Check that the oil temperature is at least 61 °C.
ACTUAL TEMP XXX If the oil temperature is too low then go to DRIVE-TRAIN, menu 4.

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

ACTION X XXXXrpm PHASE: Indicates current phase in the calibration.


0. Pre-filling of clutch
1. Calibration of clutch
4. Calibration complete
5. Calibration incorrect

CLUTCH: Indicates which clutch shall be calibrated.


F. Clutch forward
R. Clutch reverse
1. Clutch gear 1
2. Clutch gear 2
3. Clutch gear 3
4. Clutch gear 4

VDCF03.01GB Workshop Manual DCF 90-100


8 Control system – 8.5.2.3 Calibrate DRIVETRAIN 215

ACTION: Indicates action from mechanics (in the event of a


fault)
0. No action (normal condition if no malfunction).
1. Increase throttle application.
2. Reduce throttle application.
3. Select neutral position.
4. Select travel direction forward.
5. Stop the vehicle (depress the service brake if the
machine starts to move).
6. Heat the transmission, see step 4.
7. No action; the engine is controlled via the transmis-
sion control unit (D793).
8. Keep the accelerator pedal in its current position.
9. Check error codes.

SUB-PH: Internal value for sub-phase 1 or 0.

STATUS: Calibration status.


0. Calibration not in progress.
3. Calibration in progress

5 Check that the gear selector is in neutral position.


6 Start calibration by pressing Enter
7 Calibration starts (takes approx. 15 minutes) and engine speed is
raised to approx. 770 rpm.
The transmission will activate different gears during calibration.

NOTE
If the machine starts to move during calibration, use the
service brake to keep the machine stationary.

IMPORTANT
Calibration can be interrupted at any time by selecting
travel direction reverse.

8 When the engine speed decreases to idling and PHASE = 4 then


calibration is complete.
9 Switch off the ignition to store the values.

Workshop Manual DCF 90-100 VDCF03.01GB


216 8 Control system – 8.5.2.3 Calibrate DRIVETRAIN

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories 1

9 Frame, body, cab and accessories

Table of Contents 9 Frame, body, cab and accessories


mm mm mm mm mm mm

9 Frame, body, cab and accessories............................................................... 5


9.1 Controls and instruments ........................................................................... 5
9.1.1 Gear selector and multi-function lever ................................................. 11
9.1.22 Switch, direction indicators .................................................................. 12
9.2 Safety and emergency equipment ............................................................ 13
9.2.1 Emergency stop switch ........................................................................ 13
9.2.2 Seat belt ............................................................................................... 13
9.2.3 Fire extinguisher .................................................................................. 13
9.2.4 Seat buzzer .......................................................................................... 13
9.2.5 Roof grating ......................................................................................... 13
9.3 Seat .......................................................................................................... 14
9.3.1 Seat cushion ........................................................................................ 18
9.3.2 Back cushion ....................................................................................... 18
9.3.3 Electric heater ...................................................................................... 19
9.3.4 Shock absorbers .................................................................................. 20
9.3.5 Air suspension ..................................................................................... 20
9.3.6 Compressed air-suspended seat ......................................................... 20
9.3.7 Mechanical seat adjustment ................................................................ 21
9.3.8 Passenger seat .................................................................................... 21
9.3.9 Armrest ................................................................................................ 21
9.3.14 Sensor operator in seat ....................................................................... 22
9.4 Heating, ventilation and air conditioning ................................................... 23
9.4.1 Fresh air filter ....................................................................................... 31
9.4.2 Fresh air and recirculation damper ...................................................... 32
9.4.3 Cab fan ................................................................................................ 35
9.4.4 Heat exchanger heat ........................................................................... 38
9.4.5 Water valve .......................................................................................... 41
9.4.6 Engine temperature sensor ................................................................. 42
9.4.7 Compressor ......................................................................................... 43
9.4.8 Condenser ........................................................................................... 46
9.4.9 Moisture filter ....................................................................................... 47
9.4.10 Pressure switch ................................................................................... 48
9.4.11 Expansion valve ................................................................................... 49
9.4.12 Sensor temperature refrigerant ............................................................ 51
9.4.13 Heat exchanger cooling ....................................................................... 53
9.4.14 Air distributor ........................................................................................ 54
9.4.15 Air vents ............................................................................................... 55
9.4.16 Sensor temperature outlet fan ............................................................. 56
9.4.17 Sensor cab temperature ...................................................................... 57
9.4.18 Sensor outdoor temperature ................................................................ 58
9.4.19 Pause heater ....................................................................................... 59
9.5 Wiper/washer system ............................................................................... 60
9.5.1 Wiper front ........................................................................................... 60
9.5.2 Wiper roof ............................................................................................ 60

Workshop Manual DCF 90-100 VDCF03.01GB


2 9 Frame, body, cab and accessories

9.5.3 Wiper rear ............................................................................................. 60


9.5.4 Washer motor and reservoir ................................................................. 60
9.5.5 Wiper motor, front ................................................................................. 61
9.5.6 Wiper motor, roof .................................................................................. 62
9.5.7 Wiper motor, rear ................................................................................. 63
9.6 Lighting system ......................................................................................... 65
9.6.1 Headlights ............................................................................................ 70
9.6.2 Running light ........................................................................................ 70
9.6.3 Tail light ................................................................................................ 70
9.6.4 Brake light ............................................................................................ 70
9.6.5 Reversing light ...................................................................................... 71
9.6.6 Driving direction indicator ..................................................................... 71
9.6.7 Warning lights ....................................................................................... 71
9.6.8 Rotating beacon ................................................................................... 71
9.6.9 Working lights, mast ............................................................................. 72
9.6.10 Working lights, cab ............................................................................... 72
9.6.11 Interior lighting ...................................................................................... 73
9.6.12 Work lights, attachment ........................................................................ 73
9.6.13 Entry lighting ......................................................................................... 74
9.6.14 Work lights, front wing .......................................................................... 74
9.7 Signalling system ...................................................................................... 75
9.7.1 Horn ...................................................................................................... 78
9.7.2 Warning lights ....................................................................................... 79
9.7.3 Rotating beacon ................................................................................... 79
9.7.4 Warning parking brake ......................................................................... 79
9.7.5 Reversing alarm ................................................................................... 79
9.8 Entertainment and communication ........................................................... 80
9.9 Glass/windows/mirrors .............................................................................. 81
9.9.1 Windscreen .......................................................................................... 82
9.9.2 Side window ......................................................................................... 84
9.9.3 Roof window ......................................................................................... 88
9.9.4 Rear window ......................................................................................... 88
9.9.5 Rearview mirror .................................................................................... 88
9.9.6 Reversing camera ................................................................................ 89
9.9.7 Monitor, reversing camera .................................................................... 89
9.10 Cab structure and suspension .................................................................. 90
9.10.1 Cab frame ............................................................................................. 90
9.10.2 Doors .................................................................................................... 91
9.10.3 Cab undercarriage ................................................................................ 91
9.10.4 Tiltable cab ........................................................................................... 92
9.11 Cab interior ............................................................................................. 101
9.11.1 Instrument and control panels ............................................................ 101
9.11.2 Interior details, plastic ......................................................................... 102
9.11.3 Interior details, textile ......................................................................... 102
9.11.4 Floor covering ..................................................................................... 103
9.11.5 Insulation ............................................................................................ 103
9.11.6 Sun blinds ........................................................................................... 103

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories 3

9.11.7 Terminal console ............................................................................... 103


9.11.8 Reading-lamp .................................................................................... 103
9.11.9 Writing desk ....................................................................................... 104
9.12 Chassis ................................................................................................... 105
9.13 Body ....................................................................................................... 106
9.13.1 Fenders .............................................................................................. 106
9.13.2 Hood engine compartment ................................................................ 106
9.13.3 Footstep and rail ................................................................................ 107
9.13.4 Counterweights .................................................................................. 107
9.14 Central lubrication .................................................................................. 108
9.14.1 Pump unit ........................................................................................... 110
9.14.2 Distribution block ............................................................................... 111
9.14.3 Lines .................................................................................................. 111
9.15 Paint/coatings ......................................................................................... 112

Workshop Manual DCF 90-100 VDCF03.01GB


4 9 Frame, body, cab and accessories

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9 Frame, body, cab and accessories 5

9 Frame, body, cab and


mm mm mm mm mm mm

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)

A Steering lever or mini-wheel

Workshop Manual DCF 90-100 VDCF03.01GB


6 9 Frame, body, cab and accessories – 9.1 Controls and instruments

Left-hand instrument panel


16 Switch fan (S118)
17 Switch, heating (S117)
18 Switch air distribution (S139)
24..28 29 30 31 19 Switch work lights cab roof (S105-1)
19..23
Auxiliary work lights, front wing
18 20 Switch, work lights on carriage and attachment (S105-2)

004394
17
16 Auxiliary work lights, carriage and attachment
Left-hand instrument panel 21 Switch, work lights on mast (S105-3)

Auxiliary work lights, mast


22 Switch rotating beacon (S110)
23 Switch hazard lights (S109)
24 Switch headlights (S100)

25 Switch, seat heater (S143)


(May appear in driver’s seat)

26 Switch for electrically heated rearview mirrors (S199-4)


27 Spare

28 Switch for pause heater (S199-1)


29 Spare
30 Spare

31 Socket 12 VDC

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.1 Controls and instruments 7

Steering wheel panel


32 Warning lamp for low battery charging
36
35 33 Warning light, low brake pressure
34
33 34 Indicator for active error codes
32
35 Warning light, bypass of hydraulic functions

36 Indicator light, activated steering with lever or mini-wheel

37..41 37 Warning light, high coolant temperature


49
38 Warning light, low oil pressure engine
42..46 39 Indicator light, preheating
47 48
40 Warning light, low engine coolant level
41 Warning light, high gearbox oil temperature
42 Warning light, low fuel level
50 51 52 53 43 Warning light, high hydraulic oil temperature
44 Indicator lamp for main beam
45 Indicator light, travel direction indication
46 Indicator light, parking brake
47 Indicator light, locked twistlock/lock tongue (secured load)
48 Indicator light, alignment (attachment / load)
49 Indicator light, unlocked twistlock/lock tongue (load released)
64
54 50 Panel, warning and indicator lights
63
55 51 Display, control system
62
56 52 Indicator, control system
008132

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

Workshop Manual DCF 90-100 VDCF03.01GB


8 9 Frame, body, cab and accessories – 9.1 Controls and instruments

Panel for hydraulic functions


65 Lift/lower (R8071).
65
66 66 Tilt (R8072)
67
68 67 Side shift (R8073)

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

8 78 79 78 75 Switch for automatic/manual cab tilt (S199-2)


Panel for hydraulic functions and control levers
electric servo 76 Switch for manual cab tilt (S1010)

77 Switch, automatic spreading 20’-40’ (S1012-2)


78 Switch for bypassing of hydraulic functions (S1005)
69 Key for bypassing hydraulic functions
75
79 Emergency stop switch (S250)
71
73
76
78

77
008131

78 8 79 70

Panel for hydraulic functions and control lever

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.1 Controls and instruments 9

Operating menus, overview

1 2 3 4

9 8 7 6

10

009174
11 12 13 14

1. Operating menu engine and transmission 8. Operating menu service

2. Operating menu engine 9. Operating menu heating and air conditioning

3. Operating menu for oil temperature 10. Operating menu, code lock

4. Operating menu electrical system 11. Operating menu statistics, operating hours

5. Operating menu container counter 12. Operating menu statistics, fuel consumption

6. Operating menu service interval 13. Operating menu statistics, driving distance

7. Operating menu statistics 14. Operating menu statistics, lift statistics

Workshop Manual DCF 90-100 VDCF03.01GB


10 9 Frame, body, cab and accessories – 9.1 Controls and instruments

Event menus overview


Side lifting attachment with twistlocks

1 2 3 4

009176
1. Event menu start interlock
2. Event menu, twistlock alignment
3. Event menu twistlocks

4. Event menu open door

5. Event menu automatic spreading

Event menus overview


Side lifting attachment with side lock tongues

1 2 3 4

009781
1. Event menu start interlock
2. Event menu, alignment

3. Event menu open door

4. Event menu automatic spreading

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.1.1 Gear selector and multi-function lever 11

9.1.1 Gear selector and multi-function


lever
Gear and multi-function lever, description
page

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.

Upward Light signal


Down- High beams (on/off)
ward With headlights on: Gear and multi-function lever is
used to switch between high and low beams.
With headlights off: Gear and multi-function lever is
000339

A used to flash with the headlights.


The signal can be checked with the diagnostic menu,
see section 8 Control system, group 8.4.2.3 LIGHTS,
menu 3.
Inward, Horn (position A).
button The signal can be checked from the diagnostic menu,
see section 8 Control system, group 8.4.3.5 CAB,
menu 5.

Workshop Manual DCF 90-100 VDCF03.01GB


12 9 Frame, body, cab and accessories – 9.1.22 Switch, direction indicators

Gear and multi-function lever, replacement


page

1 Separate the dashboard panel.


6 attaching bolts and 2 bolts to the steering wheel shaft.
Remove the steering wheel, see Dashboard panel, replacement
page 101.
2 Undo the attaching bolts (2 x hexagonal socket bolts).
3 Unplug the connector from the KIT control unit (D790-2).
4 Fit a new lever and refit the dashboard panel.

9.1.22 Switch, direction indicators


Switch, direction indicators, replacement
page

1 Machine in service position, see section B Safety.


2 Remove the steering wheel and open the steering wheel panel.

3 Detach the direction indicator wiring harness.


4 Press together the clips on the direction indicator and detach it
from the steering wheel panel.
5 Replace the direction indicator, fitting it in the reverse order.

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.2 Safety and emergency equipment 13

9.2 Safety and emergency


equipment
9.2.1 Emergency stop switch
Emergency stop, description
page

See section 11 Common electrics, group 11.5.1.4 Emergency stop


switch voltage.

9.2.2 Seat belt


Seat belt, description
page

The seat belt is a two or a three-point belt, depending on the type of


seat fitted in the machine. The seat belt is mounted on the seat.

9.2.3 Fire extinguisher


Fire extinguisher, description
page

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.

9.2.4 Seat buzzer


Seat buzzer, description
page

See Sensor operator in seat, description page 22.

9.2.5 Roof grating


Roof grating, description
page

The roof grating protects the operator from falling objects. This consti-
tutes protection that goes beyond the legal requirements.

Workshop Manual DCF 90-100 VDCF03.01GB


14 9 Frame, body, cab and accessories – 9.3 Seat

9.3 Seat
Seats, general
page

There are three versions of driver’s seat:


• Seats, description (product alternative standard seat) page 14

• Seats, description (product alternative Bege 9120) page 15

• Seats, description (product alternative Isringhausen 6800)


page 16

As an option, the machine can be equipped with a fold-down passen-


ger seat to the left of the operator.

Seats, description (product alternative standard


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

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.3 Seat 15

Seats, description (product alternative Bege


page

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

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

Workshop Manual DCF 90-100 VDCF03.01GB


16 9 Frame, body, cab and accessories – 9.3 Seat

Seats, description (product alternative


page

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

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.3 Seat 17

Seat, changing
page

1 Machine in service position, see section B Safety.


2 Slide back the seat to its rear position, remove the front attaching
bolts.

3 Slide the seat to its front position, remove the rear attaching bolts.
4 Disconnect the seat’s connectors from the machine’s cabling.
5 Remove the seat.
6 Fit in the reverse order.

Workshop Manual DCF 90-100 VDCF03.01GB


18 9 Frame, body, cab and accessories – 9.3.1 Seat cushion

9.3.1 Seat cushion


Seat cushion, description
page

The function of the seat cushion is to provide comfort to the operator.


The seat cushion houses the driver’s seat frame and a breaker for the
buzzer. There may also be a heating coil ( ).
For location, see Seats, general page 14.

Seat cushion, changing (product alternative BE-GE)


page

1 Machine in service position, see section B Safety.


2 Loosen the rubber bellows by removing the plastic clips (position
1).
3 Unhook the upholstery’s rails (position 2) from the seat frame (po-
2 5 sition 3) and remove the upholstery.
4 Remove the padding (position 4).
4
If the seat is equipped with seat heater.
Unplug the connector for the heating coil before the padding is re-
moved.

NOTE
The seat’s heating coil is glued to the padding. Be careful if
3
the padding is to be replaced but the heating coil is to be re-
used, or if only the coil is to be replaced.
5 Assemble in reverse order.

1
006276

1. Plastic clips rubber bellows


2. Upholstery
3. Seat frame
4. Padding
5. Heating coil

9.3.2 Back cushion


Back cushion, description
page

The function of the back cushion is to provide comfort to the operator.


The back cushion houses the driver’s seat frame. There may also be
a heating coil ( ).
For location, see Seats, general page 14.

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.3.3 Electric heater 19

Back cushion, changing (product alternative BE-GE)


page

1 Machine in service position, see section B Safety


2 Detach the rubber bellows on the rear of the seat by removing the
plastic clips and folding down the rubber bellows. See Seat cush-
ion, changing (product alternative BE-GE) page 18.
3
3 Remove the backrest by first removing the attaching bolts
(position1) on the right and left side of the seat and then remove
4 the attaching bolts for the seatbelt (position 2) on the right and left
side of the seat.

4 If the seat is equipped with 3-point seatbelt.


Remove the belt guide (position 3) by removing the cover and the
attaching bolt (position 4).

5 5 If the seat is equipped with armrest (position 5).


Remove the armrest by removing the attaching bolts (position 6).
6 Place the backrest on the seat and install the attaching bolts (po-
sition 1), do not tighten. Then install the attaching bolts for the
6 seatbelt (position 2).
Tighten the attaching bolts for the seatbelt (position 2) with torque
42 Nm , then tighten the attaching bolts (position 1) with torque
33 Nm.

7 If the seat is equipped with 3-point seatbelt or armrest.


Cut holes in the upholstery for seatbelt and armrest on the new
006278

1 2 backrest before armrest or seatbelt is installed.

1. Attaching bolt backrest 8 Fit in the reverse order.


2. Attaching bolt seatbelt
3. Cover belt guide
4. Attaching bolt belt guide
5. Armrest
6. Attaching bolt armrest.

9.3.3 Electric heater


Electric heater, description
page

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.

Heating coil, changing (product alternative BE-GE)


page

See Seat cushion, changing (product alternative BE-GE) page 18.

Workshop Manual DCF 90-100 VDCF03.01GB


20 9 Frame, body, cab and accessories – 9.3.4 Shock absorbers

9.3.4 Shock absorbers


Shock absorbers, description
page

Shock absorbers are integrated in the suspension unit in the seat’s


bracket and are self-adjusting, that is, they adjust themselves accord-
ing to the operator’s body weight.

Shock absorber, changing (product alternative BE-


page

GE)

2 1 Machine in service position, see section B Safety.


2 Remove the driver’s seat from the bracket and lift it out of the ma-
chine. See Seat, changing page 17.
3 Remove the seat cushion; see Seat cushion, changing (product
alternative BE-GE) page 18.
1 4 Remove the back cushion; see Back cushion, changing (product
alternative BE-GE) page 19.
5 Remove the shock absorber’s attaching bolts (position 2 and 3).
6 Replace shock absorber (position 1).
006277

3 7 Assemble in reverse order.


1. Shock absorbers
2. Attaching bolt
3. Attaching bolt

9.3.5 Air suspension


Air suspension, description
page

The air-suspended driver’s seat consists of a seat with rubber bellows


and compressor. Air-suspension is self-adjusting, that is, adjust auto-
matically to the operator’s body weight. The compressor provides air
for the suspension unit.
For location, see Seats, general page 14.

9.3.6 Compressed air-suspended seat


Compressed air-suspended seat, description
page

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

The compressor is an external part for the air-suspended driver’s seat


that is installed on the cab floor’s underside.

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.3.7 Mechanical seat adjustment 21

9.3.7 Mechanical seat adjustment


Mechanical seat adjustment, description
page

Seat adjustment is all mechanical and is adapted by the operator with


different controls to obtain a good sitting position.
See:
• Seats, description (product alternative standard seat) page 14
• Seats, description (product alternative Bege 9120) page 15
• Seats, description (product alternative Isringhausen 6800) page
16

9.3.8 Passenger seat


Passenger seat, description
page

The passenger seat is collapsible (vertically), provided with a seat belt


and is located on the left-hand side of the driver’s seat.
001627

Passenger seat with bracket

9.3.9 Armrest
Armrests, description
page

The armrest is fixed to the backrest and is individually adjustable ver-


tically (around the attachment point). Depending on options there is
also an armrest for the left-hand side that can be equipped with:

• Mini-wheel

• Lever steering

Workshop Manual DCF 90-100 VDCF03.01GB


22 9 Frame, body, cab and accessories – 9.3.14 Sensor operator in seat

9.3.14 Sensor operator in seat


Sensor operator in seat, description
page

The operator-in-seat sensor (S230) detects whether the driver’s seat


springs are depressed, which indicates to the control system that the
1 driver’s seat is occupied. This is used to allow the control system to in-
dicate with the operator-in-seat buzzer (H853) if the operator leaves
the machine without applying the parking brake. The sensor also ena-
bles the control system to prevent a gear from being engaged if the op-
2 erator is not in the driver’s seat or to automatically disengage the gear
after 3 seconds if the operator leaves the seat with a gear engaged.
The operator-in-seat sensor (S230) is supplied power by and sends a
voltage signal to the cab control unit (D790-1). The signal can be
checked with the diagnostic menu, see section 8 Control system ,
group 8.4.3.6 CAB, menu 6.
008220

Seat seen from below


1. Sensor operator in seat (S230)
2. Buzzer (H853)

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.4 Heating, ventilation and air conditioning 23

9.4 Heating, ventilation and air


conditioning
Heating, ventilation and air conditioning,
page

description
The heating system controls heating and ventilation of the cab. The
F cab can also be equipped with a climate control system ( ).
The temperature in the cab is thermostat-controlled by the cab control
unit (D790-1). The cab temperature is regulated to the set tempera-
2 ture. The temperature can be set between 16 and 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.

6 A B Climate control system (ECC)

The climate control system (ECC) is responsible for heating, ventila-


tion, cooling and drying. The air is heated in the same way as for the
heating system (EHC).
1 During cooling, ambient air is forced through the evaporator, which
5 G cools the air. The air can then be directed in the same way as for the
000762

heating system.

Principle illustration, climate control system The function of the 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

Workshop Manual DCF 90-100 VDCF03.01GB


24 9 Frame, body, cab and accessories – 9.4 Heating, ventilation and air conditioning

Heating, ventilation and air conditioning,


page

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

Pos Explanation Signal description Reference


1 The temperature switch (S117) sends a Raise: U = 2.0–2.5 V Controls and instruments, overview page 5
voltage signal to the cab control unit Unaffected: U = 0-0.5 V D1: Diagnostic menu, see section 8 Control
(D790-1). system , group 8.4.4.5 CLIMATE, menu 5
Lower: U = 4.5-5.0 V

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

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.4 Heating, ventilation and air conditioning 25

Pos Explanation Signal description Reference


4 The cab temperature sensor (B775-1) R = 10 kΩ at 25 °C Sensor, cab temperature, description page
sends the cab control unit (D790-1) a 57
voltage signal proportional to the tem- D4: Diagnostic menu, see section 8 Control
perature. system , group 8.4.4.1 CLIMATE, menu 1

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

6 The ambient temperature sensor (B774) R = 10 kΩ at 25 °C Sensor, ambient temperature, description


sends the cab control unit (D790-1) a page 58
voltage signal proportional to tempera- D6: Diagnostic menu, see section 8 Control
ture. 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.

8 The engine produces heat when run- - -


ning. It is cooled with the cooling sys-
tem. The heat from the cooling system is
used to heat the cab air.

9 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

Workshop Manual DCF 90-100 VDCF03.01GB


26 9 Frame, body, cab and accessories – 9.4 Heating, ventilation and air conditioning

Pos Explanation Signal description Reference


14 The cab control unit (D790-1) controls Checked by control sys- Cab fan, description page 35
the fan motor (M657), which increases tem, error shown with er- D14: Diagnostic menu, see section 8 Con-
airflow in the cab. ror code. 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.

17 The frame control unit (D797-1) supplies U = 24 V AC compressor, description page 43


voltage to the compressor’s electromag- D17: Diagnostic menu, see section 8 Con-
netic clutch (645). trol system , group 8.4.4.6 CLIMATE, menu
6

18 The compressor draws gaseous refrig- - AC compressor, description page 43


erant from the evaporator, compresses
it, and forces it on to the condenser.

19 The condenser cools the refrigerant. - Condenser, description page 46


The gaseous refrigerant condenses to
liquid form and is pumped on in the cir-
cuit.

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.

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.4 Heating, ventilation and air conditioning 27

Pos Explanation Signal description Reference


23 The refrigerant circuit temperature sen- R = 10 kΩ at 25 °C Sensor, temperature in refrigerant, descrip-
sor sends the cab control unit (D790-1) tion page 51
a voltage signal proportional to temper- D23: Diagnostic menu, see section 8 Con-
ature. trol system , group 8.4.4.2 CLIMATE, menu
2.

24 Heat exchanger cooling dissipates heat - Evaporator, description page 53


from the cab air. Heat is transferred from
the air to the refrigerant and transforms
the refrigerant to a gaseous state.

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.

Heating, ventilation and air conditioning,


page

checking
1 Machine in service position, see section B Safety.
2 Navigate to the service menu and press Enter.
000056

3 Enter code for diagnosis. Code is obtained from Kalmar Indus-


tries Support.

1 23
4 5 NOTE
000060

The code decides which service menu is to be activated


(Diagnostic test, Initiation, Calibration, or Service indica-
tion).
4 Select CLIMATE.
DIAGNOSIS
CAN/POWER LIGHTS CAB Menu 1
CLIMATE HYD ENGINE
TRANSM ELSERV ATTACH
004998

OLS EXTRA

5 Check of desired temperature, inside temperature sensor and


DIAG CLIMATE 1(8) water valve.
PRESENT INPUT SIGNAL
REQUIRED TEMP XXX REQUIRED TEMP: 160 (16.0 °C) for max. cooling and 280
PRESENT TEMP XXX (28.0 °C) for max. heating. The setting is changed with the tem-
000132

WATER VALVE FEEDB. XXX perature switch.

Workshop Manual DCF 90-100 VDCF03.01GB


28 9 Frame, body, cab and accessories – 9.4 Heating, ventilation and air conditioning

PRESENT TEMP shows the temperature inside the cab. This is


measured by Sensor cab temperature (located down to the right
on the instrument panel, behind the rubber bushing). Blowing
through the hole should increase the value.
WATER VALVE FEEDB. should show 0 (closed) when the re-
quested temperature is 160 and 100 (open) when the requested
temperature is 280. The water valve is located under the cab.

Menu 2
6 Check of Sensor temperature outlet fan (B775-2), engine 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

TEMP DE-ICE XXX measured by Sensor temperature outlet fan (B775-2).


TEMP COOLANT: engine temperature sent on the CAN-bus.
TEMP AMBIENT: outdoor temperature measured by Sensor out-
door temperature (B774).
TEMP DE-ICE: cooling circuit’s temperature measured by Sen-
sor temperature refrigerant (B775-1). If the compressor is activat-
ed the value will be low. However, if heat has been selected and
the compressor is deactivated, the value will almost be equal to
TEMP COIL.

Menu 3

7 (Only machines with ECC)


DIAG CLIMATE 3(X)
PRESENT INPUT SIGNAL Checks that refrigerant circuit is filled.
PRESSURE SWITCH X PRESSURE SWITCH: 0 = not filled 1 = filled.
OPT DOOR SWITCH X
006865

The sensor is located on the 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

DRAUGHT VALVE: should work in the range 1.0-4.0 V. The dif-


ference between min. and max. should be approx 1 V. This is
checked by changing the air distribution from floor to front wind-
shield. At the same time, feel with your hand so that air blows
through different vents.

NOTE
Air to the round panel vents is not controlled by the air con-
ditioning unit.

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.4 Heating, ventilation and air conditioning 29

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.

(Only machines with ECC)


COMPRESSOR: lower temperature setting to max. cooling, after
approx. 45 seconds the compressor will be activated and the dis-
play should show "11".

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

Workshop Manual DCF 90-100 VDCF03.01GB


30 9 Frame, body, cab and accessories – 9.4 Heating, ventilation and air conditioning

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

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.4.1 Fresh air filter 31

9.4.1 Fresh air filter


Fresh air filter, description
page

The fresh air filter is located under a cover in the external unit for fresh
air intake into the cab - in front of the cab fan. A finer filter can be used
( ), but this may affect maximum airflow.

1 004999

Fresh air intake, cab


1. Fresh air filter
2. Fresh air and recirculation damper

Workshop Manual DCF 90-100 VDCF03.01GB


32 9 Frame, body, cab and accessories – 9.4.2 Fresh air and recirculation damper

9.4.2 Fresh air and recirculation damper


Fresh air filter or recirculation damper, description
page

The damper is controlled electrically and controls the air between fully
open for fresh air to recirculation of air. The damper is located in the
external unit for fresh air intake into the cab.
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.4.6 CLIMATE, menu 6 .

2 004999

Fresh air intake, cab


1. Fresh air filter
2. Fresh air and recirculation damper

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.4.2 Fresh air and recirculation damper 33

Motor, fresh air filter or recirculation damper,


page

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.

5 Remove the fresh air filter.

Workshop Manual DCF 90-100 VDCF03.01GB


34 9 Frame, body, cab and accessories – 9.4.2 Fresh air and recirculation damper

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.

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.4.3 Cab fan 35

9.4.3 Cab fan


Cab fan, description
page

The cab fan is located in the external unit for fresh air intake into the
cab. The fan consists of two single fans that are driven by a motor.
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.4.6 CLIMATE, menu 6.

1
003209

Fresh air intake, cab


1. Cab fan

Cab fan, replacement


page

1 Machine in service position, see section B Safety.


2 Remove the wiper arms.

Workshop Manual DCF 90-100 VDCF03.01GB


36 9 Frame, body, cab and accessories – 9.4.3 Cab fan

3 Remove the bolts which secure the wiper motor in the protective
plate.
4 Remove the protective plate.

5 Detach the washer hose from the protective plate.

6 Remove the fresh air filter.

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.4.3 Cab fan 37

7 Remove the bolts which secure the plate and cab fan.

8 Detach the connector from the cab fan.


9 Remove the cab fan.
10 Replace the cab fan.
11 Fit in the reverse order. Tighten the wiper arm to 16-20 Nm.

Workshop Manual DCF 90-100 VDCF03.01GB


38 9 Frame, body, cab and accessories – 9.4.4 Heat exchanger heat

9.4.4 Heat exchanger heat


Heat exchanger heat, description
page

The heat from the engine’s coolant is transmitted to the cab via the
heat exchanger. The heat exchanger is located behind the fan in the
external unit for fresh air intake into the cab.

1, 2

3
003210

Fresh air intake, cab


1. Heat exchanger heat
2. Heat exchanger cooling
3. Expansion valve and sensor for refrigerant temper-
ature

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.4.4 Heat exchanger heat 39

Heat exchanger, cooling/heating, replacement


page

WARNING
Personal injury, environmental damage

Read the safety instructions for refrigerant, see sec-


tion B Safety.

1 Machine in service position, see section B Safety.


2 Drain the AC system of R134a refrigerant.

IMPORTANT
Working on the air conditioning requires special au-
thorization.

3 Detach the AC system hoses and the coolant hoses.


4 Remove the wiper arms.
5 Remove the nuts which hold the wiper motor in the protective
plate.
6 Remove the protective plate.

7 Detach the washer hose from the protective plate.

Workshop Manual DCF 90-100 VDCF03.01GB


40 9 Frame, body, cab and accessories – 9.4.4 Heat exchanger heat

8 Remove the fresh air filter.

9 Remove the plate frame.

10 Remove the cab fan.

11 Remove the heat exchanger cover plate.

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.4.5 Water valve 41

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.

9.4.5 Water valve


Water valve, description
page

The water valve controls the climate control system’s capacity for
heating from 0 (closed valve) to 100% (open valve). The water valve
is 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

Water valve position under cab floor (from below)

Workshop Manual DCF 90-100 VDCF03.01GB


42 9 Frame, body, cab and accessories – 9.4.6 Engine temperature sensor

Water valve, replacement


page

1 Machine in service position, see section B Safety.


2 Detach the connector from the water valve.
3 Stop the flow of fluid to and from the water valve using hose
pinch-off pliers.
4 Detach the coolant hoses from the water valve.
5 Remove the water valve from the cab floor.
6 Replace the water valve.
7 Fit in the reverse order.
8 Check coolant level.

1. Water valve
2. Steering valve

9.4.6 Engine temperature sensor


Sensor, engine temperature, description
page

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.

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.4.7 Compressor 43

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

Read the safety instructions for refrigerant, see sec-


1
tion B Safety.
007865

1 Machine in service position, see section B Safety.


2 Drain the AC system of R134a refrigerant.
The illustration depicts the compressor for Volvo
TAD760VE
1. Compressor IMPORTANT
2. Rigging screw (belt tensioner)
Working on the air conditioning requires special au-
thorization.

3 Detach the coolant hoses from the compressor.


4 Loosen the turnbuckle so that the compressor belt is released.
5 Undo the hose couplings and detach the hoses from the com-
pressor intake and outlet. Plug the connections immediately to
prevent contamination.

Workshop Manual DCF 90-100 VDCF03.01GB


44 9 Frame, body, cab and accessories – 9.4.7 Compressor

6 Remove the bolts which secure the compressor.


7 Drain the oil from the old compressor (through the intake and out-
let connections) and the hoses. Measure the oil quantity.
8 Drain the oil from the new compressor.
9 Fill the new compressor with the same quantity of oil as was
drained from the old compressor - minimum 0.1 litre.

NOTE
Fill new oil through the compressor’s suction connection.
10 Fit the new compressor and other equipment in reverse order.
11 Check for leaks and refill the AC-system with refrigerant R134a,
with the intended equipment.
For volume, see the plate for the climate control system.

IMPORTANT
Working on the air conditioning requires special au-
thorization.

Pulley and electromagnetic clutch, replacement


page

There is no need to drain refrigerant from the system before replace-


ment.
1 Machine in service position, see section B Safety.
2 Slacken the belt tensioner and remove the drive belt.
3 Remove the screw from the centre of the pulley.
006263

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.4.7 Compressor 45

4 Remove the locking washer and the outer lock ring.


1

006264
1. Lock ring
2. Locking washer

5 Remove the groove.


1
006265

1. Groove

6 Remove the three screws securing the electromagnetic clutch.


006266

7 Remove the electromagnetic clutch.


8 Fit in the reverse order.
1 9 Check the function.
006267

1. Electromagnetic clutch

Workshop Manual DCF 90-100 VDCF03.01GB


46 9 Frame, body, cab and accessories – 9.4.8 Condenser

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

Read the safety instructions for refrigerant, see sec-


tion B Safety.

1 Machine in service position, see section B Safety.

1. Radiator 2 Drain the AC system of R134a refrigerant.


2. Condenser

IMPORTANT
Working on the air conditioning requires special au-
thorization.

3 Detach the inlet and outlet hoses from the condenser.


4 Remove the bolts which secure the condenser at the top edge
and lift the condenser out in a suitable way.

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.4.9 Moisture filter 47

5 Replace the condenser, fitting it in the reverse order.


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.

9.4.9 Moisture filter


Moisture filter, description
page

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

1. Fluid reservoir, moisture filter


2. Pressure switch
3. Sight glass

Workshop Manual DCF 90-100 VDCF03.01GB


48 9 Frame, body, cab and accessories – 9.4.10 Pressure switch

9.4.10 Pressure switch


Pressure switch, description
page

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

1. Fluid reservoir, moisture filter


2. Pressure switch
3. Sight glass

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.4.11 Expansion valve 49

Pressure switch, replacement


page

WARNING
2 3
1 Personal injury, environmental damage

Read the safety instructions for refrigerant, see sec-


tion B Safety.

1 Machine in service position, see section B Safety.


2 Drain the machine of refrigerant, R134a.

IMPORTANT
Working on the air conditioning requires special au-
thorization.
010024

3 Disconnect the connector from the pressure switch.

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.

9.4.11 Expansion valve


Expansion valve, description
page

The expansion valve is the part in the circuit that separates the high-
pressure side from the low-pressure side. The refrigerant arrives at the
expansion valve under high pressure and leaves it under low pres-
sure. After the expansion valve, the refrigerant converts to a gaseous
state and is transported to the compressor once again.
The amount of refrigerant that passes the evaporator varies depend-
ing on the heat load. The valve works from fully open to fully closed
and searches between these for an optimal evaporation point.

Workshop Manual DCF 90-100 VDCF03.01GB


50 9 Frame, body, cab and accessories – 9.4.11 Expansion valve

Expansion valve, replacement


page

WARNING
Personal injury, environmental damage

Read the safety instructions for refrigerant, see sec-


tion B Safety.

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.

3 Detach the AC system hoses.


4 Detach the coolant hoses.
5 Remove the heat exchanger for cooling/heating to access the ex-
pansion valve, see Heat exchanger, cooling/heating, replace-
ment page 39.
6 Replace the expansion valve.
7 Fit in the reverse order.
8 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.

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.4.12 Sensor temperature refrigerant 51

9.4.12 Sensor temperature refrigerant


Sensor, temperature in refrigerant, description
page

Refrigerant temperature sensor (position 2) detects the refrigerant


temperature in the heat exchanger cooling. This is used to control the
air conditioning.
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.4.2 CLIMATE, menu 2.

1
3

005001
2

1. Sensor cab temperature


2. Sensor temperature refrigerant
3. Sensor temperature outlet fan

Sensor, refrigerant temperature, replacement


page

WARNING
Personal injury, environmental damage

Read the safety instructions for refrigerant, see sec-


tion B Safety.

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.

3 Detach the AC system hoses from the heat exchanger.


4 Detach the coolant hoses from the heat exchanger.
5 Detach the heat exchanger to access the refrigerant temperature
sensor, see Heat exchanger, cooling/heating, replacement page
39.
6 Replace the temperature sensor.

Workshop Manual DCF 90-100 VDCF03.01GB


52 9 Frame, body, cab and accessories – 9.4.12 Sensor temperature refrigerant

7 Fit in the reverse order.


8 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.

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.4.13 Heat exchanger cooling 53

9.4.13 Heat exchanger cooling


Evaporator, description
page

The heat exchanger for cooling consists of pipes and cooling fins. The
cab air is cooled as it passes through the cooling heat exchanger. The
heat exchanger is located behind the fan in the external unit for fresh
air intake into the cab.

1, 2

3
003210

Fresh air intake, cab


1. Heat exchanger heat
2. Heat exchanger cooling
3. Expansion valve and sensor for refrigerant temper-
ature

Heat exchanger cooling, replacement


page

See Heat exchanger, cooling/heating, replacement page 39.

Workshop Manual DCF 90-100 VDCF03.01GB


54 9 Frame, body, cab and accessories – 9.4.14 Air distributor

9.4.14 Air distributor


Air distributor, description
page

The air distributor controls the air between defroster and floor and is
located behind the panel inside the cab. The damper is controlled elec-
trically by the control system.
The signal can be checked from the diagnostic menu, 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

Air distributor, replacement


page

1 Machine in service position, see section B Safety.


2 Remove the dashboard panel.
3 Remove the steering wheel shaft cover.
4 Detach the steering wheel shaft and angle it back against the
driver’s seat.
5 Remove the lower cover in front of the pedal bracket.
6 Detach the air hoses from the air distributor and detach the con-
nector.

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

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.4.15 Air vents 55

9.4.15 Air vents


Air vents, description
page

There are a number of fixed air vents in the cab’s interior: at the front
of the doors and the defroster for the windshield. There are also two
adjustable air vents (flow and direction) in the instrument panel’s out-
side corners.
There is an air inlet towards the cab’s lower part (floor).

001839

Defroster nozzles, replacement


page

1 Machine in service position, see section B Safety.


2 Remove the air damper manually.
3 Remove the bolts which hold the other part of the defroster noz-
zle in the dashboard.

Workshop Manual DCF 90-100 VDCF03.01GB


56 9 Frame, body, cab and accessories – 9.4.16 Sensor temperature outlet fan

4 Detach the air hose from the defroster nozzle.


5 Replace the defroster nozzle.

9.4.16 Sensor temperature outlet fan


Sensor, temperature outlet fan, description
page

The outlet fan temperature sensor (position 3) detects the temperature


of the air that blows out in the defroster nozzles. The air conditioning
is controlled by signals from the following sensors:
1. Sensor cab temperature
2. Sensor temperature refrigerant
1 3. Sensor temperature outlet fan

3 The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.4.2 CLIMATE, menu 2.
005001

Outlet fan temperature sensor, replacement


page

1 Machine in service position, see section B Safety.


2 Remove the dashboard panel.
3 Remove the lower protective cover in front of the steering wheel
shaft.
4 Detach the steering wheel shaft and angle it back against the
driver’s seat.

1. Instrument panel
2. Steering wheel shaft adjustment
3. Lower protective cover

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.4.17 Sensor cab temperature 57

5 Detach the temperature sensor from the air distributor.


6 Fit in the reverse order.

Air distributor including temperature sensor.

9.4.17 Sensor cab temperature


Sensor, cab temperature, description
page

The cab temperature sensor (position 1) detects the temperature of


the air in the cab.
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.4.1 CLIMATE, menu 1.

1
3
005001

1. Sensor cab temperature


2. Sensor temperature refrigerant
3. Sensor temperature outlet fan

Cab temperature sensor, replacement


page

1 Machine in service position, see section B Safety.


2 Remove the dashboard panel.

Workshop Manual DCF 90-100 VDCF03.01GB


58 9 Frame, body, cab and accessories – 9.4.18 Sensor outdoor temperature

3 Detach the hose from the temperature sensor.


4 Detach the connector from the temperature sensor.
5 Remove the temperature sensor.
6 Replace the temperature sensor.
7 Fit in the reverse order.

007985

9.4.18 Sensor outdoor temperature


Sensor, ambient temperature, description
page

The ambient temperature sensor detects the temperature of the air


outside the cab.
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.4.2 CLIMATE, menu 2.

Sensor outdoor temperature

Ambient temperature sensor, replacement


page

1 Machine in service position, see section B Safety.


2 Detach the connector from the temperature sensor.
3 Remove the temperature sensor from its mounting in the cab.
4 Replace the temperature sensor.
5 Fit in the reverse order.

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.4.19 Pause heater 59

9.4.19 Pause heater


Pause heater, description
page

1
Pause heating is an option for the heating unit, which uses residual
heat in the engine's cooling system to keep the cab warm.
An extra electrically operated water pump pumps the coolant through
the heater unit when the engine is 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

1. Pause heater switch (S0_OPT-1)


2. Control unit cab (D790-1)
3. Circulation pump pause heater (M667)

Workshop Manual DCF 90-100 VDCF03.01GB


60 9 Frame, body, cab and accessories – 9.5 Wiper/washer system

9.5 Wiper/washer system


Wiper/washer system, description
page

The wipers automatically switch off 2 minutes after the operator has
left the driver’s seat.

9.5.1 Wiper front


Wiper, front, description
page

The front wiper is the parallel wiper type, i.e. the wiper blade is moved
in a constant vertical manner over the windscreen.

9.5.2 Wiper roof


Wiper, roof, description
page

Wiper roof are of the type sector wiper. Wiping angle is approx. 180
degrees.

9.5.3 Wiper rear


Wiper, rear, description
page

The rear wiper is a sector wiper type. The wiping angle is approx. 180
degrees.

9.5.4 Washer motor and reservoir


Washer motor and reservoir, description
page

Washer motors are located on the washer fluid reservoir. There are
non-return valves on the lines from the reservoir to the washer noz-
zles, preventing the washer fluid from draining back in the line be-
tween washings. This 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.

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.5.5 Wiper motor, front 61

Washer motor and container, replacement


page

1 Machine in service position, see section B Safety.


2 Remove the protection over the washer fluid reservoir.
3 Drain the washer fluid from the container.
4 Remove the washer motors from the fluid reservoir.
5 Remove the bolts which secure the fluid container in the cab wall.
6 Change the washer fluid reservoir. Change the washer motor, if
needed.

003619
A B
A. Washer fluid reservoir
B. Washer motors

9.5.5 Wiper motor, front


Wiper motor, front, description
page

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.

Front wiper motor, replacement


page

1 Machine in service position, see section B Safety.


2 Remove the wiper arms.
3 Remove the nuts which hold the motor in the protective plate.
4 Remove the protective plate.
5 Detach the washer hose from the protective plate.

Workshop Manual DCF 90-100 VDCF03.01GB


62 9 Frame, body, cab and accessories – 9.5.6 Wiper motor, roof

6 Remove the nuts which hold the motor in the cab.


7 Detach the connector from the wiper motor.
8 Replace the motor.
9 Fit in the reverse order. Tighten the wiper arms to 16-20 Nm.

9.5.6 Wiper motor, roof


Wiper motor, roof, description
page

The wiper motor drives the roof window’s wiper. The wiper arm is
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.

Wiper motor (roof), replacement


page

1 Machine in service position, see section B Safety.


2 Remove the plastic cover.

3 Detach the washer hose and the connector to the wiper motor.

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.5.7 Wiper motor, rear 63

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.

9.5.7 Wiper motor, rear


Wiper motor, rear, description
page

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.

Rear wiper motor, replacement


page

1 Machine in service position, see section B Safety.


2 Remove the panels behind the driver’s seat.
3 Remove the screws holding the motor’s plastic cover.

4 Detach the connector from the motor.


5 Raise the plastic cover and remove the nut securing the wiper
arm. Disconnect the washer hose.

Workshop Manual DCF 90-100 VDCF03.01GB


64 9 Frame, body, cab and accessories – 9.5.7 Wiper motor, rear

6 Remove the screws securing the motor and the lock nut on the
motor.
7 Replace the wiper motor.
8 Fit in the reverse order. Tighten the wiper arms to 16-20 Nm.

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.6 Lighting system 65

9.6 Lighting system


Lighting system, function description
page

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

Pos Explanation Signal description Reference


1 The switch for cab roof work lights (S105-1) Switch in ON position: U D1: Diagnostic menu, see section 8
sends a voltage signal to the cab control unit = 24 V Control system group 8.4.2.12
(D790-1). LIGHTS, menu 12

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

Workshop Manual DCF 90-100 VDCF03.01GB


66 9 Frame, body, cab and accessories – 9.6 Lighting system

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

Cab roof work lights off:


UK3017/86 = 0 V

UK3017/87 = 0 V

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.6 Lighting system 67

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

Workshop Manual DCF 90-100 VDCF03.01GB


68 9 Frame, body, cab and accessories – 9.6 Lighting system

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

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.6 Lighting system 69

Lighting system, component positions


page

The function of lighting is to increase safety during operation and load


handling.

NOTE
It is important that the right type of bulb is used for each area. See
section F Technical data.
The machine has the following lights:

1 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)

4. Multi-function lever (S162) 19. Frame control unit, option (D797-2)


5. Control unit KIT (D790-2) 20. Frame control unit (D797-1)
6. Interior lighting (E434-1) 21. NO switch, brake lights (S216)
7. Cab roof work lights (E406L-1 & E406R-1) 22. Direction indicators front (H422 & H423)

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)

Workshop Manual DCF 90-100 VDCF03.01GB


70 9 Frame, body, cab and accessories – 9.6.1 Headlights

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.

9.6.2 Running light


Running lights, description
page

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.

9.6.3 Tail light


Tail light, description
page

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.

9.6.4 Brake light


Brake light, description
page

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.

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.6.5 Reversing light 71

9.6.5 Reversing light


Reversing light, description
page

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.

9.6.6 Driving direction indicator


Driving direction indicator, description
page

The direction indicators are located on both the front and rear of the
machine to provide surrounding traffic and the environment an indica-
tion that the machine is changing direction, i.e. turning.
The direction 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.

9.6.7 Warning lights


Hazard lights, description
page

Hazard lights (hazard) are used to warn the surroundings, hazard


lights activate all direction indicators at the same time.
The warning lights are controlled by selecting with the warning light
switch. The signal travels to the cab control unit (D790-1).
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.2.4 LIGHTS, menu 4 and 8.4.2.5 LIGHTS,
menu 5.

Machines for the North American market are equipped with flashing
brake lights front and rear during operation.

9.6.8 Rotating beacon


Rotating beacon, description
page

A rotating beacon is located high on the machine’s cab. This is used


to provide surrounding traffic and the environment an indication that a
working vehicle is moving and at work. Indication to bystanders to ex-
ercise caution.
The rotating beacon is controlled by selecting with the rotating beacon
switch. The signal travels to the cab control unit (D790-1).

Workshop Manual DCF 90-100 VDCF03.01GB


72 9 Frame, body, cab and accessories – 9.6.9 Working lights, mast

The lights and their signal can be checked from the diagnostic menu,
section 8 Control system , group 8.4.2.6 LIGHTS, menu 6.

9.6.9 Working lights, mast


Mast working lights, description
page

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.

The mast can be equipped with two auxiliary work lights ( ).

Work lights, changing (product alternative Xenon


page

lights)

DANGER
Xenon lights are activated with high voltage. Always
turn off the main electric power before working on xe-
non lights.

Handle the headlights with care since the light is un-


der gas pressure and may explode.

NOTE
The xenon light is filled with different gases and metals. Replaced
xenon headlights should be considered as hazardous waste and
should be deposited for recycling.

9.6.10 Working lights, cab


Working lights, cab, description
page

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.

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.6.11 Interior lighting 73

Work lights, changing (product alternative Xenon


page

lights)

See Work lights, changing (product alternative Xenon lights) page 72.

9.6.11 Interior lighting


Interior lighting cab, description
page

The interior lighting illuminates the cab when the doors are opened or
when activated with the interior lighting switch.
There is background 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.

9.6.12 Work lights, attachment


Work lights attachment, description
page

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.

The attachment can be equipped with two auxiliary work lights ( ).

Work lights, changing (product alternative Xenon


page

lights)

See Work lights, changing (product alternative Xenon lights) page 72.

Workshop Manual DCF 90-100 VDCF03.01GB


74 9 Frame, body, cab and accessories – 9.6.13 Entry lighting

9.6.13 Entry lighting


Entry lighting, description
page

Entry lighting is controlled by selecting with the entry lighting switch on


the step or when interior lighting comes on. 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 8.4.2.15 LIGHTS, menu 15.

2
1
010026

1 Switch, entry lighting (S141)

2 Entry lighting

9.6.14 Work lights, front wing


Front wing work lights, lighting
page

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.

Work lights, changing (product alternative Xenon


page

lights)

See Work lights, changing (product alternative Xenon lights) page 72.

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.7 Signalling system 75

9.7 Signalling system


Signal system, function description
page

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

Pos Description Signal description Reference


1 The revolving beacon switch (S110) Switch in ON position: U = D1: Diagnostic menu, see section 8 Control
sends a voltage signal to the cab 24 V system , group 8.4.2.6 LIGHTS, menu 6
control unit (D790-1).

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

Workshop Manual DCF 90-100 VDCF03.01GB


76 9 Frame, body, cab and accessories – 9.7 Signalling system

Pos Description Signal description Reference


7 The direction indicator lever (S161) Left: US161/6 = 24 V D7: Diagnostic menu, see section 8 Control
sends a voltage signal to the KIT system , group 8.4.2.4 LIGHTS, menu 4
Right: US161/1 = 24 V
control unit (D790-2).

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

15 Relay loud horn (K3016) is activated UK3016/30 = 24 V Horn, description page 78


when horn is activated. D15: Diagnostic menu, see section 8 Control
UK3016/85 = 0 V
system , group 8.4.2.6 LIGHTS, menu 6
Horn activated:
UK3016/86 = 24 V

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.

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.7 Signalling system 77

Pos Description Signal description Reference


19 In the event of warnings, the KID A clicking sound is audible Section 11 Common electrics, group
control unit (D795) activates the when then termination re- 11.5.3.12 KID control unit (D795)
warning light to draw the operator’s sistor is activated.
attention to the warning 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.

Workshop Manual DCF 90-100 VDCF03.01GB


78 9 Frame, body, cab and accessories – 9.7.1 Horn

Communication system, component position


page

The machine has the following signalling systems:

1 2 3 4 5 6

008395
19 18 17 16 15 14 13 12 10,11 9 8 7

1. Control unit KID (D795) 11. Control unit cab (D790-1)


2. Buzzer cab (H853) 12. Make-contact operator in seat (S230)
3. Control unit KIT (D790-2) 13. Horn (H850)
4. Multi-function lever (S162) 14. Switches, see Controls and instruments, overview page 5

5. Direction indicator lever (S161) 15. Loud horn (H850-1)


6. Rotating beacon (H428) 16. Frame control unit (D797-1)
7. Back-up alarm (H965) 17. Direction indicators front (H422 & H423)
8. Reversing lights (E405L & E405R) 18. Control unit attachment (D791-1)

9. Direction indicators rear (H426 & H427) 19. Buzzer automatic spreading (H9003)

10. Relay loud horn (K3016)

9.7.1 Horn
Horn, description
page

The horn is electromagnetic. Air horn can be selected ( ).


The horn is activated from the gear and multi-function lever or from the
horn switch ( ). The horn is located under the cab (the compressed
air horn is located on the cab’s front edge).
001247

The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.3.5 CAB, menu 5..

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.7.2 Warning lights 79

9.7.2 Warning lights


Hazard lights, description
page

See Hazard lights, description page 71.

9.7.3 Rotating beacon


Rotating beacon, description
page

See Rotating beacon, description page 71.

9.7.4 Warning parking brake


Warning parking brake, description
page

If the operator leaves the machine without applying the parking brake,
a buzzer sounds to alert the operator, i.e. to ensure the operator ap-
plies the parking brake.
A sensor in the 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..

9.7.5 Reversing alarm


Reversing alarm, description
page

When reverse is selected, a warning sound and the back-up lights are
activated. This is to give others in traffic an indication that the machine
is reversing. Indication to bystanders to take caution.
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.2.8 LIGHTS, menu 8.

Workshop Manual DCF 90-100 VDCF03.01GB


80 9 Frame, body, cab and accessories – 9.8 Entertainment and communication

9.8 Entertainment and


communication
Entertainment and communication, general
page

The machine is prepped with a connector for customer accessories,


see section 11 Common electrics, group 11.5.2.1 Electrical distribu-
tion box, cab.

Entertainment and communication, repair


page

Repairs should be left to authorised personnel.

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.9 Glass/windows/mirrors 81

9.9 Glass/windows/mirrors
Glass/windows/mirrors, description
page

The windows are designed to both enclose the cab and provide the op-
C erator with a good view.
The windows on the Spirit Delta cab are made of tinted hardened
D
glass, except the roof window which is made of polycarbonate plastic.

As an option, the cab can be equipped with windows of laminated


glass.
The rearview mirrors are of the convex mirror type. There is an interior
rearview mirror on all machines.

A E B 001512

A. Side windows
B. Windshield (front window)
C. Roof window
D. Rear window
E. Windshield (Side window front)

Silicone adhesive, handling advice


page

The window panes are secured with 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

Workshop Manual DCF 90-100 VDCF03.01GB


82 9 Frame, body, cab and accessories – 9.9.1 Windscreen

Hardening time:
approx. 24 hours at 20 °C
approx. 1 hour at 60 °C
Full strength is obtained after 7 days.
• In warm climates, it is advantageous to cool the container to
increase hardening time. The silicone adhesive should not
be used at temperatures above +75 °C.
• In cold climates, the hardening time can be shortened by
covering the joints so that cooling is prevented. The window
pane can be warmed with defroster or cab heater.
• The recommended storage temperature is between -30 °C
and +20 °C. Storage in a refrigerator or a colder environment
is recommended.

9.9.1 Windscreen
Windscreen, description
page

The windshield consists of the front window and side windows. The
windshield is attached to the cab with a key strip and is glued to the
roof window with silicone adhesive. Front and side windows are joined
with silicone adhesive to give good 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.

1 Machine in service position, see section B Safety.


2 Remove the key strip.
3 Remove the broken window pane and check that no glass or oth-
er particles remain in the window pane’s groove on the strip. Cut
apart silicone joints with a sharp tool.

NOTE
Make sure that no silicone adhesive remains between the
window pane and the strip by the window pane’s lower front
edge.

Figure 1: Removing key strip

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.9.1 Windscreen 83

If the roof window is to be changed, then all bolts must be


removed before the silicone adhesive is cut away.

CAUTION
Acetone may not come into contact with a roof win-
dow made of polycarbonate plastic. Acetone has a
chemical effect on the polycarbonate plastic which
reduces the roof window’s strength.

4 Clean all surfaces thoroughly. Remove old remains of silicone


with a razor blade or similar.
5 Fit masking tape on the inside and outside of the window panes
by the surfaces that are to be glued.
6 When the windshield or a side window is to be changed, then the
1 2 3
window panes must be adjusted so that the upper edge on the
side window has the same height as the top edge of the roof (see
figure 2) and so that the distance between windshield and side
window is as shown in figure 3.
Use spacers against the roof member to ensure that the distanc-
es are obtained.

1
006268

1,0
1
Figure 2: Adjusting side window - cab window
1. Side window
2. Rubber strip
3. Cab frame / door opening
006269

1,0

Figure 3: Adjusting side window - windshield


1. Masking tape
7 Install the key strip around the whole window pane.
8 Apply silicone adhesive 923854.0100 around the window panes.
Make the new joint wider than the old one to create a good seam.
The silicone should be applied from the outside of the joints, to
give a full and smooth joint.

NOTE
There must be silicone between the window panes, to avoid
contact between the window panes.

Workshop Manual DCF 90-100 VDCF03.01GB


84 9 Frame, body, cab and accessories – 9.9.2 Side window

9 Remove excess silicone adhesive from the outer vertical corners


with a tool made of cardboard as shown in figure 4. Smooth out
the joints on the inside with a finger, wet with water or soapy wa-
ter.
10 Apply silicone adhesive 923854.0100 between the strip and win-
dow pane at the bottom edge of the front corners, so-called top
sealing.
11 If the roof window is to be replaced, apply silicone adhesive
923854.0100 by the cab frame (where it was glued earlier).
12 Lay the roof window into place and check that there is a uniform
distance of one or several millimetres along the window pane’s
edges and by the protection over the frame’s sides. Then tighten
the corner bolts for the window pane.
13 Apply silicone adhesive 923854.0100 by the edges and smooth
006272

out the joints with a finger, wet with water or soapy water.

Figure 4: Tool template for silicone joint, scale 1:1


IMPORTANT
Mark the window panes with "New adhesive. Do not
touch.".

14 Remove the masking tape immediately after applying adhesive to


avoid edge formation. Hardening time is dependent on ambient
temperature, plan the change so that downtime is minimized.

9.9.2 Side window


Side window, description
page

The side windows are secured in the cab and doors with key strips.
For further details, see Glass/windows/mirrors, description page 81.

Side window, replacement


page

NOTE
The method describes a general procedure.

1 Machine in service position, see section B Safety.

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.9.2 Side window 85

2 Use special tools to detach the wedge strip.

3 Remove the wedge strip which runs around the whole window.
4 Carefully remove any glass remains from the rubber strip.

5 Fit the new window, securing it at the bottom edge.

Workshop Manual DCF 90-100 VDCF03.01GB


86 9 Frame, body, cab and accessories – 9.9.2 Side window

6 Spray soap solution on the window and rubber strip to facilitate


fitting.

7 Thread the rubber strip around the whole window; use special
tools.

8 Secure the wedge strip with a special tool.


9 Pull the wedge strip around the whole window.

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.9.2 Side window 87

10 Cut off the wedge strip approx. 2 cm too long.


11 Fit the other end of the wedge strip edge to edge.
12 Adjust the wedge strip so that the correct fit is obtained.

Workshop Manual DCF 90-100 VDCF03.01GB


88 9 Frame, body, cab and accessories – 9.9.3 Roof window

9.9.3 Roof window


Roof window, description
page

The roof window is made of polycarbonate plastic, which is a safety


feature for the operator, intended to protect the operator from falling
objects. The polycarbonate plastic is elastic.
Safety is maintained within a temperature interval of 120 °C to -45 °C
(becomes brittle at -110 °C, glass conversion temperature 145 °C).
The roof window has a patented surface layer that increases its resist-
ance to wear, UV light and chemicals.
The roof window is joined with the windshield. Joints between the win-
dow panes and between roof window and cab are sealed with silicone
adhesive. Lay a new seal of silicone adhesive when replacing.
For location, see Glass/windows/mirrors, description page 81.

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.

Check the roof window’s surface at regular intervals,


and only clean with washer fluid or mild cleaning
agents. Rinse with lukewarm water. Replace the roof
window if it is damaged, cracked, or scratched!

Roof window, replacement


page

See Windscreen, replacement page 82 for the general procedure.


The roof window is combined with the windscreen. The joint is sealed
with silicone. Add a new silicone seal when replacing.

9.9.4 Rear window


Rear window, description
page

The rear window is attached to the cab with a key strip.

On machines with hydraulic sliding cab or hydraulic cab lift and


lower, the rear window can be opened to provide an emergency exit.
For further details, see Glass/windows/mirrors, description page 81.

Rear window, replacement


page

See Side window, replacement page 84 for the general procedure.

9.9.5 Rearview mirror


Rearview mirror, description
page

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.

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.9.6 Reversing camera 89

9.9.6 Reversing camera


Reversing camera, description
page

The reversing camera is located at the rear edge of the horizontal


counterbalance weight, furthest back on the machine. It is designed to
provide improved vision when reversing. The reversing camera is wa-
tertight and has a microphone and infrared lighting for night vision. In
addition, the camera is equipped with automatic heating which is acti-
vated at ambient temperatures below +10 °C.
1
2 The reversing camera sends colour images and audio to the monitor
in the cab; see Monitor, reversing camera, description page 89.
1 007425
3
1. IR-diodes
2. Camera
3. Microphone

9.9.7 Monitor, reversing camera


Monitor, reversing camera, description
page

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

2 nals from two different cameras.


VOL
The monitor is mounted on a hinged bracket to the left in front of the
3 door in the cab.

BRI

4
007416

5
1. Choice of camera
2. Menu
3. Light intensity
4. Volume setting
5. On and off

Workshop Manual DCF 90-100 VDCF03.01GB


90 9 Frame, body, cab and accessories – 9.10 Cab structure and suspension

9.10 Cab structure and


suspension
Cab structure and suspension, description
page

The cab is mounted in a cab undercarriage via strong rubber insulators


located on the underside of the cab. This minimises vibrations from the
frame to the cab. There is an insulator at four points - one at each cor-
1 ner. Each insulator mounting has one rubber bushing and one bolt.

3
003206

4
Cab Spirit Delta
1. Cab frame
2. Door
3. Cab suspension
4. Cab undercarriage

9.10.1 Cab frame


Cab frame, description
page

The cab frame is made of high-strength steel sheet profiles. The cab
is dimensioned to handle impacts and, to some degree, dropped
loads. The frame must not be modified!
002210

Cab Spirit Delta

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.10.2 Doors 91

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

• openable window (passenger door )


Switches in the doors’ locks sense if the door is open. The switch is
used to light the interior lighting and warn of an open door.
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.2.9 LIGHTS, menu 9 or 8.4.11.5 MOVE-
CAB, menu 1.

9.10.3 Cab undercarriage


Cab substructure, description
page

The cab is mounted on a cab undercarriage via strong rubber insula-


tors located on the underside of the cab. This is to minimize vibrations
from the frame to the cab.
The cab undercarriage is fitted on the machine’s chassis (frame) via a
mounting. The chassis mounting depends on whether the machine is
equipped with hydraulic cab tilt.

Workshop Manual DCF 90-100 VDCF03.01GB


92 9 Frame, body, cab and accessories – 9.10.4 Tiltable cab

9.10.4 Tiltable cab


Tiltable cab, description
page

WARNING
If anybody goes under the tilted cab.

Fatal danger!

Check that nobody is underneath or near the cab


when it is tilted.

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.

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.10.4 Tiltable cab 93

Condition Reference Reference


value
Parking brake Released Section 4 Brakes , group 4.5 Parking brake system.

Doors Closed Doors, description page 91

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

Pos Explanation Signal description Reference

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

Workshop Manual DCF 90-100 VDCF03.01GB


94 9 Frame, body, cab and accessories – 9.10.4 Tiltable cab

Pos Explanation Signal description Reference

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

Hydraulic diagram, see section E Schematics group 10 Common hy-


draulics, Hydraulic diagram of basic machine.

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.10.4.1 Hydraulic oil pump 95

9.10.4.1 Hydraulic oil pump


Hydraulic oil pump, description
page

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

1. Hydraulic oil pump and quick-lift pump for load han-


dling.
2. Hydraulic oil pump for brake system, cooling and fil-
tering.
3. Main pump for steering and load handling.

9.10.4.2 Control valve, cab tilt


Cab tilt control valve, description
page

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.

Servo valve, cab tilt up


The servo valve for cab tilt up controls the servo pressure to the tilt
spool, so that it controls the oil pressure for cab tilt upwards. The valve
3 is electrically controlled by the cab up solenoid valve (Y6047), which
is activated by the frame control unit (D797-2).
4
The signals can be checked from the diagnostic menu, see section 8
005614

Control system , group 8.4.11.5 MOVE-CAB, menu 4.

1. Connection, tilt cylinder Servo valve, cab tilt down


2. Feed from hydraulic oil pump The servo valve for cab tilt down, controls the servo pressure to the tilt
3. Servo valve, cab up (Y6047) spool, so that it controls the oil pressure for cab tilt downwards. The
4. Servo valve, cab down (Y6048) valve is electrically controlled by the cab down solenoid valve (Y6048),
which is activated by the frame control unit (D797-2).

Workshop Manual DCF 90-100 VDCF03.01GB


96 9 Frame, body, cab and accessories – 9.10.4.2 Control valve, cab tilt

The signals can be checked from the diagnostic menu, see section 8
Control system , group 8.4.11.5 MOVE-CAB, menu 4.

Cab tilt control valve, 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 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.

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.10.4.3 Cab tilt shuttle valve 97

12 Check the function.

CAUTION
Air in the hydraulic system may cavitate and result in
product damage.

Activate the steering carefully and drive a couple of


times with lowest possible speed to avoid cavitation.

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.

The hydraulic oil level is checked with the boom com-


pletely lowered and retracted.

9.10.4.3 Cab tilt shuttle valve


Cab tilt shuttle valve, description
page

See section 10 Common hydraulics , group 10.5.3 Shuttle valve.


010029

Cab tilt shuttle valve

Workshop Manual DCF 90-100 VDCF03.01GB


98 9 Frame, body, cab and accessories – 9.10.4.4 Cab tilt brake valve

9.10.4.4 Cab tilt brake valve


Cab tilt brake valve, description
page

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

Cab tilt brake valves

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.10.4.5 Cab tilt hydraulic cylinders 99

9.10.4.5 Cab tilt hydraulic cylinders


Cab tilt hydraulic cylinders, description
page

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

Hydraulic cylinders, repairs


page

See section 10 Common hydraulics , group 10.7.1 Hydraulic cylinders.

9.10.4.6 Undercarriage of tiltable cab


Cab undercarriage cab tilt, description
page

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.

9.10.4.7 Sensor for automatic cab tilt (B7211-1)


Sensor for automatic cab tilt (B7211-1), description
page

The mast position sensor (B7211-1) activates cab tilt automatically.


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 8.4.11.5 MOVE-CAB, menu 2.

Sensor for automatic cab tilt (B7211-1), inspection and


page

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.

Workshop Manual DCF 90-100 VDCF03.01GB


100 9 Frame, body, cab and accessories – 9.10.4.8 Sensor, cab up/cab down

9.10.4.8 Sensor, cab up/cab down


Sensor, cab up/cab down, description
page

The sensors indicate when the cab is tilted up (B769-1) or down


(B769-1). When the cab is not in its lower position, machine speed is
reduced to not more than 5 km/h.
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.11.5 MOVE-CAB, menu 3.

Position sensor, checking and adjustment


page

Check and adjust the position sensor as follows:


1 Machine in service position, see section B Safety.
2 Check that the sensors are clean and free from dirt.
3 Check that the distance between the sensor and the indicator is
5 ±1 mm.
4 Adjust if necessary.

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.11 Cab interior 101

9.11 Cab interior


9.11.1 Instrument and control panels
Dashboard panel, description
page

The dashboard panel is secured to the steering column and contains


warning and indicator lamps, display (KID), function keys (KIT) and
switches.

Left-hand dashboard panel, description


page

Left instrument panel is located in the left corner of the cab. It contains
rotary controls, switches, and ventilation.

Panel for load handling functions, description


page

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 .

Dashboard panel, replacement


page

1 Machine in service position, see section B Safety.


2 Remove the steering wheel centre cover.
3 Remove the nut and the steering wheel.

Workshop Manual DCF 90-100 VDCF03.01GB


102 9 Frame, body, cab and accessories – 9.11.2 Interior details, plastic

4 Remove the bolts on the underside of the dashboard panel.

5 Remove the bolts on the top of the dashboard panel.

6 Unplug the connector from the multi-function levers, ignition


switch, KIT control unit (D790-2) and KID control unit (D795).
7 Transfer the components to the new steering wheel cover.
8 Fit in the reverse order.

9.11.2 Interior details, plastic


Interior plastic parts, description
page

The interior of the cab consists of recyclable material.

9.11.3 Interior details, textile


Interior textile parts, description
page

The interior of the cab consists of recyclable material.

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.11.4 Floor covering 103

9.11.4 Floor covering


Floor covering, description
page

The floor covering is a wear-resistant and recyclable material.

9.11.5 Insulation
Insulation, description
page

The cab insulation consists of recyclable material.

9.11.6 Sun blinds


Sun blinds, 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.

9.11.7 Terminal console


Terminal console, description
page

The function of terminal desk is to provide a work surface for a com-


puter/terminal. It is located to the right of the steering wheel, easily ac-
cessible for the operator.
008227

9.11.8 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.

Workshop Manual DCF 90-100 VDCF03.01GB


104 9 Frame, body, cab and accessories – 9.11.9 Writing desk

9.11.9 Writing desk


Writing desk, description
page

The writing table with reading light is located on a flexible attachment


to the right in front of the door in the cab. That is where work orders,
etc. can be fastened.

008228

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.12 Chassis 105

9.12 Chassis
Frame, description
page

The frame is a modular construction and consists of front section, rear


section and a beam pair. This construction provides advantages in
terms of rigidity and strength.
There are mounting points in the frame for engine, gearbox, drive axle,
steering axle, fuel and hydraulic tanks, cab, mast and body parts.
The space in the rear section of the frame is used for counterweights,
the number of which is adapted to the machine in question. The coun-
terweights are designed to allow as good a view rearwards as possi-
ble.
The front wings are bolted into the frame (which has advantages when
delivering the machine).

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

Workshop Manual DCF 90-100 VDCF03.01GB


106 9 Frame, body, cab and accessories – 9.13 Body

9.13 Body
Body, description
page

The body’s components comprise:

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 ( ).

9.13.2 Hood engine compartment


Hood engine compartment, description
page

The machine’s engine compartment is protected by a hood.


The machine compartment for transmission and driveline/axle is pro-
tected by tread plate secured with retaining bolts. The tread plate is
designed to be walked on and is grooved to provide good grip.

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.13.3 Footstep and rail 107

9.13.3 Footstep and rail


Steps and rails, description
page

The cab area has footsteps for easy access. There is a rail by the cab
area.

9.13.4 Counterweights
Counterweight, description
page

The machine has counterweights to balance the machine’s lift capac-


ity and may therefore vary in quantity and weight.
The counterweights are located at the very back of the frame for max-
imal leverage.
The machine has counterweights in the following places:
• Under the steering axle
• Furthest back on the machine there are vertical counterweights
secured in the rear edge of the frame; the outer has a towing eye.
Between the outer counterweight and the frame, there are smaller
counterweights whose dimensions and quantity are adapted to
balance the machine’s lifting capacity.
• Upper horizontal counterweight.
Under the horizontal counterweight, there are smaller counter-
weights whose dimensions and quantity are adapted to balance
the machine’s lifting capacity.

DANGER
The counterweights are factory fitted and are adapted
according to the machine's properties.

The machine's operating characteristics are changed!

Never change the quantity of counterweights.

Workshop Manual DCF 90-100 VDCF03.01GB


108 9 Frame, body, cab and accessories – 9.14 Central lubrication

9.14 Central lubrication


Central lubrication, checking
page

1 Check that no grease has been forced out through the safety
valve (position 2).
If grease has been forced out through the safety valve it means
that there is a stop in the system. Determine which line is clogged
by feeling the connections at the distribution blocks. A clogged
hose remains pressurised and the connection becomes hard.

NOTE
If several distribution blocks are connected in series, a
clogged line will be pressurised all the way to the first distri-
bution block.
2 Turn the start key to position I.
3 Operate the pump manually and check that the indicator pin
moves in and out on the distribution blocks.
To operate the pump, loosen the cover and press in the switch for
manual operation (position 5).
If the indicator pins do not move even when the pump is running,
Overview 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.

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.14 Central lubrication 109

Central lubrication, adjusting lubrication times


page

The central lubrication’s pause and run-time must be set after replace-
ment, the setting is unique to each machine, depending on the ma-
chine’s equipment. 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.

Test or extra greasing


Central lubrication can be operated manually by holding in the button
for manual operation (position 3) for 2 seconds. This starts an extra lu-
brication cycle.

Pause-time
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

Workshop Manual DCF 90-100 VDCF03.01GB


110 9 Frame, body, cab and accessories – 9.14.1 Pump unit

9.14.1 Pump unit


Pump unit, description
page

The pump unit consists of containers with stirrer, pump housing with
built-in motor, timer, pump element, filler nipple, and safety valve.
The central lubrication works with lubrication cycles (pause and 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.

Example figure components central lubrication


1. Pump unit
2. Safety valve
3. Distribution block

VDCF03.01GB Workshop Manual DCF 90-100


9 Frame, body, cab and accessories – 9.14.2 Distribution block 111

9.14.2 Distribution block


Distribution block, description
page

The distribution blocks distribute grease from the pump unit to grease
points or on to other distribution blocks. The number of distribution
blocks can vary depending on how may (and which) grease points
have been selected.
The distribution blocks consist of pistons that meter out grease to each
grease point. The pistons are driven by the grease and do not have
springs and gaskets. It is the grease that drives the pistons inside the
distributor. The shape of the pistons and channels in the distribution
block enable the pistons to move in a predetermined way. Each piston
must have completed its motion before the next piston can move. The
pistons are dependent on each other. It is technically impossible to
skip any connected grease point. If a grease point cannot be greased,
the whole system is blocked and grease is pressed out through the
safety valve.
The system’s first distribution block (i.e. the block closest to the pump)
has an indicator pin. If the pin moves forward and backward (in time
with the piston movements), this indicates that grease is pumped
Example figure components central lubrication through the system. If a distribution block is unable to supply grease
1. Pump unit to any of its lubrication points, the pin stops and accordingly the entire
2. Safety valve system.
3. Distribution block
If there is clogging in the system, that line will be 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

Explosion pressure min. 60.0 MPa

Workshop Manual DCF 90-100 VDCF03.01GB


112 9 Frame, body, cab and accessories – 9.15 Paint/coatings

9.15 Paint/coatings
Paint/coatings, description
page

The machine is painted using a single-layer paint, thickness 120 my.


For colour code (RAL) of machine in question, see machine card.
Please contact Kalmar Industries for information about other surface
treatment and material colours.

VDCF03.01GB Workshop Manual DCF 90-100


10 Common hydraulics 1

10 Common hydraulics

Table of Contents 10 Common hydraulics


mm mm mm mm mm mm

10 Common hydraulics....................................................................................... 3
10.2 Safety valves .............................................................................................. 3
10.2.1 Accumulator drain valve ........................................................................ 3
10.2.2 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

Workshop Manual DCF 90-100 VDCF03.01GB


2 10 Common hydraulics

VDCF03.01GB Workshop Manual DCF 90-100


10 Common hydraulics – 10 Common hydraulics 3

10 Common hydraulics
mm mm mm mm mm mm

10.2 Safety valves


10.2.1 Accumulator drain valve
Accumulator drain valve, description
page

The accumulator drain valve is located on the accumulator charging


valve. See section 4 Brakes, group 4.3.3 Accumulator charging valve.

009960

10.2.2 Attachment relief valve


Attachment relief valve, description
page

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 illustration depicts an open valve

Workshop Manual DCF 90-100 VDCF03.01GB


4 10 Common hydraulics – 10.2.3 Pressure limiting valve

10.2.3 Pressure limiting valve


Pressure limiting valve, description
page

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

10.2.4 Pipes and hoses


Pipes and hoses, general
page

See Pipes and hoses, general page 19.

VDCF03.01GB Workshop Manual DCF 90-100


10 Common hydraulics – 10.3 Tanks and accumulators 5

10.3 Tanks and accumulators


10.3.1 Tank
Tank, description
page

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

1. Hydraulic oil filter cover


2. Hydraulic oil filler plug
3. Level glass hydraulic oil
4. Breather filter hydraulic oil tank
5. Hydraulic oil drain plugs

008087

1. Accumulator

10.3.2 Pipes and hoses


Pipes and hoses, general
page

See Pipes and hoses, general page 19.

Workshop Manual DCF 90-100 VDCF03.01GB


6 10 Common hydraulics – 10.4 Pumps

10.4 Pumps
10.4.1 Gear pump with fixed displacement
Gear pump with fixed displacement, description
page

A gear pump with fixed displacement supplies pressure to the brake


1 system and circulates hydraulic oil through the radiator and filter; see
section 4 Brakes, group 4.3.1 Hydraulic oil pump.
The gear pump pumps oil using two gears wheels that rotate opposite
each other. One is driven by the pump’s input shaft and the other ro-
tates freely. The gear pump’s flow is directly dependent on the speed
of the input shaft.

2
3
008082

1. Hydraulic oil pump and quick-lift pump for load han-


dling.
2. Hydraulic oil pump for brake system, cooling and fil-
tering.
3. Main pump for steering and load handling.

Gear pump, changing


page

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

VDCF03.01GB Workshop Manual DCF 90-100


10 Common hydraulics – 10.4.1 Gear pump with fixed displacement 7

4 Remove the gear pump.


Remove the attaching bolts, pull the pump out backwards and lift
it away.
5 Transfer the connection adapters to the new gear pump.

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.

8 Fit the spacer ring on the axial piston pump.

Workshop Manual DCF 90-100 VDCF03.01GB


8 10 Common hydraulics – 10.4.1 Gear pump with fixed displacement

9 Brush sealing silicone on the gear pump’s sealing face against


the spacer ring; see section F Technical data.
10 Fit the gear pump and axial piston pump.
Fir the pump and check that the gear grips the shaft and that the
spacer ring is directly against the gear pump. Fit the pump’s re-
taining bolts.

11 Connect the hydraulic hoses to the gear pump.

NOTE
Check that the O-rings are intact and are fitted correctly.
009963

12 Close the drain valve on the accumulator charging valve.

NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
13 Turn on the main electric power and start the engine.
14 Check that the hose connections and seal between gear pump
and axial piston pump are airtight.
008049

15 Check the oil level in the hydraulic system; top up if needed.

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.

VDCF03.01GB Workshop Manual DCF 90-100


10 Common hydraulics – 10.4.2 Axial piston pump with variable displacement 9

10.4.2 Axial piston pump with variable


displacement
Axial piston pump with variable displacement,
page

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.

Workshop Manual DCF 90-100 VDCF03.01GB


10 10 Common hydraulics – 10.4.2 Axial piston pump with variable displacement

Axial piston pump with variable displacement,


page

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

Pos Explanation Signal description Reference


1 The lift and tilt control valve sends a See pressure plate Servo Section 7 Load handling, group 7.2.5 Lift
load signal when a function is activat- pressure lift and exten- and tilt control valve
ed. sion on left frame mem-
ber.

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.

VDCF03.01GB Workshop Manual DCF 90-100


10 Common hydraulics – 10.4.2 Axial piston pump with variable displacement 11

Pos Explanation Signal description Reference


5 The pressure reducer reduces the feed See pressure plate servo Section 7 Load handling, group 7.2.3 Pres-
pressure to servo pressure. pressure, on left frame sure reducer
member.

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.

12 If an attachment function is activated, U = 24 V Section 11 Common electrics, group


the KDU frame control unit (D797-1) 11.5.3.2 Frame control unit (D797-1)
activates the solenoid valve for main D12: Diagnostic menu, see section 8 Control
pump relief (Y6062-2). system, group 8.4.5.6 HYD, menu 6.

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.

Workshop Manual DCF 90-100 VDCF03.01GB


12 10 Common hydraulics – 10.4.2 Axial piston pump with variable displacement

Pos Explanation Signal description Reference


16 The hydraulic oil pump for load han- See pressure plate Max. Axial piston pump with variable displace-
dling increases the flow to the attach- pressure hydraulic oil ment, description page 9
ment control valve. pumps on left frame
member.

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

VDCF03.01GB Workshop Manual DCF 90-100


10 Common hydraulics – 10.4.2 Axial piston pump with variable displacement 13

Hydraulic oil pump, checking


page

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

the different pumps must always be maintained.


6 Increase engine speed to approx. 1100 rpm and run tilt function
1. Hydraulic oil pump for steering and load handling against end-position (overflow).
2. Hydraulic oil pump for load handling
Tilt in the mast to the max. position and continue requesting max.
3. Hydraulic oil pump for quick-lift
tilt in with the control lever. This causes tilt function overflow.
7 Check max. pressure on hydraulic oil pump 1, the pressure
should match the value on the pressure plate.
M Pa All pumps shall give the same pressure. The order between the
pumps is of no importance.
8 Stop the engine
9 Transfer the pressure gauge to the next pump and repeat steps
3–8 on all pumps.
009966

Workshop Manual DCF 90-100 VDCF03.01GB


14 10 Common hydraulics – 10.4.2 Axial piston pump with variable displacement

Axial piston pump with variable displacement,


page

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

8 Attach hoisting equipment to the axial piston pump.


9 Remove the axial piston pump.
Remove the retaining bolts and lift the pump away.

VDCF03.01GB Workshop Manual DCF 90-100


10 Common hydraulics – 10.4.2 Axial piston pump with variable displacement 15

10 Clean the flange on the gearbox, removing all silicone remnants.

CAUTION
Be careful and make sure that no gasket remains fall
down into the transmission.

Gasket remains may fall into the transmission and


cause product damage.

11 Transfer the connection adapters to the new axial piston pump.

NOTE
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.

15 Connect the hydraulic hoses to the axial piston pump in accord-


ance with the marking.

NOTE
Check that the O-rings are intact and fitted correctly.
009969

Workshop Manual DCF 90-100 VDCF03.01GB


16 10 Common hydraulics – 10.4.2 Axial piston pump with variable displacement

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.

18 Fit the spacer ring on the axial piston pump.

19 Brush sealing silicone on the gear pump’s sealing face against


the spacer ring; see section F Technical data.
20 Fit the gear pump in place.
Place the gear pump on the axial piston pump and install the at-
taching bolts. Be careful so that the O-ring on the spacer ring is
located correctly and that the gear pump’s shaft engages the ax-
ial piston pump’s output shaft.
21 Vent the axial piston pump, see Axial piston pump with variable
displacement, venting page 18.

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.

VDCF03.01GB Workshop Manual DCF 90-100


10 Common hydraulics – 10.4.2 Axial piston pump with variable displacement 17

22 Close the drain valve on the accumulator charging valve.

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.

Leakage and environmental damage.

The hydraulic oil level is checked with the boom com-


pletely lowered and retracted.

Workshop Manual DCF 90-100 VDCF03.01GB


18 10 Common hydraulics – 10.4.3 Pipes and hoses

Axial piston pump with variable displacement,


page

venting

NOTE
Read the safety instructions for oil before working, see section B
Safety.

1 Remove the hydraulic oil tank breather filter.


2 Connect compressed air at max. pressure max. 10 kPa to the hy-
draulic oil tank’s connection for breather filter.

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

operates under minimum load while air pockets are eliminated.


8 Stop the engine
9 Wash the engine bay.

10.4.3 Pipes and hoses


Pipes and hoses, general
page

See Pipes and hoses, general page 19.

VDCF03.01GB Workshop Manual DCF 90-100


10 Common hydraulics – 10.5 Hoses, pipes and valves 19

10.5 Hoses, pipes and valves


10.5.1 Pipes and hoses
Pipes and hoses, general
page

Hoses with ORFS couplings are used almost exclusively. For maxi-
mum service life and function, the following should be observed when
replacing hoses.
1. To avoid stresses in the connection, there should be a length of
straight hose after the connection.
2. The hose 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.

Workshop Manual DCF 90-100 VDCF03.01GB


20 10 Common hydraulics – 10.5.2 Priority valve

10.5.2 Priority valve


Priority valve, description
page

See section 5 Steering, group 5.2.2 Priority valve.

10.5.3 Shuttle valve


Shuttle valve, description
page

1. Shuttle valve attachment 009973

2. Shuttle valve control

3. Cab tilt shuttle valve


A shuttle valve chooses between two pressure signals and sends on
the strongest. The shuttle valves are used to sends load signals to the
hydraulic oil pumps. This means that the pumps are controlled by the
function that demands the highest pressure, if several functions are
activated at the same time.
Depending on option, there are two or three shuttle valves. The shuttle
valves are located on the hydraulic plate in front of the transmission
and on cab tilt control valve .
The shuttle valves choose between the following control signals:

VDCF03.01GB Workshop Manual DCF 90-100


10 Common hydraulics – 10.5.5 Collecting block, unfiltered returns 21

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.

10.5.5 Collecting block, unfiltered returns


Multiblock, unfiltered return lines, description
page

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

Workshop Manual DCF 90-100 VDCF03.01GB


22 10 Common hydraulics – 10.6 Temperature control, cleaning and hydraulic oil

10.6 Temperature control,


cleaning and hydraulic oil
Temperature control, cleaning and hydraulic oil,
page

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.

VDCF03.01GB Workshop Manual DCF 90-100


10 Common hydraulics – 10.6 Temperature control, cleaning and hydraulic oil 23

˚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

Pos Explanation Signal description Reference


1 The hydraulic oil pumps pump oil from the See pressure plate on left Axial piston pump with variable dis-
hydraulic oil tank, frame beam. placement, function description page 10

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

Workshop Manual DCF 90-100 VDCF03.01GB


24 10 Common hydraulics – 10.6 Temperature control, cleaning and hydraulic oil

Pos Explanation Signal description Reference


8 The frame control unit (D797-1) transmits Checked by control sys- Section 11 Common electrics, group
oil temperature on the CAN bus. tem; error indicated with 11.5.3.2 Frame control unit (D797-1)
error code. D8: Diagnostic menu, see section 8
Control system, group 8.4.5.1 HYD,
menu 1

9 The KID control unit (D795) shows oil tem- - Section 9 Frame, body, cab and acces-
perature in the operating menu hydraulic oil sories, group 9.1 Controls and 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.

VDCF03.01GB Workshop Manual DCF 90-100


10 Common hydraulics – 10.6.1 Tank heater 25

10.6.1 Tank heater


Tank heater, safety
page

CAUTION
The tank heater is connected to high voltage. Connec-
tion and reconnection of the tank heater may only be
performed by personnel authorized for work with high
voltage.

Tank heater, description


page

The tank can be equipped with a heater. The tank heater is designed
for cold climates.
The tank heater runs 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.

Workshop Manual DCF 90-100 VDCF03.01GB


26 10 Common hydraulics – 10.6.2 Cooler hydraulic oil

10.6.2 Cooler hydraulic oil


Hydraulic oil cooler, description
page

The working hydraulics use a through-flow cooler with electric cooling


fan (the same type of cooler as used for the brake system). The oil is
cooled when it passes the cooler, which sits inside the side panel on
the right-hand side behind the hydraulic oil tank.

009989

Hydraulic oil cooler, change


page

NOTE
Read the safety instructions for oil before working, see section B
Safety.

1 Machine in service position, see section B Safety.


2 Drain the oil from the hydraulic oil tank; see Hydraulic oil, chang-
ing page 32.
3 Mark up and disconnect hydraulic hoses from the cooler. Let the
1 oil in the cooler drain into the collection container.

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

9 Connect the hydraulic hoses to the cooler.


1. Cooling fan
2. Hydraulic connections
NOTE
3. Cooler
Check that the O-rings are intact and fitted correctly.

VDCF03.01GB Workshop Manual DCF 90-100


10 Common hydraulics – 10.6.3 Cooling fan 27

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.

10.6.3 Cooling fan


Cooling fan, description
page

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

10.6.4 Sensor hydraulic oil temperature


Sensor hydraulic oil temperature, description
page

The hydraulic oil temperature sensor (B776) detects the temperature


of the hydraulic oil. The sensor is located on the hydraulic oil tank’s
rear short end.
The sensor detects the oil temperature in the tank, determining the ac-
cumulated heat in the hydraulic oil. Because of this, the cooling fan
may continue to run after the machine has been parked and switched
off.
The hydraulic oil temperature sensor (B776) is supplied voltage by the
rear frame control unit (D797-1) and sends the unit a voltage signal
proportional to oil temperature.
The signal can be checked from the diagnostic menu, see section 8
Control system, group 8.4.5.1 HYD, menu 1.
009992

Workshop Manual DCF 90-100 VDCF03.01GB


28 10 Common hydraulics – 10.6.4 Sensor hydraulic oil temperature

Hydraulic oil temperature sensor, change


page

NOTE
Read the safety instructions for oil before working, see section B
Safety.

1 Machine in service position, see section B Safety.


2 Drain the oil from the hydraulic oil tank; see Hydraulic oil, chang-
ing page 32.
3 Disconnect the cabling from sensor hydraulic oil temperature
(B776).
4 Change sensor hydraulic oil temperature (B776).

NOTE
Check that the O-rings are intact and fitted correctly.
5 Connect the cabling to the sensor.
009992

Sensor hydraulic oil temperature (B776)


6 Fill the hydraulic oil tank with oil; see Hydraulic oil, changing page
32. The oil level should be visible in the level glass.

CAUTION
The hydraulic oil level is checked with the boom com-
pletely lowered and retracted.

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


DIAG HYD 1(6) system, group 8.4.5.1 HYD, menu 1.
HYDRAULIC OIL
TEMP XXX TEMP indicates hydraulic oil temperature in °C. Check that cor-
FAN XY rect temperature is shown.
000141

Diagnostic menu Hyd, menu 1

VDCF03.01GB Workshop Manual DCF 90-100


10 Common hydraulics – 10.6.5 Cooler bypass valve 29

10.6.5 Cooler bypass valve


Cooler bypass valve, description
page

The bypass valve protects the cooler from overpressure. The valve
opens a passage past the cooler directly to the tank if resistance in the
cooler becomes too high.

009993

Cooler bypass valve, replacement


page

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.

Dirt particles may cause machine damage.

1 Machine in service position, section B Safety.


2 Depressurize the hydraulic systems, See section B Safety.
3 Drain the oil from the hydraulic oil tank; see Hydraulic oil, chang-
ing page 32.
4 Disconnect the bypass valve from the tank.

NOTE
Note how the bypass valve faces; the valve is marked with
an arrow.
5 Install the new bypass valve, turning the valve to face the same
way as the old. Use Loctite when fitting the bypass valve.
009993

Bypass valve

Workshop Manual DCF 90-100 VDCF03.01GB


30 10 Common hydraulics – 10.6.6 Breather filter hydraulic oil tank

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.

10.6.6 Breather filter hydraulic oil tank


Breather filter hydraulic oil tank, description
page

A breather filter of insert type is mounted on the hydraulic oil tank to


protect the tank from impurities. On top of the filter housing is an indi-
cator that shows when the filter is clogged and should be changed.
009970

10.6.7 Oil filter


Hydraulic oil filter, description
page

The oil in the hydraulic system is cleaned by two return filters located
inside the hydraulic oil tank. The oil is pumped through the cooler and
back through the filters by the cooling pump. Some of the return oil
from the load handling functions also passes through the filters.
009994

VDCF03.01GB Workshop Manual DCF 90-100


10 Common hydraulics – 10.6.7 Oil filter 31

Hydraulic oil filter, replacement


page

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.

Dirt particles may cause machine damage.

1 Turn off the engine and the main electrical power.


2 Remove the cover plates (position 1) over the hydraulic oil filters.
3 Lift up the filter unit and place it in the receptacle. Let the hydrau-
lic oil drain.
4 Part the filter unit and remove the filter insert. Handle the filter in-
sert as environmentally hazardous waste. Note the position of the
parts.

1. Cover for oil filter


2. Filling point hydraulic oil
3. Level glass hydraulic oil
4. Filling point hydraulic oil
5. Breather filter hydraulic oil tank
5 Clean the filter holder’s parts. Be especially thorough with the
magnetic rod.
6 Fit the new filters and assemble the filter units.
7 Install the filter units and the covers. Tighten the screws cross-
wise.
8 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
Magnetic rod
Check the hydraulic oil level with the mast fully lowered and
the side lifting attachment retracted.

Workshop Manual DCF 90-100 VDCF03.01GB


32 10 Common hydraulics – 10.6.8 Hydraulic oil

10.6.8 Hydraulic oil


Hydraulic oil, changing
page

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.

Dirt particles may cause machine damage.

1 Machine in service position, see section B Safety.


2 Remove the filler cap and pump out the hydraulic oil in a collec-
tion container.
3 When most possible oil has been pumped out. Place a collection
container under the hydraulic oil tank’s drain plug and drain the
last of the hydraulic oil.
4 Fit the drain plug when the oil has drained.

1. Cover for oil filter NOTE


2. Filling point hydraulic oil Make sure that the seal washer is installed as well.
3. Level glass hydraulic oil
5 If the hydraulic oil filters are to be changed, change them before
4. Filling point hydraulic oil
filling the tank with oil, see Hydraulic oil filter, replacement page
5. Breather filter hydraulic oil tank
31.
6 Fill new hydraulic oil through the filler holes on the filters’ covers.
This results in filtering of the oil that is filled and protects the hy-
draulic system from impurities.
Fill oil until the oil level is in the middle of the level glass. For vol-
ume and grade, see section F Technical data.

VDCF03.01GB Workshop Manual DCF 90-100


10 Common hydraulics – 10.6.9 Hydraulic oil fine-filter 33

10.6.9 Hydraulic oil fine-filter


Fine filter hydraulic oil, description
page

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

Hydraulic oil fine filter, replacement


page

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.

Dirt particles may cause machine damage.

1 Machine in service position, see section B Safety.


2 Remove the cover.
3 Lift up the filter insert. Place it in a receptacle and let the hydraulic
oil drain.
4 Fit the new filter insert and refit the cover over the fine filter.

Workshop Manual DCF 90-100 VDCF03.01GB


34 10 Common hydraulics – 10.6.10 Pipes and hoses

10.6.10 Pipes and hoses


Pipes and hoses, general
page

See Pipes and hoses, general page 19.

VDCF03.01GB Workshop Manual DCF 90-100


10 Common hydraulics – 10.7 Auxiliaries 35

10.7 Auxiliaries
10.7.1 Hydraulic cylinders
Hydraulic cylinders, repairs
page

Fault tracing, leakage

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

Workshop Manual DCF 90-100 VDCF03.01GB


36 10 Common hydraulics – 10.7.1 Hydraulic cylinders

Dismantling of cylinders

CAUTION
Before dismantling always check that the piston rod
is clean and free from all residual paint. Also check
that connections and couplings are free from burrs
and impact marks. Make sure that the chamfer up to
the chromium surface of the piston rod is free from
burrs and residual paint.

1 Remove the cylinder from its mounting and undo the 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:

Get it absolutely straight. This is best done by hand.


Under no circumstances hit it with any mallet. If the
cylinder head is fitted crooked, the sealing lip of the
piston rod seal could be damaged, making an improp-
er seal. This applies to all types of piston rod seals.

VDCF03.01GB Workshop Manual DCF 90-100


10 Common hydraulics – 10.7.1 Hydraulic cylinders 37

Function and removal of the seals

Piston rod seal


The piston rod seal is the seal that sits in the groove in the cylinder
2
head and seals against the piston rod. This seal is greatly subject to
wear since it is both a dynamic and a static seal, i.e. it seals against a
1 moving surface on the piston rod while the sealing surface with the cyl-
inder head is fixed. There are different types of piston rod seals:
• Single V-ring seal
• Pre-stressed V-ring seal with thrust ring
3 • Compressible seal
The simple V seal has a V-shaped section with two lips that seal in
opposite directions. The hydraulic pressure works in the V-shape,
4
6 pressing the sealing lips out towards the sealing surfaces on the piston
rod and in the cylinder barrel. Even minor damage to the sealing lips
can generate large leaks. Examine the sealing lips by carefully using
a fingernail to feel around the seal. To remove, use a screwdriver to
prise the seal outward and bend it up (see illustration). It is extremely
important that the screwdriver is always inserted in the V shape so that
it cannot touch and thereby damage a sealing surface. A mark from a
screwdriver on a sealing surface can have a devastating effect and
001497

5 cause major leakage.

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

Workshop Manual DCF 90-100 VDCF03.01GB


38 10 Common hydraulics – 10.7.1 Hydraulic cylinders

The pretensioned V seal also has an O-ring in the seal’s V-shaped


2
space. The O-ring creates a strong seal at low hydraulic pressure
1 since the O-ring already presses the sealing lips out toward the sealing
surfaces when unloaded. It is just as sensitive to damage as the V
seal. Examine in the same manner. To remove, use a screwdriver to
prise the seal outward and bend it up (see illustration). It is extremely
important that the screwdriver is always inserted in the V shape so that
3 it cannot touch and thereby damage a sealing surface. A mark from a
7
screwdriver on a sealing surface can have a devastating effect and
6 4 cause major leakage.

001498

5
1. Hydraulic pressure
2. The sealing lip is pressed outward 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

VDCF03.01GB Workshop Manual DCF 90-100


10 Common hydraulics – 10.7.1 Hydraulic cylinders 39

The compressible piston rod seal consists of a solid rubber profile


2
and provides a larger sealing surface than the V seals. To remove, use
a screwdriver to prise the seal outward and bend it up (see illustration).
1
With this type of seal with sealing surfaces that cover so much of the
3 seal groove, it is particularly important that marks are not made with
the screwdriver.

6
4

5
001499

5
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

Workshop Manual DCF 90-100 VDCF03.01GB


40 10 Common hydraulics – 10.7.1 Hydraulic cylinders

Thrust ring and O-ring


The thrust ring and O-ring combination is used for sealing between two
fixed surfaces, such as between cylinder barrel and cylinder head.
The purpose of the thrust ring is to lend rigidity to the O-ring so that it
is not deformed. The O-ring is pressed against the thrust ring and the
sealing surface by the hydraulic pressure in the cylinder.
3
When the cylinder head is mounted in the barrel: Take extreme care
not to damage the O-ring.
4
2
001506

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

1. Correct fitting tool


2. Scraper, correctly fitted
3. Cylinder head
4. Play between scraper and bottom of cylinder head
recess
5. Incorrect fitting tool
6. Deformed scraper

VDCF03.01GB Workshop Manual DCF 90-100


10 Common hydraulics – 10.7.1 Hydraulic cylinders 41

A screwdriver can be used for removal. This must always be applied


1 against the outer edge of the scraper (see illustration). Carefully tap
the screwdriver down between the scraper and the cylinder head and
2 then prise out the scraper. Polish away any damage to the cylinder
head.

CAUTION
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

Workshop Manual DCF 90-100 VDCF03.01GB


42 10 Common hydraulics – 10.7.1 Hydraulic cylinders

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

that the seal is not damaged by the cylinder barrel threads.

1. Moving sealing surface to cylinder barrel Dismantling:


2. Fixed sealing surface with piston
1 Remove guide rings and thrust rings.
3. Guide ring
4. Thrust ring 2 Move the seal over to one side of the sealing groove.
5. Piston head 3 Press it up so that there is a gap between seal and piston.
6. Cylinder barrel
4 Without damaging the surface of the piston - cut off the seal with
a knife.
5 Carefully examine the seal to find any damage that can cause
leakage. This will be easier if you bend the seal sharply bit by bit
and feel over the sealing surface with a fingernail.

Assembly:
1 All double-acting piston seals are of similar design: a middle seal-
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.

VDCF03.01GB Workshop Manual DCF 90-100


10 Common hydraulics – 10.7.1 Hydraulic cylinders 43

Repairing the piston rod surface


A small impact mark on a piston rod may be sufficient to cause leak-
1 2 3
age. The chromium plating on the piston rod has a thickness of 20-50
my and can be treated to make good minor damage. This may be a
satisfactory alternative to costly disassembly.

1 Locate the damage using your fingertips and fingernails.

4 2 Use a small, highly-polished hammer and work the surrounding


material inwards towards the damage, starting from the outside.
3 Instead of a small sharp mark there will now be a small uniform
concavity in the chromium plating.
4 Polish with emery cloth, progressing from number 240 to 600.
Wrap the emery cloth round a file to give it good support. Note
that there must always be chromium plating present at the dam-
age.
5 It is important to treat small impact marks before disassembly and
assembly to avoid damaging the cylinder head.
6 Repairing larger damage on a piston rod
002952

• fill the damage with weld metal, use chromium or stainless


1. Piston steel electrodes
2. Chromium plating • remove all slag completely
3. Impact marks
• file the weld down to the same level as the chrome
4. Highly-polished hammer
• polish evenly using emery cloth

Workshop Manual DCF 90-100 VDCF03.01GB


44 10 Common hydraulics – 10.7.1 Hydraulic cylinders

Dismantling steering cylinders


It can prove extremely difficult to extract the piston rod from the cylin-
der barrel on steering cylinders because the O-ring in the cylinder
head fastens in the retaining ring groove in the cylinder barrel. It is
therefore best to remove the O-ring before trying to withdraw the pis-
ton rod from the cylinder.

1 Unscrew the end washer at the cylinder head.


2 Unscrew the connecting nipple for the hydraulic hose.
3 Insert the piston rod with piston crown until the O-ring is visible
through the nipple hole.
4 Bend the end of a length of heavy-duty steel wire, piano wire or
the like into the shape of a hook. Use this to snag the O-ring.
5 Pull the O-ring up slightly and hold it with a pair of needle-nose
pliers.
6 Continue to pull the O-ring out through the hole.
7 Hold the O-ring steady and cut it with a knife.
8 Rotate the piston rod while pulling the O-ring out through the
hole.
9 Remove the retaining ring from the cylinder barrel.
10 Carefully extract the piston rod from the cylinder barrel.
002953

VDCF03.01GB Workshop Manual DCF 90-100


11 Common electrics 1

11 Common electrics

Table of Contents 11 Common electrics


mm mm mm mm mm mm

11 Common electrics .......................................................................................... 3


11.2 Electric protection ....................................................................................... 3
11.2.1 Battery disconnect switch ...................................................................... 3
11.2.2 Fuses ..................................................................................................... 3
11.2.3 Emergency stop switch .......................................................................... 3
11.3 Batteries ..................................................................................................... 4
11.3.1 Start battery ........................................................................................... 4
11.4 Alternator .................................................................................................... 6
11.4.1 Alternator ............................................................................................... 6
11.5 Electrical distribution .................................................................................. 7
11.5.1 Power supply ......................................................................................... 7
11.5.2 Electrical distribution box ..................................................................... 15
11.5.3 Control units ......................................................................................... 17
11.5.5 Cables .................................................................................................. 26
11.6 Communication ........................................................................................ 39
11.6.1 CAN-bus .............................................................................................. 39
11.6.2 Redundant CAN bus ............................................................................ 41
11.6.3 Drivetrain CAN bus .............................................................................. 43
11.6.4 Communication between PC and machine .......................................... 44
11.6.5 RMI (Remote Machine Interface) ......................................................... 45

Workshop Manual DCF 90-100 VDCF03.01GB


2 11 Common electrics

VDCF03.01GB Workshop Manual DCF 90-100


11 Common electrics – 11 Common electrics 3

11 Common electrics
mm mm mm mm mm mm

11.2 Electric protection


11.2.1 Battery disconnect switch
Battery disconnect switch, description
page

The positive terminals of the batteries connected in series are con-


nected to the machine’s electrical system via the battery disconnect
switch. The battery disconnector cuts off all power from the batteries
to the machine’s electrical system.
A

IMPORTANT
Never turn off the voltage with the battery disconnect
switch when the engine is running. This could dam-
age the alternator.

The battery disconnect switch must not be used for


emergency stop!
010051

A. Position of battery disconnect switch

11.2.2 Fuses
Fuses, replacement
page

When checking and replacing the main fuse:


1. Switch off the main current (battery disconnect switch).
2. Remove the plastic cover.
3. Check that fuses are intact. Replace if necessary.
The fuses are 50 A.
When checking and replacing the circuit fuses:
1. Switch off the main current (battery disconnect switch).
2. Remove the cover of the electrical distribution box.
3. Check and, if necessary, replace fuses.
The fuse chart provides information about each fuse.

11.2.3 Emergency stop switch


Emergency stop, description
page

See Emergency stop switch voltage (15E), function description page


11.

Workshop Manual DCF 90-100 VDCF03.01GB


4 11 Common electrics – 11.3 Batteries

11.3 Batteries
11.3.1 Start battery
Start battery, description
page

The machine’s electrical system is supplied by two 12 V batteries con-


nected in series.
The negative terminal is connected to the frame. The positive terminal
is connected to the battery disconnector.
The batteries are charged by the alternator, see Alternator, description
page 6.

WARNING
Battery electrolyte contains corrosive sulphuric acid

Risk of corrosive injuries, health hazard!

Immediately remove electrolyte from the skin. Wash


with soap and copious amounts of water. If electrolyte
gets in the eyes, rinse with copious amounts of water
and seek medical help immediately.

WARNING
Risk of explosion!

Personal injury!

During charging, hydrogen gas forms around the bat-


teries. Sparks could ignite the hydrogen gas, causing
an explosion. Disconnect the battery with the battery
disconnect switch.

WARNING
Risk of explosion if the battery short circuits (also
causes loss of capacity).

Fire hazard, personal injury!

The battery's terminals may not be connected to each


other or commonly to ground (chassis).

VDCF03.01GB Workshop Manual DCF 90-100


11 Common electrics – 11.3.1 Start battery 5

Starter battery, replacement


page

1 Machine in service position, see section B Safety.


2 Disconnect the cables from the battery terminals, starting with the
negative (minus) cable.
3 Replace the batteries.
4 Connect the cables to the battery terminals. Connect the nega-
tive cable last of all.

NOTE
Take great care when reconnecting the cables to prevent
short circuiting.

Workshop Manual DCF 90-100 VDCF03.01GB


6 11 Common electrics – 11.4 Alternator

11.4 Alternator
11.4.1 Alternator
Alternator, description
page

The alternator generates current during operation and supplies this to


the batteries. The alternator produces AC current and has an integrat-
ed charge regulator.
The alternator is driven by the engine via a belt. Faults are indicated
by the warning lamp for low battery charging.
The signal can be checked from the diagnostic menu, section 8 Con-
trol system, section 8.4.6.4 ENGINE, menu 4.
010052

Alternator, replacement
page

See supplier documentation, engine.

VDCF03.01GB Workshop Manual DCF 90-100


11 Common electrics – 11.5 Electrical distribution 7

11.5 Electrical distribution


11.5.1 Power supply
11.5.1.2 Redundant voltage feed of control
units
Redundant voltage feed for control units, description of
page

operation

1 2 3 4 5

D1 D3 D4 D5

D2
D793 D794
- +
D10 D9

D790-1 D791 D797-2


6, 7 10 9
11 8
D795 D790-2 D797-1

008686
D11 D8

Pos Explanation Signal description Reference


1 The NC switch, operator’s door (S U = 24 V Section 9 Frame, body, cab and accessories , group
266-LE) or the NC switch, passen- 9.10.2 Doors
ger door (S 266-RI) sends a volt- D1: Diagnostic menu, see section 8 Control system,
age signal to the cab control unit group 8.4.2.9 LIGHTS, menu 9 or 8.4.11.5 MOVE-
(D790-1) when the door is opened. CAB, menu 1

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

Workshop Manual DCF 90-100 VDCF03.01GB


8 11 Common electrics – 11.5.1.2 Redundant voltage feed of control units

Pos Explanation Signal description Reference


5 The switch for entry lighting (S141) U = 24 V Section 9 Frame, body, cab and accessories, group
sends a voltage signal to the cab 9.6 Lighting
control unit (D790-1). D5: Diagnostic menu, see section 8 Control system ,
group 8.4.2.15 LIGHTS, menu 15

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

UK2:8 = 24 V D9: Diagnostic menu, see section 8 Control system,


group 8.4.1.13 CAN/POWER, menu 13

10 UK2:7 = 24 V Attachment control unit (D791), description page 21

UK2:8 = 24 V D10: Diagnostic menu, see section 8 Control system,


group 8.4.1.15 CAN/POWER, menu 15

11 UK2:7 = 24 V D11: KID control unit (D795), description page 26

UK2:8 = 24 V Diagnostic menu, see section 8 Control system,


group 8.4.1.9 CAN/POWER, menu 9

VDCF03.01GB Workshop Manual DCF 90-100


11 Common electrics – 11.5.1.3 Ignition voltage (15) 9

11.5.1.3 Ignition voltage (15)


Ignition voltage (15), description of operation
page

Condition Reference value Reference


Battery disconnect switch In position 1 Battery disconnect switch, description page 3

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

Pos Explanation Signal description Reference


1 The switch for warning lights U = 24 V Section 9 Frame, body, cab and accessories, group 9.6.7
(S109) sends a voltage sig- Warning lights
nal to the cab control unit D1: Diagnostic menu, see section 8 Control system,
(D790-1). group 8.4.2.5 LIGHTS, menu 5

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.

Workshop Manual DCF 90-100 VDCF03.01GB


10 11 Common electrics – 11.5.1.3 Ignition voltage (15)

Pos Explanation Signal description Reference


4 Ignition voltage relay K315- U = 24 V -
1 supplies voltage to fuse
holder in the cab electrical
distribution box and in the
frame electrical distribution
box.

5 The fuses feed voltage to U = 24 V -


control units, relays, sole-
noid valves and other elec-
tronic components.

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

VDCF03.01GB Workshop Manual DCF 90-100


11 Common electrics – 11.5.1.4 Emergency stop switch voltage (15E) 11

11.5.1.4 Emergency stop switch voltage (15E)


Emergency stop switch voltage (15E), function description
page

Condition Reference Reference


value
Redundant voltage Activated. Redundant voltage feed for control units, description of operation page 7
feed

Ignition voltage Activated. Ignition voltage (15), description of operation page 9

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.

Workshop Manual DCF 90-100 VDCF03.01GB


12 11 Common electrics – 11.5.1.4 Emergency stop switch voltage (15E)

Pos Explanation Signal description Reference


4 The emergency stop switch voltage relay UK3009-1/87 = 24 V Electrical distribution box frame, descrip-
(K3009-1) also sends a voltage signal to the tion page 16
UK3009-2/87 = 0 V
cab control unit (D790-1), which verifies that D4: Diagnostic menu, see section 8 Control
emergency stop switch voltage relay system, group 8.4.1.6 CAN/POWER,
K3009-1 is active but emergency stop menu 6
switch voltage relay K3009-2 is inactive.
This verifies that the operation breaker is
working.

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.

VDCF03.01GB Workshop Manual DCF 90-100


11 Common electrics – 11.5.1.5 Voltage converter 13

Emergency stop switch, checking


page

1 Start the machine and active any load handling function.


2 Activate lift
3 Press in the emergency stop switch and check that the lift move-
ment stops.
4 Reset the emergency stop switch (turn in the arrows’ direction)
and check that the lift function works again.

004770

Emergency stop switch

11.5.1.5 Voltage converter


Voltage converter, description
page

The voltage converter is located under a protective casing to the left


behind the driver’s seat.
The voltage converter converts 24 volts to 12 volts. 12 V power is
available for accessories through a connector in the cab electrical dis-
tribution box and through a socket on the instrument panel.
Connector X067 in cab electrical distribution box (contains 15-voltage,
30-voltage, ground and 12 V).

CAUTION
The max. output of the voltage converter is 12 V/20 A.

Workshop Manual DCF 90-100 VDCF03.01GB


14 11 Common electrics – 11.5.1.5 Voltage converter

Voltage converter, replacement


page

1 Machine in service position, see section B Safety.


2 Remove the covers behind the driver’s seat.
3 Detach the electrical cables from the converter.
4 Remove the voltage converter.
5 Fit in the reverse order.

The voltage converter is located behind the driver’s


seat.

VDCF03.01GB Workshop Manual DCF 90-100


11 Common electrics – 11.5.2 Electrical distribution box 15

11.5.2 Electrical distribution box


11.5.2.1 Electrical distribution box cab
Electrical distribution box cab, description
page

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.

3 The connector contains the following connections:


1. Ignition voltage
4
2. Battery voltage
5 3. Ground
4. 12 V voltage from the voltage converter
008693

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.

Workshop Manual DCF 90-100 VDCF03.01GB


16 11 Common electrics – 11.5.2.2 Electrical distribution box frame

11.5.2.2 Electrical distribution box frame


Electrical distribution box frame, description
page

The electrical distribution box is mounted on the side of the machine.


5 6
4 Also located there are:
7
3 • Circuit fuses.
2
8 • Socket for communication with the engine and transmission; see
1
Communication between PC and machine, description page 44.
• Main fuses.
9
• Transmission control unit (D793)
10
• Power relays for voltage feed to the machine’s functions.
11
12
13
007958

14
1. Circuit fuses, emergency stop switch voltage
(15E)F58-3
2. Circuit fuses, ignition voltage (15) F58-2
3. Circuit fuses, battery voltage (30) F58-1
4. Engine diagnostic socket, VODIA (Volvo engine)
5. Transmission diagnostic socket
6. Main fuses
7. Transmission control unit (D793)
8. Attachment connection terminal
9. Lift/lower relay K3007
10. Tilt in/out relay K3002
11. Ignition switch relay K315-2
12. Ignition switch power relay K315-1
13. Emergency stop switch power relay K3009-1
14. Emergency stop switch power relay K3009-2

-
1
-
2
- 1
3
-
4
5 -
-
6
007184

1. Termination resistor

VDCF03.01GB Workshop Manual DCF 90-100


11 Common electrics – 11.5.3 Control units 17

11.5.3 Control units


Control units, position
page

1 2 3 4

009172
9 8 7 6

1. Control unit attachment (D791-1) 6. Control unit, Volvo engine (D794)


2. Control unit KID (D795) 7. Control unit, Cummins engine (D794)
3. Control unit KIT (D790-2) 8. Frame control unit (D797-1)

4. Control unit cab (D790-1) 9. Frame control unit, option (D797-2)


5. Transmission control unit (D793)

Workshop Manual DCF 90-100 VDCF03.01GB


18 11 Common electrics – 11.5.3.1 Control unit cab (D790-1)

11.5.3.1 Control unit cab (D790-1)


Cab control unit (D790-1), description
page

The cab control unit (D790-1) is the central control unit of the control
2 1
system. The cab control unit (D790-1) sends activation signals to other
units and controls and monitors their functions. It administrates work
in the control unit network. The control unit controls the redundant volt-
age feed and handles communication via a redundant CAN bus and
gateway for the drivetrain CAN bus. The cab control unit (D790-1) also
processes all input signals from cab controls and transmits these sig-
5 6 nals on the CAN bus.
4
3

000041
2 The 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.

Light 3 Long single flash yellow during communication with the


control unit display (D795). This is a basic condition of
fault tracing.
Short single flash yellow during communication with
the engine control unit (D794) and transmission control
unit (D793).
Double flash yellow (short and long flash) during com-
munication with the display and engine or transmis-
sion.

Light 4 Red light on at active error.

Control unit cab, change


page

1 Machine in service position, see section B Safety.


2 Remove the cover from the electrical distribution box.
3 Unplug the cab control unit (D790-1) connectors.
4 Change control unit.
5 Check that the new control unit matches the machine’s forklift
number (Z-number).
6 Calibrate the new control unit; see section 8 Control system,
group 8.5.2.3 Calibrate DRIVETRAIN.

VDCF03.01GB Workshop Manual DCF 90-100


11 Common electrics – 11.5.3.2 Frame control unit (D797-1) 19

11.5.3.2 Frame control unit (D797-1)


Frame control unit (D797-1), description
page

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.

Light 2 Flashes green when one or more of the following is


missing: redundant voltage feed left, redundant volt-
000043
age feed right or 15-voltage.
6 5 Shines green when redundant voltage feed left, redun-
1. Light 1, battery voltage dant voltage feed right and 15-voltage are supplied
2. Light 2, redundant voltage feed and power supply voltage.
3. Light 3, communication
Light 3 Single yellow flash during communication with the KID
4. Light 4, fault indication
control unit (D795) or cab control unit (D790-1).
5, Control signals (input and output signals)
6. Power feed (redundant voltage feed control units, Double yellow flash during communication with the KID
redundant CAN bus) and input data control unit (D795) and the cab control unit (D790-1).

Light 4 Red light on at active error.

Frame control unit (D797-1), replacement


page

1 Machine in service position, see section B Safety.


2 Detach the cables from the frame control unit (D797-1).
3 Change control unit.
4 Check that the new control unit matches the machine’s forklift
number (Z-number).
5 Calibrate the new control unit; see section 8 Control system,
group 8.5.2.1 Calibrate SCALE.

Workshop Manual DCF 90-100 VDCF03.01GB


20 11 Common electrics – 11.5.3.3 Frame control unit (D797-2)

11.5.3.3 Frame control unit (D797-2)


Frame control unit (D797-2), description
page

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.

Light 2 Flashes green when one or more of the following is


missing: redundant voltage feed left, redundant volt-
age feed right or 15-voltage.
000043

6 5 Shines green when redundant voltage feed left, redun-


1. Light 1, battery voltage dant voltage feed right and 15-voltage are supplied
2. Light 2, redundant voltage feed and power supply voltage.
3. Light 3, communication
Light 3 Single yellow flash during communication with the KID
4. Light 4, fault indication
control unit (D795) or cab control unit (D790-1).
5, Control signals (input and output signals)
6. Power feed (redundant voltage feed control units, Double yellow flash during communication with the KID
redundant CAN bus) and input data control unit (D795) and the cab control unit (D790-1).

Light 4 Red light on at active error.

Frame control unit (D797-2), replacement


page

1 Machine in service position, see section B Safety.


2 Detach the cables from the frame control unit (KDU D797-2).
3 Change control unit.
4 Check that the new control unit matches the machine’s forklift
number (Z-number).
5 Calibrate the new control unit; see section 8 Control system,
group 8.5.2.2 Calibrate STEERING.

VDCF03.01GB Workshop Manual DCF 90-100


11 Common electrics – 11.5.3.5 Attachment control unit (D791) 21

11.5.3.5 Attachment control unit (D791)


Attachment control unit (D791), description
page

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).

4 Light 1 Green light on when there is battery voltage to the unit.


The light is physically controlled by voltage feed to the
control unit.

Light 2 Flashes green when one or more of the following is


000043
missing: redundant voltage feed left, redundant volt-
6 5 age feed right or 15-voltage.
1. Light 1, battery voltage Shines green when redundant voltage feed left, redun-
2. Light 2, redundant voltage feed and power supply dant voltage feed right and 15-voltage are supplied
3. Light 3, communication voltage.
4. Light 4, fault indication
Light 3 Single yellow flash during communication with the KID
5, Control signals (input and output signals)
control unit (D795) or cab control unit (D790-1).
6. Power feed (redundant voltage feed control units,
redundant CAN bus) and input data Double yellow flash during communication with the KID
control unit (D795) and the cab control unit (D790-1).

Light 4 Red light on at active error.

Attachment control unit, replacement


page

1 Machine in service position, see section B Safety.


2 Disconnect the cabling from the control unit.
3 Change control unit.
4 Check that the new control unit matches the machine’s forklift
number (Z-number).
5 Check the initiation values for attachment functions; see section
8 Control system, group 8.5.1.2 ATTACHMENT.
6 The control unit is not calibrated.

Workshop Manual DCF 90-100 VDCF03.01GB


22 11 Common electrics – 11.5.3.9 Transmission control unit (D793)

11.5.3.9 Transmission control unit (D793)


Transmission control unit (D793), description
page

The transmission control unit (D793) is part of drivetrain control and


1 2 3
handles gearbox function, selection of gear at load and engine speed,
etc.
The transmission control unit (D793) is connected via separate CAN
D
M bus communication to the engine, which is connected to the cab con-
E
F S trol unit (D790-1). The cab control unit (D790-1) sends drivetrain infor-
mation on to other units.
The control unit has two function keys and three status lights (see il-
lustration).
000045
Function button M Select display group.
1. Display Function button S Select display group mode.
2. Status lights
3. Function keys Status light D Yellow light indicates test mode.

Status light E Yellow light indicates fault in unit.

Status light F Red light during reset.

Control units can show information in the display in three display


groups with various status information. The M and S function keys are
used to navigate in the display and select display group and status in-
formation.
The following status information can be shown in the display:
Display group I
• GPOS - shows transmission’s direction of rotation
• VSPD - shows speed in km/h
• dist - shows distance driven in km or miles
Display group II
• CPOS - shows gear position
• Tspd - shows measured turbine speed in km/h or mph
• Espd - shows measured engine speed in rpm
• Ospd - shows measured speed out from the transmission in rpm
• Srat - shows the turbine speed ratio (Tspd)/engine speed (Espd)
• TQ I - shows measured torque (Nm) of transmission in
• Ttmp - shows measured temperature in the oil sump (Celsius or
Fahrenheit)
• Ctmp - shows measured temperature in the converter (Celsius or
Fahrenheit)
Display group III
• Err - shows error codes (current and history)

VDCF03.01GB Workshop Manual DCF 90-100


11 Common electrics – 11.5.3.10 Engine control unit (D794) 23

Transmission control unit, replacement


page

1 Machine in service position, see section B Safety.


2 Detach the cables from the transmission control unit (D793).

1 3 Change control unit.


4 Check that the new control unit matches the machine’s forklift
number (Z-number).
5 Calibrate the new control unit; see section 8 Control system,
group 8.5.2.3 Calibrate DRIVETRAIN and section 2 Transmis-
sion, group 2.8 Control system, transmission.

007959

1. Transmission control unit (D793)

11.5.3.10 Engine control unit (D794)


Engine control unit (D794), description (Volvo TAD760VE
page

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

cal distribution box; see Communication between PC and machine,


1. Connector OEM description page 44.
2. Connector Actuator The control unit monitors the following values to optimize engine per-
3. Connector Sensor formance.
• engine rpm
• camshaft’s position
• boost pressure
• charge-air temperature
• coolant temperature
• 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.

Workshop Manual DCF 90-100 VDCF03.01GB


24 11 Common electrics – 11.5.3.10 Engine control unit (D794)

Engine control unit (D794), description (Cummins QSB6.7


page

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.

Engine control unit, replacement


page

See supplier documentation engine.

CAUTION
Each control unit is individually calibrated to the en-
gine in question. Switching of control units between
engines is absolutely forbidden.

VDCF03.01GB Workshop Manual DCF 90-100


11 Common electrics – 11.5.3.11 KIT control unit (D790-2) 25

11.5.3.11 KIT control unit (D790-2)


KIT control unit (D790-2), description
page

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

1. Panel, warning and indicator lights


2. Panel, keys

KIT control unit (D790-2), replacement


page

1 Machine in service position, see section B Safety.


2 Remove the steering wheel and open the steering wheel panel.
3 Detach the KIT control unit (D790-2) from the steering wheel pan-
el.
4 Detach the connector sockets.
5 Remove the warning panel for warning and indicator lights.
6 Fit in the reverse order.
7 The KIT control unit (D790-2) is not calibrated.

Workshop Manual DCF 90-100 VDCF03.01GB


26 11 Common electrics – 11.5.3.12 Control unit KID (D795)

11.5.3.12 Control unit KID (D795)


KID control unit (D795), description
page

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.

KID control unit (D795), replacement


page

1 Machine in service position, see section B Safety.


2 Remove the steering wheel and open the steering wheel panel.
3 Detach the connector from the KID control unit (D795).
4 Detach the KID control unit (D795) from the steering wheel panel.
5 Fit in the reverse order.
6 The KID control unit (D795) is not calibrated.

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.

Connec- Location Function


tor
X001 Control unit cab (D790-1) Power supply and earth connection Control unit cab (D790-1)

X002 Control unit cab (D790-1) Front windscreen wiper


Heater fan
Actuator motor, recirculation
Rear window wiper
Motor, rotating beacon
Reversing light

VDCF03.01GB Workshop Manual DCF 90-100


11 Common electrics – 11.5.5 Cables 27

Connec- Location Function


tor
X004 Control unit cab (D790-1) Water valve
Air distributor
Interior temperature sensor
Ambient temperature sensor
Temperature sensor, outlet fan
Sensor temperature refrigerant
Air conditioning sensor
Front windscreen wiper motor

X005 Control unit cab (D790-1) Switch, left panel


Switch option
Window washer, roof rear
Switch warning light (Hazard)
Setting fan speed
Setting temperature
Air distribution
Fan and recirculation controls
Accelerator pedal
Alignment bypass

X006 Control unit cab (D790-1) Instrument illumination


Switch work lights
Switch, rotating beacon
Switch, headlights
Switch option
Seat heater
Accelerator pedal
Release pedal

X007 Control unit cab (D790-1) Operating lever


Twistlock
Spreading

Workshop Manual DCF 90-100 VDCF03.01GB


28 11 Common electrics – 11.5.5 Cables

Connec- Location Function


tor
X008 Control unit cab (D790-1) Switch, levelling
Switch, spreading
Switch, bypass
Emergency stop switch
Switch, parking brake
Switch, reversible driver’s seat/cab tilt
Sensor twistlocks
Switch 30-35 stop
Switch, aut. 20-40
Switch option
Instrument illumination
Switch, electric servo panel

X009 Control unit cab (D790-1) Background illumination, switches


Lever steering or mini-wheel
Switch, horn

X009-2 Control unit cab (D790-1) Control lever

X010 Control unit cab (D790-1) Sensor alignment


Water valve
Horn
Relay, seat heating
Relay, work lighting
Hour counter
Relay, Compressor
Control current relay K315-1, K3009-1, K3009-2, K315-2, K3002 and
K3007
Front windscreen washing
Windscreen wiper, roof

X011 Control unit cab (D790-1) Ignition switch


Switches, cab doors
Switch, entry lighting
Interior lighting
Redundant feed, cab control unit (D790-1)
Horn
Switch, seat
Feedback relay K3009-1

X012 Control unit cab (D790-1) Windscreen wiper, rear


Windscreen wiper, roof

VDCF03.01GB Workshop Manual DCF 90-100


11 Common electrics – 11.5.5 Cables 29

Connec- Location Function


tor
X013 Control unit cab (D790-1) CAN-bus
RS232

X015 Control unit KIT (D790-2) CAN-bus


Power supply and earth connection, Control unit KIT (D790-2)

X016 Control unit KIT (D790-2) Ignition switch

X017 Control unit KIT (D790-2) Switch, horn


Control, windscreen wipers
Control, gear
Control, main and dipped beams

X018 Control unit KIT (D790-2) Sensor, steering wheel lock


Buzzer
Switch, direction indicators
Switch interior lighting

X020 Control unit KID (D795) CAN-bus


RS232
Power supply and earth connection, Control unit KID (D795)

X033 Air conditioning system Control, fan


Control, temperature
Control, air distribution
Fan and recirculation controls
Instrument illumination

X034 Air conditioning system Heater fan


Water valve

X035 Air conditioning system Valve, air distribution


Interior temperature sensor
Temperature sensor, outlet fan

X036 Air conditioning system Actuator motor, recirculation


Sensor temperature refrigerant

X038 Instrument panel, cab Accelerator pedal


Release pedal

Workshop Manual DCF 90-100 VDCF03.01GB


30 11 Common electrics – 11.5.5 Cables

Connec- Location Function


tor
X039 Electrical distribution box cab Relay, Compressor, seat with air suspension
Switch warning light (Hazard)
Switch, cab door
Actuator motor, recirculation
Fan motor, heating
Water valve, ECC
Air conditioning sensor
Ambient temperature sensor

X040 Electrical distribution box cab Alignment bypass


Window washer, roof/rear
Accelerator pedal

X048 Electrical distribution box cab Termination resistor

X049 Electrical distribution box cab Termination resistor

X050 Electrical distribution box cab RS232 Control unit cab (D790-1)

X051 Electrical distribution box cab Feedback relay K3009-1


Power supply, Control unit cab (D790-1)
CAN-bus

X052 Electrical distribution box cab CAN-bus


Control relays K315-1, K3009-1, K3009-2 and K315-2

X054 Electrical distribution box cab Interior lighting


Reversing light
Rotating beacon

X055 Electrical distribution box cab Windscreen wiper, roof


Current, CD player
Current, COM radio

X056 Electrical distribution box cab Rotating beacon


Working lights, cab

X057 Electrical distribution box cab Windscreen wiper, rear

X058 Electrical distribution box cab Motor, windscreen washers


Engine heater start inhibitor, bridged

X059 Electrical distribution box cab CAN-bus

X060 Electrical distribution box cab CAN-bus


Interior lighting
Engine heater start inhibitor, bridged

VDCF03.01GB Workshop Manual DCF 90-100


11 Common electrics – 11.5.5 Cables 31

Connec- Location Function


tor
X060A Extension X060 CAN-bus
Interior lighting
Engine heater start inhibitor, bridged

X061 Electrical distribution box cab Earth connection, Control unit KID (D795)
Power supply, Control unit KIT (D790-2)

X061A Extension X061 Earth connection, Control unit KID (D795)


Power supply, Control unit KIT (D790-2)

X062 Electrical distribution box cab Horn


Compressed air horn
Map lighting
Cigarette lighter 12V
Windscreen wiper front
Heater fan motor
Actuator, recirculation

X063 Electrical distribution box cab Sensor operator in seat


Seat heater
Compressed-air damped seat

X065 Electrical distribution box cab Ambient temperature sensor

X066 Electrical distribution box cab Accelerator pedal


Interior lighting
Switch, entry lighting

X067 Electrical distribution box cab Customisation

X069 Electrical distribution box cab Sensor, twistlock open/closed


Twistlock relay
Spreading relay

X070 Electrical distribution box cab Sensor twistlocks


Spreading relay
RMI

X072 To Right Behind Seat Power outlet

X080 Instrument panel, cab Switch, mast/attachment work lights


Switch, main beams
Switch, rotating beacon
Switch, seat heater
Switch, option

Workshop Manual DCF 90-100 VDCF03.01GB


32 11 Common electrics – 11.5.5 Cables

Connec- Location Function


tor
X081 Instrument panel, cab Switch, option
Switch warning light (Hazard)
Extra sensors
Hour counter

X082 Instrument panel, cab NC switch, cab doors

X090 Electric servo panel, cab Electric servo


Electric servo, lift/lower
Electric servo, tilt
Electric servo, side shift
Electric servo, spreading
Electric servo, auxiliary

X091 Electric servo panel, cab Horn


Switch, spreading
Switch, twistlock
Switch, levelling

X092 Electric servo panel, cab Switch, twistlock


Reversible operator's seat

X168 Electrical distribution box frame Power supply attachment control unit

X201 Electrical distribution box frame Earth connection and power supply, Control unit transmission (D793)

X203 Electrical distribution box frame Termination resistor

X204 Front edge of frame Mast work lights

X205 Electrical distribution box frame CAN-bus


Transmission control unit (D793)

X207 Front edge of frame Sensor alignment


Sensor twistlocks

X209 Front edge of frame Power supply, cab control unit (D790-1)
CAN bus, frame control unit (D797-1)
CAN bus, 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)

VDCF03.01GB Workshop Manual DCF 90-100


11 Common electrics – 11.5.5 Cables 33

Connec- Location Function


tor
X212 Frame control unit (D797-1) Power supply and ground connection, frame control unit (D797-1)
CAN bus, frame control unit (D797-1)
Temperature hydraulic oil
Emergency stop switch voltage
Sensor, fuel level
D+ alternator

X214 Front edge of frame CAN bus, 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

X230 Beneath driver’s seat Sensor operator in seat

X235 Front edge of frame Lift/lower valve


Tilt valve
Mast valves

X240 Front edge of frame Power supply

X241 Front edge of frame Option

X242 Front edge of frame Option

X243 Front edge of frame Low beam rear


High beam rear
Tail light front
Switch, reversible driver’s seat
Control valve, reversible driver’s seat
Directional control valve, steering forward/rearward

X244 Front edge of frame Side shift valve


Spreading valve
Control valve load handling
Control valve, mini-wheel/lever steering

X245 Under cab Switch, reversible driver’s seat


Position sensor, reversible driver’s seat

X247 Front edge of frame Brake light forward

X248 Front edge of frame Mast position sensor


Position sensor, automatic cab tilt

Workshop Manual DCF 90-100 VDCF03.01GB


34 11 Common electrics – 11.5.5 Cables

Connec- Location Function


tor
X251 Control unit transmission (D793), 30-pin connector for Transmission control unit (D793)
electrical distribution box frame

X252 Control unit transmission (D793), 18-pin connector for Transmission control unit (D793)
electrical distribution box frame

X253 Gear box Solenoid valves, transmission


Pressure sensor, transmission

X259 Gear box Temperature sensor, transmission oil for radiator

X261 Electrical distribution box frame RS232 Control unit transmission (D793)

X264 Electrical distribution box frame Solenoid valve brake transmission

X270 Lamp bracket left front Main and dipped beams


Driving direction indicator
Side marker lights

X271 Lamp bracket front Main and dipped beams


Driving direction indicator
Side marker lights

X272 Lamp bracket left rear Tail light


Brake light
Driving direction indicator
Side marker lights

X273 Lamp bracket right rear Tail light


Brake light
Driving direction indicator
Side marker lights

X275 Rear edge of frame Tail light


Brake light
Driving direction indicator
Side marker lights
Reversing alarm

X276 Under cab Entry lighting


Switch, entry lighting

X278 Between engine and gearbox Compressor air conditioning


Relay, start key

X279 Engine control unit (D794) Power supply and earth connection, Control unit engine (D794)
CAN-bus Drivetrain

X280 Engine Coolant level

X301 Mast Mast position sensor

VDCF03.01GB Workshop Manual DCF 90-100


11 Common electrics – 11.5.5 Cables 35

Connec- Location Function


tor
X302 Mast Position sensor, automatic cab tilt

X400 Attachment control unit (D791) Power supply and ground connection, attachment control unit (D791)

X401 Attachment control unit (D791) CAN bus, attachment control unit

X403 Carriage middle Sensor, abutment right side


Sensor, twistlocks right side
Work lighting, right side

X404 Carriage middle Sensor, abutment left side


Sensor, twistlocks left side
Work lighting, left side

X415 Attachment, right side Indicator light locked twistlocks


Indicator light, unlocked twistlocks
Indicator light alignment

X421 Attachment control unit (D791) 42-pin connector for Control unit attachment (D791)

X422 Attachment control unit (D791) Power supply and earth connection, Control unit attachment (D791)
CAN bus Control unit attachment option (D791)
Emergency stop switch voltage

X425 Carriage middle Sensor, stop at 30’ left


Sensor, end position 20-40’ left

X426 Carriage middle Sensor, stop at 30’ right


Sensor, end position 20-40’ right

X428 Cab Rotating beacon

X612 Air conditioning system Actuator motor, recirculation

X645 Engine Compressor air conditioning

X651 Cab Motor, windscreen washers

X657 Cab Heater fan

X660 Engine Alternator

X690 Cab Accelerator pedal

X759 Engine Coolant level

X774 Cab Ambient temperature

X775 Cab Temperature sensor, cab, fan, refrigerant

X815 Cab Power assisted system

X825 Cab Mini-wheel

X900 Cab CD player

Workshop Manual DCF 90-100 VDCF03.01GB


36 11 Common electrics – 11.5.5 Cables

Connec- Location Function


tor
X901 Voltage converter, cab Voltage converter 24 V/12 V
Socket 24 V

VDCF03.01GB Workshop Manual DCF 90-100


11 Common electrics – 11.5.5 Cables 37

Signal types, general


page

The machine’s control units use a number of different types of signals


to receive signals from sensors and switches and control solenoid
valves, lights, etc. The table below describes the different signal types.

Signal type Explanation Usage area

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.

Accuracy is ±0.5 °C in the interval 0 –100 °C (sensor’s measurement in-


accuracy not included). Outside of the interval 0 –100 °C, accuracy is
±2 °C.

Voltage An analogue signal 0–5 V. The work range is 0.5 to 4.5 V. E.g. accelerator pedal
and analogue cab con-
trols (operating lever and
heater controls).

Analogue outputs

Current feedback A modulated signal between 0 V and system voltage, i.e. 24 V. The work Hydraulics, e.g. lifting/
voltage out, PWM range is 0 to 2 A. lowering of the boom.
A modulated signal is a digital signal translated to an analogue (continu- Used when the output
ous) signal adapted for a purpose, such as solenoid valve control. signal actuates propor-
When the spool in a solenoid valve gets hot, resistance drops. This gen- tional solenoid valves.
erates a lower current through the valve spool, which can cause the
valve’s servo pressure to remain constant. An internal 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.

Workshop Manual DCF 90-100 VDCF03.01GB


38 11 Common electrics – 11.5.5 Cables

Signal type Explanation Usage area

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.

Open load 0.15 A


Max. instantaneous current load, 8 A

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.

Open load 0.9 A


Max. instantaneous current load, 35 A

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).

Open load 0.15 A


Max. instantaneous current load, 8 A
The H-bridge works with two outputs in a pair. At logic one (1), one output
gives voltage while the other output is grounded. At logic zero (0), the out-
puts switch voltage levels.

VDCF03.01GB Workshop Manual DCF 90-100


11 Common electrics – 11.6 Communication 39

11.6 Communication
11.6.1 CAN-bus
CAN bus, description
page

Communication between the control units takes place using so-called


1 2
"CAN buses" (Controller Area Network) based on the ISO 11898
standard and CAN specification 2.0B.
The CAN bus is a fast control bus with logical hardware circuits. A sim-
120 ohm 120 ohm
ple technology that is highly reliable (low error frequency), which is a
requirement for control signals to be able to regulate systems based
on varying conditions and requirements.
CAN specifies:
5 5
• that the signal traffic is carried by "twisted pair" cables
3
4 • that termination resistors (position 1) are necessary (adapted to
2 cables’ impedance) so that the pulse train (position 4) can obtain
U [V]

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

B C D E F G CAN works in messages sent in frames of 8 bytes (64 bits). A com-


000027

plete message is approx. 100 bits long. The illustration 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.

Workshop Manual DCF 90-100 VDCF03.01GB


40 11 Common electrics – 11.6.1 CAN-bus

Control field (D)


Indicates how the length of the data segment that follows.
Data segment (E)
Contains the information to be conveyed to control units in the net-
work.
Checksum for error detection (F)
Calculates a checksum for the message. This makes it possible for the
receiving control unit to detect errors in the sent message.
Acknowledge (G)
The transmitting control unit sets a bit to logic one (1) when the mes-
sage is sent. The first control unit to receive the message sends it on
and sets the bit to logic zero (0).

Communication
The CAN network consists of control units and segment. The segment
(bus) is a twisted pair cable that leads CAN + and CAN - signal levels
from control unit to control unit.
Each control unit measures the potential difference of its two inputs.
3,5 V The potential difference generates logic zero and logic one. The illus-
tration depicts an approved interval according to the standard for po-
tential levels. CAN + has a recommended value of 3.5 V and CAN -
U [V]

has 1.5 V. As a worst case scenario, the potential difference can be


0,5 V 0.5 V and still be approved. In practice, a potential difference of 2 V is
recommended for reliable communication.
Pulse trains can only be observed using an oscilloscope, NOT with a
1,5 V digital multimeter.
When a message is sent, all control units in the network listen. Mes-
sages are saved in the control unit and relevant information is proc-
essed. The control unit that receives the message first confirms
000028

t [S] receipt (sets an acknowledge bit). The transmitting control unit then
knows that the message has been received by at least one 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),

VDCF03.01GB Workshop Manual DCF 90-100


11 Common electrics – 11.6.2 Redundant CAN bus 41

HLP High Layer Protocol


CAN only specifies messages and how communication shall take
place, i.e. one protocol. In order to manage the network the CAN pro-
tocol needs to be supplemented by a HLP which specifies:
• flow control
• transport of data above a length of 8 bits in 8 bit messages (divi-
sion)
• how control units are addressed in the network
• how bits in the message's data field shall be interpreted

11.6.2 Redundant CAN bus


Redundant CAN bus, description
page

The redundant CAN bus handles communication between all of the


D791 D790-1 D790-2 D795 machine’s control units except the transmission control unit (D793)
CAN R CAN L CAN R CAN L CAN R CAN L
and the engine control unit (D794). These have a separate CAN bus;
see Drivetrain CAN bus, description page 43.
CAN L CAN R CAN L CAN R
009750

D797-2 D797-1

Principle illustration, redundant CAN bus


Redundant CAN bus means that the control units are connected to a
D790-1 D791 D797-1 network that communicates via a CAN bus (see CAN bus, description
CAN L CAN R CAN L CAN R CAN L CAN R
page 39) and that there are double communication routes on the net-
4 1 2 work. The network is divided into control units and segments (seg-
3 ments are cables between the control units). The number of active
CAN R CAN L
segments depends on the number of control units the machine has,
009752

D795 which depends on the machine’s equipment level (options).

Segment numbering starts from the CAN-R (right)


connection
The network is built on the CAN kingdom principle, which means that
D790-1 D791 D797-2 D797-1 one control unit is central and is the master unit. In this case, it is the
CAN L CAN R CAN L CAN R CAN L CAN R CAN L CAN R
cab control unit (D790-1). Other control units in the network are sec-
5 1 2 3 ondary (slaves) and handle special areas, e.g. machine components.
4 The control units have two CAN bus connections - CAN L (left) and
CAN R CAN L
CAN R (right). The control units are connected to one another in series
009751

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.

Workshop Manual DCF 90-100 VDCF03.01GB


42 11 Common electrics – 11.6.2 Redundant CAN bus

Connection of redundant CAN bus

Condition Refer- Reference


ence
value
Battery disconnect switch In position Battery disconnect switch, description page 3
1

Redundant voltage feed Activated. Redundant voltage feed for control units, description of operation page 7

D791 S1 D790-1 S5 D795 S4

2 1, 7 5
S2
D790-2
6
3 4

009754
D797-2 S3 D797-1

Pos Explanation Signal description Reference


1 The cab control unit (D790-1) establish- Checked by control sys- Cab control unit (D790-1), description page
es redundant CAN bus communication tem, error shown with er- 18
by sending a request on the CAN bus ror code. Diagnostic menu, see section 8 Control sys-
via CAN R. tem, group 8.4.1.1 CAN/POWER, menu 1
and 8.4.1.2 CAN/POWER, menu 2

2 The attachment control unit (D791) A clicking sound is audi- Attachment control unit (D791), description
sends a response back on the CAN bus ble when then termina- page 21
via CAN L and sends the request on via tion resistor is activated. Diagnostic menu, see section 8 Control sys-
CAN R. tem, group 8.4.1.1 CAN/POWER, menu 1
Termination resistors in the control and 8.4.1.2 CAN/POWER, menu 2
nodes ensure communication segment
by segment.

3 The frame control unit (D797-2) sends a A clicking sound is audi- Frame control unit (D797-2), description
response back on the CAN bus via CAN ble when then termina- page 20
L and sends the request on via CAN R. tion resistor is activated. Diagnostic menu, see section 8 Control sys-
Termination resistors in the control tem, group 8.4.1.1 CAN/POWER, menu 1
nodes ensure communication segment and 8.4.1.2 CAN/POWER, menu 2
by segment.

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.

VDCF03.01GB Workshop Manual DCF 90-100


11 Common electrics – 11.6.3 Drivetrain CAN bus 43

Pos Explanation Signal description Reference


5 The KID control unit (D795) sends a re- A clicking sound is audi- KID control unit (D795), description page 26
sponse back on the CAN bus via CAN L ble when then termina- Diagnostic menu, see section 8 Control sys-
and sends the request on via CAN R. tion resistor is activated. tem, group 8.4.1.1 CAN/POWER, menu 1
Termination resistors in the control and 8.4.1.2 CAN/POWER, menu 2
nodes ensure communication segment
by segment.

6 The KIT control unit (D790-2) is not con- A clicking sound is audi- KIT control unit (D790-2), description 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.

11.6.3 Drivetrain CAN bus


Drivetrain CAN bus, description
page

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

Workshop Manual DCF 90-100 VDCF03.01GB


44 11 Common electrics – 11.6.4 Communication between PC and machine

11.6.4 Communication between PC and


machine
Communication between PC and machine,
page

description
The machine has three or four sockets for communication between
control units and PC. Two are located in 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

1. Diagnostic socket machine


2. Engine diagnostic socket (Cummins engine), drive-
train CAN bus
3. Engine diagnostic socket, VODIA (Volvo engine)
4. Diagnostic socket transmission

VDCF03.01GB Workshop Manual DCF 90-100


11 Common electrics – 11.6.5 RMI (Remote Machine Interface) 45

11.6.5 RMI (Remote Machine Interface)


RMI (Remote Machine Interface), description
page

Remote Machine Interface is a tool for listening to the machine at a


distance. The interface consists of a control unit which is connected to

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.

As an option, there is a GPS-antenna, making it possible to read


off the machine’s position.

NOTE
RMI only sends data from the machine, no data can be sent to
the machine. RMI cannot be used to control the machine.

Workshop Manual DCF 90-100 VDCF03.01GB


46 11 Common electrics – 11.6.5 RMI (Remote Machine Interface)

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes 1

D Error codes

Table of Contents D Error codes


mm mm mm mm mm mm

Error codes ..................................................................................................... 3


Error codes, explanation ........................................................................................ 3
Error code menu, description ................................................................................. 4
Reading out error code ........................................................................................... 7
1 Engine ............................................................................................................. 9
Error codes engine, general ................................................................................... 9
Error codes engine (engine alternative Cummins QSB6.7) ................................. 11
Error codes engine (engine alternative Volvo TAD760VE) .................................. 35
2 Transmission................................................................................................ 50
Error codes, transmission ..................................................................................... 50
8 Control system ............................................................................................. 59
Error codes machine ............................................................................................ 59

Workshop Manual DCF 90-100 VDCF03.01GB


2 D Error codes

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – Error codes 3

Error codes
mm mm mm mm mm mm

Error codes, explanation


page

The error codes are explained in table form for Engine, Transmission
as well as Control system. They are sorted according to error code
number.
The error code table has the following information:
• Code, error code's number, shown in field C on display.
C
• Description, explanation of the error code and when it's generat-
D E ed.
• Limitation, in case of certain error codes certain functions are im-
B
000389

paired or limited to protect the machine and operator.


• Action, information of what should be checked to find the cause of
B. Error code level (symbol)
the error code.
C. Error code number
D. Cause of error (symbol) • Diagnostic menu, reference to suitable diagnostic menu to fix the
E. Function (symbol) problem, read signal value or check the function.
In addition to the explanation of the display figure, the description
of the diagnostic menus contains reference to circuit diagrams
that are found in section E Schematics and reference to function
group for further information about functions and components.
• Function group is a reference to which function group the error
code is connected. This field is used to search for more informa-
tion as necessary. The function group can be used to find different
types of information.
Sections 0-12 contain a description of the function and its compo-
nents, component position and work instructions for different
work.

Workshop Manual DCF 90-100 VDCF03.01GB


4 D Error codes – Error codes

Error code menu, description


page

The control system’s display is divided into four fields that show infor-
C mation (see figure to the left).

D E • Field B: Error code level shown with a symbol.


• Field C: Indicates error code.
B

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.

Field B: Error code level


The control system gives error code information in three levels which
are indicated with a symbol in the lower left corner (B) on the display
unit.
• Stop
C Indicates a serious malfunction that may affect operator safety or
cause machine breakdown. The error code must be taken care of
D E
immediately. Stop working with the machine and contact service
immediately.
000350

The error code is shown automatically on the display.

• Warning
C Indicates machine malfunction that should be taken care of as
soon as possible. After finished work shift with the machine, con-
D E
tact service as soon as possible.
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.

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – Error codes 5

Field C: Error code number


The control system gives error codes from three sub-systems:
• Machine:
C
Shown with error code number XXX on display.
D E

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

Field D: Type of error


1. Too high/too low temperature.
1 2 3
2. Incorrect signal to solenoid valve.
3. Incorrect hydraulic pressure.
4. Incorrect sensor signal.

4 5 6 5. Incorrect signal from control.


6. Incorrect signal to bulb.
7. Incorrect signal, for example, open circuit.

7
000396

Workshop Manual DCF 90-100 VDCF03.01GB


6 D Error codes – Error codes

Field E: Affected function


1. Attachment
1 2 3
2. Rotation of attachment
3. Side shift of attachment
4. Length adjustment attachment
4 5 6
5. Leveling attachment
6. Twistlocks
7. Forks up/down
7 8 9 8. Tilt forks
9. Side shift forks
10. Spreading forks

10 11 12 11. Rotation forks


12. Overload protection
13. Hydraulic functions
14. Brake system
13 14 15
15. Steering
16. Engine
17. Transmission
16 17 18
18. Central lubrication
19. Control unit
20. Hardware-related error
19 20 21 21. Cab
22. Air conditioning system
23. Fuel system
22 23 24 24. Headlights
25. Windshield wipers
26. Battery voltage
25 26 27 27. Bulb for lighting
010153

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – Error codes 7

Reading out error code


page

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.

1 Turn the start key to position I.

WARNING
Risk of machine damage.

In case of error codes of level “WARNING” and


“STOP”, serious machine damage may result if the
engine is started.

Do not start the engine until the cause of the error


code has been identified or repaired.

2 Navigate to the service menu and press Enter.


000056

3 Safety menu is shown. 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.

Workshop Manual DCF 90-100 VDCF03.01GB


8 D Error codes – Error codes

5 Note error code number (field C) to not forget.


C
• Error code level is shown with a symbol in field B
D E • Error code is shown in field C

B • Error cause is shown with a symbol in field D

000389
• 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.

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – 1 Engine 9

1 Engine
mm mm mm mm mm mm

Error codes engine, general


page

When contacting engine suppliers, use Volvo/Cummins codes.


• Display indicates error code according to SAE J1939
SPN / FMI
• Flash indicates error code according to a flash code specified by
the engine supplier.
• J1587 indicates error code according to SAE J1587 (for Volvo:
Vodia).
PID, PPID, SID, PSID / FMI

Table 1. Specification FMI

FMI Description SAE-text


0 Too high value. Valid data, but higher than normal operating range.

1 Too low value. Valid data, but lower than normal operating range.

2 Incorrect data. Intermittent or incorrect data.

3 Electrical problem. Abnormally high voltage or short-circuiting to higher voltage.

4 Electrical problem. Abnormally low voltage or short-circuiting to lower voltage.

5 Electrical problem. Abnormally low current or open circuit.

6 Electrical problem. Abnormally high current or short-circuiting to frame ground.

7 Mechanical problem. Incorrect response from mechanical system.

8 Mechanical problem or electrical problem. Abnormal frequency.

9 Communication error. Abnormal update rate.

10 Mechanical problem or electrical problem. Abnormally wide variations.

11 Unknown malfunction. Non-identifiable error.

12 Component error. Defective unit or component.

13 Incorrect calibration. Values outside calibration values.

14 Unknown malfunction. Special instructions.

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

19 Communication error. Received network data in error

20-30 Reserved for SAE assignment

Workshop Manual DCF 90-100 VDCF03.01GB


10 D Error codes – 1 Engine

FMI Description SAE-text


31 FMI is not available or the condition that is Not available or condition exists
identified by the SPN exists.

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – 1 Engine 11

Error codes engine (engine


alternative Cummins QSB6.7)


Description Limitation Action Connec- Diagnos-
tions and tic menu
compo-
nents
Code J1587
84 / 2 P084 / 2 Machine Speed Sensor Cir- Engine speed limit- Check cabling D794 ENGINE,
cuit - Data Erratic, Intermit- ed to Maximum En- between con- menu 2
tent or Incorrect. The ECU gine Speed without trol unit and
794 lost the machine speed VSS parameter val- component.
signal. ue. Cruise control, Check the sen-
Gear-Down Protec- sor.
tion, and Road
Speed Governor
will not work.

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.

91 / 0 P91 / 0 Accelerator Pedal or Lever Severe derate in - - ENGINE,


Position Sensor 1 - Data power output of the menu 1
Valid but Above Normal Op- engine. Limp home
erational Range - Most Se- power only.
vere Level. A frequency of
more than 1500 Hz has
been detected at the fre-
quency throttle input to the
ECU 794.

91 / 1 P91 / 1 Accelerator Pedal or Lever Severe derate in - - ENGINE,


Position 1 Sensor Circuit power output of the menu 1
Frequency - Data Valid but engine. Limp home
Below Normal Operational power only.
Range - Most Severe Level.
A frequency of less than 100
HZ has been detected at the
frequency throttle input to
the ECU 794.

Workshop Manual DCF 90-100 VDCF03.01GB


12 D Error codes – 1 Engine

Description Limitation Action Connec- Diagnos-


tions and tic menu
compo-
nents
Code J1587
91 / 19 P91 SAE J1939 Multiplexing Ac- Engine may only Use diagnostic - -
celerator Pedal or Lever idle or engine will menu to find in-
Sensor System Error - Re- not accelerate to full correct seg-
ceived Network Data Error. speed. ment.
The OEM machine electron-
ic control unit (VECU) de-
tected a fault with its
accelerator pedal.

91 / 2 P31 / 2 Position sensor accelerator - - ENGINE,


pedal menu 1

91 / 3 P091 / 3 Accelerator Pedal or Lever Severe derate in Check cabling - ENGINE,


Position Sensor Circuit - power output of the between con- menu 1
Shorted High. High voltage engine. Limp home trol unit and
detected at accelerator ped- capability only. component.
al or lever position circuit. Check the
component.

91 / 4 P091 / 4 Accelerator Pedal or Lever Severe derate in Check cabling - ENGINE,


Position Sensor Circuit - power output of the between con- menu 1
Voltage Below Normal or engine. Limp home trol unit and
Shorted to Low Source. Low capability only. component.
voltage detected at acceler- Check the
ator pedal or lever position component.
signal circuit.

94 / 1 P94 / 1 Fuel pump delivery pressure Possibly hard to - D794 -


- data valid but below normal start; low power;
operational range - moder- possible engine
ately severe level. The ECU smoke. Engine can
794 has detected the fuel possibly not start.
pressure in the fuel rail is
lower than the commanded
performance.

94 / 2 P094 / 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.

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – 1 Engine 13

Description Limitation Action Connec- Diagnos-


tions and tic menu
compo-
nents
Code J1587
94 / 18 P94 / 0 Fuel pump delivery pressure None or possible - D794 -
- data valid but above nor- engine noise asso-
mal operational range - ciated with higher
moderately severe level. injection pressures
The ECU 794 has detected (especially at idle or
fuel pressure in the fuel rail light load). Engine
that is higher than the com- power is reduced.
manded pressure.

97 / 3 P097 / 3 Water-in-fuel indicator sen- None on perform- Check cabling D794 -


sor circuit - Voltage above ance. No water-in- between con-
normal or short circuited to fuel warning availa- trol unit and
high source. High voltage ble. component.
detected at the water-in-fuel Check the sen-
circuit. sor.

97 / 4 P097 / 4 Water-in-fuel indicator sen- None on perform- Check cabling D794 -


sor circuit - Voltage below ance. No water-in- between con-
normal or short circuited to fuel warning availa- trol unit and
low source. Low voltage de- ble. component.
tected at the water-in-fuel Check the sen-
circuit. sor.

97 / 15 P097 / 0 Water-in-fuel indicator - Possible white Drain water - -


Data valid but above normal smoke, loss of pow- from the fuel.
operational range - least se- er, or hard starting
vere level. Water has been
detected in the fuel filter.

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.

Workshop Manual DCF 90-100 VDCF03.01GB


14 D Error codes – 1 Engine

Description Limitation Action Connec- Diagnos-


tions and tic menu
compo-
nents
Code J1587
100 / 3 P100 / 3 Oil Pressure Sensor Circuit - None on perform- Check cabling D794 ENGINE,
Voltage Above Normal, or ance. No engine between con- menu 6
Shorted to High Source. protection for oil trol unit and
High signal voltage detected pressure. component.
at the engine oil pressure Check the sen-
circuit. 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.

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – 1 Engine 15

Description Limitation Action Connec- Diagnos-


tions and tic menu
compo-
nents
Code J1587
102 / 4 P102 / 4 Intake Manifold Pressure Derate in power Check cabling D794 ENGINE,
Sensor Circuit - Voltage Be- output of the en- between con- menu 6
low Normal or Shorted to gine. trol unit and
Low Source. Low signal volt- component.
age detected at the intake Check the sen-
manifold pressure circuit. sor.

103 / 10 P103 / Turbocharger speed - invalid Possible-low-pow- Check cabling D794 -


10 rate of change detected. The er estimated turbo- between con-
turbocharger speed sensor charger speed will trol unit and
has detected an erroneous be used. component.
speed value. Check the sen-
sor.

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

Workshop Manual DCF 90-100 VDCF03.01GB


16 D Error codes – 1 Engine

Description Limitation Action Connec- Diagnos-


tions and tic menu
compo-
nents
Code J1587
105 / 4 P105 / 4 Intake Manifold Air Temper- Possible white Check cabling D794 ENGINE,
ature 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 the ECU 794. No component.
signal voltage detected at in- engine protection Check the sen-
take manifold air tempera- for intake manifold sor.
ture 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.

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – 1 Engine 17

Description Limitation Action Connec- Diagnos-


tions and tic menu
compo-
nents
Code J1587
110 / 0 P110 / 0 Engine Coolant Tempera- Progressive power Check coolant - ENGINE,
ture - Data Valid but Above derate increasing in level. menu 7
Normal Operational Range - severity from time Check that ra-
Most Severe Level. Engine after alert. If the En- diator is clean.
coolant temperature signal gine Protection
indicates engine coolant Check if there’s
Shutdown feature is
temperature above engine enabled, engine will air in coolant
protection critical limit. system.
shut down 30 sec-
onds after the red Check the cap
STOP lamp starts on the expan-
flashing. sion tank.
Check the sen-
sor.
Check thermo-
stat.

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.

Workshop Manual DCF 90-100 VDCF03.01GB


18 D Error codes – 1 Engine

Description Limitation Action Connec- Diagnos-


tions and tic menu
compo-
nents
Code J1587
110 / 15 P110 / 0 Engine Coolant Tempera- Progressive power Check coolant D794 ENGINE,
ture High - Data Valid but derate increasing in level. menu 7
Above Normal Operational severity from time of Check that ra-
Range - Least Severe Level. alert. diator is clean.
Engine coolant temperature
Check if there’s
signal indicates coolant tem-
air in coolant
perature is above the engine
system.
coolant temperature engine
protection warning limit. Check the cap
on the expan-
sion tank.
Check the sen-
sor.
Check thermo-
stat.

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.

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – 1 Engine 19

Description Limitation Action Connec- Diagnos-


tions and tic menu
compo-
nents
Code J1587
111 / 3 P111 / 3 Coolant Level Sensor Circuit None on perform- Check cabling D794 -
- Voltage Above Normal or ance. between con-
Shorted to High Source. trol unit and
High signal voltage detected component.
at engine coolant level cir- Check the sen-
cuit. sor.

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 / 0 P94 / 0 Injector Metering Rail None or possible - D794 -


Number 1 Pressure - Data engine noise asso-
Valid But Above Normal Op- ciated with higher
erating Range - Most Severe injection pressures
Level. The ECU 794 has de- (especially at idle or
tected that fuel pressure in light load). Engine
the rail fuel is higher than the power is reduced.
commanded pressure.

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.

157 / 3 P157 / 3 Injector Metering Rail Power and or speed - D794 -


Number 1 Pressure Sensor derate.
Circuit - Voltage Above Nor-
mal or Shorted to High
Source. High signal voltage
detected at rail fuel pressure
sensor circuit.

157 / 4 P157 / 4 Injector Metering Rail Power and or speed - D794 -


Number 1 Pressure Sensor derate.
Circuit - Voltage Below Nor-
mal or Shorted to Low
Source. Low signal voltage
detected at the rail fuel pres-
sure sensor circuit.

Workshop Manual DCF 90-100 VDCF03.01GB


20 D Error codes – 1 Engine

Description Limitation Action Connec- Diagnos-


tions and tic menu
compo-
nents
Code J1587
157 / 16 P157 / 0 Injector Metering Rail 1 None or possible - D794 -
Pressure - Data Valid but engine noise asso-
Above Normal Operational ciated with higher
Range - Moderately Severe injection pressures
Level. The ECU 794 has de- (especially at idle or
tected that fuel pressure is light load). Engine
higher than commanded power is reduced.
pressure.

157 / 18 P157 / 1 Fuel Pump Delivery Pres- Possibly hard to - D794 -


sure Low - Data Valid but start, low power, or
Below Normal Operational engine smoke. En-
Range - Moderately Severe gine can possibly
Level. The ECU 794 has de- not start.
tected that fuel pressure is
lower than commanded
pressure.

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.

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – 1 Engine 21

Description Limitation Action Connec- Diagnos-


tions and tic menu
compo-
nents
Code J1587
168 / 18 S168 / 1 Battery 1 Voltage - Data Val- Engine may stop Check fuses. D794 -
id but Below Normal Opera- running or be diffi- Check batter-
tional Range - Moderately cult to start. ies and alterna-
Severe Level. ECU 794 sup- tor.
ply voltage is below the min-
imum system voltage level.

171 / 3 P171 / 3 Ambient temperature sen- - D794 -


sor, circuit fault- Abnormally
high voltage or short-circuit
to higher voltage.

171 / 4 P171 / 4 Ambient temperature sen- - D794 -


sor, circuit fault - Abnormally
low voltage or short-circuit to
lower voltage.

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.

Workshop Manual DCF 90-100 VDCF03.01GB


22 D Error codes – 1 Engine

Description Limitation Action Connec- Diagnos-


tions and tic menu
compo-
nents
Code J1587
251 / 2 P251 / 2 Real-Time Clock Power In- None on perform- - - -
terrupt - Data Erratic, Inter- ance. Data in the
mittent or Incorrect. Real- ECU 794 will not
time clock lost power. have accurate time
and date informa-
tion.

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.

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – 1 Engine 23

Description Limitation Action Connec- Diagnos-


tions and tic menu
compo-
nents
Code J1587
611 / 2 P089 / 2 Auxiliary Intermediate (PTO) Intermediate speed - D794 -
Speed Switch Validation - control switch may
Data Erratic, Intermittent, or not operate correct-
Incorrect. The position of the ly.
intermediate speed control
switch 1 does not match the
position of the intermediate
speed control validation
switch.

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 3 Circuit - Possible hard start- - D794 -


Voltage Below Normal, or ing and rough run-
Shorted to Low Source. Low ning.
voltage detected on the +5
volt sensor supply circuit to
the engine speed sensor.

611 / 4 S232 / 4 Sensor Supply Voltage 4 Engine will only die. - D794 -
Circuit - Voltage Below Nor-
mal or Shorted to Low
Source. Low voltage detect-
ed at +5 VDC sensor supply
circuit to the accelerator
pedal position sensor.

611 / 15 S151 / 0 Turbocharger compressor Fuel is limited in an - D794 -


outlet temperature - data attempt to decrease
above normal. High turbo- the calculated tur-
charger compressor outlet bocharger com-
temperature has been calcu- pressor outlet
lated by the ECU 794. temperature.

612 / 2 P190 / 2 Engine Magnetic Crankshaft Fueling to the injec- - D794 -


Speed/Position lost both of tors is disabled, and
two signals - Data Erratic, In- the engine can not
termittent, or Incorrect. The be started.
ECU 794 has detected that
the primary engine speed
sensor and the backup en-
gine speed sensor signals
are reversed.

Workshop Manual DCF 90-100 VDCF03.01GB


24 D Error codes – 1 Engine

Description Limitation Action Connec- Diagnos-


tions and tic menu
compo-
nents
Code J1587
627 / 2 S251 / 2 Power Lost without Ignition Possible no notice- Check fuses. D794 -
Off - Data Erratic, Intermit- able performance Check batter-
tent or Incorrect. Supply volt- effects or engine ies and alterna-
age to the ECU 794 fell dying or hard start- tor.
below 6.2 volts momentarily, ing. Fault informa-
or the ECU 794 was not al- tion, trip
lowed to power down cor- information, and
rectly (retain battery voltage maintenance moni-
for 30 seconds after key tor data can be in-
OFF). accurate.

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.

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – 1 Engine 25

Description Limitation Action Connec- Diagnos-


tions and tic menu
compo-
nents
Code J1587
630 / 2 S253 / 2 Engine Control Module Data Possible no notice- Re-program D794 -
Lost - Data Erratic, Intermit- able performance the software in
tent or Incorrect. Severe loss effects or engine Control unit en-
of data from the ECU 794. dying or hard start- gine (D794).
ing. Fault informa-
tion, trip
information, and
maintenance moni-
tor data can be in-
accurate.

630 / 31 S240 / Engine Control Module Cali- Possible no notice- - D794 -


11 bration Program Memory able performance
(RAM) Corruption - Condi- effects or engine
tion Exists. Severe loss of dying or hard start-
data from the ECU 794. ing. Fault informa-
tion, trip
information, and
maintenance moni-
tor data can be in-
accurate.

633 / 31 S018 / Fueling Actuator Number 1 Possible low power. - D794 -


11 Circuit Error Conditions Ex-
ists. Fuel pump actuator cir-
cuit resistance too high or
too low.

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.

Workshop Manual DCF 90-100 VDCF03.01GB


26 D Error codes – 1 Engine

Description Limitation Action Connec- Diagnos-


tions and tic menu
compo-
nents
Code J1587
641 / 3 S027 / 3 VGT actuator driver circuit - Possible low power. - D794 -
voltage above normal or Power removed
shorted to high source. from the turbo-
charger actuator
motor.

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.

644 / 2 S030 / 2 External Speed Command Primary or second- Check cabling - -


Input (Multiple Unit Synchro- ary engines may be between con-
nization) - Data Erratic, In- shut down trol unit and
termittent, or Incorrect. The component.
throttle input signal to the Check compo-
primary or secondary engine nent.
for multiple unit synchroniza-
tion is less than 3 percent or
more than 97 percent.

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.

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – 1 Engine 27

Description Limitation Action Connec- Diagnos-


tions and tic menu
compo-
nents
Code J1587
651 / 7 S001 / 7 Injector Solenoid Driver Cyl- Engine will shut Check cabling D794 -
inder 1 - 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 1. jector.

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.

Workshop Manual DCF 90-100 VDCF03.01GB


28 D Error codes – 1 Engine

Description Limitation Action Connec- Diagnos-


tions and tic menu
compo-
nents
Code J1587
654 / 7 S004 / 7 Injector Solenoid Driver Cyl- Engine will shut Check cabling D794 -
inder 4 - 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 4. 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.

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – 1 Engine 29

Description Limitation Action Connec- Diagnos-


tions and tic menu
compo-
nents
Code J1587
677 / 4 S39 / 4 Starter Relay Circuit - Volt- The engine will not Check cabling D794 ENGINE,
age Below Normal or Short- have starter lockout between con- menu 5
ed to Low Source. Low protection. trol unit and
voltage detected at starter component.
lockout circuit. Check the re-
lay.

697 / 3 S057 / 3 Auxiliary PWM Driver #1 - Can not control - D794 -


Voltage Above Normal or transmission.
Shorted to High Source.
High signal voltage detected
at the analog torque circuit.

697 / 4 S057 / 4 Auxiliary PWM Driver #1 - Can not control - D794 -


Voltage Below Normal or transmission.
Shorted to Low Source. Low
signal voltage detected at
the analog torque circuit.

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.

Workshop Manual DCF 90-100 VDCF03.01GB


30 D Error codes – 1 Engine

Description Limitation Action Connec- Diagnos-


tions and tic menu
compo-
nents
Code J1587
723 / 7 S064 / 7 Engine Speed Sensor/Posi- Engine will run der- Check cabling D794 -
tion Camshaft and Crank- ated. Excessive between con-
shaft Misalignment - smoke, hard start, trol unit and
Mechanical System Not Re- and rough idle pos- component.
sponding Properly or Out of sible. Check the sen-
Adjustment. Mechanical sor.
misalignment between the
crankshaft and camshaft en-
gine speed sensors.

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.

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – 1 Engine 31

Description Limitation Action Connec- Diagnos-


tions and tic menu
compo-
nents
Code J1587
1043 / 3 S221 / 3 Accelerator Pedal or Lever Engine will only idle. Check cabling D794 -
Position Sensor Supply Volt- between con-
age Circuit - Voltage Above trol unit and
Normal or Shorted to High component.
Source. High voltage detect- Check compo-
ed at sensor supply circuit nent.
for the accelerator pedal or
lever position sensor.

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.

Workshop Manual DCF 90-100 VDCF03.01GB


32 D Error codes – 1 Engine

Description Limitation Action Connec- Diagnos-


tions and tic menu
compo-
nents
Code J1587
1073 / 3 S029 / 3 Engine Brake Actuator Cir- Engine brake on Check cabling D794 -
cuit #2 - Voltage Above Nor- cylinders 4, 5, and 6 between con-
mal or Shorted to High can not be activat- trol unit and
Source. Open circuit or high ed. component.
voltage detected at the en- Check compo-
gine brake solenoid number nent.
2 signal circuit.

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.

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – 1 Engine 33

Description Limitation Action Connec- Diagnos-


tions and tic menu
compo-
nents
Code J1587
1080 / 3 S232 / 3 Sensor Supply 2 Circuit - Engine power der- Check cabling D794 -
Voltage Above Normal or ate. between con-
Shorted to High Source. trol unit and
High voltage detected at component.
sensor supply number 2 cir- Check the sen-
cuit. 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.

1137 / 2 S114 / 2 Multiple Unit Synchroniza- Multi-Unit synchro- - D794 -


tion Switch - Data Erratic, In- nization feature is
termittent, or Incorrect. disabled.
Multi-Unit synchronous ON/
OFF switch and Multi-Unit
synchronous complimenta-
ry ON/OFF switch have dif-
ferent values in the ECU
794.

1172 / 3 /3 Turbocharger Number 1 Engine power der- - D794 -


Compressor Inlet Tempera- ate.
ture Sensor Circuit - Voltage
Above Normal or Shorted to
High Source. High signal
voltage detected at the tur-
bocharger compressor inlet
air temperature circuit.

1172 / 4 /4 Turbocharger Number 1 Engine power der- - D794 -


Compressor Inlet Tempera- ate.
ture Sensor Circuit - Voltage
Below Normal or Shorted to
Low Source. Low signal volt-
age detected at the turbo-
charger compressor inlet air
temperature sensor circuit.

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.

Workshop Manual DCF 90-100 VDCF03.01GB


34 D Error codes – 1 Engine

Description Limitation Action Connec- Diagnos-


tions and tic menu
compo-
nents
Code J1587
1347 / 4 S126 / 4 High Fuel Pressure Solenoid Engine will run - D794 -
Valve Circuit - Voltage Be- poorly at idle. En-
low Normal or Shorted to gine will have low
Low Source. Electronic fuel power. Fuel pres-
control actuator shorted low. sure will be higher
than commanded.

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.

1378 / 31 S153 / Change Lubricating Oil and None on perform- - D794 -


11 Filter - Condition Exists. ance; maintenance
Change engine oil and filter. reminder only.

1388 / 3 P223 / 3 Auxiliary Pressure Sensor None on perform- - D794 -


Input 1 Circuit - Voltage ance.
Above Normal, or Shorted to
High Source. High signal
voltage detected at the OEM
pressure circuit.

1388 / 4 P223 / 4 Auxiliary Pressure Sensor None on perform- - D794 -


Input 1 Circuit - Voltage Be- ance.
low Normal, or Shorted to
Low Source. Low signal volt-
age or open circuit detected
at the OEM pressure circuit.

2789 / 15 /0 Exhaust gas temperature - Derate in power - D794 -


data above normal. High ex- output of the engine
haust temperature has been in attempt to de-
calculated by the electronic crease the calculat-
control system. ed exhaust gas
temperature value.

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – 1 Engine 35

Error codes engine (engine


alternative Volvo TAD760VE)


Description Limitation Action Connec- Diag-
tions and nostic
compo- menu
nents
Code Flas J1587
h
94/1 3.8 PID94/1 Low fuel pressure No limitation. Change fuel filter. - -
(feed). Change fuel pre-filter.
Check if pressure can
be built up with the
hand pump.

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.

97/0 2.1 PID97/0 Water in fuel. No limitation. Drain water separator. - -


Clean metal filter in
the fuel feed’s hose
connection on the en-
gine.
Check fuel filter and
fuel pre-filter.

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.

Workshop Manual DCF 90-100 VDCF03.01GB


36 D Error codes – 1 Engine

Description Limitation Action Connec- Diag-


tions and nostic
compo- menu
nents
Code Flas J1587
h
100/0 6.6 PID100/ Low engine oil Engine will shut Check oil level. - EN-
0 pressure. down. Change oil filter. GINE,
menu 6
Check the system
pressure valves and
the safety valve in the
lubrication system.
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

Check fuel quality and


injectors.

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.

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – 1 Engine 37

Description Limitation Action Connec- Diag-


tions and nostic
compo- menu
nents
Code Flas J1587
h
106/5 3.4 PID106/ Sensor boost Reduced engine Check cabling be- D794/A:22 EN-
5 pressure, cable power. tween control unit and GINE,
open circuit. component. menu 7
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.

Workshop Manual DCF 90-100 VDCF03.01GB


38 D Error codes – 1 Engine

Description Limitation Action Connec- Diag-


tions and nostic
compo- menu
nents
Code Flas J1587
h
158/1 3.9 PID158/ Low battery volt- Engine may be Check and charge the D794/B:57, -
1 age. difficult to start. batteries. B:60
Check the alternator.
Check the battery ca-
bles.

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.

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – 1 Engine 39

Description Limitation Action Connec- Diag-


tions and nostic
compo- menu
nents
Code Flas J1587
h
629/3 9.9 SID254/ Engine control The engine will Change the control - -
3 unit (D794), inter- not start. unit.
nal fault.

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.

Workshop Manual DCF 90-100 VDCF03.01GB


40 D Error codes – 1 Engine

Description Limitation Action Connec- Diag-


tions and nostic
compo- menu
nents
Code Flas J1587
h
639/2 6.5 SID231/ Communication Engine off: en- Use diagnostic menu D794/ CAN/
2 error with Engine gine cannot be to find incorrect seg- B:51, B:55 POWER,
control unit started. ment. menu 3
(D794), configura- Engine on: en- Check cabling be-
tion error. gine goes to idle tween control unit and
and can only be component.
stopped by using Check the control unit.
the emergency
stop.

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 6.4 PSID201 Communication Instruments and Use diagnostic menu - -


1675/ /9 error with Engine controls do not to find incorrect seg-
9 control unit work. ment.
(D794), configura- Check cabling be-
tion error. tween control unit and
component.
Check the control unit.

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.

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – 1 Engine 41

Description Limitation Action Connec- Diag-


tions and nostic
compo- menu
nents
Code Flas J1587
h
651/4 7.1 SID1/4 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.

Workshop Manual DCF 90-100 VDCF03.01GB


42 D Error codes – 1 Engine

Description Limitation Action Connec- Diag-


tions and nostic
compo- menu
nents
Code Flas J1587
h
652/7 7.2 SID2/7 Incorrect com- Runs rough at Check fuel pressure. D794/A:16 -
pression or defec- low rpms and low Check valve clear-
tive injector load. ance.
cylinder 2.
Check cabling be-
tween control unit and
component.
Check the injector.
Perform compression
test and check cylin-
der 2.

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.

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – 1 Engine 43

Description Limitation Action Connec- Diag-


tions and nostic
compo- menu
nents
Code Flas J1587
h
653/ 7.3 SID3/12 Electric failure, in- Engine runs on 5 Check cabling be- D794/A:32 -
12 jector cylinder 3. cylinders, sounds tween control unit and
rough and has re- component.
duced power. Check the injector.

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.

Workshop Manual DCF 90-100 VDCF03.01GB


44 D Error codes – 1 Engine

Description Limitation Action Connec- Diag-


tions and nostic
compo- menu
nents
Code Flas J1587
h
655/5 7.5 SID5/5 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.

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – 1 Engine 45

Description Limitation Action Connec- Diag-


tions and nostic
compo- menu
nents
Code Flas J1587
h
656/7 7.6 SID6/7 Incorrect com- Runs rough at Check fuel pressure. D794/A:40 -
pression or defec- low rpms and low Check valve clear-
tive injector load. ance.
cylinder 6.
Check cabling be-
tween control unit and
component.
Check the injector.
Perform compression
test and check cylin-
der 6.

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.

679/3 - SID42/3 Pressure relief Engine speed Check cabling be- - -


valve, short- limited to 1100 tween control unit and
circuited to volt- rpm. component.
age. Check the component.

Workshop Manual DCF 90-100 VDCF03.01GB


46 D Error codes – 1 Engine

Description Limitation Action Connec- Diag-


tions and nostic
compo- menu
nents
Code Flas J1587
h
679/4 - SID43/4 Pressure relief Engine speed Check cabling be- - -
valve, short- limited to 1100 tween control unit and
circuited to rpm. component.
ground. Check the component.

679/5 - SID43/5 Pressure relief Engine speed Check cabling be- - -


valve, open cir- limited to 1100 tween control unit and
cuit. rpm. component.
Check the component.

679/7 - PSID97/ Pressure relief Engine speed Check cabling be- - -


7 valve, mechanical limited to 1100 tween control unit and
defect. rpm. component.
Reduced engine Check the component.
power.

679/ - PSID97/ Pressure relief Engine speed Check cabling be- - -


11 11 valve, unidenti- limited to 1100 tween control unit and
fied problem. rpm. component.
Reduced engine Check the component.
power.

679/ - PSID97/ Pressure relief Engine speed Check cabling be- - -


14 14 valve, defective limited to 1100 tween control unit and
component. 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.

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – 1 Engine 47

Description Limitation Action Connec- Diag-


tions and nostic
compo- menu
nents
Code Flas J1587
h
1079/ 9.3 SID 232/ Reference voltage No limitation. Check cabling be- D794/B:17 -
3 3 5 V no. 1 to sen- tween control unit and
sor, short- component.
circuited to volt- Check the sensor.
age.

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.

Workshop Manual DCF 90-100 VDCF03.01GB


48 D Error codes – 1 Engine

Description Limitation Action Connec- Diag-


tions and nostic
compo- menu
nents
Code Flas J1587
h
1239/ - PSID 96/ Sensor fuel pres- Engine speed Check cabling be- D794/B:16 -
7 7 sure, mechanical limited to 1100 tween control unit and
defect. rpm. component.
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.

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – 1 Engine 49

Description Limitation Action Connec- Diag-


tions and nostic
compo- menu
nents
Code Flas J1587
h
- - PPID High fuel pres- Engine speed Check fuel feed. - -
435/0 sure. limited to 1100
rpm.
High engine pow-
er. (Powerful en-
gine)

- - 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.

Workshop Manual DCF 90-100 VDCF03.01GB


50 D Error codes – 2 Transmission

2 Transmission
mm mm mm mm mm mm

Error codes, transmission


page

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

00/50 Memory error in con- Transmission locked in - - -


trol unit transmission. neutral (shutdown).

00/51 Memory error in con- Transmission locked in - - -


trol unit transmission. neutral (shutdown).

00/52 Memory error in con- Transmission locked in - - -


trol unit transmission. neutral (shutdown).

00/53 Memory error in con- Transmission locked in - - -


trol unit transmission. neutral (shutdown).

20/60 Sensor oil pressure Transmission locked in Check 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

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – 2 Transmission 51

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.

Workshop Manual DCF 90-100 VDCF03.01GB


52 D Error codes – 2 Transmission

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)

46/05 Max. torque for inch- - - - -


ing has been exceed-
ed.

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.

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – 2 Transmission 53

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.

54/00 Reference voltage - Check cabling between - CAN/


sensor 5 V short- control unit and compo- POWER,
circuiting to frame nent. menu 12
ground. Check the sensor.

54/01 Reference voltage - Check cabling between - CAN/


sensor 5 V open cir- control unit and compo- POWER,
cuit. nent. menu 12
Check the sensor.

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.

Workshop Manual DCF 90-100 VDCF03.01GB


54 D Error codes – 2 Transmission

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.

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – 2 Transmission 55

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.

Workshop Manual DCF 90-100 VDCF03.01GB


56 D Error codes – 2 Transmission

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.

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – 2 Transmission 57

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).

77/02 All gear packs Transmission locked in - - -


disengaged. neutral (shutdown).

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.

Workshop Manual DCF 90-100 VDCF03.01GB


58 D Error codes – 2 Transmission

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.

90/xx - 99/ System error. Transmission locked in - D793/ -


xx neutral (shutdown). A:20

95/71 Control unit cannot in- - -


terpret input data.

99/90 Incorrect software in - -


control unit
transmission.

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – 8 Control system 59

8 Control system
mm mm mm mm mm mm

Error codes machine


page

Cod Description Limitation Action Connec- Diagnos- Group


e tions and tic menu
components
1 Communication er- – Use diagnostic menu to D797-1 CAN/ 11.6.2 Re-
ror with frame con- find incorrect segment. POWER, dundant
trol unit (D797-1) menu 1-3 CAN-bus

2 Communication er- – Use diagnostic menu to D797-2 CAN/ 11.6.2 Re-


ror with frame con- find incorrect segment. POWER, dundant CAN
trol unit (D797-2) menu 1-3 bus

3 Communication er- – Use diagnostic menu to D791-1 CAN/ 11.6.2 Re-


ror with attachment find incorrect segment. POWER, dundant
control unit (D791- menu 1-3 CAN-bus
1).

8 Communication er- – Use diagnostic menu to D795 CAN/ 11.6.2 Re-


ror with KID control find incorrect segment. POWER, dundant
unit (D795) menu 1-3 CAN-bus

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.

Workshop Manual DCF 90-100 VDCF03.01GB


60 D Error codes – 8 Control system

Cod Description Limitation Action Connec- Diagnos- Group


e tions and tic menu
components
20 Accelerator pedal Accelerator Calibrate the gas pedal, D790-1/K6:11 CALIBRA- 1. Engine
not calibrated pedal for for- see the section 8 Con- – R690-1 TION:
ward opera- trol system, group DRIVE-
tion not 8.5.2.3 Calibrate DRIVE- TRAIN,
working. En- TRAIN. menu 1
gine speed and 2
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.

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – 8 Control system 61

Cod Description Limitation Action Connec- Diagnos- Group


e tions and tic menu
components
32 Incorrect 5 V refer- Analogue Check the wiring be- D790-1/K4:5, K CAN/ 11.5.3.1 Con-
ence voltage to an- controls in the tween the control unit 5:11, K5:13, POWER, trol unit cab
alogue cab cab not work- and component with the K7:2, K 9:7 menu 7
controls. Voltage ing (mini- diagnostic menu.
under 4.9 V or over wheel/joy- Check component.
5.1 V. stick, control
lever and con-
trols for air
conditioning).

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).

Workshop Manual DCF 90-100 VDCF03.01GB


62 D Error codes – 8 Control system

Cod Description Limitation Action Connec- Diagnos- Group


e tions and tic menu
components
43 Transistor has Left cab re- Check bulb. D790-1/K2:6 – LIGHTS, 9.6.5 Back-up
been triggered due versing light Check cabling between E405L menu 8 light
to short circuit or not working. the control unit and the
open circuit in cir- component with diag-
cuit for left revers- nostic menu.
ing light (E405L).

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).

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – 8 Control system 63

Cod Description Limitation Action Connec- Diagnos- Group


e tions and tic menu
components
50 Transistor has Air distribu- Check cabling between D790-1/K4:3 – CLIMATE, 9.4.14 Air dis-
been triggered due tion in cab the control unit and the Y672/5 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).

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).

52 Transistor has Bypass of ex- Check component. D790-1/K5:3 – - -


been triggered due ternal top lift Check the wiring.
to short circuit or attachment
open circuit in cir- not working.
cuit for bypass of
external top lift at-
tachment.

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.

Workshop Manual DCF 90-100 VDCF03.01GB


64 D Error codes – 8 Control system

Cod Description Limitation Action Connec- Diagnos- Group


e tions and tic menu
components
56 Transistor has Work lights Check cabling between D790-1/ K7:8 – LIGHTS, 9.6.10 Work-
been triggered due 20’ not work- the control unit and the R3017-2/86 menu 12 ing lights, cab
to short circuit or ing. component with diag-
open circuit in cir- nostic menu.
cuit for relay for 20’ Check the component.
working lights.

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).

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – 8 Control system 65

Cod Description Limitation Action Connec- Diagnos- Group


e tions and tic menu
components
63 Transistor has No ignition Check cabling between D790-1/K10:10 CAN/ 11.5.1.3 Igni-
been triggered due voltage to the the control unit and the – K315-1/86 POWER, tion voltage
to short circuit or machine’s component with diag- menu 5 (15)
open circuit in cir- Control units. nostic menu.
cuit for relay for ig- Check the component.
nition voltage
(K315-1).

64 Transistor has No emergen- Check cabling between D790-1/K10:11 CAN/ 11.5.1.4


been triggered due cy stop switch the control unit and the – K3009-1/86 POWER, Emergency
to short circuit or voltage to the component with diag- menu 6 stop switch
open circuit in cir- machine’s nostic menu. voltage
cuit for relay for control units. Check the component.
emergency stop
switch voltage
(K3009-1).

65 Transistor has No emergen- Check cabling between D790-1/K10:12 CAN/ 11.5.1.4


been triggered due cy stop switch the control unit and the – K3009-2/86 POWER, Emergency
to short circuit or voltage to the component with diag- menu 6 stop switch
open circuit in cir- machine’s nostic menu. voltage
cuit for relay for control units. Check the component.
emergency stop
switch voltage
(K3009-2).

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).

Workshop Manual DCF 90-100 VDCF03.01GB


66 D Error codes – 8 Control system

Cod Description Limitation Action Connec- Diagnos- Group


e tions and tic menu
components
69 Transistor has No voltage Check cabling between D790-1/K10:16 - 11.5.1.3 Igni-
been triggered due feed to engine the control unit and the – K315-2/86 tion voltage
to short circuit or and transmis- component with diag- (15)
open circuit in cir- sion. nostic menu.
cuit for relay for Check the component.
drivetrain ignition
voltage (K315-2).

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.

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – 8 Control system 67

Cod Description Limitation Action Connec- Diagnos- Group


e tions and tic menu
components
86 Faulty signal from Accelerator Check the wiring be- D790-1/K6:12 VBFS, 1 Engine
auxiliary accelera- pedal for rear- tween the control unit – B690-2/2 menu 4
tor pedal (B690-2). ward opera- and component with the
Signal voltage un- tion not diagnostic menu.
der 0.2 V or over working. En- Check component.
4.8 V. 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.

DCF360-450CSG Extension left


Faulty signal from not working.
control lever for ex-
tension left
(R8074). Signal
voltage under 0.2 V
or over 4.8 V.

Workshop Manual DCF 90-100 VDCF03.01GB


68 D Error codes – 8 Control system

Cod Description Limitation Action Connec- Diagnos- Group


e tions and tic menu
components
91 DCF370-500/ Extra load Check the wiring be- D790-1/K7:7 – ELSERV, 7.1.1 Control
DCF90-100 handling tween the control unit R8075-1/3 menu 2 lever
Faulty signal from function not and component with the (P5)
auxiliary function working. diagnostic menu.
control lever Check component.
(R8075-1). Signal
voltage under 0.2 V
or over 4.8 V.

DCF360-450CSG Levelling not


Faulty signal from working.
levelling control le-
ver (R8075-1). Sig-
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.

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – 8 Control system 69

Cod Description Limitation Action Connec- Diagnos- Group


e tions and tic menu
components
95 DCF370-500/ Extra load Check cabling between D790-1/K9:9 – ELSERV, 7.1.1 Control
DCF90-100 handling the control unit and the R8075-2/3 menu 2 lever
Faulty signal from function not component with diag- (P7)
auxiliary function working. nostic menu.
control lever Check the lever.
(R8075-2). Signal
voltage under 0.2 V
or over 4.8 V.

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.

Workshop Manual DCF 90-100 VDCF03.01GB


70 D Error codes – 8 Control system

Cod Description Limitation Action Connec- Diagnos- Group


e tions and tic menu
components
101 Redundant voltage – Check cabling between D797-1/K2:7 CAN/ 11.5.1.2 Re-
feed left 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.

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.

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – 8 Control system 71

Cod Description Limitation Action Connec- Diagnos- Group


e tions and tic menu
components
108 Transistor has High beam Check bulb. D797-1/K1:15 LIGHTS, 9.6.1 Head-
been triggered due not working. Check the lamp holder. – E402L-1, menu 3 lights
to short circuit or E402R-1
Check cabling between
open circuit in cir-
the control unit and the
cuit for high beam
component with diag-
(E402R-1, E402L-
nostic menu.
1).

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).

Workshop Manual DCF 90-100 VDCF03.01GB


72 D Error codes – 8 Control system

Cod Description Limitation Action Connec- Diagnos- Group


e tions and tic menu
components
113 Electric servo Lift and lower Check cabling between D797-1/K1:4 – ELSERV, DCF370-500:
Transistor has not working. the control unit and the Y6004/1, menu 3 7.2.6 Control
been triggered due component with diag- Y6005/1 and 4 valve, load
to short circuit or nostic menu. handling
open circuit in cir- Check the solenoid DCF360-
cuit for solenoid valves. 450CSG:
valve, lift mast 7.2.5 Control
(Y6005) and sole- valve, lift and
noid valve, lower tilt
mast (Y6004)

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).

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – 8 Control system 73

Cod Description Limitation Action Connec- Diagnos- Group


e tions and tic menu
components
114 Electric servo Tilt not work- Check cabling between D797-1/K1:5 – ELSERV, DCF370-500:
Transistor has ing. the control unit and the Y6010/1, menu 5 7.7.5 Control
been triggered due component with diag- Y6011/1 and 6 valve, load
to short circuit or nostic menu. handling
open circuit in cir- Check the solenoid DCF360-
cuit for solenoid valve. 450CSG:
valve, tilt in (Y6011) 7.7.5 Control
and solenoid valve, valve, lift and
tilt out (Y6010) tilt

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.

Workshop Manual DCF 90-100 VDCF03.01GB


74 D Error codes – 8 Control system

Cod Description Limitation Action Connec- Diagnos- Group


e tions and tic menu
components
118 Transistor has Tail lights not Check bulb. D797-1/K1:33 LIGHTS, 9.6.3 Rear
been triggered due working. Check the lamp holder. – H412L/1, menu 2 lights
to short circuit or H412R/1
Check cabling between
open circuit in cir-
the control unit and the
cuit for tail light
component with diag-
(H412L, H412R).
nostic menu.

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).

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – 8 Control system 75

Cod Description Limitation Action Connec- Diagnos- Group


e tions and tic menu
components
125 Transistor has Regenera- Check cabling between D797-1/K1:11 ELSERV, 7.2.6 Valve
been triggered due tion not work- the control unit and the – Y6051/1 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, right (Y6051).

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).

132 Vehicle Data file Some func- - - - -


missing. tions in ma-
chine not
working.

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.

Workshop Manual DCF 90-100 VDCF03.01GB


76 D Error codes – 8 Control system

Cod Description Limitation Action Connec- Diagnos- Group


e tions and tic menu
components
137 Electric servo Lift mast not Check cabling between D797-1/K1:16 ELSERV, DCF370-500:
Faulty signal from working. the control unit and the – Y6005/2 menu 3 7.7.5 Control
solenoid valve for component with diag- valve, load
lift mast (Y6005). nostic menu. handling
Return current Check the solenoid DCF360-
does not match valve. 450CSG:
control current. 7.7.5 Control
valve, lift and
tilt

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.

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – 8 Control system 77

Cod Description Limitation Action Connec- Diagnos- Group


e tions and tic menu
components
138 Electric servo Lower mast Check cabling between D797-1/K1:17 ELSERV, DCF370-500:
Faulty signal from not working. the control unit and the – Y6004/2 menu 4 7.7.5 Control
solenoid valve for component with diag- valve, load
lower mast nostic menu. handling
(Y6004). Return Check the solenoid DCF360-
current does not valve. 450CSG:
match control cur- 7.7.5 Control
rent. valve, lift and
tilt

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.

Workshop Manual DCF 90-100 VDCF03.01GB


78 D Error codes – 8 Control system

Cod Description Limitation Action Connec- Diagnos- Group


e tions and tic menu
components
140 Electric servo Tilt out not Check cabling between D797-1/K1:19 ELSERV, DCF370-500:
Faulty signal from working. the control unit and the – Y6010/2 menu 6 7.7.5 Control
solenoid valve for component with diag- valve, load
tilt out (Y6010). 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 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).

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – 8 Control system 79

Cod Description Limitation Action Connec- Diagnos- Group


e tions and tic menu
components
142 DCF370-500 Tilt not work- Check cabling between D797-1/K1:35 OLS, 7.10.5 Sepa-
Transistor has ing. the control unit and the – Y6012/1 menu 7 rate top lift at-
been triggered due component with diag- tachment
to short circuit or nostic menu.
open circuit in cir- Check the solenoid
cuit for solenoid valve.
valve, stop tilt
(Y6012)

DCF360-450CSG Disconnec- Check cabling between D797-1/K1:35 HYD, 10.4.2 Axial


Transistor has tion of attach- the control unit and the – Y6062/1 menu 6 piston pump
been triggered due ment pump component with diag- with variable
to short circuit or not working. nostic menu. displacement
open circuit in cir- Check the solenoid
cuit for solenoid valve.
valve, hydraulic
pump disengage-
ment (Y6062).

DCF90-100 Quick-lift Check cabling between D797-1/K1:35 HYD, 10.4.2 Axial


Transistor has pump en- the control unit and the – Y6062/1 menu 6 piston pump
been triggered due gagement not component with diag- with variable
to short circuit or working. nostic menu. displacement
open circuit in cir- Check the solenoid
cuit for solenoid valve.
valve, hydraulic
pump disengage-
ment (Y6062).

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).

Workshop Manual DCF 90-100 VDCF03.01GB


80 D Error codes – 8 Control system

Cod Description Limitation Action Connec- Diagnos- Group


e tions and tic menu
components
145 High brake oil tem- Reduced Check that cooling fan is D797-1/K2:6 – HYD, 4.8.10 Sen-
perature. braking ca- working. B772/1 menu 2 sor brake oil
pacity. If the Check that cooler isn’t temperature
temperature clogged.
continues to
Check the brake oil lev-
rise, speed is
el.
limited to 5
km/h. Check the sensor.

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

Check the sensor.

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.

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – 8 Control system 81

Cod Description Limitation Action Connec- Diagnos- Group


e tions and tic menu
components
152 Redundant voltage – Check cabling between D797-2/K2:8 CAN/ 11.5.1.2 Re-
feed right 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).

Workshop Manual DCF 90-100 VDCF03.01GB


82 D Error codes – 8 Control system

Cod Description Limitation Action Connec- Diagnos- Group


e tions and tic menu
components
160 Transistor has Auxiliary work Check the lights. Check D797-2/K1:42 LIGHTS, 9.6.9 Working
been triggered due lights, frame the wiring between the – E404R-2/1, menu 11 lights mast
to short circuit or front, not control unit and compo- E404L-2/1 9.6.10 Work-
open circuit in cir- working. nent with the diagnostic ing lights, cab
cuit for auxiliary menu.
work lights (E404R- 9.6.12 Work
Check component. lights, attach-
2, E404L-2).
ment

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).

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – 8 Control system 83

Cod Description Limitation Action Connec- Diagnos- Group


e tions and tic menu
components
166 Transistor has Side shift left Check cabling between D797-2/K1:31 ELSERV, 7.4.5 Control
been triggered due not working. the control unit and the – Y6020/1 menu 7 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 left valve.
(Y6020).

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).

Workshop Manual DCF 90-100 VDCF03.01GB


84 D Error codes – 8 Control system

Cod Description Limitation Action Connec- Diagnos- Group


e tions and tic menu
components
171 Transistor has Change of Check cabling between D797-2/K1:10 VBFS, 5.2.15 Direc-
been triggered due steering an- the control unit and the – Y636-2/1 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 ing. valve.
rearward (Y636–2).

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).

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – 8 Control system 85

Cod Description Limitation Action Connec- Diagnos- Group


e tions and tic menu
components
174 Reversible opera- Rotation of Check the wiring be- D797-2/K1:39 VBFS, 9.3.10.1 Con-
tor's seat driver’s seat tween the control unit – Y646-2/1 menu 2 trol valve, re-
Transistor has not working and component with the versible
been triggered due diagnostic menu. driver’s seat
to short circuit or Check component.
open circuit in cir-
cuit for solenoid
valve, reversible
driver’s seat, anti-
clockwise (Y646-2).

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.

Workshop Manual DCF 90-100 VDCF03.01GB


86 D Error codes – 8 Control system

Cod Description Limitation Action Connec- Diagnos- Group


e tions and tic menu
components
190 Faulty signal from Spreading not Check cabling between D797-2/K1:19 ELSERV, 7.5.5 Control
solenoid valve, working. the control unit and the – Y6018/2, menu 9 valve load
spreading out component with diag- Y6019/2 and 10 handling
(Y6018) and sole- nostic menu.
noid valve, spread- Check the solenoid
ing in (Y6019). valve.
Return 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.

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – 8 Control system 87

Cod Description Limitation Action Connec- Diagnos- Group


e tions and tic menu
components
254 Incorrect control Functions Check fuse F58-3/1, D791-1/K2:11 CAN/ 11.5.1.4
switch voltage to at- normally sup- change if needed. – F58-3/1:1 POWER, Emergency
tachment control plied emer- Check cabling between menu 15 stop switch
unit (D791-1). gency stop the control unit and the voltage
switch volt- component with diag-
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).

Workshop Manual DCF 90-100 VDCF03.01GB


88 D Error codes – 8 Control system

Cod Description Limitation Action Connec- Diagnos- Group


e tions and tic menu
components
259 DCF360-450CSG Auxiliary at- Check bulb. D791-1/K1:28 LIGHTS, 9.6.12 Work
Transistor has tachment Check the lamp holder. – E404-4L/1, menu 13 light attach-
been triggered due work lights E404-4-R/1 ment
Check cabling between
to short-circuit or not working.
the control unit and the
open circuit in cir- component with diag-
cuit for auxiliary at- nostic menu.
tachment work
lights (E404-4L,
E404-4-R).

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).

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – 8 Control system 89

Cod Description Limitation Action Connec- Diagnos- Group


e tions and tic menu
components
262 DCF360-450CSG Extension left Check cabling between D791-1/K1:3 – ATTACH, 7.3.2 Control
Transistor has out of attach- the control unit and the Y6046-2/1 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, extension left
out (Y6046-2).

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).

DCF90-100 Spreading Check cabling between D791-1/K1:17 ATTACH, 7.3.2 Control


Transistor has right in of at- the control unit and the – Y6019R/2 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, spreading
right in (Y6019R).

Workshop Manual DCF 90-100 VDCF03.01GB


90 D Error codes – 8 Control system

Cod Description Limitation Action Connec- Diagnos- Group


e tions and tic menu
components
264 DCF360-450CSG Extension Check cabling between D791-1/K1:5 – ATTACH, 7.3.2 Control
Transistor has right out of at- the control unit and the Y6046-4/1 menu 19 valve attach-
been triggered due tachment not component with diag- ment
to short circuit or functioning. nostic menu.
open circuit in cir- Check the solenoid
cuit for solenoid valve.
valve, extension
right out (Y6046-4).

DCF90-100 Spreading Check cabling between D791-1/K1:17 ATTACH, 7.3.2 Control


Transistor has right out of at- the control unit and the – Y6018R/2 menu 19 valve attach-
been triggered due tachment 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
right out (Y6018R).

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).

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – 8 Control system 91

Cod Description Limitation Action Connec- Diagnos- Group


e tions and tic menu
components
266 DCF360-450CSG Anticlock- Check cabling between D791-1/K1:31 ATTACH, 7.8.2 Control
Transistor has wise levelling the control unit and the – Y6035/1 menu 16 valve attach-
been triggered due of attachment component with diag- ment
to short circuit or not function- nostic menu.
open circuit in cir- ing. Check the solenoid
cuit for control valve.
valve, levelling anti-
clockwise (Y6035).

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).

Workshop Manual DCF 90-100 VDCF03.01GB


92 D Error codes – 8 Control system

Cod Description Limitation Action Connec- Diagnos- Group


e tions and tic menu
components
270 Transistor has Twistlock/lock Check cabling between D791-1/K1:9 – ATTACH, 7.9.1.2 Con-
been triggered due tongue not the control unit and the Y6039/1 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, open twist- valve.
lock/lock tongue
(Y6039).

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).

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – 8 Control system 93

Cod Description Limitation Action Connec- Diagnos- Group


e tions and tic menu
components
273 DCF360-450CSG Indicator light Check bulb. D791-1/K1:29 ATTACH, 7.9.1 Twist-
Transistor has alignment Check the lamp holder. – H563/1 menu 10 locks
been triggered due twistlock not
Check cabling between
to short circuit or working.
the control unit and the
open circuit in cir- component with diag-
cuit for alignment nostic menu.
indicator light
(H564).

DCF90-100 Indicator light, Check bulb. D791-1/K1:29 ATTACH, 7.9.1


Transistor has locked twist- Check the lamp holder. – H563/1 menu 10 Twistlocks
been triggered due lock/lock
Check cabling between
to short circuit or tongues not
the control unit and the
open circuit in cir- working.
component with diag-
cuit for indicator nostic menu.
light, locked twist-
lock/lock tongues
(H563).

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.

Workshop Manual DCF 90-100 VDCF03.01GB


94 D Error codes – 8 Control system

Cod Description Limitation Action Connec- Diagnos- Group


e tions and tic menu
components
288 DCF360-450CSG Extension Check cabling between D791-1/K1:17 ATTACH, 7.3.2 Control
Faulty signal from right of at- the control unit and the – Y6046-3/2, menu 19 valve
solenoid, exten- tachment not component with diag- Y6046-4/2 and 20 attachment
sion right in working. nostic menu.
(Y6046-3) and so- Check the solenoid
lenoid valve, exten- valve.
sion right out
(Y6046-4). Return
current does not
match control
current.

DCF90-100 Spreading Check cabling between D791-1/K1:17 ATTACH, 7.3.2 Control


Faulty signal from right not work- the control unit and the – Y6019R/2, menu 19 valve
solenoid, spreading ing. component with diag- Y6018R/2 and 20 attachment
right in (Y6019R) nostic menu.
and solenoid valve, Check the solenoid
spreading right out valve.
(Y6018R). 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.

VDCF03.01GB Workshop Manual DCF 90-100


D Error codes – 8 Control system 95

Cod Description Limitation Action Connec- Diagnos- Group


e tions and tic menu
components
290 Faulty signal from Attachment Check cabling between D791-1/K1:19 ATTACH, 7.5.2 Control
solenoid, spreading spreading not the control unit and the – Y6018/2, menu 13 valve attach-
out (Y6018) and so- working. component with diag- Y6019/2 and 14 ment
lenoid valve, nostic menu.
spreading in Check the solenoid
(Y6019). Return valve.
current does not
match control cur-
rent.

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.

Workshop Manual DCF 90-100 VDCF03.01GB


96 D Error codes – 8 Control system

Cod Description Limitation Action Connec- Diagnos- Group


e tions and tic menu
components
299 Twistlock sensor in- Lift and Check that Sensors D791-1/K2:15 ATTACH, 7.9.1.7 Sen-
dicates that right 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.

500 Time for service. - Check that servicing has - - C Preventive


been performed. If serv- maintenance
icing has been per-
formed following the
Kalmar Industries serv-
ice schedule, reset the
service indicator; see
section 8 Control sys-
tem, group 8.2.4 Service
indicator.

VDCF03.01GB Workshop Manual DCF 90-100


E Schematics 1

E Schematics

Table of Contents E Schematics


mm mm mm mm mm mm

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

Workshop Manual DCF 90-100 VDCF03.01GB


2 E Schematics

VDCF03.01GB Workshop Manual DCF 90-100


E Schematics – 10 Common hydraulics 3

10 Common hydraulics
mm mm mm mm mm mm

Hydraulic diagrams, compilation


page

Designation Drawing number


Hydraulic diagram DCF 90-100, electric servo page 4 A47749.0100

Workshop Manual DCF 90-100 VDCF03.01GB


4 E Schematics – 10 Common hydraulics

Hydraulic diagram DCF 90-100,


page

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

009920 (A47749.0100 ver.1)


12
2

29

30
3

11
10
7
1

VDCF03.01GB Workshop Manual DCF 90-100


E Schematics – 10 Common hydraulics 5

1. Side shift cylinder 17. Brake valve


2. Cylinder, twistlock/lock tongue 18. NC switch, low brake pressure (S204)
3. Overcentre valve 19. Solenoid valve parking brake (Y642)
4. Control valve attachment 20. Switch (NO), parking brake (S200)
4a. Solenoid valve, side shift left (Y6020) and side shift right 21. NO switch, declutch (S220)
(Y6021) 22. NO switch, brake lights (S216)
4b. Solenoid valve, open twistlock/lock tongue (Y6039) and 23. Parking brake caliper
lock twistlock/lock tongue (Y6040)
24. Brake cylinder
4c. Solenoid valve, spreading out left (Y6018L) and spread-
25. Wheel brake
ing in left (Y6019L)
26. Drive axle block
4d. Solenoid valve, spreading out right (Y6018R) and
spreading in right (Y6019R) 27. Accumulator charge valve
4e. Solenoid valve, levelling right (Y6035) and levelling left 28. Oil cooler
(Y6036) 29. Pressure limiting valve
5. Spreading cylinder 30. Solenoid valve, quick-lift (Y6062)
6. Levelling cylinder 31. Solenoid valve, main pump relief (Y6062-2)
7. Lift cylinder 32. Return filter
8. Tilt cylinder 33. Pressure filter
9. Accumulator 34. Steering cylinder
10. Pressure reducing valve 35. Steering valve
11. Accumulator 36. Control valve for lever steering/mini-wheel, solenoid valve
12. Servo filter for steering right (Y636-3) and steering left (Y636-4)
13. Control valve for lift and tilt, control valve for lift mast 37. Quick-lift pump
(Y6005) and lower mast (Y6004), tilt in (Y6011) and tilt out 38. Hydraulic oil pump
(Y6010)
39. Hydraulic oil pump
14. Cab tilt cylinder
40. Hydraulic oil pump, booms
15. Control valve for cab tilt, control valve for cab tilt up
41. Priority valve
(Y6047) and cab tilt down (Y6048)
42. Breather filter
16. Accumulator
42. Tank

Workshop Manual DCF 90-100 VDCF03.01GB


6 E Schematics – 11 Common electrics

11 Common electrics
mm mm mm mm mm mm

Circuit diagram, description


page

A circuit diagram is divided into circuit names (drawing numbers) and


consists of a set of numbered pages.
The following is an explanation of symbols in circuit diagrams:
• X is connection terminal (followed by number)
• Designation 353-2
353 is component designation (see Component designations
page 7 for description of each component). 2 indicates that it is the
second component of this type in the specific diagram.
• Sensors etc. are drawn in resting position on circuit, that is, with-
out voltage.
• Colour cables:
White cable = ground signal
Grey cable = other cables
• Fuse box, for example F58, means fuse box with 8 fuses
• An arrow symbol indicates a reference to another circuit diagram
• 20015.0001 electrical drawings-post designations K-standard.
K-standard 1: norms, rules
K-standard 2: cables, general physical
K-standard 5: Designation and marking system, item designations
circuit drawings
• Ground connection:
1: X37-A is ground connection in the electrical distribution box. A
connection terminal for ground. Frame connection-connection ter-
minal to chassis.
2: Zero reference is found in control units.

VDCF03.01GB Workshop Manual DCF 90-100


E Schematics – 11 Common electrics 7

Component designations
page

The components in circuit diagrams have a prefix and number, the


prefix describes the type of component, the number which component.
Component list with component number, prefix and designation is pro-
vided as an appendix after the circuit diagrams.

Prefix Description
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

D Binary element, delay unit, memory. Example: control unit.

E Lighting and heating unit.

F Protective device. Example: fuse.

G Alternator, power supply device. Example: fuse.

H Signal device. Example indicator light.

K Relay, connector.

L Inductance, reactance.

M Motor. Example: electric motor.

N Analogue element. Example: operation amplifier.

P Measuring instrument, testing equipment. Example: operating hour gauge.

Q Electrical connector for power circuit. Example: circuit breaker.

R Resistor. Example: potentiometer.

S Electric switch for control circuit, selector. Example: switch.

T Transformer.

U Modulator, converter or transformer. Example: frequency converter

V Conduit, semiconductor. Example: diode, transistor

W Transmission route, wave-guide, antenna. Example: cable, bus bar.

X Outlet/socket, connecting device Example: connection terminal.

Y Electrically controlled mechanical device: Example: solenoid valve, hydraulic valve.

Z Transformer, network, hybrid, filter, equaliser, limiter. Example: cable balancing network.

Workshop Manual DCF 90-100 VDCF03.01GB


8 E Schematics – 11 Common electrics

Circuit diagrams, compilation


page

Circuit diagrams are attached as an appendix in the following order.


The circuit diagram for the basic machine has drawing number
A49226.0100.

Sheet Designation
0.0-1 Crossreference list

0.0-2 Crossreference list

0.0-3 Crossreference list

0.0-4 Crossreference list

0.1-1 Truth table opt.

1.0-1 Circuit, drivetrain, engine

1.0-2A Circuit, Volvo TAD722 engine

1.0-2B1 Circuit, Cummins QSM11 engine

1.0-2B2 Circuit, Cummins QSM11 engine

1.0-2C Circuit, Volvo 950,1240,1250 engine

1.0-2D Circuit, Volvo TAD760 engine

1.0-2E1 Circuit, Cummins QSB6.7 engine

1.0-2E2 Circuit, Cummins QSB6.7 engine

2.0-1 Circuit, drivetrain gearbox

2.0-2A1 Circuit, TE32 gearbox

2.0-2A2 Circuit, TE32 gearbox

2.0-2A3 Circuit, TE32 gearbox

2.0-2B1 Circuit, TE17 gearbox

2.0-2B2 Circuit, TE17 gearbox

2.0-2B3 Circuit, TE17 gearbox

4.0-1 Circuit, brake system

4.8-1 Circuit, brake oil cooling

5.2-1 Circuit, lever/mini-wheel steering

5.2-2 Circuit, lever/mini-wheel steering

7.0-1 Circuit, electric servo levers

7.0-2 Circuit, electric servo joystick

7.0-4 Circuit, accessory attachment

7.0-5 Circuit, accessory attachment

7.0-7 Circuit, lifting height

7.2-1 Circuit, lift/lower electric servo

VDCF03.01GB Workshop Manual DCF 90-100


E Schematics – 11 Common electrics 9

Sheet Designation
7.2-2 Circuit, freelift sensors

7.2-3 Circuit, freelift sensors

7.2-6 Circuit, mast valves

7.3-1 Circuit, gantry attachment

7.4-1 Circuit, side shift, electric servo

7.4-2 Circuit, side shift gantry

7.5-1 Circuit 20-40, 30-35 stop

7.5-2 Circuit, spreading gantry

7.5-3 Circuit, 20’-40’ opt.

7.7-1 Circuit, tilt electric servo

7.7-2 Circuit, tilt indication

7.8-1 Circuit, levelling gantry

7.9-1 Circuit, twistlock

7.9-2 Circuit, sensor gantry

7.9-3 Circuit, pliers Avesta

7.10-1 Circuit, 5th function electric servo

7.10-2 Circuit, option gantry

8.2-1 Circuit, bypassing

8.2-2 Circuit, overload system

8.2-3 Circuit, mast sensor OLS

8.2-4 Circuit RMI

9.0-1 Circuit, std. opt.

9.1-1 Circuit, optional equipment

9.1-2 Circuit, hour counter

9.3-1 Circuit, seat heating

9.3-2 Circuit, air suspension seat

9.3-3 Circuit, reversible driver’s seat

9.3-4 Circuit, reversible driver’s seat

9.3-5 Circuit, reversible driver’s seat

9.3-6 Circuit, reversible driver’s seat

9.3-7 Circuit, reversible driver’s seat

9.4-1 Circuit, climate system

9.4-2 Circuit, climate system

9.5-1 Circuit, wipers

Workshop Manual DCF 90-100 VDCF03.01GB


10 E Schematics – 11 Common electrics

Sheet Designation
9.6-1 Circuit, work lights 20’-40’

9.6-2 Circuit, work lights, carriage

9.6-3 Circuit, work lights, mast

9.6-4 Circuit lighting

9.6-5 Circuit lighting

9.6-6 Circuit lighting

9.6-7 Circuit, direction indicators & hazard

9.6-8 Circuit, interior lighting

9.6-9 Circuit, work lights, option

9.6-10 Circuit, work lights, option

9.6-11 Circuit, entry lighting

9.6-12 Circuit, aux. lights, attachment

9.6-13 Circuit, work lights, option, hood lamp

9.6-14 Circuit, work lights, option carriage

9.7-1 Circuit, alarm, audible signals

9.7-2 Circuit, back-up alarm

9.7-3 Circuit, compressor horn

9.7-4 Circuit for horn, servo panel

9.8-1 Circuit, radio

9.8-2 Circuit, printer

9.9-1 Circuit, rearview mirror heating

9.10-1 Circuit, cab tilt/sliding cab

9.14-1 Circuit, central lubrication

10.4-1 Circuit, hydr. pump disengagement

10.6-1 Circuit, hydraulic oil cooling

11.5-1 Circuit, current

11.5-2 Circuit, current

11.5-3 Circuit, current

11.5-4 Circuit, current

11.5-5 Circuit, current

11.5-6 Circuit, emergency stop switch current

11.5-7 Circuit 24/12V

11.5-8 Circuit 24V socket

11.5-9 Circuit, option, ground power

VDCF03.01GB Workshop Manual DCF 90-100


E Schematics – 11 Common electrics 11

Sheet Designation
11.5-10 Circuit, option, ground

11.5-11 Circuit, option, ground

11.6-1 Circuit CAN bus ground

11.6-2A Circuit, CAN bus KDU opt.

11.6-2B Circuit, CAN bus KDU opt.

11.6-2C Circuit, CAN bus KDU opt.

Circuit diagrams are attached as an appendix in the following order.


The circuit diagram for the side lifting attachment has drawing number
A50400.0100.

Sheet Designation
0.0_1 Crossreference list

7.4_1 Circuit, side shift

7.5_1 Circuit, spreading

7.5_2 Circuit, spreading buzzer

7.5_3 Circuit, spreading sensors

7.8_1 Circuit, levelling

7.9_1 Circuit, open/lock

7.9_2 Circuit, open/lock sensors

7.9_3A Circuit, indicator lights

7.9_3B Circuit, indicator lights

7.9_4 Circuit, alignment sensors

7.9_5A Circuit, alignment sensors

7.9_5B Circuit, alignment sensors

9.6_1 Circuit, work lights, carriage/attachment

9.14_1 Circuit, central lubrication

11.5_1 Circuit, current

11.5_2 Circuit, current

11.6_1 Circuit, CAN bus

Workshop Manual DCF 90-100 VDCF03.01GB


12 E Schematics – 11 Common electrics

VDCF03.01GB Workshop Manual DCF 90-100


1 2 3 4 5 6 7 8

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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F F

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 Kretsar DCF370­, DCE300­330 DCF300­,DCE300­ 0
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 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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hörigen användas. Överträdelse härav beivras med
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F F

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 Korsreferens lista DCF300­,DCE300­ 0.0_1
CJS 050128 A47137.0100
Name

 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

Pin Number Drawing Function Type


B B
Power /11.5_4.B5

CAN /11.6_1.E8

2:6 /4.8_1.A8 SENSOR BRAKE OIL TEMP. Temperature Input

2:11 /11.5_4.A5 Emergency stop Input

KDU contact K2
2:13 /10.6_1.A8 SENSOR HYDR. OIL TEMP. Temperature Input

2:15 /1.0_1.F8 SENSOR FUEL LEVEL Reostat In

2:16 /1.0_1.E1 D+ D+

C C

­D797­1

Pin Number Drawing Function Type Pin Number Drawing Function Type

1:1 /9.6_3.D1 LAMPS WORK LIGHT MAST 6A 1:21 /8.2_2.A7 SENSOR HYDR. SCALE LIFT Analog In 0­5V


1:2 /9.6_5.C1 SIDE POSITION LIGHT 1.5A 1:22 /8.2_2.D7 SENSOR HYDR. SCALE TILT Analog In 0­5V
1:3 /4.8_1.C1 RELAY COOLING FAN BRAKE OIL 1.5A 1:23 /7.7_2.D8 SENS.TILT ANGLE/FEEDBACK BRK FAN Analog In 0­5V
1:4 /7.2_1.C1 VALVE LIFT / LOWER 1.5A 1:24 /7.2_6.E8 SENSOR MAST POS/REGENERATING Analog In 0­5V
1:5 /7.7_1.C1 VALVE TILT 1.5A 1:25 /9.4_2.E1 COMPRESSOR AIR­CONDITION 1.5A
1:6 /8.2_2.C7 SENSOR HYDR. SCALE 0V Ref 1:26 /7.0_7.C8 SENSOR CAB TILT Dig In / 1.5A
1:7 /9.6_6.C1 BRAKE LIGHT LEFT 1.5A 1:27 /2.0_1.C8 SWITCH DECLUTCHING Analog In 0­5V
1:8 /8.2_2.A1 SENSOR HYDR. SCALE Analog Ref 5V 1:28 /9.6_5.B1 LAMP DIPPED LIGHT 6A
1:9 /9.6_6.C1 BRAKE LIGHT RIGHT 1.5A 1:29 /9.4_2.F1 COMPRESSOR AIR­CONDITION 1.5A
1:10 /9.7_2.B1 REVERSING ALARM 1.5A 1:30 /9.6_7.E1 LAMP DIRECTION LEFT 2.5A
D 1:11 /7.2_2.C7 MAST DOWN / REGENERATING LIFT Dig In / 1.5A 1:31 /9.6_7.D1 LAMP DIRECTION RIGHT 2.5A
D
1:12 /7.2_2.B7 CARRIAGE UP / REGENERATING LIFT Dig In / 1.5A 1:32 /1.0_1.F1 RELAY STARTING KEY 1.5A

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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Den får ej heller delgivas annan eller annars obe­
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F

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 Korsreferens lista DCF300­,DCE300­ 0.0_2
CJS 050128 A47137.0100
Name

 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

Pin Number Drawing Function Type

Power /11.5_5.D5

CAN /11.6_2C.E3

2:6 Temperature Input

2:11 /11.5_5.C4 Emergency stop Input

KDU contact K2
B B
2:13 Temperature Input

2:15 Reostat In

2:16 D+

­D797­2

Pin Number Drawing Function Type Pin Number Drawing Function Type


C C
1:1 /9.3_5.C1 HEAD LIGHT REAR 6A 1:21 /11.5_10.B8 OPT. Analog In 0­5V
1:2 /5.2_2.B1 VALVE MICRO STEERING RIGHT 1.5A 1:22 /11.5_10.B8 OPT. Analog In 0­5V
1:3 /5.2_2.C1 VALVE MICRO STEERING LEFT 1.5A 1:23 /11.5_10.C8 OPT. Analog In 0­5V
1:4 /7.10_1.B1 VALVE EXTRA FUNCT. OUT 1.5A 1:24 /11.5_9.C1 OPT. Analog In 0­5V
1:5 /7.10_1.C1 VALVE EXTRA FUNCT. IN 1.5A 1:25 /9.3_5.D1 LAMP REAR LIGHT FRONT 1.5A
1:6 /11.5_10.B1 OPT. 0V Ref 1:26 /11.5_11.D1 OPT. Dig In / 1.5A
1:7 /9.3_3.D1 SWITCHES SEAT POS. F/R 1.5A 1:27 Analog In 0­5V
1:8 /11.5_10.A1 OPT. Analog Ref 5V 1:28 /11.5_9.B1 OPT. 6A
1:9 /9.3_6.B1 VALVE STEERING FORWARD 1.5A 1:29 /9.3_7.A1 VALVE SEAT ROTATION C.W 1.5A
1:10 /9.3_6.C1 VALVE STEERING REVERSE 1.5A 1:30 /7.4_1.C1 VALVE SIDESHIFT RIGHT 2.5A
1:11 /11.5_11.B1 OPT. Dig In / 1.5A 1:31 /7.4_1.B1 VALVE SIDESHIFT LEFT 2.5A
1:12 /11.5_11.C1 OPT. Dig In / 1.5A 1:32 /7.5_1.E1 VALVE SPREADING IN 1.5A

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

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

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 Korsreferens lista DCF300­,DCE300­ 0.0_3
CJS 050128 A47137.0100
Name

 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

Pin Number Drawing Function Type

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

C Pin Number Drawing Function Type Pin Number Drawing Function Type C


1:1 /9.6_2.C2 WORK LIGHT LEFT 6A 1:21 /7.10_2.B7 OPT. Analog In 0­5V
1:2 /7.3_1.B2 PROJECTING LEFT IN 1.5A 1:22 /7.9_2.D8 SENSOR UNLOCKED TW. LEFT Analog In 0­5V
1:3 /7.3_1.B2 PROJECTING LEFT OUT 1.5A 1:23 /7.9_2.E8 SENSOR LOCKED TW. LEFT Analog In 0­5V
1:4 /7.3_1.C2 PROJECTING RIGHT IN 1.5A 1:24 /7.9_2.B8 SENSOR LOCKED TW. RIGHT Analog In 0­5V
1:5 /7.3_1.D2 PROJECTING RIGHT OUT 1.5A 1:25 /7.9_1.C2 LAMP UNLOCKED TW 1.5A
1:6 /7.10_2.C7 OPT. 0V Ref 1:26 /7.9_2.C8 SENSOR ALIGNMENT REAR RIGHT Dig In / 1.5A
1:7 /7.9_1.E2 VALVE LOCK TWISTLOCK 1.5A 1:27 /7.9_2.E8 SENSOR ALIGNMENT REAR LEFT Analog In 0­5V
1:8 /7.10_2.B2 OPT. Analog Ref 5V 1:28 /7.5_3.D1 WARN. SIGNAL AUT. SPREADING 6A
1:9 /7.9_1.F2 VALVE UNLOCK TWISTLOCK 1.5A 1:29 /7.9_1.D2 LAMP LOCKED TW 1.5A
1:10 /7.9_2.C2 SENSORS ATTACHMENT 1.5A 1:30 /7.8_1.B2 VALVE LEVELLING LEFT 2.5A
1:11 /7.10_2.E7 SENSOR OPT. Dig In / 1.5A 1:31 /7.8_1.A2 VALVE LEVELLING RIGHT 2.5A
1:12 /7.5_2.D7 SENSOR DAMPING 20­40 Dig In / 1.5A 1:32 /7.4_2.B2 VALVE SIDESHIFT LEFT 1.5A

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

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

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 Korsreferens lista DCF300­,DCE300­ 0.0_4
CJS 050128 A47137.0100
Name

 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

D797­1 alt 1 X213


C D797­1 alt 2 X213 C
D797­1 alt 3 X213
D797­1 alt 4 X213
D797­1 + alt 5 X249 X240 X213
D797­2
D797­1 + alt 6 X249 X240 X213
D797­2
D797­1 + alt 7 X213 X249 X240
D D797­2 D
alt 8

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

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

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 Sanningstabell opt. DCF300­,DCE300­ 0.1_1
CJS 050316 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
Truth table opt. A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8

­X005 ­X040m ­X040f ­X066f ­X066f ­X040f ­X040m ­X005


Analog reference 5V K5:13 13 00513A 4 4 A0404 2 5V 0V 3 A0405 5 5 00512A 12 K5:12 0V reference
­D790­1  / 9.3_3.D2  / 9.3_3.E2 ­D790­1
/0.0_1.D1 /0.0_1.D1
POT. ACCELERATOR POT. ACCELERATOR

­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

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.
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

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.
PREHEATER ­D794
ENGINE
F D5.1 F

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 motor TAD 722 DCF300­,DCE300­ 1.0_2A
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 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

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

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 motor Cummins QSM11 DCF300­,DCE300­ 1.0_2B1
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 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

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

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 motor Cummins QSM11 DCF300­,DCE300­ 1.0_2B2
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 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

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.
50
ALTERNATOR STARTER
W
F F

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 motor 950,1240,1250 DCF300­,DCE300­ 1.0_2C
CJS 050128 A47137.0100
Name

 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

­X22A ­X22f ­X22m


1 221 1 1/6
2 222 30 2 2/6
C C
3 223 225 3 3/6
Diagnostics engine. 4/6
5 225 30 5 5/6
222 6/6

­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

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 motor TAD760 DCF300­,DCE300­ 1.0_2D
CJS 051123 A47137.0100
Name

 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

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.
­X210m 50/50
CAN_J1939_+ 3 2103 30
F  / 1.0_1.C6 F
CAN_J1939_­ 4 2104
 / 1.0_1.D6

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 motor QSB6,7 DCF300­, DCE300­ 1.0_2E1
CJS 070123 A47137.0100
Name

 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

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

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 motor QSB6,7 DCF300­, DCE300­ 1.0_2E2
CJS 070123 A47137.0100
Name

 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

­X038f ­X038m ­S220­1 ­X038m ­X038f ­X006


790­1:5­1/24V 0811 0381A 1 1 BK 1 2 BN 2 2 0382A 00614 14 K6:14 Input
 / 9.1_1.C2 ­D790­1
BU 3 /0.0_1.B4

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

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

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 växellåda DCF300­,DCE300­ 2.0_1
CJS 050128 A47137.0100
Name

 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

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

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 växellåda TE32 DCF300­,DCE300­ 2.0_2A1
CJS 050128 A47137.0100
Name

 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

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

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 växellåda TE32 DCF300­,DCE300­ 2.0_2A2
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 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

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

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 växellåda TE32 DCF300­,DCE300­ 2.0_2A3
CJS 050128 A47137.0100
Name

 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

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

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 växellåda TE17 DCF300­, DCE300­ 2.0_2B1
CJS 061129 A47137.0100
Name

 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

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 2

F 2K2
F

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 växellåda TE17 DCF300­, DCE300­ 2.0_2B2
CJS 061129 A47137.0100
Name

 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

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

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 växellåda TE17 DCF300­, DCE300­ 2.0_2B3
CJS 061129 A47137.0100
Name

 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

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

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 Bromssystem DCF300­,DCE300­ 4.0_1
CJS 050128 A47137.0100
Name

 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

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

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 kyln. bromsl olja DCF300­,DCE300­ 4.8_1
CJS 050128 A47137.0100
Name

 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

­X825­Pm ­R825­1 ­X825­Pm


3
1 YE 1 2 GN 2

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

­X825­Hm ­X825­Hf ­X009Af ­X009Am ­X009


­R825­2 YE 2 2 0099A 9 9 0099 9 K9:9 Analog Input
­D790­1
3 /0.0_1.B6
GY 1 2 BU
POT. MIC STEER/6TH LEV (P7)

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

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 ­XB770m ­XB770f ­X018
3 3 0183 3 K8:3 0V ref F
­D790­2

SENSOR STEERING WHEEL

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 spak/miniratt styrning DCF300­,DCE300­ 5.2_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 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

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

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 spak/miniratt styrning DCF300­,DCE300­ 5.2_2
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 lever/micro wheel A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8

­XR8071m ­XR8071f ­X090m ­X090f ­X007


­R8071 RD 0903 0073 Analog Input
3 3 3 3 3 K7:3
­D790­1
/0.0_1.C4
A POT. LIFT / LOWER (P1) A
­X007 ­X090f ­X090m ­XR8071f ­XR8071m ­X090m ­X090f ­X007
Analog reference 5V 3 0V reference
K7:2 2 0072 2 2 0902A 1 1 GN 1 2 YE 2 2 0901A 1 1 0071 1 K7:1
­D790­1 ­D790­1
/0.0_1.C4 /0.0_1.B4
POTENTIOM. EL. SERVO LIFT / LOWER (P1) POTENTIOM. EL. SERVO

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

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.
0902E
0901E

­XR8075­1m ­XR8075­1f ­X090m ­X090f ­X007


­R8075­1 RD 0907 0077 Analog Input
3 3 7 7 7 K7:7
­D790­1
/0.0_1.C4
POT. EXTRA (P5)
­XR8075­1f ­XR8075­1m
3
1 1 GN 1 2 YE 2 2

EXTRA (P5)
E E
LEVELLING

0902F
0901F

­XR8075­2m ­XR8075­2f ­X090m ­X090f ­X009


­R8075­2 RD 0908 0099 Analog Input
3 3 8 8 9 K9:9
­D790­1

POT 7TH LEVER (P7)
­XR8075­2f ­XR8075­2m
3

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 1 GN 1 2 YE 2 2

F EXTRA (P7) F
PROJECTION RIGHT

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 elservo spakar DCF300­,DCE300­ 7.0_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 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)

D ­X090m ­X090f ­X007f D


P3 11 11 0905 5 5 0075 5 K7:5 Analog Input
­D790­1

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)

­X090m ­X090f ­X007f


P4 1 1 0906 6 6 0076 6 K7:6 Analog Input
­D790­1
­X007f ­X090f ­X090m
0V Reference K7:1 1 0071 1 1 0901 10 10 POT. (P4)
­D790­1

POTENTIOM. EL. SERVO

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

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 elservo joystick DCF300­,DCE300­ 7.0_2
CJS 050128 A47137.0100
Name

 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

­X207f ­X207m ­R820­3 ­X207m ­X207f ­X070m ­X070f ­X010


1 1 1 2 2 2 0701 1 1 A0103 3 K10:3 Input
­D790­1
/0.0_1.B6
820 Ohm
SENSOR ALIGNMENT

­X207m ­X207f
C 2076 6 6 2026 Unlock TW C
 / 7.0_5.E2

­R820­4 ­X207m ­X207f ­X070m ­X070f ­X069f ­X069m ­X008


3 3 0702 2 2 A0692 2 2 0089 9 K8:9 Input
­D790­1
/0.0_1.D4
820 Ohm
SENSOR UNLOCK TW

­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

­X005 ­X040m ­X040f ­X040f ­X040m ­X005


PWM (NPN) K5:3 3 0053A 1 1 A0401 6 6 00514 14 K5:14 Input (K10:3)
­D790­1 ­D790­1
/0.0_1.C1 /0.0_1.D1

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.
OVERRIDE ALIGNMENT OVERRIDE ALIGNMENT

F F

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 tillbehörsaggregat DCF300­,DCE300­ 7.0_4
CJS 050128 A47137.0100
Name

 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

­X202f ­X202m ­X208f ­X208m ­X208Am


CHASSIS 2023 3 3 OG_/_3 3 3 OG_/_3 3
 / 9.7_2.C7 CHASSIS

D ­X202f ­X202m ­X208f ­X208m ­X208Am D


58­3/3:1 2024 4 4 YE_/_4 4 4 YE_/_4 4
 / 11.5_6.D7 24V

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

­X202f ­X202m ­X208f ­X208m ­X208Am


Alignment 2025 5 5 GN_/_5 5 5 GN_/_5 5
 / 7.0_4.B7 SENSOR ALIGNMENT
Se krets aggregat
See circuit attachment

E ­X202f ­X202m ­X208f ­X208m ­X208Am E


Unlock TW 2026 6 6 BU_/_6 6 6 BU_/_6 6
 / 7.0_4.C7 SENSOR UNLOCK TWISTLOCK

­X202f ­X202m ­X208f ­X208m ­X208Am


Lock TW 2027 7 7 VT_/_7 7 7 VT_/_7 7
 / 7.0_4.D7 SENSOR LOCK TWISTLOCK

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

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 tillbehörsaggregat DCF300­,DCE300­ 7.0_5
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 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

B B 302B B B 2482C CHASSIS


 / 7.2_6.F7

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

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 lyfthöjd DCF300­,DCE300­ 7.0_7
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 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

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

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 lyft/sänk elservo DCF300­,DCE300­ 7.2_1
CJS 050128 A47137.0100
Name

 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

 / 7.2_3.C6 ­X236Lf ­X211


24V D797­1/1:12 C 21112 12 K1:12 Dig In / 1.5A
 / 7.2_6.B1 ­D797­1
/0.0_2.D2
CARRIAGE UP / REGENERATING LIFT

B ­X236Lf  / 7.2_3.C6 ­X236Lf B


90012B A 58­2/5:2 CHASSIS B 237B
 / 7.2_3.B3  / 7.2_6.B7

58­2/5:2 90012A ­X90012


 / 11.5_1.B8

 / 7.2_3.D6 ­X236Rf ­X211


24V D797­1/1:11 C 21111 11 K1:11 Dig In / 1.5A
 / 7.2_6.D1 ­D797­1
/0.0_2.D2
MAST DOWN / REGENERATING LIFT
C C

­X236Rf  / 7.2_3.D6 ­X236Rf


90012C A 58­2/5:2 CHASSIS B 236B
 / 7.2_3.C3  / 7.2_6.D7

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 6062 ­X90032 37209 CHASSIS


 / 10.4_1.C7  / 11.5_1.D6

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

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 frilyft sensorer DCF300­,DCE300­ 7.2_2
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 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

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

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 frilyft sensorer DCF300­,DCE300­ 7.2_3
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 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

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 ventiler stativ DCF300­,DCE300­ 7.2_6
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 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

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

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 aggregat gantry DCF300­,DCE300­ 7.3_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 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

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 Sidoföring elservo DCF300­,DCE300­ 7.4_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 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

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 sidoföring gantry DCF300­,DCE300­ 7.4_2
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 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

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 20­40, 30­35 stopp DCF300­,DCE300­ 7.5_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 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

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 spridning gantry DCF300­,DCE300­ 7.5_2
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 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

­X421 ­XH9003f ­XH9003m ­H9003


6A K1:28 28 42128 1 1 RD +
­D791
/0.0_4.D5 2 2 BK ­
D D
WARN. SIGNAL AUT. SPREADING
WARNING SIGNAL AUT. SPREADING

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

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

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 20­40 opt. DCF300­,DCE300­ 7.5_3
CJS 050128 A47137.0100
Name

 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

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

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 tilt elservo DCF300­,DCE300­ 7.7_1
CJS 050128 A47137.0100
Name

 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

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 tiltindikering DCF300­,DCE300­ 7.7_2
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 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

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 skevning gantry DCF300­,DCE300­ 7.8_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 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

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.
/0.0_4.D2 ­X90060
VALVE UNLOCK TWISTLOCK
F UNLOCK TW F

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 Twistlock DCF300­,DCE300­ 7.9_1
CJS 050128 A47137.0100
Name

 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

­X403Am ­X403Af ­X403Bf ­X403Bm ­XB7202Rf ­XB7202Rm


1 1 4031 1 1 4031 ­X90054 4031A A A ­X403Bm ­X403Bf ­X403Af ­X403Am ­X421
A 4033 3 3 4033 3 3 42140 40 K1:40 Dig In / 1.5A A
BN ­D791
­B7202R ­XB7202Rm ­XB7202Rf /0.0_4.D5
BK C C
SENSOR ALIGNMENT FRONT RIGHT
B B 4032A 4032 2 2 4032 2 2 4032
ALIGNMENT FRONT RIGHT
BU ­X90055

­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

C ­X421 42110C 24V D791­1/1:10 C


 / 7.10_2.E2
1.5A K1:10 10 42110A ­X90058 769B CHASSIS
­D791  / 7.10_2.F7
/0.0_4.D2 42110D 24V D791­1/1:10 7211B CHASSIS
 / 7.10_2.A2  / 7.10_2.A7
SENSORS ATTACHMENT CHASSIS W401 ­X90059 4032
­X404Am ­X404Af  / 11.5_5.B7
4041A 1 1 42110E 4042

­X404Bf ­X404Bm ­XB7202Lf ­XB7202Lm


­X90083 4041B 1 1 4041 ­X90056 4041A A A ­X404Bm ­X404Bf ­X404Am ­X404Af ­X421
4043 3 3 4043 3 3 42113 13 K1:13 Analog In 0­5V
BN ­D791
­B7202L ­XB7202Lm ­XB7202Lf /0.0_4.D2
BK C C
SENSOR ALIGNMENT FRONT LEFT
B B 4042A 4042 2 2 4042B 4042A 2 2 4042
ALIGNMENT FRONT LEFT
BU ­X90057 ­X90084

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

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 givare gantry DCF300­,DCE300­ 7.9_2
CJS 050128 A47137.0100
Name

 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

­X208Am ­X208Af ­X242m


A 1 1 BN_/_1 1 D797­2/1:41 A
 / 11.5_10.A5
2 2

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

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 tång Avesta DCF300­,DCE300­ 7.9_3
CJS 050128 A47137.0100
Name

 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

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 5:e funkt. elservo DCF300­,DCE300­ 7.10_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 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 ­X409f ­X421


1.5A K1:36 36 42136 7 4 4216 6 K1:6 0V Ref
­D791 ­D791
/0.0_4.D5 /0.0_4.C2
OPT. OPT.
C C

­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

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 option gantry DCF300­,DCE300­ 7.10_2
CJS 050128 A47137.0100
Name

 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

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 förbikoppling DCF300­,DCE300­ 8.2_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 override A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8

A A

­X211 ­X768­1f ­X768­1m ­B768­1 ­X768­1m ­X768­1f


Analog Ref 5V K1:8 8 2118A ­X90031 2118B A A 768-1A 1 2 768-1B B B 2116B
­D797­1 P ­X211
/0.0_2.D2 3 768-1C C C 21121 21 K1:21 Analog In 0­5V
U ­D797­1
SENSOR HYDR. SCALE /0.0_2.C5
HYDRAULIC SCALE LIFT
SENSOR HYDR. SCALE LIFT

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

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

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 överlastsystem DCF300­,DCE300­ 8.2_2
CJS 050128 A47137.0100
Name

 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

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

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 givare stativ OLS DCF300­,DCE300­ 8.2_3
CJS 050216 A47137.0100
Name

 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

9 K1:9 0V REF BUZZER K1:14


B B
KID

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

­XF51­1 ­F51­1 ­XF51­1 ­X070m ­X070f


Batt + GY 1 2 0709 9 9 A0599
 / 11.5_1.D3 1 2
5A

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

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 RMI DCF300­,DCE300­ 8.2_4
CJS 060529 A47137.0100
Name

 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

­X211 ­X213f  / 9.6_9.C2  / 9.6_9.C7 ­X213f


6A K1:42 42 21142 1 24V D797­1/1:42 CHASSIS 2 2132 CHASSIS
­D797­1  / 9.14_1.B2  / 9.14_1.C7  / 7.2_2.E5
/0.0_2.E5
CENTRAL LUB. / WORK LIGHT 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

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

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 std. opt. DCF300­,DCE300­ 9.0_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 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

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 extra utrustning DCF300­,DCE300­ 9.1_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 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

­X010 ­X039f ­X039m ­X081f ­X081m


0.5A K10:9 9 A0109A 1 1 0391 9 9 0819 0812L CHASSIS
­D790­1  / 9.1_1.D2
/0.0_1.C6
HOUR MET/RELAY AIR SEAT

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

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 timräknare DCF300­,DCE300­ 9.1_2
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 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

B CHASSIS 0812D 10 10 9 9 0806B B


 / 9.1_1.F2
CHASSIS 0812E SEAT HEATER
 / 9.6_4.B2

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

­X063f ­X063m ­XE803m ­XE803f ­E803 ­XE803f ­XE803m ­X063m ­X063f


4 4 0634 1 1 YE 1 2 BK 2 2 0633 3 3 W06
SEAT HEATER

­X37­D

E CHASSIS 0633A E
 / 9.3_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

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 Stolsvärme DCF300­,DCE300­ 9.3_1
CJS 050128 A47137.0100
Name

 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

790­1/10:9 A0109B 86 85 86 85 W07


 / 9.1_2.C2

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.
Den får ej heller delgivas annan eller annars obe­
hörigen användas. Överträdelse härav beivras med
stöd av gällande lag.
F F

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 luftfjädrad stol DCF300­,DCE300­ 9.3_2
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 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

­X008 ­X092f ­X092m


1.5A K8:15 15 00815A 2 2 0922A 24V D790­1/8:15
­D790­1  / 7.5_1.B2
/0.0_1.E4
LIGHT SW. S169/S1010

­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

­XS220­3m ­S220­3 ­XS220­3m


790­1:5­1/24V 1 BK 1 2 BN 2 790­1/6:14
 / 2.0_1.C3  / 2.0_1.C6
BU 3

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.
DECLUTCHING REAR

F F

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 vändbar förarstol DCF300­,DCE300­ 9.3_3
CJS 050128 A47137.0100
Name

 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

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

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 vändbar förarstol DCF300­,DCE300­ 9.3_4
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 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

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 vändbar förarstol DCF300­,DCE300­ 9.3_5
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 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

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

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 vändbar förarstol DCF300­,DCE300­ 9.3_6
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 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

­X221 ­X243f ­X243m ­X246f ­X246m


1.5A K1:34 34 22134 7 7 2437 A A 9/10 4/10
­D797­2
/0.0_3.D5
DAMPING TURNABLE SEAT
BU
BN

10/10
WH

C C
A
B

­X37­798
­XM675f
­XM675f

­Y676
­X221 ­X243Bf ­X243Bm ­XY676f ­XY676m ­XY676m ­XY676f
B

1.5A K1:35 35 22135 1 1 243B1 1 1 GY BU 2 2 24312D CHASSIS


­D797­2  / 9.3_6.D5
­XM675m
­XM675m

/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

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 vändbar förarstol DCF300­,DCE300­ 9.3_7
CJS 060124 A47137.0100
Name

 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

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.
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

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 klimatsystem DCF300­,DCE300­ 9.4_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 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

9 ­X034m ­X034f ­X039m ­X039f ­X010


OG 8 8 0398 8 8 A0104 4 K10:4 Analog Input
­D790­1
/0.0_1.B6
POT. WATER VALVE

­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

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.
1.5A K1:29 29 21129
­D797­1
/0.0_2.D5
F COMPRESSOR AIR­CONDITION F

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 klimatsystem DCF300­,DCE300­ 9.4_2
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 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

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.
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

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 torkare DCF300­,DCE300­ 9.5_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 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

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 arbetsljus 20­40 DCF300­,DCE300­ 9.6_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 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

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 arbetsljus vagn DCF300­,DCE300­ 9.6_2
CJS 050128 A47137.0100
Name

 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

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 arbetsljus stativ DCF300­,DCE300­ 9.6_3
CJS 050128 A47137.0100
Name

 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

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 belysning DCF300­,DCE300­ 9.6_4
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 lights A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8

270:2 270:2 ­E400L


A ­X270f  / 9.6_13.A1  / 9.6_13.A8 ­X270m A
21128C 2 2 2 1 1 2

DIPPED LIGHT FRONT LEFT

271:2 271:2 ­E400R


­X211 ­X271f  / 9.6_13.C1  / 9.6_13.C8 ­X271m
6A K1:28 28 21128A ­X90028 21128B 2 2 2 1 1 2
­D797­1
/0.0_2.D5
LAMP DIPPED LIGHT DIPPED LIGHT FRONT RIGHT

B B

­X270/271f X211:1 ­X270/271m 270:1 ­E402L­1


 / 9.6_13.E2 ­X270f  / 9.6_13.A1 ­X270m
21115C 1 1 21115D 1 1 1 1 1 2 1 6A
24V­K304­2­87
 / 9.6_13.F5
HEAD LIGHT FRONT LEFT

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

270:5 270:5 ­H416­1 ­X270m 270:6 270:6 ­X270f


­X211 ­X270f  / 9.6_13.A1  / 9.6_13.A8 ­X270m  / 9.6_13.A8  / 9.6_13.A1
1.5A K1:2 2 2112A ­X90006 2112B 5 5 5 1 1 2 1 6C 6 6 6 2706
­D797­1
/0.0_2.C2 ­X90047
SIDE POSITION LIGHT SIDE POSITION FRONT LEFT

6B CHASSIS
 / 9.6_7.D8

271:5 271:5 ­H417­1 ­X271m 271:6 271:6 ­X271f


­X271f  / 9.6_13.D1  / 9.6_13.D8 ­X271m  / 9.6_13.D8  / 9.6_13.D1
D 2112C 5 5 5 1 1 2 1 6C 6 6 6 2716 D
­X90046
­X37­207A

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

58­2/5:1 771A ­S216


 / 7.7_2.C2
58­2/5:1 2481
 / 7.2_6.E1 P
58­2/5:1 246-1 ­X211
 / 9.4_1.A2
58­2/5:1 216-246 ­X90043 216-1A 1 2 21120 20 K1:20 Analog In 0­5V
 / 11.5_1.B8 ­D797­1
58­2/5:1 216-1B /0.0_2.E2
E  / 2.0_1.C2 BRAKE LIGHTS E
PRESSURE SWITCH BRAKE 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.
F F

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 belysning DCF300­,DCE300­ 9.6_5
CJS 050128 A47137.0100
Name

 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

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 belysning DCF300­,DCE300­ 9.6_6
CJS 050128 A47137.0100
Name

 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

271:4 271:4 ­H423 CHASSIS


­X211 ­X271f  / 9.6_13.C1  / 9.6_13.C8 ­X271m  / 9.3_5.D7
2.5A K1:31 31 21131A ­X90065 21131B 4 4 4 1 1 2 1 6B CHASSIS
­D797­1  / 9.6_5.D7
/0.0_2.D5 CHASSIS
D  / 9.3_4.C7 D
LAMP DIRECTION RIGHT Direction Right Front

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

270:4 270:4 ­H422 CHASSIS


­X211 ­X270f  / 9.6_13.A1  / 9.6_13.A8 ­X270m  / 9.3_4.B7
2.5A K1:30 30 21130A ­X90003 21130B 4 4 4 1 1 2 1 6B CHASSIS
­D797­1  / 9.6_5.C7
/0.0_2.D5 CHASSIS
E  / 9.3_5.E7 E
LAMP DIRECTION LEFT Direction Left Front

­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

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 blinkers & hazard DCF300­,DCE300­ 9.6_7
CJS 050128 A47137.0100
Name

 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

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 innerbelysning DCF300­,DCE300­ 9.6_8
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 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

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 arbetsljus option DCF300­,DCE300­ 9.6_9
CJS 050128 A47137.0100
Name

 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

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 arbetsljus option DCF300­,DCE300­ 9.6_10
CJS 050128 A47137.0100
Name

 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

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 instegsbelysning DCF300­,DCE300­ 9.6_11
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 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

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 extra bel. aggr DCF300­,DCE300­ 9.6_12
CJS 050405 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 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

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 arbetsljus option lamphuv DCF300­, DCE300­ 9.6_13
CJS 060823 A47137.0100
Name

 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

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 arbetsljus option vagn DCF300­, DCE300­ 9.6_14
CJS 070921 A47137.0100
Name

 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

­X011 ­X062f ­X062m ­H850


3A K11:11 11 A01111A 1 1 0621 +
­D790­1
/0.0_1.D6 0622 ­
HORN
Horn

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

­X018 ­XH853f ­XH853m ­XH853m ­XH853f


1.5A K8:4 4 0184 1 1 RD 1 2 BK 2 2 02014 790­2/1:14
­D790­2  / 11.6_1.B2
/11.5_4.F4
BUZZER
BUZZER

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

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 larm, ljudsignaler DCF300­,DCE300­ 9.7_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 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

­X211 ­X275f ­X275m ­XH965f ­XH965m ­H965


1.5A K1:10 10 21110 9 9 2759 1 1 RD +
­D797­1
/0.0_2.D2 10 10 27510 2 2 BK ­
REVERSING ALARM
REVERSING ALARM

C C

37210 2023 CHASSIS


 / 7.0_5.D2

­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

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 backalarm DCF300­,DCE300­ 9.7_2
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 reversing alarm A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8

A A

­K3016

0621 A01111B 86 85 86 85 W04


 / 9.7_1.C2
/9.7_3.C4
COMPRESSOR HORN

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

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

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 kompressor horn DCF300­,DCE300­ 9.7_3
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 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

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

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 tuta servopanel DCF300­,DCE300­ 9.7_4
CJS 050128 A47137.0100
Name

 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

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

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 radio DCF300­,DCE300­ 9.8_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 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

KID_GND 1825 5 5 90925 GND


 / 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

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

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 skrivare DCF300­,DCE300­ 9.8_2
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 printer A49226.0100 15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8

A A

B B

­X241m ­XE802Rf ­XE802Rm ­E802R­1 ­XE802Rm ­XE802Rf ­X241m


24V D797­2/1:11 2 GY 1 1 BN 1 2 BU 2 2 BK 1 CHASSIS
 / 11.5_11.B3  / 11.5_11.B6

­E802R­2
BN 1 2 BU

C C

­X241m ­XE802Lf ­XE802Lm ­E802L­1 ­XE802Lm ­XE802Lf ­X241m


24V D797­2/1:12 3 GY 1 1 BN 1 2 BU 2 2 BK 4 CHASSIS
 / 11.5_11.C3  / 11.5_11.D6

­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

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 värme backspeglar DCF300­,DCE300­ 9.9_1
CJS 050223 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 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

­X008 ­X092f ­X092m


B 1.5A K8:15 15 00815A 2 2 0922A 24V D790­1/8:15 B
­D790­1  / 7.5_1.B2
LIGHT SW. S169/S1010

­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

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 centralsmörjning DCF300­,DCE300­ 9.14_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 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

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

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 urkoppl. hydr pump DCF300­,DCE300­ 10.4_1
CJS 050128 A47137.0100
Name

 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

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 kyln. hydraul olja DCF300­,DCE300­ 10.6_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 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

­F58­5 A0012 58­5/1:1 ­X37­B


 / 11.5_4.C2
A0711A A:1 25 A 1:1 A0013 58­5/1:2
A:1 1:1  / 11.5_4.C2
AA2-B1 A:2 A:2 1:2 1:2 A0014 58­5/1:2
 / 11.5_4.C2
B:1 10 A 2:1 A0615 58­5/2:1
B:1 2:1  / 11.5_4.F2
B:2 2:2
D A0711E C:1 15 A 3:1 A0396 58­5/3:1 D
C:1 3:1  / 9.4_2.C2
AC2-D1 C:2 C:2 3:2 3:2 A0028 58­5/3:2
 / 9.4_2.D2

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

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_2
CJS 050128 A47137.0100
Name

 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

­X060Am ­X060Af ­X060m ­X060f ­X011


0608 8 8 0608 8 8 1 K11:1 Input
­D790­1
/0.0_1.C6
SWITCH IGNITION

­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

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_3
CJS 050128 A47137.0100
Name

 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 + ­

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
­X37­A

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_4
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 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

­X400­2D W400 CHASSIS


B  / 9.6_2.D8 B
­X400­1A ­X400­1B ­X422 ­D791 ­X400­2C W401 CHASSIS
58­3/1:1 RD 4221 1 K2:1  / 7.9_2.C5
 / 11.5_6.D7 Main power W402 CHASSIS
­X422  / 7.9_1.F7
Power supply/Ground
­X400­1C 4229 9 K2:9 K2:12 12 42212 ­X400­2B
Main power Ground ­X400­2A
42210 10 K2:10 Main power Ground K2:14 14 42214 BU CHASSIS
 / 11.5_1.E7
/0.0_4.B4

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

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_5
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 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

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 manöverbrytare DCF300­,DCE300­ 11.5_6
CJS 050128 A47137.0100
Name

 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

­X055f ­X055m ­X905f


A0558 8 8 0558 2
A0556 6 6 0556 1 Com. Radio 12V

C C
OPTION ADAPTER

­X062f ­X062m ­XE804f ­XE804m ­XE804Af


A0626 6 6 0626 1 1 804A1B 1
Cig. 12V
2 2 804A2B 2

+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

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 24/12V DCF300­,DCE300­ 11.5_7
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 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

­X901.1m ­X901.2m ­X901.2f


58­5/7:1 W14A
 / 11.5_2.E6

­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

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 24V uttag DCF300­,DCE300­ 11.5_8
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 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

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

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 option grund kraft DCF300­,DCE300­ 11.5_9
CJS 050128 A47137.0100
Name

 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

­X221 ­X242f ­X242f ­X221


Analog Ref 5V K1:8 8 2218 5 D797­2/1:41 1 22141 41 K1:41 Analog In 0­5V
­D797­2  / 7.9_3.A7 ­D797­2
/0.0_3.D2 /0.0_3.D5
OPT. OPT.

­X221 ­X242f ­X242f ­X221


0V Ref K1:6 6 2216 6 2 22121 21 K1:21 Analog In 0­5V
­D797­2 ­D797­2
/0.0_3.C2 /0.0_3.C5
OPT. OPT.
B B

­X242f ­X242f ­X221


58­2/4:1 W237 7 58­2/4:1 D797­2/1:22 3 22122 22 K1:22 Analog In 0­5V
 / 11.5_1.B8  / 7.9_3.A2  / 7.9_3.B7 ­D797­2
/0.0_3.C5
OPT.

­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

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 option grund DCF300­,DCE300­ 11.5_10
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 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.

­X221 ­X241f ­X241f


Dig In / 1.5A K1:26 26 22126 6 CHASSIS 4 W235C
­D797­2  / 9.9_1.D7
/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 ­X241f
Dig In / 1.5A K1:40 40 22140 5
­D797­2
/0.0_3.D5
OPT.

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

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 option grund DCF300­,DCE300­ 11.5_11
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 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

­X013 KCU ­X013 ­X050


1 K13:1 TX
K13:10 10 A01310 3
+
2 K13:2 CAN J1939 RS232 K13:11 11 A01311 2
­ RX

No extra KDU => connect X209Af and 209Am K13:3 K13:12 12 A01312 5


Shield Ground
­X013
 / 11.6_2A.C7 4 K13:4
L+
 / 11.6_2B.B7 ­X209Am 5 K13:5 CAN
CAN+ 4 0514 L­
D  / 11.6_2C.B7 K13:6 D
Shield
­X051m ­X051f ­X013 ­D790­1

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

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

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 KDU opt. DCF300­,DCE300­ 11.6_2A
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 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

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 KDU opt. DCF300­,DCE300­ 11.6_2B
CJS 050128 A47137.0100
Name

 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

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

K2:8 8 2228 2 RED+2


+  / 11.6_1.F2
CAN­BUS K2:4 4 2224 30 4 CAN+
R+  / 11.6_1.F2
CAN K2:5 5 2225 3 CAN­
R­  / 11.6_1.F2

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

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 KDU opt. DCF300­,DCE300­ 11.6_2C
CJS 050128 A47137.0100
Name

 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

Pin Number Drawing Function Type Pin Number Drawing Function Type

1:1  /9.6_1.B1 WORK LIGHT LEFT 6A 1:21  /7.9_4.D8 SENSOR DETECT RIGHT UPPER Analog In 0­5V


1:2  /7.5_1.A2 VALVE SPREADING LEFT IN 1.5A 1:22  /7.9_2.A8 SENSOR UNLOCKED LEFT Analog In 0­5V
1:3  /7.5_1.A2 VALVE SPREADING LEFT OUT 1.5A 1:23  /7.9_2.D8 SENSOR LOCKED LEFT (LOWER) Analog In 0­5V
1:4  /7.5_1.D2 VALVE SPREADING RIGHT IN 1.5A 1:24  /7.9_2.D8 SENSOR LOCKED RIGHT (LOWER) Analog In 0­5V
C 1:5  /7.5_1.D2 VALVE SPREADING RIGHT OUT 1.5A 1:25  /11.5_2.B2 LAMP UNLOCKED 1.5A
C
1:6 0V Ref 1:26  /7.9_4.E8 SENSOR ALIGNMENT RIGHT (LOWER) Dig In / 1.5A
1:7  /7.9_1.B1 VALVE LOCK CONTAINER 1.5A 1:27  /7.9_4.C8 SENSOR ALIGNMENT LEFT (LOWER) Analog In 0­5V
1:8 Analog Ref 5V 1:28  /7.5_2.B2 SUMMER AUT. SPREADING 6A
1:9  /7.9_1.C1 VALVE UNLOCK CONTAINER 1.5A 1:29  /11.5_2.E2 LAMP LOCKED 1.5A
1:10  /11.5_2.A2 SUPPLY SENSORS 1.5A 1:30  /7.8_1.B2 VALVE LEVELLING LEFT 2.5A
1:11  /11.5_2.D2 SENSOR ALIGNMENT UPPER LEFT Dig In / 1.5A 1:31  /7.8_1.C2 VALVE LEVELLING RIGHT 2.5A
1:12  /7.5_3.B8 SENSOR DAMPING LEFT Dig In / 1.5A 1:32  /7.4_1.B1 VALVE SIDESHIFT LEFT 1.5A

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

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 Korsreferens lista DCF80­100­45E 0.0_1
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
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

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 sidoföring DCF80­100­45E 7.4_1
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 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

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 spridning DCF80­100­45E 7.5_1
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 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

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 summer spridning DCF80­100­45E 7.5_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 buzzer spreading A50400.0100 03
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8

A A

­X425f ­X425m ­XB769Lf ­XB769Lm


D791­1:10­24V 42110D 1 1 4251A ­XSP13 4251B A A
 /11.5_2.A5
BN
­B769L ­XB769Lm ­XB769Lf ­X425m ­X425f ­X421
BK C C 4253 3 3 42112 12 K1:12 Dig In / 1.5A
­D791
 /0.0_1.C3
DAMPING 20/40 LEFT
BU SENSOR DAMPING LEFT
B B
­XB777Lf ­XB777Lm
B 4251C A A B
BN
­B777L ­XB777Lm ­XB777Lf ­X425m ­X425f ­X421
BK C C 4254 4 4 42120 20 K1:20 Analog In 0­5V
­D791
 /0.0_1.D3
30­35 STOP LEFT
BU SENSOR 30­35 STOP LEFT
B B 4252B
­X425m ­X425f
4252C ­XSP15 4252A 2 2 4252 CHASSIS
 /11.5_2.E8

C C

­X426m ­X426f ­XB769Rf ­XB769Rm


D791­1:10­24V 42110E 1 1 4261A ­XSP14 4261B A A
 /11.5_2.A5
BN
­B769R ­XB769Rm ­XB769Rf ­X426f ­X426m ­X421
BK C C 4263 3 3 42140 40 K1:40 Dig In / 1.5A
­D791
 /0.0_1.D5
D DAMPING 20/40 RIGHT D
BU SENSOR DAMPING 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.
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

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 spridning DCF80­100­45E 7.5_3
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 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

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 skevning DCF80­100­45E 7.8_1
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 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

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 öppna/låsa DCF80­100­45E 7.9_1
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 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

­XB7205LUf XSP2­24V ­XB7205LUm


A  /7.9_5B.E4 A
4042D
4032D

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

 /7.9_5A.B7 ­X404f ­X421


D791­1:27­24V 7 42127 27 K1:27 Analog In 0­5V
 /7.9_5B.B7 ­D791
 /0.0_1.C5
SENSOR ALIGNMENT LEFT (LOWER)
C C

­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

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_4
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

­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

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 arbetsljus vagn/aggregat DCF80­100­45E 9.6_1
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 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

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 centralsmörjning DCF80­100­45E 9.14_1
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 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

­X400­1A ­X400­1B ­X422 ­D791


See wiring chassi 4221 1 K2:1
Main power
­X400­1C Power supply/Ground ­X422
4229 9 K2:9 Main power Ground K2:12 12 W400-2B1 CHASSIS
 /11.5_2.A8
42210 10 K2:10 Main power Ground K2:14 14 W400-2B2 CHASSIS
 /11.5_2.A8

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

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 DCF80­100­45E 11.5_1
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 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

­X421 ­X415f  /7.9_3A.A2


1.5A K1:25 25 42125 1 D791­1:25­24V
­D791  /7.9_3B.B1
 /0.0_1.C5
LAMP UNLOCKED

B B

­X421 ­X415f W404L CHASSIS


 /9.6_1.B7
1.5A K1:34 34 42134 5 D791­1:34­24V
­D791  /7.9_3B.C1 W404R CHASSIS
 /0.0_1.D5  /9.6_1.B7
LAMP ALIGNMENT (UPPER) W400-2C ­XSP20 W9003 CHASSIS
 /7.5_2.C7

­X421 ­X415f  /7.9_3A.C2


1.5A K1:39 39 42139 2 D791­1:39­24V
­D791  /7.9_3B.D1
 /0.0_1.D5
C C
LAMP ALIGNMENT (LOWER)

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

D ­X421 ­X404f ­X404m ­XB7205LUf  /7.9_2.E5 D


Dig In / 1.5A K1:11 11 42111 5 5 4045 C D791­1:11­24V
­D791  /7.9_5B.E5
 /0.0_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.
­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

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 DCF80­100­45E 11.5_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 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

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

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 DCF80­100­45E 11.6_1
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 CAN­BUS A50400.0100 03
1 2 3 4 5 6 7 8
E Schema - Komponentförteckning / E Schematics - List of Components 1

Komponentförteckning / List of Components


Number Categ. Svenska English
30 G Batteri Battery
32 A Kretskort elcentral Printed circuit board, Junction box
37 X Terminal stomanslutning Earthing terminal on chassis
39 X Terminal minusanslutning Terminal, negative terminal
51 F Säkringshållare 1-polig Fuse holder, 1-pole
52 F Säkringshållare 2-polig Fuse holder, 2-pole
56 F Säkringshållare 6-polig Fuse holder, 6-pole
58 F Säkringshållare 8-polig Fuse holder, 8-pole
59 F Säkringshållare 12-polig Fuse holder, 12-pole
62 F Batterihandske 2-polig Battery connector, 2-pole
64 F Batterihandske 4-polig Battery connector, 4-pole
72 X Stickuttag 2-polig Outlet, 2-pole
77 X Stickuttag 7-polig Outlet, 7-pole
78 X Stickuttag extra 7-polig Outlet, extra, 7-pole
100 S Strömställare ljus Switch, light
101 S Strömställare omk hel/halvljus Switch, main/dipped beam
102 S Strömställare dimljus Switch, fog light
103 S Strömställare fjärrljus Switch, distance light
104 S Strömställare lastljus Switch, mast lights
105 S Strömställare arbetsljus Switch, working lights
106 S Strömställare containerljus Switch, container light
107 S Strömställare park broms Switch, parking brake
108 S Strömställare centr smörjning Switch, central lubricator
109 S Strömställare varningsljus Switch, hazard lights
110 S Strömställare rot varningsljus Switch, rotating hazard beacon
111 S Strömställare fönsterhiss Switch, window regulator
112 S Strömställare kylanläggning (AC) Switch, air conditioner (AC)
113 S Strömställare styrning alt Switch, alternative steering
114 S Strömställare läsbelysning Switch, reading light
115 S Strömställare instr belysning Switch, instrument illumination
116 S Strömställare innerbelysning Switch, interior lighting
117 S Strömställare värme Switch, heating
118 S Strömställare fläktm värme Switch, heater fan
119 S Strömställare vindrutetorkare Switch, wiper
120 S Strömställare spolare Switch, washer
121 S Strömställare blackout Switch, blackout
122 S Strömställare nöd hydraulpump Switch, emergency hydraulic pump
123 S Strömställare backspegel Switch, observation mirror
124 S Strömställare kallstart Switch, cold start
125 S Strömställare avgasbroms Switch, exhaust brake
126 S Strömställare diff spärr/broms Switch, diff. Block
127 S Strömställare värmesystem diesel Switch, heating system diesel
128 S Strömställare kraftuttag sida Switch, power take off side
129 S Strömställare kraftuttag bak Switch, power take off rear
130 S Strömställare hög/lågväxel Switch, high/low gear
131 S Strömställare färdväljare fram Switch, gear selector forward
132 S Strömställare färdväljare bak Switch, gear selector rear
135 S Strömställare växelväljare Switch, gear shift
136 S Strömställare framhjuls styrning Switch, forward wheel steering
137 S Strömställare 4-hjuls styrning Switch, 4-wheel steering
138 S Strömställare crab styrning Switch, crab steering

Verkstadsmanual / Workshop Manual DCF


E Schema - Komponentförteckning / E Schematics - List of Components 2

Number Categ. Svenska English


139 S Strömställare defroster Switch, defroster
141 S Strömställare Stegbelysning Switch, Steplight
142 S Strömställare fot Switch, foot
143 S Strömställare sitsvärme Switch, seat heater
144 Q Batterifrånskiljare Battery disconnecting switch
145 S Strömställare AT-regulator Switch, AT-regulator
147 S Strömställare körvisare Switch, direction indicators
149 S Strömställare signalhorn Switch, horn
150 S Strömställare startlås/ellas Switch, main key switch
152 S Strömställare intervalltorkare Switch, intermittent wiper
156 S Strömställare kupevärmare Switch, cab heating
157 S Strömställare stoltilt Switch, seat tilt
158 S Strömställare dimbakljus Switch, rear fog light
159 S Strömställare extra fram/back väljare Switch, extra direction selector
160 S Strömställare komb fram/back Switch, combi-forward/reverse
161 S Strömställare komb signal, ljus hel/halv Switch, combi-horn, light main/dipped beam,
spol,torkare m intervall körvisare washer, wiper (intermittent), direction
indicator
162 S Strömställare komb signal ljus hel/halv, Switch, combi horn, light main/dipped beam,
spol, torkare m 2 int, fram/bacK washer, wiper w 2int., forward/revers

163 S Strömställare start på 2-an Switch, start 2nd gear


165 S Strömställare stolvärme Switch, seat heater
166 S Strömställare låsning vändskiva Switch, interlocking of turntable
167 S Strömställare luftfjädring Switch, pneumatic springing
168 S Strömställare låsn stol Switch, interlocking of seat
169 S Strömställare stolsvändning Switch, reversible seat
170 S Strömställare förångare (LPG) Switch, evaporator (LPG)
171 S Strömställare v-skiva upp/ner Switch, fifth wheel up/down
172 S Strömställare v-skiva fr/back Switch, fifth wheel forward/reverse
173 S Strömställare v-skiva skevning Switch, fifth wheel, levelling
174 S Strömställare,utskjut Switch, projecting
175 S Strömställare hyttlyft upp Switch, cab hoist up
176 S Strömställare hyttlyft ner Switch, cab hoist down
177 S Strömställare hyttskjutning Switch, cab movement
178 S Strömställare nollställning Switch, reset
179 S Strömställare Aut/man växling Switch Aut/man gearshifting
180 S Strömställare fyrhjulsdrift Switch, 4-WD
190 S Strömställare klimatanläggning Switch, air conditioner
191 S Strömställare recirkulation Switch, re-circulation
192 S Strömställare vattenavskiljare
195 S Strömställare joy-stick X Switch, joy-stick X
196 S Strömställare joy-stick X+Y Switch, joy-stick X+Y
197 S Strömställare längs/tvärskörning Switch, length/sideways driwing
198 S Strömställare flytläge skevning Switch, equalizing fifth wheel
199 S Strömställare option Switch, option
200 S Brytkontakt lampa park broms Contact, breaking,warning lamp,parking
brake
201 S Brytkontakt lampa färdbroms Contact, breaking, warning lamp, brake
202 S Brytkontakt lampa oljetryck motor Contact, breaking, warning lamp, oil
pressure engine
204 S Brytkontakt tryck ackumulator Contact, breaking, pressure accumulatortank

205 S Brytkontakt innerbelysning Contact, breaking, interior lighting

Verkstadsmanual / Workshop Manual DCF


E Schema - Komponentförteckning / E Schematics - List of Components 3

Number Categ. Svenska English


206 S Brytkontakt handskfack belysning Contact, breaking, glove
207 S Slutkontakt diff spärr Contact, making, diff. interlock
208 S Slutkontakt lampa temperatur spolkrets Contact, making, warning lamp temperature
bromsar brake
214 S Slutkontakt överväxel Contact, making, over drive
215 S Slutkontakt temp motor Contact, making, temperature engine
216 S Slutkontakt bromsljus Contact, making, brake lights
217 S Slutkontakt backljus Contact, making, reversing light
218 S Slutkontakt AT-regulator Contact, making, AT-control
219 S Slutkontakt lampa luftfilter Contact, making, indicating light air filter
220 S Brytkontakt drivning Contact, breaking, drive cut off
221 S Slutkontakt temp växellåda Contact, making, temperature gear box
222 S Slutkontakt lampa temp moment - Contact, making, warning lamp temperature
förstärkare torque amplifier.
223 S Släpkontakt signal Contact, brush, horn
224 S Slutkontakt insprutningspump Contact, making, injection pump
225 S Brytkontakt säkerhetsbälte Contact, breaking, seat belt
228 S Slutkontakt hyttlåsning Contact, making, cab locking
229 S Slutkontakt stolslåsning Contact, making, seat locking
230 S Brytkontakt stol Contact, breaking, seat
231 S Slutkontakt fotkontroll stolvändning Contact, making, seat rotation, foot switch

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

246 S Slutkontakt tryck kylmedia Contact, pressure refrigerant


250 S Manöverbrytare Operating Switch
251 S Slutkontakt vändbar förarstol Contact, making, VBFS
260 S Slutkontakt lyft steg 1 Contact, making, hoist step 1
261 S Slutkontakt lyft steg 2 Contact, making, hoist step 2
262 S Slutkontakt tilt Contact, making, tilting
263 S Slutkontakt gaffelspridning Contact, making, fork positioning
264 S Slutkontakt sidoföring Contact, making, sideshift
265 S Slutkontakt stativ in/ut Contact, making, lifting mast in-out
266 S Brytkontakt hyttdörr Contact, breaking cab door
267 S Slutkontakt bromstryck Contact, making, brake pressure
268 S Slutkontakt kompressor Contact, making, Compressor
269 S Slutkontakt sax inne Contact, making extender in
270 S Slutkontakt överlastskydd Contact, making, overload protection
299 S Slut/brytkontakt option Contact, making/braking option
300 K Relä hel/halvljus Relay, main/dipped beam

Verkstadsmanual / Workshop Manual DCF


E Schema - Komponentförteckning / E Schematics - List of Components 4

Number Categ. Svenska English


301 K Relä dimljus Relay, fog light
302 K Relä fjärrljus Relay, distance light
303 K Relä lastljus Relay, mast light
304 K Relä arbetsljus Relay, working light
305 K Relä backljus Relay, reversing light
306 K Relä helljus Relay, main beam
307 K Relä halvljus Relay, dipped beam
308 K Relä bromsljus Relay, brake light
309 K Relä parkeringsbroms Relay, parking light
310 K Relä körvisare vä Relay, direction indicator left
311 K Relä körvisare hö Relay, direction indicator right
312 K Relä startelement Relay,element preheater
313 K Relä vändbar förarstol Relay, rotating driver´s seat (VBFS)
314 K Relä parkeringsbroms Relay, parking brake
315 K Relä tändningslås Relay, ignition key
316 K Relä torkare Relay, wiper
317 K Relä strålkastartorkare Relay, roading lights wiper
318 K Relä AT-regulator Relay, AT-regulator
319 K Relä varningsblinkers Relay, hazard blinkers
320 K Relä elektrisk stopp Relay, electical stop
321 K Relä intervalltorkare Relay, intermittent wiper
322 K Relä kylvätskenivå Relay, coolant level
323 K Relä blinkers Relay, blinkers
324 K Relä rangespärr Relay, range interlock
325 K Relä blinkande bromsljus (back) Relay, flashing brake lights (reversing)
326 K Relä blinkande bromsljus (runt) Relay, flashing hazard brake lights
327 K Relä växel neutral Relay, gear neutral
328 K Relä växelskifte Relay, gear shift
329 K Relä växel hög/låg Relay, high/low gear
330 K Relä startspärr Relay, start interlock
331 K Relä drivning fram Relay, forward driving
332 K Relä drivning bak Relay, reversing driving
333 K Tidrelä förvärmning Time relay, automatically preheating
334 K Relä frikoppling/drivbrytning Relay, free wheel/drive disconnection
335 K Relä växelventil 1:a (diesel, gas) Relay, gear change valve 1-gear
(diesel,LPG)
336 K Relä växelventil 2:a (diesel, gas) Relay, gear change valve 2-gear
(diesel,LPG)
337 K Relä drivriktning motor Relay, motor drive direction
338 K Relä kylfläkt drivmotor Relay, cooling fan drive motor
339 K Relä kylfläkt elskåp Relay, cooling fan electrical box
340 K Tidrelä fördröjt tillslag Time relay, start delay
341 K Tidrelä fördröjt frånslag Time relay, stop delay
342 K Relä drivning 2/4 hjul Relay, switching 2/4 WD
343 K Relä dimbakljus Relay, fog light rear
344 K Relä momentförstärkare Relay, torque amplifier
345 K Relä låsning vändskiva Relay, interlocking of turntable
346 K Relä frikoppling stollåsning Relay, releasing of seat interlocking
347 K Relä stolvändning/ljussignal Relay, multifunction, seat rotation/light signal

348 K Relä fläktmotor värmare Relay, fan heating


349 K Relä fartreglage Relay, speed control
350 K Relä pumpkontaktor/pumpkontroll Relay, pump contactor/pump control
351 K Relä hyttlyft upp Relay, cab hoist up

Verkstadsmanual / Workshop Manual DCF


E Schema - Komponentförteckning / E Schematics - List of Components 5

Number Categ. Svenska English


352 K Relä hyttlyft ner Relay, cab hoist down
353 K Relä säkerhetsslinga Relay, safety loop
354 K Relä styrsystem Relay, signal control system
355 K Relä sensorstyrning Relay, sensor control
356 K Skiftrelä längskörning/tvärskörning Shift relay, length/sideways driving
357 K Relä roterande varningsljus Relay, hazard beacon
358 K Relä komressor luft Relay, compressor air
359 K Relä Hydrauloljekylare Relay hydraulic oil cooler
360 K Relä startsolenoid Relay, starting solenoid
361 K Relä kompressor AC Relay, compressor air conditione
362 K Relä vattenventil AC Relay, water valve air conditioner
363 K Relä kondensor AC Relay, condenser air conditione
364 K Relä stolsbrytare Relay seat switch
365 K Relä fönsterhiss upp Relay, electrical screen elevator up
366 K Relä fönsterhiss ner Relay, electrical screen elevator down
367 K Relä styrning Relay, steerin
368 K Relä lågt bromstryck Relay, low brake pressure
369 K Relä centralsmörjning Relay, central lubrication
370 K Relä centralsmörjning, aggregat Relay, central lubrication, attatchment
371 K Relä lyfthöjd Relay, liftheight
372 K Relä blinkande varn.ljus, höjdbegränsn. Relay, flashing beacon, lifting height limiter

373 K Relä bakljus Relay light


375 K Huvudkontaktor reglersystem Main contactor, operating control
376 K Kontaktor fram reglersystem Contactor, forward operating control
377 K Kontaktor bak reglersystem Contactor, reversing operating control
378 K Kontaktor by-pass Contactor, ¿by-pass¿ operating control/
reglersystem/Fältförsvagning Field weakening
379 K Kontaktor pumpmotor Contactor, pump motor
380 K Kontaktor Contactor
381 K Kontaktor återladdning Contactor, recharging
382 K Relä, förbikoppling säkerhetssystem Relay, by-pass safety system
383 K Relä, Stolsvärme Relay, heated seat
384 K Relä vattenseparator Relay, waterseparator
385 K Relä bränslepump insprutning Relay, fuel injection pump
386 K Relä, hög motortemperatur. Relay, high motor temperature
387 K Relä alternativ gaspedal Relay alternative throttle pedal
388 K Relä, Extra färdriktningsväljare Relay, Extra direction selector
389 K Relä, Pausvärme Relay, Paus heat
399 K Relä option Relay, option
400 E G-lampa vä fram Light bulb, roading light left hand front
400 E G-lampa hö fram Light bulb, roading light right hand rear
401 E G-lampa vä bak Light bulb, roading light left hand front
401 E G-lampa hö bak Light bulb, roading light right hand rear
402 E G-lampa fjärrljus Light bulb, distance light
403 E G-lampa lastljus Light bulb, mast light
404 E G-lampa arbetsljus Light bulb, working light
405 E G-lampa backljus Light bulb, rear light
406 E G-lampa cont belysning vänster Container light left-hand
406 E G-lampa cont belysning höger Container light right-hand
408 E G-lampa park ljus vä fram Light bulb, parking light, left-hand forward
408 E G-lampa park ljus hö fram Light bulb, parking light, right-hand forward

410 H G-lampa broms ljus vä fram Light bulb, brake light, left-hand forward

Verkstadsmanual / Workshop Manual DCF


E Schema - Komponentförteckning / E Schematics - List of Components 6

Number Categ. Svenska English


410 H G-lampa broms ljus hö fram Light bulb, brake light, right-hand forward
411 H G-lampa broms ljus vä bak Light bulb, brake light, left-hand rear
411 H G-lampa broms ljus hö bak Light bulb, brake light, right-hand rear
412 H G-lampa bak ljus vä bak Light bulb, rear light, left-hand rear
412 H G-lampa bak ljus hö bak Light bulb, rear light right-hand rear
413 H G-lampa bak ljus vä fram (VBFS) Light bulb, rear light, left-hand forward
(VBFS)
413 H G-lampa bak ljus hö fram (VBFS) Light bulb, rear light,right-hand forward
(VBFS)
416 H G-lampa sidomarkering vä fram Light bulb, side position light, left-hand
forward
416 H G-lampa sidomarkering vä bak Light bulb, side position light, left-hand rear

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

420 H G-lampa positionsljus vänster Light bulb, position light, left-hand


421 H G-lampa positionsljus höger Light bulb, position light, right-hand
422 H G-lampa körvisare vä fram Light bulb, direction indicator left-hand
forward
423 H G-lampa körvisare hö fram Light bulb, direction indicator right-hand
forwrd
426 H G-lampa körvisare vä bak Light bulb, direction indicator left-hand rear

427 H G-lampa körvisare hö bak Light bulb, direction indicator right-hand rear

428 H G-lampa roterande varningsljus Light bulb, flashing beacon lamp


429 E G-lampa cigarettändare belysning Light bulb, cigarett lighter illumination
431 E G-lampa instrument belysning Light bulb, instrument illumination
432 E G-lampa handsfack belysning Light bulb, glove pocket light
433 E G-lampa instegs belysning Light bulb, step-in lighting
434 E G-lampa innerbelysning Light bulb, interior lighting
435 E G-lampa låsbelysning Light bulb, reading lighting
436 E G-lampa identifikationsljus Light bulb, identification light
437 E G-lampa identifikationsljus/takskylt Light bulb, identification light/roof sign
438 E G-lampa motorrumsbelysning Light bulb, engine compartment light
439 E Nummerskyltsbelysning Light license plate
440 E G-lampa värmereglage belysning Light bulb, heating control light
445 H G-lampa körvisare vä (extra) Light bulb, extra direction indicator left
446 H G-lampa körvisare hö (extra) Light bulb, extra direction indicator right
451 H G-lampa dimbakljus vänster Light bulb, fog light rear left
452 H G-lampa dimbakljus höger Light bulb, fog light rear right
453 H G-lampa bromsljus/körvisare vänster Light bulb, brake light/dir. indicator left-hand

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

Verkstadsmanual / Workshop Manual DCF


E Schema - Komponentförteckning / E Schematics - List of Components 7

Number Categ. Svenska English


457 H G-lampa positionsljus blackout höger Light bulb, position light blackout right-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

464 E G-lampa cont belysning IR vänster Light bulb,Container light IR left-hand


464 E G-lampa cont belysning IR höger Light bulb,Container light IR right-hand
465 H G-lampa röd saxagregat ute Light-bulb, red extender exended
466 H G-lampa orange vertikalhålning på Light bulb, orange vertical hold on
467 H G-lampa grön klämtryck OK Light bulb, green clamp pressure OK
468 G-Lampa Röd Maxlast Light bulb,Red Overload
500 H Kont lampa körvisare Indicating lamp, direction indicator
501 H Kont lampa körvisare (extra) Indicating lamp, direction indicator extra
503 H Varn lampa oljetryck motor Warning lamp, oil pressure engine
504 H Kont lampa helljus Indicating lamp, main beam
505 H Varn lampa laddning Warning lamp, loading
506 H Varn lampa laddning (extra) Warning lamp, loading extra
507 H Varn lampa färdbroms Warning lamp, brake
508 H Varn lampa parkerings broms Warning lamp, parking brake
509 H Varn lampa nivå kylvatten Warning lamp, coolant level
510 H Kont lampa diff spärr Indicating lamp, diff. interlock
512 H Varn lampa temp momentförst Warning lamp, temperature converter
514 H Kont lampa överväxel Indicating lamp, overdrive clutch
519 H Kont lampa halvljus Indicating lamp, dipped lights
524 H Kont lampa luftfilter Indicating lamp, air filter
525 H Kont lampa UNIKAT Indicating lamp, UNIKAT
528 H Kont lampa förvärmning Indicating lamp, preheating
530 H Kont lampa framhjuls styrning Indicating lamp, forward wheel steering
531 H Kont lampa 4-hjuls styrning Indicating lamp, 4-wheel steering
532 H Kont lampa crab styrning Indicating lamp, crab steering
533 H Kont lampa hyd.pump Indicating lamp, emergency hyd. pump
547 H Varn lampa centralvarning Warning lamp, central warning
549 H Varn lampa oljetryck v-låda Warning lamp, oil pressure gear box
550 H Varn lampa hyttlåsning Warning lamp, cab lock

Verkstadsmanual / Workshop Manual DCF


E Schema - Komponentförteckning / E Schematics - List of Components 8

Number Categ. Svenska English


551 H Varn lampa temp v-låda Warning lamp, temperature gear box
552 H Varn lampa bromstryck Warning lamp, brake pressure
554 H Varn lampa temp spolkrets bromsar Warning lamp, temp. cooling system brakes

555 H Varn lampa temp kylvatten mot Warning lamp, temperature coolant engine

556 H Varn lampa låsning vändskiva Warning lamp, interlocking of turntable


560 H Varn lampa temp drivmotor el Warning lamp, temperature, drive motor
561 H Varn lampa temp pumpmotor el Warning lamp, temperature, pump motor
562 H Varn lampa öppen twistlock Warning lamp, unlocked twist lock
563 H Varn lampa låst twistlock Warning lamp, locked twist lock
564 H Varn lampa anliggning Warning lamp, alignement
565 H Varn lampa temp motor el Warning lamp ,temperature motor
569 H Kont lampa elvärme Indicating lamp, electric heater
569 H Kont lampa elvärme Indicating lamp, electric heater
570 H Varn lampa överkoppling säkerhetssystem Warning lamp, by-pass safety system

571 H Kont lampa bränslenivå Indicating lamp, fuel level


572 H Varningslampa lyfthöjd Warning lamp lifting height
573 H Kontroll lampa motor information Indicator lamp engine information
574 H Kontroll lampa stödben nere Indicator lamp support jacks down
575 H Kontroll lampa stödben ur arb.läge Indicator lamp support jacks out of working
pos
576 H Kontroll lampa anliggning främre ben Indicator lamp, alignment front legs
577 H Kontroll lampa anliggning bakre ben Indicator lamp, alignment rear legs
578 H Kontroll lampa klämläge främre ben Indicator lamp, clamp position front legs
579 H Kontroll lampa klämläge bakre ben Indicator lamp, clamp position rear legs
580 H Kontroll lampa främre ben uppe Indicator lamp, front legs upper position
581 H Kontroll lampa främre ben nere Indicator lamp, front legs lower position
582 H Varningslampa överlast Warning lamp overload
583 H Kontroll lampa anliggning ett ben Indicator lamp, alignment one leg
584 H Kontroll lampa anliggning alla ben Indicator lamp, alignment all legs
599 H Kont lampa option Indicating lamp, option
600 Y M-ventil avgasbroms Solenoid valve, exhaust brake
601 Y M-ventil diff spärr Solenoid valve, diff. interlock
602 Y M-ventil broms Solenoid valve, brake
603 Y M-ventil värme Solenoid valve, heater
604 Y M-ventil kraftuttag sida Solenoid valve, power take off, side
605 Y M-ventil kraftuttag bak Solenoid valve, power take off, rear
606 Y M-ventil 2/4 hjulsdrift Solenoid valve, 2/4WD
607 Y M-ventil hög/låg växel Solenoid valve, high/low gear
608 M Pumpaggregat hyttlyft Pump unit, cab hoist
609 M Ställmotor gaspådrag Regulating motor, throttle
610 Y M-ventil hydraulsystem allm Solenoid valve, hydraulics, general
611 Y M-ventil flödesbegränsning Solenoid valve, flow restriction
612 M Ställmotor recirkulation Regulating motor, re-circulation
613 Y M-ventil momentförstärkare Solenoid valve, torque amplifier
614 Y M-ventil rangespärr Solenoid valve, ranging interlock
615 Y M-ventil hjulvridning Solenoid valve, wheel turning
616 Y M-ventil kallstart Solenoid valve, cold start aid
617 Y M-ventil AT-regulator by-pass Solenoid valve, AT-regulator ¿by-pass¿
618 Y M-ventil vatten klimatanläggning Solenoid valve, water air conditioner
620 Y M-ventil vändskiva upp Solenoid valve, fifth wheel up
621 Y M-ventil vändskiva ner Solenoid valve, fifth wheel down

Verkstadsmanual / Workshop Manual DCF


E Schema - Komponentförteckning / E Schematics - List of Components 9

Number Categ. Svenska English


622 Y M-ventil vändskiva fram Solenoid valve, fifth wheel forward
623 Y M-ventil vändskiva bak Solenoid valve, fifth wheel rear
624 Y M-ventil skevning hö Solenoid valve, levelling right hand
625 Y M-ventil skevning vä Solenoid valve, levelling left hand
626 Y M-ventil AT-regulator Solenoid valve, AT-regulator
627 Y M-ventil vakuum Solenoid valve vacuum
628 Y M-ventil bränsleblandning Solenoid valve fuelmixture
630 Y M-ventil v-låda fram Solenoid valve, gear box, forward gear
631 Y M-ventil v-låda back Solenoid valve, gear box, rear gear
632 Y M-ventil v-låda spole 1 Solenoid valve, gear box, 1 gear
633 Y M-ventil v-låda spole 2 Solenoid valve, gear box, 2 gear
634 Y M-ventil v-låda spole 3 Solenoid valve, gear box, 3 gear
635 Y M-ventil klämtryck Solenoid valve, clamping pressure
636 Y M-ventil styrning Solenoid valve, steering
637 Y M-ventil flytläge skevning Solenoid valve, equalizing fifth wheel
638 Y M-ventil stopp insprut pump Solenoid valve, stop injection pump
639 Y M-ventil låsning orbitrol ls Solenoid valve, locking LS orbitrol
640 Y M-ventil gasol Solenoid valve, LPG
641 Y M-ventil förångare (LPG) Solenoid valve, evaporator (LPG)
642 Y M-ventil park broms Solenoid valve, parking brake
643 Y M-ventil låsning stol (VBFS) Solenoid valve, seat locking (VBFS)
644 Y M-ventil låsning vändskiva Solenoid valve, fifth wheel locking
645 Y Magnetkoppling komp AC Magnetic clutch, compressor AC
646 Y M-ventil stolsvändning Solenoid valve, seat rotation
647 Y M-ventil stolstilt Solenoid valve, seat tilt
648 Y M-ventil luftfjädring Solenoid valve, pneumatic springing
649 B Termostat klimatannläggning Thermostat, air condition
650 M Torkarmotor fram
650 M Torkarmotor fram
650 M Torkarmotor fram
650 M Torkarmotor fram
651 M Vindrutespolarmotor Washer motor
652 M Strålkastarmotor Light motor
653 M Strålkastarspolarmotor Light washer motor
654 M Startmotor Starter motor
655 M Kylfläkt drivmotor (EC) Cooling fan, main motor (EC)
656 M Kylfläkt elskåp (EC) Cooling fan, electrical box (EC)
657 M Fläktmotor värme Heating fan
658 G Generator (extra) Alternator extra
659 G Generator utan laddregulator Alternator without loading regulator
660 G Generator med laddregulator Alternator with loading regulator
661 M Fönsterhissmotor Screenelevator motor
662 G Laddregulator Loading regulator
663 M Doseringspump klimatanläggning Dosage pump, air condition
664 M Cirk pump klimatanläggning Circulating pump, air condition
665 V Diod Diode
666 M Fläktmotor cirkulation Circulation fan
667 M Cirkulationspump värmesystem Circulation pump heating system
668 M Kylfläkt hydraulolja Cooling fan, hydraulic oil
669 E Värmare kupe/ motor diesel Heater compartment/engine diesel
670 M Kompressor Compressor
671 M Doseringspump diesel Dosage pump diesel
672 M Spjäll motor, ECC Draught valve motor, ECC
673 Y Vatten ventil motor, ECC Water valve motor, ECC

Verkstadsmanual / Workshop Manual DCF


E Schema - Komponentförteckning / E Schematics - List of Components 10

Number Categ. Svenska English


674 M Kylfläkt bromsolja Cooling fan, brake fluid
675 M Motor, Stolsvändning Motor, Seat rotation
676 Y Solenoid Broms stolsvändning Solenoid brake , seat rotation
685 A Reglerenhet termostat AC Control unit, termostat AC
690 B Fartreglage (EC) Speed control (EC)
693 M Pump centralsmörjning Pump, central lubrication
694 M Styrmotor Steering motor
695 M Drivmotor (EC) Drive motor (EC)
696 M Pumpaggregate nödstyrning Pump, emergency steering
697 B Elbroms Electric brake
698 M Pumpmotor (EC) Pump motor (EC)
699 Y M-ventil option Solenoid valve, option
700 P Hastighetsmätare Speedometer
701 P Mätare oljetemp v-låda Gear box oil temperature gauge
702 P Klocka Clock
703 P Varvtalsmätare Engine rev meter
704 P Tryckluftsmätare Air pressure gauge
705 P Mätare oljetryck v-låda Gear box oil pressure gauge
706 P Termometer temp kylvätska motor Temperature gauge, engine coolant
707 P Bränslemätare Fuel gauge
708 P Timräknare Hour meter
709 P Kapacitetsmätare batteri Capacity gauge, battery
710 P Tidur motor/kupevärmare Timer, engine- and cab heater
711 P Räknare, impuls Counter, impulse
712 P Mätare oljetryck motor Motor oil pressure gauge
714 P Mätare, temp. Hydraulolja Hydraulic fluidtemperature, guage
715 P Extra instrument allm Extra instrument, general
720 S Givare vändbar förarstol Transmitter, revolving driver´s seat (VBFS)
740 D FleetManager kontrollenhet FleetManager control unit
741 U FleetManager batterifilter FleetManager battery filter
742 D FleetManager kortläsare FleetManager card device
743 D FleetManager accelerations givare FleetManager acceleration sensor
751 B Givare varvtal turbin Transmitter, speed turbin
752 B Givare varvtal inre växellåda Transmitter, speed internal gear chain
753 B Varvtalsgivare motor Transmitter, engine revolution
754 B Givare lufttryck Transmitter, air pressure
755 B Givare hydraulfilter indikering Transmitter, hydraulics filter indication
756 B Temperatur kylvätska motor Transmitter, engine coolant temperature
757 B Bränslenivågivare Transmitter, fuel level
758 B Varvtalsgivare v-låda Transmitter, gear box revolution
759 B Nivåindikator kylvätska Transmitter, coolant level
760 B Givare rev-spärr/aut-vxl trans Transmitter, reversing interlock / automatic
gear change system (on gearbox output
shaft)
761 B Givare rev-spärr/aut-vxl motor Transmitter, reversing interlock / automatic
gear changing system (engine speed)

762 B Givare temp,spolkrets bromsar Transmitter, brake flushing circuit


763 B Givare nivå hydraulolja Transmitter, hydraulic fluid level
764 B Givare servotryck växellåda Transmitter, gear box servo pressure
765 B Givare oljetryck v-låda Transmitter, oil pressure gear box
766 B Givare oljetemp. v-låda Transmitter, oil temperature gear box
767 B Givare oljetryck motor Transmitter, oil pressure engine
768 B Givare oljetryck hydraulik Transmitter, hydraulic pressure

Verkstadsmanual / Workshop Manual DCF


E Schema - Komponentförteckning / E Schematics - List of Components 11

Number Categ. Svenska English


769 B Givare ändläge Transmitter, end position
770 B Givare rattutslag Transmitter, steering wheel angle
771 B Givare vinkel Transmitter, angle
772 B Givare temp bromsolja Transmitter, temperature brake fluid
773 B Givare närvaro Transmitter, presence
774 B Givare utomhustemp Transmitter, ambient temperature
775 B Givare temp klimatanläggning Transmitter, temperature air condition
776 B Givare temp hydraulolja Transmitter, hydraulic temperature
777 B Givare läge Transmitter, position
778 B Givare drivbrytning Transmitter, drive break
779 A Reglersystem återladdning (EC) Control system, recharging (EC)
780 A Reglersystem åkmotor (EC) Control system main motor (EC)
781 A Reglersystem pumpmotor (EC) Control system pump motor (EC)
782 A Logik interface 2 drivmotorer Logic (interface) two main motors (EC)
783 A Logik interface gaspådrag Logic (interface) throttle
784 A Logik interface bromsregl Logic (interface) brake control
785 A Logik interface styrsystem Logic (interface) control system
786 A Servoförstärkare styrsystem Servo amplifier steering system
789 B Givare allmän Transmitter, common
790 D Elektronisk kontrollenhet ECU, hytt Electronic Control Unit ECU, cab
791 D Elektronisk kontrollenhet aggregat Electronic Control Unit, attachment
792 D Elektronisk kontrollenhet styrning Electronic Control Unit, steering system
793 D Elektronisk kontrollenhet växellåda Electronic Control Unit, gearbox
794 D Elektronisk kontrollenhet motor Electronic Control Unit, engine
795 P Display Display
796 D Elektronisk kontrollenhet, lasthantering Electronic Control Unit, Loadhandling
797 D Elektronisk kontrollenhet, ram Electronic Control Unit, frame
798 D Elektronisk kontrollenhet, stolvändning Electronic Control Unit, seat rotation
799 A Logik allm (option) Logic, general (option)
800 S Startelement Start element
802 E Eluppvärmd backspegel Electrical heated observation mirror
803 E Eluppvärmd stol Electrical heated seat
804 E Cigarettändare Cigarett lighter
805 E Elvärme hytt Electrical heating cab
806 A Aggregat klimatanläggning Aggregate, air conditioner
807 R Potentiometer Potentiometer
808 E Eluppvärmd lufttorkare Electrical heater air dryer
810 A Kondensor AC, fläkt Condensor AC, fan
815 S Manöverspak Control lever
820 R Motstånd Resistor
821 C KONDENSATOR CAPACITOR
822 Z Signalfilter Signal filter
823 U Signalomvandlare höger Signal amplifier, right
824 U Signalomvandlare vänster Signal amplifier, left
825 R Reglage spakstyrning Controls, (steering with control levers).
826 Y Ventil spakstyrning Valve, (steering with control levers).
827 A Växellåda Gearbox
828 R Shuntmotstånd Shunt-resitor
830 L Tändspole Ignition coil
835 E Tändstift Ignition plug
840 S Strömfördelare Distributor
850 H Signalhorn Horn
853 H Summer Buzzer
888 E Lufttork, kompressor Air Dryer, Compressor

Verkstadsmanual / Workshop Manual DCF


E Schema - Komponentförteckning / E Schematics - List of Components 12

Number Categ. Svenska English


900 A Radio/bandspelare Radio/tape recorder
901 U Spänningsomvandlare Voltage converter
902 B Högtalare Loud speaker
903 W Antenn radio Aerial, radio
905 A Kommunikationsradio Communication radio
906 W Antenn kommunikationsradio Aerial, communication radio
907 A Monitor Monitor
908 A Kamera Camera
909 A Skrivare Printer
910 U Spänningsomvandlare 80V/24V Voltage converter 80 V / 24 V
911 A Dataterminal Dataterminal
940 A Logik batterivakt Logic switch , battery watch
941 U Laddningsutjämnare Even charger
950 A Logik transistortändning Logic transistor ignition
955 A Logik övervarvningsskydd (LPG) Logic overspeed protection (LPG)
960 A Logik rev-spärr/aut-vxl Logic unit, reversing interlock/automatic gear
changing
961 A Motor/kupevärmare Engine- and cab heater
962 E Logik slitageind kol elmotor Logic indication of wear, brush electrical
motor
965 H Backvarnare Reversing alarm
1001 S Strömställare, TW Switch, TW
1002 S Strömställare, lossa TW Switch, unlocking of TW
1003 S Strömställare, låsa TW Switch, locking of TW
1004 S Strömställare, stopp vid 30'-35' Switch, stop at 30 -35¿
1005 S Strömställare, förbikoppling av Switch, overriding of the safety system
säkerhetssystem
1006 S Strömställare, fällning främre ben Switch, front legs down
1007 S Strömställare, fällning bakre ben Switch, rear legs down
1008 S Strömställare, klämma/lossa ben Switch, clamping/-releasing legs
1009 S Strömställare, Motor information Switch, Engine information
1010 S Srömställare, tilt av hytt Switch, tilt of cab
1011 S Strömställare IR ljus Switch IR light
1012 S Strömställare utskjut 20¿-40¿ Switch, Extension 20¿-40¿
1013 S Strömställare stödben Switch, Support jacks
1014 S Strömställare förbikoppling rotationstopp Switch, over ride rotation stop
1015 S Strömställare förbikoppling höjdbeg/tp-beg Switch, over ride height limit/tp-limit

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

Verkstadsmanual / Workshop Manual DCF


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Number Categ. Svenska English


1030 S Strömställare läraringång givare ultraljud Switch, teaching ultrasonic sensor
1031 S Strömställare, Over Height Upp/Ned Switch, Over Height Up/Down
1032 S Brytare backljus Switch reverse light.
1033 S Flytta korta armen Move short arm
1034 S Strömställare förbikoppling startspärr Switch Override Start interlock
1035 S Strömställare Val av klämtryck Switch, Clamp pressure selection
1036 S Strömställare Korta Armen av/på Switch , Short Arm on/off
1037 S Strömställare låsning skevning Switch, lock levelling
1038 S Strömställare Övre armpar/Sidoföring Switch Upper arms/Sideshift
1039 S Strömställare Inching Switch, Inching
1040 S Switch stopp motor Switch, Stop engine
1041 S Strömställare motorrumsbelysning Switch, light engine compartment
1042 S Strömställare höjdjustering stol Switch, Seat height level
1043 S Strömställare längdjustering stol Switch, Seat for/aft adjustment
1044 S Strömställare Tankväljare Switch, Tankselector
1045 S Strömställare Avstängning backalarm Switch, Rev. Alarm on/off
2000 D Elektronisk kontrollenhet, proportionalventil Electronic control unit, propotional valve

3001 K Relä rotation Relay, rotation


3002 K Relä tilt Relay, tilt
3003 K Relä sidoföring Relay, side shifting
3004 K Relä längdinställning Relay, length adjustment
3005 K Relä twist lock Relay, twist lock
3006 K Relä spridning Relay, spreading
3007 K Relä lyft/sänk Relay, lifting/lowering
3008 K Relä hydraulfunktion extra Relay, extra hydraulic function
3009 K Relä manöverbrytare hydr Relay, operating switch
3010 K Relä bromsljus vxl std/blackout Relay, brake light shift std/blackout
3011 K Relä backljus vxl std/blackout Relay, reversing light shift std/blackout
3012 K Relä arb.bel hytt vxl std/blackout Relay, working light cab, shift std/blackout

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

3015 K Relä vxl bromsljus/blinkers hö Relay, shift brake light/direction indicator


right
3016 K Relä signalhorn relay, horn
3017 K Relä containerbelysning Relay, Container light
3018 K Relä containerbelysning IR Relay, Container light IR
3305 K Relä VBFS, backljus Relay, rotating driver´s seat, reversing light

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

Verkstadsmanual / Workshop Manual DCF


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Number Categ. Svenska English


3332 K Relä VBFS, drivning bak Relay, rotating driver´s seat, reversing
driving
3349 K Relä VBFS, fartreglage Relay, rotating driver´s seat, speed control

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

6004 Y M-ventil sänk Solenoid valve, lower


6005 Y M-ventil lyft Solenoid valve, lift
6006 Y M-ventil bom ut Solenoid valve, boom out
6007 Y M-ventil bom in Solenoid valve, boom in
6008 Y M-ventil vridning medsols Solenoid valve, rotation clockwise
6009 Y M-ventil vridning motsols Solenoid valve, rotation counter-clockwise
6010 Y M-ventil tilt ut Solenoid valve, tilt out
6011 Y M-ventil tilt in Solenoid valve, tilt in
6012 Y M-ventil tilt Solenoid valve, tilt
6013 Y M-ventil fällning främre ben Solenoid valve, lowering front legs
6014 Y M-ventil fällning bakre ben Solenoid valve, lowering rear legs
6015 Y M-ventil klämma/lossa ben Solenoid valve, clamping/releasing legs
6016 Y M-ventil Hyttskjutning fram Solenoid valve, cab movement forward
6017 Y M-ventil Hyttskjutning bak Solenoid valve, cab movement reverse
6018 Y M-ventil spridning ut Solenoid valve, spreading out
6019 Y M-ventil spridning in Solenoid valve, spreading in
6020 Y M-ventil sidoföring vänster Solenoid valve, side shift left
6021 Y M-ventil sidoföring höger Solenoid valve, side shift right
6022 Y M-ventil extra hydraulfunktion ut Solenoid valve, extra hydraulic function out

6023 Y M-ventil extra hydraulfunktion in Solenoid valve, extra hydraulic function in


6024 Y M-ventil stativ ut Solenoid valve, mast out
6025 Y M-ventil stativ in Solenoid valve, mast in
6026 Y M-ventil höger framhjul styrning vänster Solenoid valve, right front wheel, steering left

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

Verkstadsmanual / Workshop Manual DCF


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Number Categ. Svenska English


6031 Y M-ventil höger bakhjul styrning höger Solenoid valve, right rear wheel, steering
right
6032 Y M-ventil vänster bakhjul styrning vänster Solenoid valve, left rear wheel, steering left

6033 Y M-ventil vänster bakhjul styrning höger Solenoid valve, left rear wheel, steering right

6034 Y M-ventil skevning Solenoid valve, levelling


6035 Y M-ventil skevning höger Solenoid valve, levelling right
6036 Y M-ventil skevning vänster Solenoid valve, levelling left
6037 Y M-ventil kylfläkt Solenoid valve, Cooling fan
6038 Y M-ventil frikoppling koppling Solenoid valve, lockup clutch
6039 Y M-ventil öppna twistlock Solenoid valve, unlocked twist lock
6040 Y M-ventil låsa twistlock Solenoid valve, locked twist lock
6041 Y M-ventil nöd, twistlock Solenoid valve, emergency, twistlock
6042 Y M-ventil mellan bom Solenoid valve, middle boom
6043 Y Magnetventil, fällning torn (RTCH) Solenoid valve, boom lowering (RTCH)
6044 Y M-ventil blockering twistlock Solenoid valve, blocking twistlock
6045 Y M-ventil blockering lyft Solenoid valve, blocking lift
6046 Y M-ventil utskjut Solenoid valve, projecting
6047 Y M-ventil, hyttilt upp Solenoid valve, cab tilt up
6048 Y M-ventil, hyttilt ner Solenoid valve, cab tilt down
6049 Y M-ventil, kylkrets broms Solenoid valve, cooling cicuit brake
6050 Y M-ventil blockering utskjut Solenoid valve, blocking projecting
6051 Y M-ventil, regenerering höger Solenoid valve, regeneration right
6052 Y M-ventil, regenerering vänster Solenoid valve, regeneration left
6053 Y M-ventil, körläge Solenoid valve, driving position
6054 Y M-ventil, klämma ihop Solenoid valve, clambing in
6055 Y M-ventil, klämma isär Solenoid valve, clambing out
6056 Y M-ventil, främre knä ut Solenoid valve, front knee out
6057 Y M-ventil, främre knä in Solenoid valve, front knee in
6058 Y M-ventil, bakre knä ut Solenoid valve, rear knee out
6059 Y M-ventil, bakre knä in Solenoid valve, rear knee in
6060 Y M-ventil, främre ben upp Solenoid valve, front legs up
6061 Y M-ventil, bakre ben upp Solenoid valve, rear legs up
6062 Y M-ventil, urkoppling hydraulpump Solenoid valve interruption hydraulic pump
6063 Y M-ventil, stödben upp Solenoid valve, brace up
6064 Y M-ventil, stödben ner Solenoid valve, brace down
6065 Y M-ventil, frikoppling vridbroms Solenoid valve, lockup rotation brake
6066 Y M-ventil, v-låda, drivning Solenoid valve, gearbox, drive
6067 Y M-ventil, v-låda, oljetryck till 1:a/3:e växeln Solenoid valve, gearbox,oilpressure to
1st/3rd gear
6068 Y M-ventil sax/rotation Solenoid valve externder/rotation
6069 Y M-ventil, v-låda, oljetryck till 2:a/4:e växeln Solenoid valve, gearbox,oilpressure to
2nd/4th gear
6070 Y M-ventil Over Height upp Solenoid valve, Over Height up
6071 Y M-ventil Over Height ner Solenoid valve, Over Height down
6072 Y M-ventil klämtryck Solenoid valve clamp pressure
6073 Y Propertional ventil, Opti speed Proportional valve, Opti speed
6074 Y M-ventil, v-låda, växelväljare för 2:a/4:e Solenoid valve, gearbox, gearswitch for
växeln 2nd/4th gear
6075 Y M-ventil, v-låda, växelväljare för 1:a/3:e Solenoid valve, gearbox, gearswitch for
växeln 1st/3rd gear
6076 Y M-ventil blockering sänk Solenoid valve, blocking lower
6077 Y M-ventil Inching Solenoid valve, Inching

Verkstadsmanual / Workshop Manual DCF


E Schema - Komponentförteckning / E Schematics - List of Components 16

Number Categ. Svenska English


6078 Y M-ventil,Avstängning Övre klämarm Solenoid valve, upper arm off
6079 Y M-Ventil, Sidoföring/Övre armar Solenoid valve, Sideshift/Upper arms
6080 Y M-ventil, aktivering hyttkörning Solenoid valve, activate sliding cab
7200 S Givare, axeltryck höger Sensor, axle pressure right
7201 S Givare, axeltryck vänster Sensor, axle pressure left
7202 S Givare, anliggning vänster fram Sensor, alignment left front
7202 S Givare, anliggning höger fram Sensor, alignment right front
7203 S Givare, anliggning vänster bak Sensor, alignment left rear
7203 S Givare, anliggning höger bak Sensor, alignment right rear
7204 S Givare, öppen vänster twistlock Sensor, unlocked twistlock left
7204 S Givare, öppen höger twistlock Sensor, unlocked twistlock right
7205 S Givare, låst vänster twistlock Sensor, locked twistlock left
7205 S Givare, låst höger twistlock Sensor, locked twistlock right
7206 S Givare, gaffel aggregat Sensor, fork attachment
7207 S Givare, 2WD/4WD Sensor, 2WD/4WD
7208 S Givare, hytt i körläge Sensor, Cab in drive position
7209 S Givare, oljefilter indikering Sensor, Oil filter indication
7210 S Givare, hytt i transportläge Sensor, Cab in transportation position
7211 S Givare, lyfthöjd Sensor, lifting height
7212 S Givare, körläge Sensor, driving position
7213 S Givare, Anliggning främre ben Sensor, Alignment front legs
7214 S Givare, Anliggning bakre ben Sensor, Alignment rear legs
7215 S Givare, kläm främre ben Sensor, Clamp front legs
7216 S Givare, kläm bakre ben Sensor, Clamp rear legs
7217 S Givare, främnre knä Sensor, front knee
7218 S Givare, bakre knä Sensor, rear knee
7219 S Givare, främre ben Sensor, front legs
7220 S Givare, bakre ben Sensor, rear legs
7221 S Givare, styraxel Sensor, steering axle
7222 S Givare, stödben uppe Sensor, brace up
7223 S Givare, stödben nere Sensor, brace down
7224 B Givare, mätläge våg Sensor, measurepoint scale
7225 B Givare, rotationsstopp Sensor, rotation stop
7226 B Givare, tryck lyftcylinder Sensor, pressure lift cylinder
7227 B Givare, tryck klämma Sensor, pressure clamp
7228 B Givare lyfthöjd analog Sensor lift height analogue
7229 B Givare tiltvinkel analog Sensor tilt angle analogue
7230 B Givare ultraljud last position Sensor, ultrasonic load position
7231 B Givare, Over Height, Ben uppe Sensor, Over Height, Leg upper position
7232 B Givare,IR Last position Givare,IR Load position
7233 B Givare lambda sond Sensor lambda sond
7234 B Givare vatten i bränsle Transmitter water in fuel
8071 R Potentiometer lyft/sänk Potentiometer lift/lower
8072 R Potentiometer tilt Potentiometer tilt
8073 R Potentiometer sidoföring Potentiometer side shifting
8074 R Potentiometer spridning Potentiometer spreading
8075 R Potentiometer extra Potentiometer extra
8076 R Potentiometer mast in/ut Potentiometer reach in/out
8077 R Potentiometer höger framhjul Potentiometer right front wheel
8078 R Potentiometer vänster framhjul Potentiometer left front wheel
8079 R Potentiometer höger bakhjul Potentiometer right rear wheel
8080 R Potentiometer vänster bakhjul Potentiometer left rear wheel
8081 R Potentiometer tiltvinkel Potentiometer tilt angle
8082 R Potentiometer fläkthastighet, ECC Potentiometer fan speed, ECC

Verkstadsmanual / Workshop Manual DCF


E Schema - Komponentförteckning / E Schematics - List of Components 17

Number Categ. Svenska English


8083 R Potentiometer temperatur, ECC Potentiometer temperature, ECC
8084 R Potentiometer spjäll, ECC Potentiometer draught valve, ECC
8085 R Potentiometer rotation Potentiometer rotation
8086 R Potentiometer sax Potentiometer extender
8087 R Potentiometer klämma Potentiometer clamp
8088 R Potentiometer skevning Potentiometer levelling
8089 R Potentiometer kroklåsning Potentiometer flaps
8090 V Laser, pappersaggretgat Lase, Pulp an Paper
8091
9000 M Motor höj/sänkbar stolspelare Motor rise/lower seat column
9001 D Åkerströms fjärrkontroll Åkerströms Remote Control
9002
9003 H Varningssignal aut. rörelse Warning alarm aut. movement
9888 A test
93774 K Relä hållkrets Relay, Holdcircuit

Verkstadsmanual / Workshop Manual DCF


F Technical data 1

F Technical data

Table of Contents F Technical data


mm mm mm mm mm mm

Technical data ................................................................................................ 3


Specifications for data and volume ........................................................................ 3
Oils and lubricants, recommendation ..................................................................... 6
Tightening torques, recommendations ................................................................... 8
Tightening torques, ORFS-couplings ..................................................................... 9
Tightening torque, climate control system connections ........................................ 11
Unit explanations .................................................................................................. 11
Conversion table, SI-units .................................................................................... 12
Conversion table, length ....................................................................................... 13
Conversion table, area ......................................................................................... 13
Conversion table, volume ..................................................................................... 13
Conversion table, weight ...................................................................................... 14
Conversion table, pressure .................................................................................. 14

Workshop Manual DCF 90-100 VDCF03.01GB


2 F Technical data

VDCF03.01GB Workshop Manual DCF 90-100


F Technical data – Technical data 3

Technical data
mm mm mm mm mm mm

Specifications for data and volume


page

Data

1 Engine Volvo TAD760VE Cummins QSB6.7

Power acc. to ISO 3046 (net power) 180 kW at 2200 rpm 164 kW at 2200 rpm

Torque ISO 3046 1100 Nm at 1500 rpm 949 Nm at 1500 rpm

Alternator, output 1920 W (24 V / 80 Ah) 1680 W (24 V / 70 Ah)

Start battery, voltage – capacity 24 V (2x12 V – 140 Ah)

2 Transmission Dana-Spicer Off Highway TE17

No. of gears forward – reverse 3-3

3 Driveline/axle
Drive axle, type Kessler D81
Kessler D91

4 Brakes
Parking brake Spring brake - Drive wheels

Service brake Wet Disc Brakes - Drive wheels

5 Steering Hydraulic servo

6 Suspension
Dimension, front and rear 14.00x24

Tyre pressure (also see pressure 1.0 MPa


plate)

9 Cab Spirit Delta

Equivalent sound pressure level in max. 70 dB(A)


cab.
(Value with standard engine)

Vibration level as per EN13059 < 0.6 m/s²

Workshop Manual DCF 90-100 VDCF03.01GB


4 F Technical data – Technical data

9.6 Frame, body, cab and accessories, lighting system

Bulb Output (W) Socket


Control lights 1.2 W2x4.6d

Interior lighting 10 S8.5

Tail light 5 BA15s

Brake light 21 BA15s

Driving direction indicator 21 BA15s

Running lights 5 W2.1x9.5d

Headlights (high and low beams) 55/50 P43t-38

Reversing light 70 PK22s

Working lights 70 PK22s

35 D1S Xenon tubes. The insert and


Working light Xenon ballast must be changed as a unit.

Rotating beacon 70 PK22s

VDCF03.01GB Workshop Manual DCF 90-100


F Technical data – Technical data 5

Volumes
For oil types see Oils and lubricants, recommendation page 6.

1. Engine Volvo TAD760VE Cummins QSB6.7

Engine oil incl. filter 23 litres 20 litres

Fuel tank 400 litres

Fuel quality Diesel according to EN590.

Cooling system 22 litres 29 litres

2 Transmission Dana TE17

Oil volume, gearbox 37 litres during change

3. Driveline/axle Kessler D81 - Kessler D91

Differential 42 litres - 54 litres

Hub reduction 2x4 litres

9 Frame, body, cab and accessories


Refrigerant, air conditioning R134a

Refrigerant volume See air conditioning plate

Lubricant, air conditioning ZEXEL PAG oil ZXL100

Windshield washer fluid, volume 5 litres

10 Common hydraulics
Hydraulic oil tank, volume 360 litres

Hydraulic oil system, volume 450 litres

Workshop Manual DCF 90-100 VDCF03.01GB


6 F Technical data – Technical data

Oils and lubricants,


page

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

°F -40 -22 -4 +14 +32 +50 +68 +86 +104

1.8 Engine, lubrication system


Volvo TAD760VE: VDS-3 *)
-15 °C SAE 15W40 (engine oil)
Cummins: API: CH-4 / ACEA: E5
SAE 5W30 (engine oil)

2.6 Transmission, lubrication system

ATF DEXRON III DEXRON III

3.3 Driveline/axle, drive axle

API GL-5 SAE 80W140

SAE 75W90

7 Load handling

Planetary gear, hydraulic motor, SAE 80W140


hypoid oil API GL-5
SAE 75W90

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).

VDCF03.01GB Workshop Manual DCF 90-100


F Technical data – Technical data 7

ACEA = Association des Constructeurs Européenne d’Automobiles


API = American Petroleum Institute
VDS = Volvo Drain System

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.

Workshop Manual DCF 90-100 VDCF03.01GB


8 F Technical data – Technical data

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 Bolt Nut Lubrication

1 untreated untreated oil

2 bright-galvanized untreated or bright-galvanized dry or oil

3 hot-galvanized untreated dry or oil

Quality 8,8 10,9 12,9

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

M121,25 96 Nm 85 Nm 108 Nm 135 Nm 162 Nm

M161,5 230 Nm 205 Nm 260 Nm 323 Nm 388 Nm

M181,5 330 Nm 294 Nm 373 Nm 466 Nm 559 Nm

M-thread

M4 3.2 Nm 2.9 Nm 3.6 Nm 4.6 Nm 5.5 Nm

M5 6.4 Nm 5.7 Nm 7.2 Nm 9.1 Nm 11 Nm

M6 11 Nm 9.8 Nm 12.5 Nm 16 Nm 19 Nm

M8 26 Nm 24 Nm 30 Nm 38 Nm 45 Nm

M10 52 Nm 47 Nm 59 Nm 74 Nm 89 Nm

M12 91 Nm 81 Nm 103 Nm 128 Nm 154 Nm

M16 220 Nm 198 Nm 250 Nm 313 Nm 375 Nm

M20 430 Nm 386 Nm 490 Nm 620 Nm 732 Nm

M24 750 Nm 668 Nm 848 Nm 1050 Nm 1270 Nm

M30 1480 Nm 1317 Nm 1672 Nm 2080 Nm 2500 Nm

UNC-thread

VDCF03.01GB Workshop Manual DCF 90-100


F Technical data – Technical data 9

Quality 8,8 10,9 12,9

1/4 12.5 Nm 11.1 Nm 14.1 Nm 17.6 Nm 20 Nm

5/16 25 Nm 22.3 Nm 28.3 Nm 35 Nm 42 Nm

3/8 44 Nm 39 Nm 50 Nm 62 Nm 73 Nm

7/16 70 Nm 62 Nm 79 Nm 100 Nm 118 Nm

1/2 107 Nm 95 Nm 121 Nm 151 Nm 178 Nm

9/16 153 Nm 136 Nm 173 Nm 216 Nm 255 Nm

5/8 210 Nm 187 Nm 237 Nm 298 Nm 353 Nm

3/4 370 Nm 390 Nm 418 Nm 524 Nm 619 Nm

7/8 594 Nm 528 Nm 671 Nm 839 Nm 990 Nm

1 889 Nm 791 Nm 1005 Nm 1260 Nm 1480 Nm

1 1/8 1260 Nm 1120 Nm 1424 Nm 1780 Nm 2100 Nm

1 1/4 1760 Nm 1565 Nm 1990 Nm 2490 Nm 2940 Nm

1 3/8 2320 Nm 2065 Nm 2620 Nm 3280 Nm 3870 Nm

1 1/2 3060 Nm 2720 Nm 3455 Nm 4320 Nm 5100 Nm

Tightening torques, ORFS-


page

couplings
Pipe and hose coupling

Pipe diameter Tightening torques


mm inch Nm

6 1/4 23-25

8 5/16
33-38
10 3/8

12 1/2 51-57

14 -

15 - 80-90

16 5/8

18 3/4
120-130
20 -

22 7/8
150-170
25 1"

Workshop Manual DCF 90-100 VDCF03.01GB


10 F Technical data – Technical data

Pipe diameter Tightening torques


mm inch Nm

28 -

30 - 180-200

32 1"1/4

35 -
200-240
38 1"1/2

Socket width Tightening torques


mm inch Nm

17 11/16 23-25

22 13/16 33-38

24 15/16 51-57

36 1 3/8 120-130

41 1 5/8 150-170

Flange coupling

UNF-UN Metric-ISO BSSP


Thread Tightening torques Thread Tightening torques Thread Tightening torques (Nm)
(inch) (Nm) (mm) (Nm) (inch)

7/16-20 21 10x1 20 1/8-28 20

1/2-20 27 12x1,5 35 1/4-19 35

9/16-18 40 14x1,5 45 3/8-19 70

3/4-16 78 16x1.5 55 1/2-14 100

7/8-14 110 18x1.5 68 3/4-14 190

1"1/16-12 180 20x1.5 80 1"-11 300

1"3/16-12 230 22x1.5 98 1"1/4-11 330

1"5/16-12 285 26x1.5 170 1"1/2-11 400

1"5/8-12 320 27x2 180

1"7/8-12 400 33x2 310

42x2 330

48x2 400

VDCF03.01GB Workshop Manual DCF 90-100


F Technical data – Technical data 11

Tightening torque, climate control


page

system connections
O-rings, radiator hoses

Hose diameter Thread Tightening torques

mm inch inch Nm

6 1/4" 7/16" 7-14 Nm

10 3/8" 5/8" 14-20 Nm

10 3/8" 11/16" 14-20 Nm

12 1/2" 3/4" 14-27 Nm

16 5/8" 7/8" 27-41 Nm

19 3/4" 1 1/16" 34-47 Nm

Pressure switch 3/8" 7-14 Nm

The above values are to be considered guidelines and may vary de-
pending on installation.

Unit explanations
page

Unit Abbreviation

Newton metre Nm

Kilo pound metre kpm

Kilo pascal kPa

Mega pascal MPa

Kilowatt kW

kilojoule kJ

British termel unit Btu

Calorie ca

Inch in

Feet ft

Yard yd

Mile mile

Centimetre cm

Metre m

Kilometre km

Workshop Manual DCF 90-100 VDCF03.01GB


12 F Technical data – Technical data

Conversion table, SI-units


page

SI-unit Recalculation fac- Non-SI Recalculation fac- SI


tor tor

Torque

Nm x 10,2 = kg·cm x 0,8664 = lb·in

Nm x 0,74 = lbf·ft x 1,36 = Nm

Nm x 0,102 = kg·m x 7,22 = lb·ft

Pressure (Pa = N/ m2)

kPa x 4,0 = in.H 2O x 0,249 = kPa

kPa x 0,30 = in.Hg x 3,38 = kPa

kPa x 0,145 = psi x 6,89 = kPa

bar x 14,5 = psi x 0,069 = bar

kp/ cm2 x 14,22 = psi x 0,070 = kp/cm2

N/ mm2 x 145,04 = psi x 0,069 = bar

MPa x 145 = psi x 0,00689 = MPa

Power (W = J/s)

kW x 1,36 = hp (cv) x 0,736 = kW

kW x 1,34 = bhp x 0,746 = kW

kW x 0,948 = Btu/s x 1,055 = kW

W x 0,74 = ft·lb/s x 1,36 =W

Energy (J = Nm)

kJ x 0,948 = Btu x 1,055 = kJ

J x 0,239 = calorie x 4,19 =J

Speed and acceleration

m/s2 x 3,28 = ft/s2 x 0,305 = m/s2

m/s x 3,28 = ft/s x 0,305 = m/s

km/h x 0,62 = mph x 1,61 = km/h

Horsepower/torque

Bhp x 5252 rpm= TQ (lb·ft) TQ x rpm 5252 = bhp

Temperature

ºC = (ºF – 32)/1,8 ºF = (ºC x 1,8) + 32

Flow factor

l/ min (dm3 /min) x 0,264 = US gal/ min x 3.785 = litre/min

VDCF03.01GB Workshop Manual DCF 90-100


F Technical data – Technical data 13

Conversion table, length


page

Unit cm m km in ft yd mile

cm 1 0,01 0,00001 0,3937 0,03281 0,01094 0,000006

m 100 1 0,001 39,37 3,2808 1,0936 0,00062

km 100000 1000 1 39370,7 3280,8 1093,6 0,62137

in 2,54 0,0254 0,000025 1 0,08333 0,02777 0,000015

ft 30,48 0,3048 0,000304 12 1 0,3333 0,000189

yd 91,44 0,9144 0,000914 36 3 1 0,000568

mile 160930 1609,3 1,6093 63360 5280 1760 1

1 mm = 0,1 cm - 1 mm = 0,001 m

Conversion table, area


page

Unit cm2 m2 km2 a ft2 yd2 in2

cm2 1 0,0001 - 0,000001 0,001076 0,000012 0,155000

m2 10000 1 0,000001 0,01 10,764 1,1958 1550,000

km2 - 1000000 1 10000 1076400 1195800 -

a 0,01 100 0,0001 1 1076,4 119,58 -

ft2 - 0,092903 - 0,000929 1 0,1111 144,000

yd2 - 0,83613 - 0,008361 9 1 1296,00

in2 6,4516 0,000645 - - 0,006943 0,000771 1

1ha = 100a - 1mile2 = 259ha = 2,59 km2

Conversion table, volume


page

Unit cm3 = cc m3 l in3 ft3 yd3

cm3 = ml 1 0,000001 0,001 0,061024 0,000035 0,000001

m3 1000000 1 1000 61024 35,315 1,30796

dm3 (l) 1000 0,001 1 61,024 0,035315 0,001308

in3 16,387 0,000016 0,01638 1 0,000578 0,000021

ft3 28316,8 0,028317 28,317 1728 1 0,03704

yd3 764529,8 0,76453 764,53 46656 27 1

1gal (US) = 3785,41 cm3 = 231in3 = 0,83267gal (UK)

Workshop Manual DCF 90-100 VDCF03.01GB


14 F Technical data – Technical data

Conversion table, weight


page

Unit g kg t oz lb

g 1 0,001 0,000001 0,03527 0,0022

kg 1000 1 0,001 35,273 2,20459

t 1000000 1000 1 35273 2204,59

oz 28,3495 0,02835 0,000028 1 0,0625

lb 453,592 0,45359 0,000454 16 1

1ton (metric) = 1.1023 ton (US) = 0.9842 ton (UK)

Conversion table, pressure


page

Unit kp/cm2 bar Pa = N/m2 kPa lbf/in2 lbf/ft2

kp/ cm2 1 0,98067 98066,5 98,0665 14,2233 2048,16

bar 1,01972 1 100000 100 14,5037 2088,6

Pa = N/m2 0,00001 0,001 1 0,001 0,00015 0,02086

kPa 0,01020 0,01 1000 1 0,14504 20,886

lbf/in2 0,07032 0,0689 6894,76 6,89476 1 144

lbf/ft2 0,00047 0,00047 47,88028 0,04788 0,00694 1

kg/cm2 = 735,56Torr (mmHg) = 0,96784atm

VDCF03.01GB Workshop Manual DCF 90-100


G Terminology and index 1

G Terminology and index

Table of Contents G Terminology and index


mm mm mm mm mm mm

Terminology and index.................................................................................. 3


Terminology ............................................................................................................ 3
Index ....................................................................................................................... 6

Workshop Manual DCF 90-100 VDCF03.01Gb


2 G Terminology and index

VDCF03.01Gb Workshop Manual DCF 90-100


G Terminology and index – Terminology and index 3

Terminology and index


mm mm mm mm mm mm

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.

Workshop Manual DCF 90-100 VDCF03.01Gb


4 G Terminology and index – Terminology and index

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.

VDCF03.01Gb Workshop Manual DCF 90-100


G Terminology and index – Terminology and index 5

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.

Workshop Manual DCF 90-100 VDCF03.01Gb


6 G Terminology and index – Terminology and index

Index
page

Designation Section Function group


A near accident is a warning! B Safety -

About the documentation A Foreword -

About the machine version A Foreword -

About the Workshop Manual A Foreword -

Accelerator pedal 1 Engine 1.1.2

Accumulator 4 Brakes 4.3.4

Accumulator 7 Load handling 7.7.2

Accumulator charging valve 4 Brakes 4.3.3

Accumulator charging valve 4 Brakes 4.8.4

Accumulator drain valve 10 Common hydraulics 10.2.1

Accumulator servo circuit 7 Load handling 7.2.4

Air cleaning system 1 Engine 1.6.1

Air distributor 9 Frame, body, cab and accessories 9.4.14

Air intake and exhaust outlet 1 Engine 1.6

Air pollution B Safety -

Air suspension 9 Frame, body, cab and accessories 9.3.5

Air vents 9 Frame, body, cab and accessories 9.4.15

Alternator 11 Common electrics 11.4

Alternator 11 Common electrics 11.4.1

Armrest 9 Frame, body, cab and accessories 9.3.9

ATTACH, DCF 90-100 with lifting hook attachment 8 Control system 8.4.9

ATTACH, DCF 90-100 with twistlock attachment 8 Control system 8.4.9

ATTACH, DCF360-450CSG 8 Control system 8.4.9

Attachment relief valve 7 Load handling 7.4.7

Attachment relief valve 10 Common hydraulics 10.2.2

Auxiliaries 10 Common hydraulics 10.7

Axial piston pump with variable displacement 10 Common hydraulics 10.4.2

Back cushion 9 Frame, body, cab and accessories 9.3.2

Batteries 11 Common electrics 11.3

Battery disconnect switch 11 Common electrics 11.2.1

Body 9 Frame, body, cab and accessories 9.13

Brake light 9 Frame, body, cab and accessories 9.6.4

VDCF03.01Gb Workshop Manual DCF 90-100


G Terminology and index – Terminology and index 7

Designation Section Function group


Brake pedal 4 Brakes 4.1.1

Brake valve 4 Brakes 4.3.5

Brakes 4 Brakes 4

Breather filter hydraulic oil tank 4 Brakes 4.8.11

Breather filter hydraulic oil tank 10 Common hydraulics 10.6.6

Buzzer, automatic spread 20'-40' 7 Load handling 7.5.7

Bypass 8 Control system 8.2.2

CAB 8 Control system 8.4.3

Cab fan 9 Frame, body, cab and accessories 9.4.3

Cab frame 9 Frame, body, cab and accessories 9.10.1

Cab interior 9 Frame, body, cab and accessories 9.11

Cab structure and suspension 9 Frame, body, cab and accessories 9.10

Cab undercarriage 9 Frame, body, cab and accessories 9.10.3

Cables 11 Common electrics 11.5.5

Calibration 8 Control system 8.5.2

CAN bus drivetrain 11 Common electrics 11.6.3

CAN/POWER 8 Control system 8.4.1

CAN-bus 11 Common electrics 11.6.1

Central lubrication 9 Frame, body, cab and accessories 9.14

Chassis 9 Frame, body, cab and accessories 9.12

Circuit diagram, description E Schematics -

Circuit diagrams, compilation E Schematics -

CLIMATE 8 Control system 8.4.4

Clothing, etc. B Safety -

Collecting block, unfiltered returns 10 Common hydraulics 10.5.5

Common electrics 11 Common electrics 11

Common electrics E Schematics -

Common hydraulics 10 Common hydraulics 10

Common hydraulics E Schematics -

Communication 11 Common electrics 11.6

Communication between PC and machine 11 Common electrics 11.6.4

Complete machine, description 0 Complete machine -

Component designations E Schematics -

Compressed air-suspended seat 9 Frame, body, cab and accessories 9.3.6

Workshop Manual DCF 90-100 VDCF03.01Gb


8 G Terminology and index – Terminology and index

Designation Section Function group


Compressor 9 Frame, body, cab and accessories 9.4.7

Condenser 9 Frame, body, cab and accessories 9.4.8

Conditions A Foreword -

Container counter 7 Load handling 7.10.1

Control levers 7 Load handling 7.1.1

Control system 8 Control system 8

Control system D Error codes -

Control system engine 1 Engine 1.9

Control unit transmission 2 Transmission 2.8.1

Control unit, engine 1 Engine 1.9.1

Control units 11 Common electrics 11.5.3

Control valve attachment 7 Load handling 7.4.2

Control valve attachment 7 Load handling 7.5.2

Control valve attachment 7 Load handling 7.8.2

Control valve, lift and tilt 7 Load handling 7.2.5

Control valve, lift and tilt 7 Load handling 7.7.5

Controls and instruments 1 Engine 1.1

Controls and instruments 2 Transmission 2.1

Controls and instruments 4 Brakes 4.1

Controls and instruments 7 Load handling 7.1

Controls and instruments 8 Control system 8.1

Controls and instruments 9 Frame, body, cab and accessories 9.1

Conversion table, area F Technical data -

Conversion table, length F Technical data -

Conversion table, pressure F Technical data -

Conversion table, SI-units F Technical data -

Conversion table, weight F Technical data -

Conversion table, volume F Technical data -

Coolant 1 Engine 1.7.7

Coolant B Safety -

Cooler hydraulic oil 10 Common hydraulics 10.6.2

Cooling fan 1 Engine 1.7.5

Cooling fan 4 Brakes 4.8.9

Cooling fan 10 Common hydraulics 10.6.3

VDCF03.01Gb Workshop Manual DCF 90-100


G Terminology and index – Terminology and index 9

Designation Section Function group


Cooling system 1 Engine 1.7

Cooling system 2 Transmission 2.7

Copyright A Foreword -

Counterweights 9 Frame, body, cab and accessories 9.13.4

Diagnostics 8 Control system 8.4

Distribution block 9 Frame, body, cab and accessories 9.14.2

Documentation sections A Foreword -

Doors 9 Frame, body, cab and accessories 9.10.2

Drive axle 3 Driveline/axle 3.3

Drive axle block 4 Brakes 4.3.6

Drive axle block 4 Brakes 4.8.5

Driveline/axle 3 Driveline/axle 3

Driving direction indicator 9 Frame, body, cab and accessories 9.6.6

Electric heater 9 Frame, body, cab and accessories 9.3.3

Electric motors B Safety -

Electric protection 11 Common electrics 11.2

Electrical distribution 11 Common electrics 11.5

Electrical distribution box 11 Common electrics 11.5.2

ELSERV 8 Control system 8.4.8

Emergency stop switch 9 Frame, body, cab and accessories 9.2.1

Emergency stop switch 11 Common electrics 11.2.3

Engine D Error codes -

ENGINE 8 Control system 8.4.6

Engine heater 1 Engine 1.7.10

Engine temperature sensor 9 Frame, body, cab and accessories 9.4.6

Entertainment and communication 9 Frame, body, cab and accessories 9.8

Entry lighting 9 Frame, body, cab and accessories 9.6.13

Environment B Safety -

Error code menu 8 Control system 8.1.10

Error code menu, description D Error codes -

Error codes D Error codes -

Error codes engine (engine alternative Volvo TAD760VE) D Error codes -

Error codes engine, general D Error codes -

Error codes machine D Error codes -

Workshop Manual DCF 90-100 VDCF03.01Gb


10 G Terminology and index – Terminology and index

Designation Section Function group


Error codes, explanation D Error codes -

Error codes, transmission D Error codes -

Exhaust system 1 Engine 1.6.3

Expansion valve 9 Frame, body, cab and accessories 9.4.11

EXTRA 8 Control system 8.4.11

Feedback A Foreword -

Felkoder motor (motoralternativ Cummins QSB6.7) D Error codes -

Fenders 9 Frame, body, cab and accessories 9.13.1

Fire and explosion risks B Safety -

Fire extinguisher 9 Frame, body, cab and accessories 9.2.3

Flex plates 2 Transmission 2.2.1

Floor covering 9 Frame, body, cab and accessories 9.11.4

Fluid or gas under pressure B Safety -

Footstep and rail 9 Frame, body, cab and accessories 9.13.3

Foreword A Foreword -

Form for copying 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

Fresh air filter 9 Frame, body, cab and accessories 9.4.1

Fuel system 1 Engine 1.2

Fuel system B Safety -

Fuel tank 1 Engine 1.2.1

Function descriptions A Foreword -

Function group breakdown A Foreword -

Fuses 11 Common electrics 11.2.2

Gear pump with fixed displacement 10 Common hydraulics 10.4.1

Gear selector and multi-function lever 2 Transmission 2.1.1

Gear selector and multi-function lever 9 Frame, body, cab and accessories 9.1.1

General A Foreword -

General B Safety -

General B Safety -

General safety information B Safety -

Glass/windows/mirrors 9 Frame, body, cab and accessories 9.9

Headlights 9 Frame, body, cab and accessories 9.6.1

VDCF03.01Gb Workshop Manual DCF 90-100


G Terminology and index – Terminology and index 11

Designation Section Function group


Heat exchanger cooling 9 Frame, body, cab and accessories 9.4.13

Heat exchanger heat 9 Frame, body, cab and accessories 9.4.4

Heating, ventilation and air conditioning 9 Frame, body, cab and accessories 9.4

Hood engine compartment 9 Frame, body, cab and accessories 9.13.2

Horn 9 Frame, body, cab and accessories 9.7.1

Hoses, pipes and valves 10 Common hydraulics 10.5

HYD 8 Control system 8.4.5

Hydraulic and brake systems, depressurizing B Safety -

Hydraulic cylinders 10 Common hydraulics 10.7.1

Hydraulic diagram DCF 90-100, electric servo E Schematics -

Hydraulic diagrams, compilation E Schematics -

Hydraulic oil 4 Brakes 4.8.14

Hydraulic oil 10 Common hydraulics 10.6.8

Hydraulic oil fine-filter 10 Common hydraulics 10.6.9

Hydraulic oil pump 4 Brakes 4.3.1

Hydraulic oil pump 4 Brakes 4.5.1

Hydraulic oil pump 4 Brakes 4.8.3

Hydraulic oil pump 5 Steering 5.2.1

Hydraulic oil pump 7 Load handling 7.2.1

Hydraulic oil pump 7 Load handling 7.4.1

Hydraulic oil pump 7 Load handling 7.5.1

Hydraulic oil pump 7 Load handling 7.7.1

Hydraulic oil pump 7 Load handling 7.8.1

Hydraulic oil tank 4 Brakes 4.8.1

Ignition switch 1 Engine 1.1.1

Important information A Foreword -

Initiation 8 Control system 8.5.1

Instrument and control panels 9 Frame, body, cab and accessories 9.11.1

Insulation 9 Frame, body, cab and accessories 9.11.5

Intercooler 1 Engine 1.6.4

Interior details, plastic 9 Frame, body, cab and accessories 9.11.2

Interior details, textile 9 Frame, body, cab and accessories 9.11.3

Interior lighting 9 Frame, body, cab and accessories 9.6.11

Levelling 7 Load handling 7.8

Workshop Manual DCF 90-100 VDCF03.01Gb


12 G Terminology and index – Terminology and index

Designation Section Function group


Levelling cylinder 7 Load handling 7.8.3

Lift cylinder 7 Load handling 7.2.7

Lifting carriage 7 Load handling 7.2.11

Lifting carriage 7 Load handling 7.4.5

Lifting carriage 7 Load handling 7.8.4

Lifting equipment B Safety -

Lifting heavy components B Safety -

Lifting hook 7 Load handling 7.9.2

Lifting/lowering 7 Load handling 7.2

Lighting system 9 Frame, body, cab and accessories 9.6

LIGHTS 8 Control system 8.4.2

Lines 9 Frame, body, cab and accessories 9.14.3

Link arm 5 Steering 5.2.6

Load carrier 7 Load handling 7.9

Load handling 7 Load handling 7

Load retention valve 7 Load handling 7.7.6

Lubrication system 2 Transmission 2.6

Main beam, side lifting attachment 7 Load handling 7.5.5

Mast 7 Load handling 7.2.9

Mast 7 Load handling 7.7.8

Mast position sensor 7 Load handling 7.2.10

Mechanical seat adjustment 9 Frame, body, cab and accessories 9.3.7

Moisture filter 9 Frame, body, cab and accessories 9.4.9

Monitor, reversing camera 9 Frame, body, cab and accessories 9.9.7

Monitoring 8 Control system 8.2

M-valve parking brake 4 Brakes 4.5.3

NC (normally closed) switch, brake pressure 4 Brakes 4.3.7

NO (normally open) switch, brake lights 4 Brakes 4.3.8

NO (normally open) switch, coolant level 1 Engine 1.7.8

Noise B Safety -

Normally closed (NC) switch, disengagement 2 Transmission 2.8.2

Nut, washer and clamp 6 Suspension 6.3.3

Oil cooler 2 Transmission 2.6.3

Oil cooler 2 Transmission 2.7.3

VDCF03.01Gb Workshop Manual DCF 90-100


G Terminology and index – Terminology and index 13

Designation Section Function group


Oil filter 4 Brakes 4.3.2

Oil filter 4 Brakes 4.5.2

Oil filter 4 Brakes 4.8.12

Oil filter 10 Common hydraulics 10.6.7

Oil filter 2 Transmission 2.6.4

Oils B Safety -

Oils and lubricants, recommendation F Technical data -

OLS 8 Control system 8.4.10

Optional equipment A Foreword -

Ordering of documentation A Foreword -

Other functions 7 Load handling 7.10

Overload protection 8 Control system 8.2.1

Paint/coatings 9 Frame, body, cab and accessories 9.15

Parking brake NC switch 4 Brakes 4.5.5

Parking brake system 4 Brakes 4.5

Parking brake unit 4 Brakes 4.5.4

Passenger seat 9 Frame, body, cab and accessories 9.3.8

Pause heater 9 Frame, body, cab and accessories 9.4.19

Pipes and hoses 4 Brakes 4.3.10

Pipes and hoses 4 Brakes 4.5.6

Pipes and hoses 4 Brakes 4.8.13

Pipes and hoses 5 Steering 5.2.13

Pipes and hoses 7 Load handling 7.2.13

Pipes and hoses 7 Load handling 7.4.8

Pipes and hoses 7 Load handling 7.5.8

Pipes and hoses 7 Load handling 7.7.9

Pipes and hoses 7 Load handling 7.8.6

Pipes and hoses 10 Common hydraulics 10.2.4

Pipes and hoses 10 Common hydraulics 10.3.2

Pipes and hoses 10 Common hydraulics 10.4.3

Pipes and hoses 10 Common hydraulics 10.5.1

Pipes and hoses 10 Common hydraulics 10.6.10

Position sensor positioning 7 Load handling 7.5.6

Power assisted system 5 Steering 5.2

Workshop Manual DCF 90-100 VDCF03.01Gb


14 G Terminology and index – Terminology and index

Designation Section Function group


Power supply 11 Common electrics 11.5.1

Power-assisted brake system 4 Brakes 4.3

Pressure limiting valve 10 Common hydraulics 10.2.3

Pressure reducer 7 Load handling 7.2.3

Pressure reducer 7 Load handling 7.7.3

Pressure switch 9 Frame, body, cab and accessories 9.4.10

Priority valve 5 Steering 5.2.2

Priority valve 10 Common hydraulics 10.5.2

Propeller shaft 3 Driveline/axle 3.2

Pump unit 9 Frame, body, cab and accessories 9.14.1

Pumps 10 Common hydraulics 10.4

Radiator and expansion tank 1 Engine 1.7.4

Radiator bypass valve 10 Common hydraulics 10.6.5

Read the operator's manual/maintenance manual A Foreword -

Reading instructions A Foreword -

Reading out error code D Error codes -

Reading-lamp 9 Frame, body, cab and accessories 9.11.8

Rear window 9 Frame, body, cab and accessories 9.9.4

Rearview mirror 9 Frame, body, cab and accessories 9.9.5

Redundant CAN bus 11 Common electrics 11.6.2

References between different information types A Foreword -

Refrigerant B Safety -

Reversing alarm 9 Frame, body, cab and accessories 9.7.5

Reversing camera 9 Frame, body, cab and accessories 9.9.6

Reversing light 9 Frame, body, cab and accessories 9.6.5

Rims 6 Suspension 6.3.2

RMI (Remote Machine Interface) 11 Common electrics 11.6.5

Roof grating 9 Frame, body, cab and accessories 9.2.5

Roof window 9 Frame, body, cab and accessories 9.9.3

Rotating beacon 9 Frame, body, cab and accessories 9.6.8

Rotating beacon 9 Frame, body, cab and accessories 9.7.3

Rotating components and tools B Safety -

Running light 9 Frame, body, cab and accessories 9.6.2

Safety B Safety -

VDCF03.01Gb Workshop Manual DCF 90-100


G Terminology and index – Terminology and index 15

Designation Section Function group


Safety and emergency equipment 9 Frame, body, cab and accessories 9.2

Safety concerns everyone! B Safety -

Safety instructions B Safety -

Safety valves 10 Common hydraulics 10.2

Seat 9 Frame, body, cab and accessories 9.3

Seat belt 9 Frame, body, cab and accessories 9.2.2

Seat buzzer 9 Frame, body, cab and accessories 9.2.4

Seat cushion 9 Frame, body, cab and accessories 9.3.1

Sensor cab temperature 9 Frame, body, cab and accessories 9.4.17

Sensor hydraulic oil temperature 4 Brakes 4.8.10

Sensor hydraulic oil temperature 10 Common hydraulics 10.6.4

Sensor hydraulic pressure lift cylinder 7 Load handling 7.2.8

Sensor operator in seat 9 Frame, body, cab and accessories 9.3.14

Sensor outdoor temperature 9 Frame, body, cab and accessories 9.4.18

Sensor temperature outlet fan 9 Frame, body, cab and accessories 9.4.16

Sensor temperature refrigerant 9 Frame, body, cab and accessories 9.4.12

Sensor, fuel level 1 Engine 1.2.2

Service indicator 8 Control system 8.2.4

Service position B Safety -

Servo filter 7 Load handling 7.2.2

Servo filter 7 Load handling 7.7.4

Settings 8 Control system 8.5

Several mechanics on the same machine B Safety -

Shock absorbers 9 Frame, body, cab and accessories 9.3.4

Shuttle valve 5 Steering 5.2.9

Shuttle valve 7 Load handling 7.2.6

Shuttle valve 7 Load handling 7.4.4

Shuttle valve 10 Common hydraulics 10.5.3

Side shift 7 Load handling 7.4

Side shift cylinder 7 Load handling 7.4.3

Side window 9 Frame, body, cab and accessories 9.9.2

Signalling system 9 Frame, body, cab and accessories 9.7

Solvents B Safety -

Specifications for data and volume F Technical data -

Workshop Manual DCF 90-100 VDCF03.01Gb


16 G Terminology and index – Terminology and index

Designation Section Function group


Speed limitation 8 Control system 8.2.3

Spreader beam 7 Load handling 7.5.4

Spreading 7 Load handling 7.5

Spreading cylinder 7 Load handling 7.5.3

Start battery 11 Common electrics 11.3.1

Start/stop 1 Engine 1.11

Starter motor 1 Engine 1.11.1

Steering 5 Steering 5

Steering axle cradle 5 Steering 5.2.5

Steering axle cradle 6 Suspension 6.2.1

Steering cylinder 5 Steering 5.2.4

Steering valve 5 Steering 5.2.3

Stopping device 1 Engine 1.11.2

Storage A Foreword -

Sun blinds 9 Frame, body, cab and accessories 9.11.6

Suspension 6 Suspension 6

Suspension 6 Suspension 6.2

Switch, automatic spreading 7 Load handling 7.1.13

Switch, direction indicators 9 Frame, body, cab and accessories 9.1.22

Switch, lock twistlock/lock tongue 7 Load handling 7.1.2

Switch, spreading 20'-40' 7 Load handling 7.1.3

Switch, stop at 30' 7 Load handling 7.1.4

Tail light 9 Frame, body, cab and accessories 9.6.3

Tank 10 Common hydraulics 10.3.1

Tank heater 10 Common hydraulics 10.6.1

Tanks and accumulators 10 Common hydraulics 10.3

Technical data F Technical data -

Temperature control, cleaning and hydraulic oil 4 Brakes 4.8

Temperature control, cleaning and hydraulic oil 10 Common hydraulics 10.6

Tensioned springs B Safety -

Terminal console 9 Frame, body, cab and accessories 9.11.7

Thermal bypass valve 4 Brakes 4.8.8

Tightening torque, climate control system connections F Technical data -

Tightening torques, ORFS-couplings F Technical data -

VDCF03.01Gb Workshop Manual DCF 90-100


G Terminology and index – Terminology and index 17

Designation Section Function group


Tightening torques, recommendations F Technical data -

Tilt 7 Load handling 7.7

Tilt cylinder 7 Load handling 7.7.7

Tiltable cab 9 Frame, body, cab and accessories 9.10.4

Torque converter/Clutch system 2 Transmission 2.2

TRANSM 8 Control system 8.4.7

Transmission 2 Transmission 2

Transmission D Error codes -

Transmission cable harness 2 Transmission 2.8.3

Transmission control system 2 Transmission 2.8

Troubleshooting cable harness 0 Complete machine -

Troubleshooting hydraulic hoses 0 Complete machine -

Troubleshooting with error code, example 0 Complete machine -

Troubleshooting without an error code, example 0 Complete machine -

Troubleshooting, general work instructions 0 Complete machine -

Twistlocks 7 Load handling 7.9.1

Tyre and rim system 6 Suspension 6.3

Tyre and rim system B Safety -

Tyres 6 Suspension 6.3.1

Unit explanations F Technical data -

Valve block quick-lift 7 Load handling 7.2.12

Valve block, main pump relief 7 Load handling 7.4.6

Valve block, main pump relief 7 Load handling 7.8.5

Warning information A Foreword -

Warning lights 9 Frame, body, cab and accessories 9.6.7

Warning lights 9 Frame, body, cab and accessories 9.7.2

Warning parking brake 9 Frame, body, cab and accessories 9.7.4

Washer motor and reservoir 9 Frame, body, cab and accessories 9.5.4

Water valve 9 Frame, body, cab and accessories 9.4.5

Wheel brake 4 Brakes 4.3.9

Wheel brake 4 Brakes 4.8.6

Wheel hub 5 Steering 5.2.8

Wheel hub 6 Suspension 6.2.3

Wheel spindle 5 Steering 5.2.7

Workshop Manual DCF 90-100 VDCF03.01Gb


18 G Terminology and index – Terminology and index

Designation Section Function group


Wheel spindle 6 Suspension 6.2.2

Vibrations B Safety -

Windscreen 9 Frame, body, cab and accessories 9.9.1

Wiper front 9 Frame, body, cab and accessories 9.5.1

Wiper motor, front 9 Frame, body, cab and accessories 9.5.5

Wiper motor, rear 9 Frame, body, cab and accessories 9.5.7

Wiper motor, roof 9 Frame, body, cab and accessories 9.5.6

Wiper rear 9 Frame, body, cab and accessories 9.5.3

Wiper roof 9 Frame, body, cab and accessories 9.5.2

Wiper/washer system 9 Frame, body, cab and accessories 9.5

Work lights, attachment 9 Frame, body, cab and accessories 9.6.12

Work lights, front wing 9 Frame, body, cab and accessories 9.6.14

Working lights, cab 9 Frame, body, cab and accessories 9.6.10

Working lights, mast 9 Frame, body, cab and accessories 9.6.9

Working under machine B Safety -

Workshop manual contents A Foreword -

Writing desk 9 Frame, body, cab and accessories 9.11.9

VDCF03.01Gb Workshop Manual DCF 90-100

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