DCT80 Workshop Manual[1]

Empty Container Handler 8-9 tonnes

Publ. no VDCT01.02GB Workshop Manual in original

WORKSHOP MANUAL

DCT 80-90

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

2 Transmission

DCT 80-90

3 Driveline/axle 4 Brakes 5 Steering 6 Suspension 7 Load handling 8 Control system 9 Frame, body, cab and accessories 10 Common hydraulics 11 Common electrics 12 Common pneumatics D Error codes E Schematics F Technical data G Terminology and index

A:1

A Foreword

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

Workshop Manual DCT 80-90

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A:2

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A Foreword – Foreword

A:3

A Foreword About the Workshop Manual General Thank you for choosing Cargotec as your machine supplier. We hope that we will meet your expectations.

Conditions The instructions are based on the use of generally available standard tools. All lifting devices, such as slings, straps and ratchet blocks, must meet the national standards and regulations in force for lifting devices. Cargotec will not accept any responsibility in the event of a modification performed without permission from Cargotec. Further, Cargotec will not accept any responsibility if other lifting devices, tools or work methods are used other than those described in this manual.

Storage

NOTE The workshop manual should be accessible to service personnel.

About machine version The information in this publication corresponds with the machine's design and appearance on delivery from Cargotec. Deviations may arise due to customer adaptations. Cargotec reserves the right to make changes to specifications and equipment without prior notice. All information and data in this manual are valid at the time of publication.

DANGER External equipment may only be used if it is approved by Cargotec. Extreme hazard to personal health and risk of property damage! Only use equipment that is approved by Cargotec.

Copyright Cargotec Sweden AB Duplication of the content in this manual, in whole or in part, is strictly prohibited without written permission from Cargotec Sweden AB. All duplication by any means, such as copying, printing, etc., is prohibited.


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A Foreword – Reading instructions

Reading instructions Warning information Warnings provide information about potential dangers that, if the warnings are not followed, could result in injury or product damage.

DANGER Situation that could lead to severe personal injury or death if regulation is not followed.

WARNING Situation that could lead to personal injury if regulation is not followed.

CAUTION Situation that could lead to product damage if regulation is not followed.

Important information Important information is denoted with NOTE and is intended to facilitate the work process, handling or to increase understanding of the information.

NOTE Important information not related to safety.

Read operator's manual 000262

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

Read the operator's manual

001128

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

Read the Maintenance manual

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A:5

The workshop manual's contents The workshop manual contains information to facilitate maintenance (part replacement) and is a supplement to the maintenance manual. Accompanying the workshop manual is supplier documentation for engine, transmission and drive axle. Where possible, the workshop manual provides reference to supplier documentation instead of printing the same information twice. Methods for preventive maintenance and certain checks are found in the maintenance manual, no references are given for these. Use the function groups to locate the information in the maintenance manual. The workshop manual is divided into the following sections. A

Foreword

General information about the workshop manual's purpose, contents and reading instructions as well as survey for feedback of views and any inaccuracies.

B

Safety

Keep in mind for your safety.

C

Preventive maintenance

Reference to maintenance manual: Preventive maintenance.

0

Complete machine

1

Engine

2

Transmission

3

Power transmission

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

Error code information and instructions for reading error code information.

E

Schematics

Wiring diagrams, hydraulic diagrams and list of electrical components.

F

Technical data

Technical data, conversion tables, information for conversion of units.

G

Terminology and index

General terminology and abbreviations, explanation of terms and abbreviations that can appear in the sections, index for headings in the manual.

Technical description, comprehensive function descriptions and a description of the function of components included in the machine, divided into function groups. The components used for each respective function are described under each subfunction. Consequently, common components are described in several locations, but in general under the first function to use the component. Together with the general description is a detailed description of what is unique about the specific subfunction. The next subfunction to use the same component only has a description what is unique for the new function. Work instructions for corrective maintenance (replacement of components).


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Function group structure The information in the manual is divided in a structure of functions at different levels, based on the machine's design and use, called function groups. The upper level (called main group) determines area, e.g. group 7 Load handling. The second level (called two-digit) determines function, e.g. 7.2 Lifting/lowering. The third and fourth levels are used to break down functions into smaller parts (components). The function groups' structure for main group and two-digit group level are common for all machines from Cargotec, e.g. 4.3 Power-assisted brake system. Machine-unique adaptations of function groups are made at the third and fourth group level, e.g. 4.3.9 Wheel brake and 4.3.9.1 Disc pack. This means that certain function groups (headings) will be left out in the documentation for certain machines since the machine is missing that specific function or component. In turn, this means that there may be jumps in the function groups' numbering, e.g. the three-digit heading level 4.8.7 Oil cooler may be included for some machines, but is missing for others. The function groups are intended to be used as search terms in order to find different types of information between different sections and manuals. The information in a function group is divided in smaller sections according to the type of content, e.g. description or replacement. The maintenance manual and workshop manual contain different information. The maintenance manual only contains the information needed for preventive maintenance and simpler troubleshooting. The workshop manual contains more in-depth information and repair instructions. References between sections in the same manual are indicated with section and group number, e.g., "see section 4 Brakes, group 4.3.9 Wheel brake". References within a section are indicated with a page number, e.g. "see Sensor fuel level, description page 24". References between Maintenance manual and Workshop manual are not given. If more information about a function group is required then the primary recommendation is to search under the same function group in the other manual. For more in-depth information on where different types of information are located and what references are made, see References between different information types, page A:7.

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A:7

References between different information types The maintenance manual and workshop manual are mainly divided into function groups, see The workshop manual's contents, page A:5. Certain parts are broken out as separate parts to increase usability, e.g. "Technical data". The basic rule of searching for information is to use the function groups to find different types of information regarding the function or component in question. As a complement to this, there are references in accordance with the below.

Function descriptions

Hydraulic diagrams

(Technical description)

(Section E)

Component descriptions

Error codes

(Technical description, normally in Workshop manual)

(Section D)

Diagnostics

Wiring diagrams

(Technical description, group 8.4)

(Section E) •

From Function description to Component description, to enable fast finding of more information about the different components that create a function.

•

From Function description to Hydraulic diagram, to enable fast finding of the right hydraulic diagram for the function in question.

•

From Component description or Function description to Diagnostics, to enable fast finding of the right diagnostic menu that can be used to check the component (only applies to electrical components).

•

From Diagnostics to Wiring diagrams, to enable fast finding of the right circuit diagram for further troubleshooting.

•

From Diagnostics to Component description or Function description, to enable fast finding of more information about the component's appearance and position when troubleshooting.

•

From Error codes to Diagnostics, to enable fast finding of the right diagnostic menu to troubleshoot component or function in question.

•

From Error codes to Function description or Component description, to enable fast finding of more information about components or function.


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Product alternatives and optional equipment The information in the manual is divided into modules. If a product alternative or optional equipment is fitted, handling may differ from that indicated in the modules depending on what is being described. See below. Special equipment is not described in the manual. If uncertain as to what equipment is fitted to the machine, use the machine card to determine which information is relevant. See Machine card, page A:9.

Product alternative Product alternative describes options that are fitted instead of a specific piece of standard equipment (e.g. engine alternative). Equivalent information for different product alternatives is described consecutively in separate segments within the same function group. To indicate that there are different alternatives, "Product alternative" is added to the heading together with a simple description of the alternative, e.g. "(Product alternative Climate control system ECC)". In addition, the alternative that is an option is marked with the symbol for optional equipment. 000264

Optional equipment

Symbol for optional equipment

Optional equipment Optional equipment refers to options that can be added to standard equipment for more or improved functions. Information on auxiliary equipment is described in separate segments together with the standard equipment as the basis. The optional equipment description covers how the equipment option affects the standard function and what additional components are involved.

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A:9

Machine card

NOTE If the machine has been modified after delivery, information on the machine card may be incomplete or incorrect.

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

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


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Function descriptions The function descriptions are schematic overviews that describe how a function works as well as which components and signals work together. The function descriptions describe the function in a logical flow from input signal to desired output signal. Most functions require that preset conditions are fulfilled for the function to be activated. In these cases, the conditions are listed above the illustration. The function descriptions use symbols to illustrate components such as valves, sensors, etc. 4 B ro m s a r S e rv o b ro m s s y s te m

4 :5

4 .3 S e r v o b r o m s s y s te m S e r v o b r o m s s y s te m , fu n k tio n s b e s k r iv n in g

1 10

14

D790-2

B P

D11

D797-1

10, 13

T

5

Pa

4

D12

2

6

D9

C

2 C

12

Pa

LB

ACK M

P

P

T

T

8 7

3

P

9

C

9

11

3

B

7

P os

F ö r k la r in g

S ig n a lb e s k r iv n in g

H ä n v is n in g

1

H y d ra u lo lje p u m p b ro m s o c h s ty rn in g p u m p a r o lja frå n h y d ra u lo lje ta n k e n .

S e try c k s k y lt p å v ä n s te r ra m b a lk .

H y d ra u lo lje p u m p b ro m s o c h s ty rn in g , b e s k riv n in g , s id a 4 :8

2

Ven och Ven in te

-

3

V e n tilb lo c k b ro m s a r le d e r o lja n v id a re till a c k u m u la to re r o c h d riv a x e lb lo c k .

-

4

A c k u m u la to re rn a la g ra r h y d ra u lo lje try c k .

S e try c k s k y lt p å v ä n s te r ra m b a lk .

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

5

B ro m s v e n tile n s ty r try c k frå n a c k u m u la to re rn a till b ro m s c y lin d e rn p ro p o rtio n e llt m o t p e d a ltry c k e t.

-

B ro m s v e n til, b e s k riv n in g , s id a 4 :1 8

6

D riv a x e lb lo c k e t fö rd e la r b ro m s try c k e t till h ju lb ro m s a rn a .

-

tilb lo c k p rio rite tilb lo c k k rä v e r

a c k u m u la to rla d d n in g s rin g s v e n til s ty r try c k till b ro m s a r n ä r s ty rn in g e n h y d ra u lk ra ft.

4

5

6 014621

8

015034

1

Example of function description 1.

Hydraulic line

6.

Signal description, reference value for signal out from component

7.

Description of the component's function

8.

Position number, reference to position in illustration

9.

Position number in illustration, reference to row in table

- Hydraulic force: solid double line - Hydraulic control signal: dashed double line) 2.

3.

Flag measuring outlet (Check point), indicates that there is measuring outlet for checking the hydraulic pressure Flag diagnostic test, indicates that the signal can be checked with diagnostics, see section 8 Control system, group 8.4 Diagnostics

4.

Illustration of function, (applied brake)

5.

Reference to description of component

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10. Electrical wiring - Electric power: solid single line - Electrical control signal: dashed single line



Symbol explanation function descriptions

1

2

3

4

5

Symbol explanation function descriptions The following symbols are used in function descriptions. The symbols are based on standard symbols for wiring and hydraulic diagrams.

6

7

8

9

A:11

M

10

1.

Electric control signal

2.

Electric force

3.

Hydraulic control signal

4.

Hydraulic force

5.

Hydraulic motor

6.

Hydraulic oil pump with variable displacement

7.

Hydraulic oil pump with fixed displacement

8.

Electric motor

9.

Accumulator

10. Disc brake 11. Filter

11

12. Radiator

12

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

D790-1

13

15. Restriction

14

16. Adjustable restriction

D797-F

17. Inductive position sensor

15

16

17

18

18. Electrically controlled servo valve 19. Thermal bypass valve

19

°C

21

°C

23 Pa

20. Temperature-controlled switch 21. Temperature sensor

20 °C 22

22. Pressure sensor 23. Pressure-controlled switch

Pa

24. Hydraulic cylinder 25. Double-acting hydraulic cylinder

24

26. Spring brake cylinder 27. Valve block

25

28. Shuttle valve

26

27

28

29

014726

29. Non-return valve


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A Foreword – About the documentation

About the documentation The documentation's parts The documentation for the machine consists of the following parts:

Operator's manual The operator's manual is delivered with the machine in the cab.

Documentation kit Maintenance manual and spare parts catalogue with machine card are supplied for the machine as a separate documentation kit.

Supplementary documentation There is supplementary documentation that can be ordered for the machine. •

Workshop manual.

•

Supplier documentation for engine, transmission, and drive axle.

Ordering documentation Documentation is ordered from your Cargotec dealer. Always indicate publication number when ordering. For publication number, see machine card.

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A Foreword – Feedback

A:13

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

Cargotec Sweden AB Technical Documentation Torggatan 3 SE-340 10 Lidhult SWEDEN Fax: +46 372 263 93

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

Phone: ...............................................................................................................................................................

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

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

Name / Publication number: ............................................................................................................................. Section / page number: ................................................................................................................................ ................

Suggestions, views, remarks, etc.

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

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

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

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

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

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


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B:1

B Safety

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


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B:2

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B Safety – Safety

B:3

B Safety General safety information Safety concerns everyone! The safety information concerns everyone who works with the machine! Persons who do not follow the safety instructions given in this manual must make absolutely sure that the work is performed without risks of personal injury and without risks of damage to the machine or property! Remember to: •

follow the instructions in this manual

•

be trained for the work in question

•

follow local laws, safety rules and regulations

•

use the correct equipment and tools intended for the work in question

•

wear the correct clothing

•

use common sense and work carefully. Do not take any risks!

In this publication Cargotec has documented and warned for situations and risks that may occur in connection with the use of, as well as service or repair of, the machine during normal circumstances. For this reason it is important that all who work with the machine, or repair or service the machine, read and follow the information in the Maintenance Manual and Operator's Manual.

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


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B:4

B Safety – Safety instructions

Safety instructions General Read and observe the following safety instructions below before starting to work with the machine: •

Service position, page B:4

•

Hydraulic and brake systems, depressurising, page B:5

•

Oils, page B:6

•

Fuel system, page B:7

•

Clothing, etc., page B:8

•

Several mechanics on the same machine, page B:8

•

Working under the machine, page B:8

•

Lifting heavy components, page B:9

•

Vibration, page B:9

•

Noise, page B:10

•

Dissolvent, page B:10

•

Fire and explosion risk, page B:11

•

Fluid or gas under pressure, page B:13

•

Coolant, page B:14

•

Refrigerant, page B:14

•

Air pollution, page B:15

•

Tensioned springs, page B:16

•

Electric motors, page B:16

•

Rotating components and tools, page B:16

•

Tyres and rims, page B:17

•

Lifting equipment, page B:17

•

Spare parts, page B:18

•

Non-ionised radiation, page B:18

Service position General

General Service position is used for service, maintenance and other situations when the machine needs to be secured. Service position entails: The machine is parked, i.e. parking brake applied.

•

Trolley and attachment in totally lowered position

•

Mast tilted fully forward.

•

Engine off.

•

System voltage switched off (with the battery disconnector).

009797

•

Machine with trolley and attachment in totally lowered position

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B:5

Hydraulic and brake systems, depressurising 1

Machine in service position, see Service position, page B:4.

2

Depressurise the hydraulic system. Turn system voltage on, turn the starter key to position I and activate the load handling functions several times.

3

Turn the start key to position 0 and switch off the system voltage.

4

Depressurise the brake system by opening the drain valve on the accumulator charging valve.

NOTE Keep the accumulator drain valve open as long as work is in progress.

NOTE

014618

After the work has been finished, close the drain valve and tighten the lock ring.


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B:6


5

Depressurise the attachment. Open relief valve top lift.

CAUTION Hydraulic oil may be directed the wrong way. Risk of damage to the fine filter for hydraulic oil.

014620

Check that the relief valve for the attachment is closed before starting the engine.

The figure above shows open valve.

Oils The following safety instructions must be followed for work when handling oils.

WARNING Hot and pressurised oil. Avoid skin contact with the oil, use protective gloves. Hot oil can cause burn injuries, rashes and irritation! The oil may also be corrosive to mucous membranes in, e.g. the eyes, skin and throat.

IMPORTANT Always clean the area around components and connections before they are loosened. Dirt in oil systems causes increased wear, resulting in subsequent material damage. Always take action to avoid spills. In locations where drainage containers cannot be used, use a pump or hose for safe handling. Always check that plugs are sealed tightly before receptacles are moved. Handle all oil as environmentally hazardous waste. Oils freely discharged cause environmental damage and can also be a fire hazard. Waste oils/fluids must always be handled by an authorised company.

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B:7

Fuel system The following safety instructions must be followed for work when handling fuel.

DANGER Pay attention to the risk of fire when working on the fuel system. Work on the fuel system must be avoided when the engine is warm since fuel can spill on hot surfaces and may ignite. Make sure that open flames, sparks, or red-hot/glowing objects have been extinguished before starting work on or near the fuel system. Do not smoke near the machine during work on the fuel system.

WARNING The engine's fuel system operates at very high pressure. The pressure is so high that the jet can injure the skin, resulting in severe injuries. Risk of personal injury. Use protective gloves and protective safety glasses, avoid skin contact with fuel. If a component is being loosened then hold a rag over the connection as protection and collect the fuel. Fuel is corrosive to mucous membranes in e.g. the eyes, skin and throat.

CAUTION Always clean the area around components and connections before they are loosened. Dirt in the fuel may cause malfunctions and engine stop in undesirable situations as well as increase wear, resulting in subsequent material damage.

IMPORTANT Always take action to avoid spills. In locations where drainage containers cannot be used, use a pump or hose for safe handling. Always check that plugs and connections are sealed tightly before receptacles are moved. Handle the fuel as environmentally hazardous waste. Fuel freely discharged cause environmental damage and can also be a fire hazard. Fuel must always be handled by a company authorised for this activity.


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B:8


Clothing, etc. Clothes should be in good repair. Remove loosely hanging garments (e.g. tie, scarf). Do not wear clothes with wide sleeves, wide trouser legs, etc. Remove jewellery as it may conduct electricity and get caught in moving parts. Long hair should be adequately gathered since it can easily get caught in moving parts. Exercise caution when working with welding or an naked flame since hair easily catches on fire.

Several mechanics on the same machine

WARNING If several mechanics are working on the same vehicle, extra care must be taken so that accidental movements do not injure any other person. Communicate so that everyone knows where everyone is, and what they are doing. Risks Work with wheels or axle suspension, mountings, etc., may result in components on the other side moving and causing damage or injury. Operations controlled from the operator's station, e.g. all movement of lifting equipment, may cause severe personal injury.

Safety precautions •

Make sure that the machine's lifting equipment is completely lowered or secured in some other way.

•

Move the battery disconnector to position zero and remove the key.

•

Be aware of the risks when several persons are working around the vehicle.

•

Make your co-workers aware of what you are working with.

•

Do not work with the drive wheels on the both sides of the machine at the same time.

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

Risks Mechanical or hydraulic tools and lifting devices may fall over or accidentally lower due to malfunctions or incorrect use.

Safety precautions

VDCT01.02GB

•

Use axle stands and supports that stand securely.

•

Lifting tools should be inspected and type approved for use.



B:9

Lifting heavy components

WARNING Careless handling of heavy components may lead to serious personal injury and material damage. Use type approved lifting tools or other tools to move heavy components. Make sure that the device is sturdy and intact.

Risks Unsuitable lifting straps, etc. may break or slide. The centre of gravity of the component may shift while work is in progress, and the component may then make unexpected movements which may cause severe personal injury and material damage. A component lifted with lifting equipment may start to turn if the centre of gravity shifts. A component lifted using an overhead crane may start to swing back and forth, which can cause severe crushing injuries or material damage.

Safety precautions Lifting with lifting device. Use lifting tools or other tools, in particular when there are such tools available adapted for specific work operations. See the workshop manual for methods. If lifting must be performed without lifting device: •

Lift near the body.

•

Keep your back vertical. Raise and lower with legs and arms, do not bend your back. Do not rotate your body while lifting. Ask for assistance in advance.

•

Wear gloves. They're often good protection to reduce crushing and cutting injuries to fingers.

•

Always use protective shoes.

Vibration Use of vibrating tools, e.g. impact nut runner or grinder, for an extended period of time may cause injuries as vibration is transmitted from the tool to hands. In particular when fingers are cold.


Use heavy gloves that protect against the cold and the transfer of vibrations.

•

Switch between work duties to give the body time to rest.

•

Vary your work position and grip so that your body is not affected in only one position by the vibration.


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B:10


Noise Noise louder than 85 dB (A) that lasts for longer than 8 hours is considered to damage hearing. (Limit values may differ between different countries.) High pitches (high frequencies) do more damage than low pitches with the same sound level. Noise in the form of impulse sounds may also be damaging, e.g. hammer strikes.

Risks At noise levels higher than the limit values hearing damage may occur. In more severe cases, hearing damage can become permanent.


Use hearing protection. Make sure that it's tested and protects against the right noise level.

•

Limit noise with noise-absorbing screens, for example, noise-absorbing materials in roof and on walls.

Dissolvent Fluids that (as opposed to water) dissolve grease, paint, lacquer, wax, oil, glue, rubber, etc. are called organic dissolvents. Example: Petroleum spirits, petrol, thinner, alcohols, diesel, xylene, trichloroethylene, toluene. Many dissolvents are flammable.

Risks Products with dissolvents give off fumes that may cause dizziness, headache and nausea. They may also irritate mucous membranes in the throat and bronchi. If dissolvent comes in direct contact with the skin it can dry and crack. Increased risk of skin allergies. Dissolvents may also cause injury if they penetrate through the skin and are absorbed by the blood. If the body is continuously exposed to dissolvents, there may be damage to the central nervous system. This manifests itself in sleeping problems, depression, nervousness, poor memory and general tiredness. Continuous inhalation of petrol and diesel fumes is suspected to cause cancer.

Safety precautions

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•

Avoid inhaling dissolvent fumes by providing good ventilation, or wearing a fresh-air mask or respiratory device with a suitable filter for the toxic gases.

•

Never leave a dissolvent container without tight-sealing lid.

•

Use dissolvents with a low content of aromatic substances. This reduces the risk of injury.

•

Avoid skin contact.

•

Use protective gloves.

•

Make sure that work clothes are dissolvent-resistant.



B:11

Fire and explosion risk

DANGER In the event of fire the operator's safety must not be compromised. If given the opportunity, take the following action at the slightest sign of fire: 1. Stop the machine and turn the ignition key to stop position. 2. Leave the cab. 3. Switch off the system voltage with the battery disconnector. 4. Alert the rescue services. 5. Try to extinguish the fire. If this is not possible, leave the machine and the risk area.

DANGER Smoke can be extremely toxic. Smoke subdues, suffocates and can kill people! Smoke can cause damage to lungs and respiratory organs even in small quantities. Avoid breathing fumes, do not stand in the smoke. Use breathing apparatus for fire fighting and work with burnt material. Examples of fire and explosion prone substances are oils, petrol, diesel fuel oil, organic solvents (paint, plastics, detergents), rust preventive agents, welding gas, gas for heating (acetylene), high concentrations of dust particles consisting of combustible materials. Rubber tyres are flammable and can cause fire with explosive development.

Risks Examples of the cause of ignition are welding, cutting with gas flame, tobacco smoking, sparks when grinding with grinding machines, contact between hot engine parts and flammable materials, heat generation in rags soaked with oil or paint (linseed oil) and oxygen. Oxygen containers, lines and valves must be kept clean of oil and grease. Fumes from e.g. fuel are heavier than air and may "run" down a slope, or down into a grease pit, where welding flames, grinding sparks or cigarette embers may cause an explosion. Vaporised fuel has a very powerful explosive effect.


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B:12


Special cases Diesel fuel oil with added petrol has a lower flashpoint. Risk of explosion even at room temperature. The explosion risk for heated diesel fuel oil is higher than for petrol. When changing the oil in the engine, hydraulic system and transmission, keep in mind that the oil may be hot and cause burn injuries. Welding on or in the vicinity of the machine. If diesel or other oils have leaked and soaked rags, Absol/absorbing agents, paper or other porous material then glowing welding sparks can cause ignition and the explosive spread of fire. When a battery is being recharged the battery electrolyte water is divided into oxygen and hydrogen gas. This mixture is highly explosive. The risk of explosion is especially high when a booster battery or a rapid-charge unit is used, as they increase the risk of sparks. There is a lot of electronic equipment on today's machines. When welding, the control units must be disconnected and the electric power must be switched off with the battery disconnector. Powerful welding currents may otherwise short-circuit the electronics, destroy expensive equipment or cause an explosion or fire. Never weld on painted surfaces (remove paint, by blasting at least 10 cm around the welding or cutting point). Use gloves, breathing protection and protective glasses. Also, welding work must not be done near plastic or rubber materials without first protecting them from the heat. Paints, plastics and rubber develop a number of substances when heated that may be hazardous to health. Exercise caution with machines that have been exposed to intense heat or fire.

Safety precautions

DANGER Residue from fuel, oils, grease or other flammable materials on the engine or in the engine compartment is a fire hazard. Fire hazard! Remove residue of flammable materials in the engine compartment as soon as they are detected. Be extra careful on hot surfaces such as exhaust systems, manifolds or turbochargers. If leakage of oil, fuel or coolant is detected, the reason should be investigated and the fault corrected before starting the engine.

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•

Make it a habit to make a visual inspection of the engine and engine compartment before starting the engine and after operation, when the engine has been stopped. This helps to quickly detect if anything abnormal has happened or is about to happen. Look particularly closely for oil, fuel or coolant leakage, loose bolts, worn or poorly tensioned drive belts, loose connections, damaged hoses and electrical cables. The inspection only takes a few minutes and can prevent serious faults and costly repairs.

•

Store a hazardous substance in an approved and sealed container.

•

Make sure that there is no ignition source near flammable or explosive substances.

•

Make sure that ventilation is adequate or there is an air extraction unit when handling flammable substances.



B:13

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

Risks Risk of damage/injury in connection with work on: •

Hydraulic systems (e.g., working hydraulics and brake system).

•

Fuel system.

•

Tyre changing.

•

Air conditioning.

•

Cooling system.


Use protective goggles and protective gloves.

•

Never work in a pressurised system.

•

Never adjust a pressure limiting valve to a higher pressure than the manufacturer's recommendations.

•

A hydraulic hose that swells, e.g. at a connection, shows evidence that it is about to rupture. Replace it as soon as possible! Check the connections thoroughly.

•

Use fluid when checking for leaks.

•

Never blow clothes clean with compressed air.

•

A discarded pressure accumulator must first be depressurised and then punctured before it is discarded (to avoid risk of explosion). Carefully, drill a hole with 3 mm diameter after depressurising.

•

Never use your hands to check for any leaks. A fine jet from a hydraulic hose may have such high pressure that it easily cuts through e.g. a hand and causes very severe injuries.

•

First open the cooling system cap for the filling point slowly, so that the high pressure is released. Hot steam and coolant may otherwise spray out.


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B:14


Coolant The coolant in the machine's cooling system consists of water, anti-corrosion compound and anti-freeze fluid, for example, ethylene glycol. Coolant must not be drained into the sewer system or directly onto the ground.

Risks The cooling system is at high pressure when the engine is warm. Hot coolant may jet out and cause scalding in the event of leaks or when the cap on the expansion tank (filling point) is opened. Ingesting ethylene glycol and anti-corrosion compound is dangerous and hazardous to health.


Use protective gloves and protective safety glasses if there is a risk of splashing or spraying.

•

First open the cap for the filling point slowly, so that the high pressure is released. Exercise caution. Hot steam and coolant may jet out.

•

If possible, avoid working on the cooling system when the coolant is hot.

Refrigerant Refrigerant is used in the machine's air conditioning system. Work on the air conditioning system must be performed by accredited/authorised and trained personnel in accordance with national legislation and local regulations.

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

Safety precautions

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•

Use special instructions and equipment for refrigerant according to the manual when working on the air conditioning system. Special certification and authorisation must often be held by the person who may do the work. (Observe national legislation and local regulations!)

•

Use protective gloves and protective safety glasses if there is a risk of leaks.

•

Make sure that heat-producing sources or objects are not close by (cigarette glow, welding flame).



B:15

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

Carbon monoxide (fumes) is contained in exhaust gases. Odourless and therefore particularly dangerous.

•

Nitrogen oxides (nitrous gases) are present in exhaust fumes.

•

Welding smoke is particularly hazardous to health when welding on oily surfaces, galvanised or lacquered materials.

•

Oil mist for example, is formed when applying anti-corrosion agent.

•

Grinding dust and gases are generated when grinding and heating plastics, lacquer, anti-corrosion agents, lubricants, paint, etc.

•

Isocyanates are present in certain paints, fillers, adhesives and foam plastics used on machines.

Risks Sulphuric acid mist is corrosive and injures the respiratory tracts. (Generated when heating certain plastics and paints.) Isocyanates can be released in the form of steam, dust (or present in aerosol) when cutting, grinding or welding. May cause mucous membrane irritation with asthma-like symptoms and impaired lung function. Even brief exposure to high concentrations may cause problems with persistent hypersensitivity.


Make sure of adequate ventilation with fresh air when welding, battery charging and other work when hazardous gases are formed.

•

Use suitable protective gloves and breathing protection when there is a risk of oil mist. Make sure that the protection is oil-resistant.

•

Apply oil-resistant protective lotion to unprotected skin.

•

Make sure that an eyewash station is in the immediate vicinity when working with corrosive substances.

•

Avoid unnecessary operation of the machine in the workshop. Connect extraction equipment to the exhaust pipe so that exhausts are routed out from the workshop.


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B:16


Tensioned springs Examples of tensioned springs: 1.

Torque springs in, e.g. pedals

2.

Thrust spring (cup springs) in parking brake cylinder

3.

Lock rings

4.

Gas springs

Risks If a tensioned spring releases, it is shot out by the spring force and can also take adjoining parts with it. Small springs can cause eye injuries amongst other things. Parking brake springs are tensioned with high force and can cause very severe accidents if they are accidentally released in an uncontrolled manner. Gas springs and gas-charged shock absorbers are tensioned with high force and can cause very severe accidents if they are accidentally released in an uncontrolled manner.


Use protective safety glasses.

•

Lock rings should be of a suitable type and in good condition.

•

Follow the instructions in this and other manuals when performing maintenance and replacing parts and components.

•

Always use the tools recommended.

Electric motors Safety precautions Always switch off the battery disconnector when working on electric motors. Always block the machine's wheels, make sure that the parking brake is activated and that the gear selector is in neutral position before starting any work on the machine.

Rotating components and tools Examples of rotating components and tools: •

Cooling fan

•

Drive belts

•

Propeller shafts

•

Drills

•

Grinding machines

Risks Rotating components, e.g. fans or shafts, can cause severe injury if touched. Drills, lathes, grinders or other machines with rotating parts can cause severe accidents if clothing or hair gets caught and becomes wound into the machine.

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B:17


Do not use gloves when working with a drill.

•

Remove loose, hanging clothing, scarf or tie.

•

Never use clothing with wide sleeves or trouser legs.

•

Make sure that clothing is intact and in good condition.

•

Long hair should be gathered up in a hair net or similar.

•

Remove large or loose hanging jewellery from hands, arms and neck.

Tyres and rims

DANGER Tyres should be regarded as pressure reservoirs. If handled incorrectly, they constitute fatal danger. Parts could be thrown out with explosive force and cause severe injuries. Never repair damaged tyres, wheel rims or lock rings. Tyre changes must be performed by authorised personnel.

Risks Dismantling of wheels: Tyres, rims and lock rings may be ejected. Inflating of tyres: Tyres, rims or lock rings may be ejected.


Always deflate the tyre before starting to work on the wheel.

•

Check that tyres, rims and lock rings are not damaged. Never repair damaged wheel rims or lock rings.

•

Wheels shall be inflated on the machine or in a protective device, designed and dimensioned so that it can handle or dissipate a shock wave from a tyre explosion as well as catch the ejected parts.

•

Use protective screen and protective safety glasses.

Lifting equipment When working on the machine in general, and with the machine's lifting equipment in particular, the greatest caution must be exercised with respect to securing the mast, carriage and attachment. Always make a habit of lowering the carriage to its lowest position before working on the machine.

Risks If the machine's lifting equipment is not lowered or secured, there is a risk of crushing. Risk of crushing is particularly great when depressurising the hydraulic system, see Hydraulic and brake systems, depressurising, page B:5.

Safety precautions Do not begin work until the carriage has been fully lowered. If the nature of the work requires the carriage to be raised then this must be secured in some way. Workshop Manual DCT 80-90

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B:18


Spare parts

WARNING For safety reasons, the following spare parts may only be replaced with genuine spare parts: •

Brake valve

•

Drive axle

•

Steering valve (Orbitrol)

•

Steering valve incl. priority valve

•

Steering axle

•

Steering cylinder

•

Rim

•

Mast, carriage

•

Lift cylinder incl. load control valve

•

Lifting chains

•

Chain tightener and shaft

•

Lift cylinder

•

Valve block lift

•

Tilt cylinder

•

Twistlock

•

Control breaker (for hydraulic function)

•

Emergency stop

•

Accumulator

•

Main valve load handling

•

Accumulator charging valve

•

All control units

Non-ionised radiation

WARNING Optional equipment such as two-way radio, telephone, etc. may emit non-ionising radiation. Risk of interference with active or non-active medical products. Use two-way radio, telephone, etc. when no persons with active or non-active medical products are in the vicinity.

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B:19

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


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B:20

B Safety – Environment

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

Recycling Conscientious recycling of the machine is the starting point for the life cycle to come full circle, and for being able to recycle and make use of material in new products. According to calculations by Cargotec, the machine is more than 90% recyclable by weight.

Environmentally hazardous waste Components such as batteries, oils, and various chemicals and other items that may constitute environmentally hazardous waste must be handled and taken care of in an environmentally safe and sound manner. Discarded batteries contain substances hazardous to personal health and the environment. Therefore, handle batteries in an environmentally safe manner and according to national regulations.

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

Air conditioning The refrigerant in the air conditioning for the cab adds to the "greenhouse effect" if released into the open air. Special training is required for all service work on the air conditioning. Many countries also require certification by a governing authority for such work. When scrapping an air conditioning unit, the refrigerant shall be taken care of by a certified company.

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

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B Safety – Environment

B:21

Declarations The machine does not contain asbestos. The machines contains lead in batteries and in electric cabling. In certain models, there are lead castings as counterweight. If the machine is equipped with air conditioning, refrigerant of type R134a is used, in an amount totalling between 1-3 kg.


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B:22

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C:1

C Preventive maintenance

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


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C:2

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0:1

0 Complete machine

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


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0:2

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0 Complete machine – Complete machine

0:3

0 Complete machine Complete machine, description Kalmar DCT 80-90 is a forklift truck for empty container handling. The machine has a lifting capacity of 8-9 tonnes depending on the model. The engine is a straight six-cylinder, four-stroke, turbocharged low-emission diesel engine with a unit injector, air to air intercooling and electronically controlled fuel injection.

5

The transmission is hydromechanical with gear wheels constantly engaged and has three gears in each direction. Engine power is transmitted using a torque converter. The power transmission consists of a propeller shaft and one rigid drive axle with differential and hub reduction. Drive takes place on the front wheels. The service brakes are wet multiple disc brakes which are attached to the drive wheel hub. The parking brake is the disc brake type and operates on the drive axle input shaft.

7

Steering operates on the rear wheels with a double acting hydraulic cylinder. The steering axle is suspended in the frame with pendulum suspension.

6

The wheels are attached to the hubs with studs and nuts. Double wheels are fitted on the drive axle; single wheels on the steering axle.

1

2

1.

Steering axle

2.

Engine

3.

Frame

4.

Drive axle

5.

Mast

6.

Side lift attachment

7.

Cab

3

4

014183

Load handling comprises components and functions for handling loads. The load is lifted with the side lift attachment secured to a trolley that sits on a mast. Load handling is divided into the functions: lift and lower, tilt, side shift, spreading and load securing. •

Lifting/lowering is the function used to raise and lower the trolley.

•

Side shifting is moving the side lift attachment sideways along the trolley.

•

Spreading is adjusting the width between the Twistlocks on the side lift attachment.

•

Tilt is used to angle the load in the longitudinal direction of the truck with the help of the mast.

•

Load securing is to lock the load to the side lift attachment.

The control system consists of functions for warning the operator of dangerous situations and faults. The control system has diagnostic resources that simplify troubleshooting. The frame carries the machine. The frame houses the engine, transmission, drive axle and steering axle. Fuel and hydraulic oil tanks are fitted to the side of the frame. The cab is located at the rear of the frame. The hydraulic system is fed by two hydraulic oil pumps. The pumps are mounted on the transmission's power take off. One fixed pump feeds load handling and the other fixed pump feeds the brake system, steering and the cooling circuit over a combined priority valve and accumulator charging valve. The hydraulic oil tank is located on the right side of the machine. The hydraulic oil filters are return filters fitted in the hydraulic oil tank.


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0:4


The machine's electrical system is built around control units at strategic locations on the machine. The control units receive signals from sensors and contacts and control components in the vicinity of each control unit. The control units have a redundant power supply and communicate via a redundant CAN bus. Th engine and transmission have their own control units from each supplier. These control units communicate via the CAN bus with a control unit in the cab.

Troubleshooting, general work instructions When troubleshooting, it is important that the work is structured and logical. The purpose of the troubleshooting described in the maintenance manual is to exclude components as the source of a fault so that the real source can be identified. A suggested structured work method is described below. When troubleshooting, it is important to understand how the machine functions. Certain faults can be identified directly using function descriptions. Sections 0–12 contain descriptions of the various functions of the machine.

Troubleshooting procedure 1

2

Check that there is battery voltage available. •

Battery disconnector, must be in position 1.

•

Battery voltage, should be 22–30 V.

•

Fuses, check that they are intact.

Check that all oil and fluid levels are normal. •

Fuel

•

Engine oil

•

Transmission oil

•

Hydraulic oil

•

Coolant

•

Washer fluid

3

Check if there are error codes.

4

If there are error codes, use the error code lists as a guide. See Troubleshooting with an error code, example, page 0:6. The error code lists contain recommended actions for every error code. Error code lists are available in section D Error codes.

5

If there is no error code or the problem persists, use the function description for the function affected in section 0–12. The function description contains information on which components are involved in the function and how these components work together. In some cases, there is information on what conditions are required in order for it to be possible to activate the function. Measurement points are marked with flags (C for measuring outlet, D for diagnostic menu).

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0:5

Troubleshooting without an error code, example 1

Choose suitable section 0–12 to locate the function and subfunction that have caused the symptom.

2

Read the function description for the function in question to get an overall understanding of which components are affected and how these interact.

3

Use the function description and check the signals for the function affected in order to locate where in the function chain that the signal or reaction is incorrect.

4

The fault is probably between the two units where the signal is incorrect. Start by checking the component that should be sending the signal.

5

If the component that is to send the signal seems to be intact, check the transmission of the signal (electric cables or hydraulic hoses). For electric cables, see Troubleshooting cable harnesses, page 0:8. For hydraulic hoses, see Troubleshooting hydraulic hoses, page 0:9.

6

If the cables or hoses between the components seem to be intact, then check the component that receives the signal.


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0:6


Troubleshooting with an error code, example Error codes are indicators of malfunctions detected by the control system. Many error codes are connected to electrical malfunctions but there are also error codes that interpret associations between one or several signals that indicate a non-electrical malfunction. It is important to not draw conclusions too hastily based on an error code. 1 Read out error codes from the display, e.g. error code 34. 2

Use the error code lists and search information about the error code, see "Example of error code information in error code list" below. The error code lists are available in section D Error codes. For detailed instructions for reading out error code, see section D Error codes.

3

Follow the instructions in the field "Action".

4

Use diagnostic menus and circuit diagrams to determine if the input signal to the control unit is correct; see section 8 Control system, group 8.4 Diagnostics as well as section E Schematics.

5

Use the function group to find more information if needed. In section 0–12 there is function description, the function's included components and their position as well as, in certain cases, work instructions for how components are checked, cleaned or adjusted.

6

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

7

If the component's measurement values are correct, continue by troubleshooting electric cables and hydraulic hoses. For electric cables, see Troubleshooting cable harnesses, page 0:8. For hydraulic hoses, see Troubleshooting hydraulic hoses, page 0:9.

8

If the wiring is not defective, then connect the cable to the control unit.

NOTE The system voltage must be switched off with the battery disconnector! 9

Disconnect the cable harness from the component in question.

10 Switch on the system voltage with the battery disconnector. 11 Turn the ignition key to operating position. 12 Check that voltage reaches the component.

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0:7

Table Example of error code information in error code list

Code 34

Description

Limitation

Action

Signal error from parking brake switch, indicates released and applied at same time or nothing at all.

Parking brake cannot be released.

Check cabling between the control unit and the component with diagnostic menu.

Connections and components D791-1/K8:5 S107, K8:13 S107

Diagnostic menu

Function group

HYD, menu 5

4.1.2 Parking brake control

Check component.


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0:8


Troubleshooting cable harnesses NOTE Perform troubleshooting for all cables in the same way to avoid damage to control units, components or measuring equipment. 1

Study the circuit diagram in question, check where the suspected cable is connected and if, and if so where, it is spliced.

2

Turn off the system voltage with the battery disconnector.

3

Unplug the connector at the control unit or component in question.

CAUTION Wipe and re-grease the connectors. Risk of corrosion on contact surfaces. Clean all connectors loosened during troubleshooting using electronic cleaner 923836.0826 and re-grease them with connector grease 923836.0552. 4

Check if there is an open circuit.

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

5

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a.

Measure resistance between connections to the component in the connector at the control unit or component.

b.

The resistance must correspond with the component. Otherwise there may be an open circuit or short circuit in cable harness and/or component.

Check if there is a short circuit to the frame: a.

Unplug the connector at both the control unit and the component in question.

b.

Measure the resistance in one cable at a time. Measure between the cable and a frame-connected part of the machine.

c.

The multimeter should show infinite resistance.



0:9

Troubleshooting hydraulic hoses

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

Depressurise the hydraulic and brake systems, see section B Safety.

2

Study the hydraulic diagram in question, check between which components the suspect hose is connected and if, and if so where, it is spliced.

3

Locate the hose on the machine. Start at one component and follow the hose to the next component.

4

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


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0:10

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1:1

1 Engine

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


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1:2

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1 Engine – Engine

1:3

1 Engine Engine, general Engine alternative The machine can be equipped with one of the following engine alternatives: •

Yuchai YC6A240-30 (stage III in accordance with directive 2006/42 EC)

•

Cummins QSB6.7 97/68/EC)

(stage III in accordance with directive

If there are differences between engine alternatives, this is written in brackets after headings or under figures in order to clarify what is being shown.

Component supplier documentation The workshop manual only describes components and work descriptions that concern installation in the machine. For descriptions and instructions for the engine's components and systems, refer to the relevant supplier documentation. References to supplier documentation are only provided in exceptional cases. If information about a component is not found, the component supplier documentation should be used.


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1:4

1 Engine – Engine

Engine alternative Yuchai YC6A240-30, functional description rpm kph

˚C .

0

bar

I

P

II III

1, 6

11 D11

D1 5, 7, 19

D6 D790-2

D795

D790-1 2, 12, 23

D797-1

18, 22

4, 8, 17, 21 D20 D8

3, 13, 16, 24 D794

20

D3 H2O

H2O

15

14

M

9

015015

10

SENSORS Pos

Explanation

Signal description

Reference

1

The ignition key lock sends a voltage signal to Control unit, cab (D790-1) when the ignition key is turned to position 1.

U = 24 V

Ignition key lock, description, page 1:20

2

Control unit, cab (D790-1) sends Ignition on over the CAN bus.

Checked by control system, error shown with error code.

Section 11 Common electrics, group 11.5.3.1 Control unit, cab

3

When required, the Control unit, engine (D794) activates the preheating coil. Status signal is also sent to Control unit, frame (D797-1).

U = 24 V

Section 11 Common electrics, group Frame control unit (D797-1)

4

Control unit, frame (D797-1) sends preheating active on the CAN bus.


D3: Diagnostic menu, see section 8 Control system, group 8.4.6.5 ENGINE menu 5

5

Control unit KIT (D790-2) activates indicator light, preheating.

-

Section 11 Common electrics, group 11.5.3.11 Control unit, KIT

6

The ignition key lock sends a voltage signal to Control unit KIT (D790-2) when the ignition key is turned to start position.

U = 24 V


7

Control unit KIT (D790-2) sends a start signal on the CAN bus.



8

Control unit, frame (D797-1) supplies voltage to Relay, starter motor (K360) on the starter motor.

U = 24 V

Section 11 Common electrics, group 11.5.3.2 Frame control unit

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D1: Diagnostic menu, see section 8 Control system, group 8.4.1.5 CAN/POWER, menu 5 and 8.4.6.4 ENGINE, menu 4





1 Engine – Engine

1:5

Pos

Explanation

Signal description

Reference

9

The starter motor cranks the engine.

-

Starter motor, description, page 1:31 D8: Diagnostic menu, see section 8 Control system, group 8.4.6.5 ENGINE menu 5

10

The engine's sensor sends signals to Control unit, engine (D794) that controls the injectors so the engine starts.


Section 11 Common electrics, group 11.5.3.10 Control unit, engine

11

The accelerator pedal sends a voltage signal proportional the depression to Control unit, cab (D790-1).

U = 0.5-4.5 V

Section 9 Frame, body, cab and accessories, group 9.1 Controls and instruments

Lower voltage than 0.5 V and higher voltage than 4.5 V is used to detect faults in cable harnesses and controls.


12

Control unit, cab (D790-1) sends a message with the rpm request on the CAN bus.



13

Control unit, engine (D794) increases the engine speed.

-


14

Make-contact (closing switch) coolant level sends a voltage signal to Control unit frame front (D797-F) if the coolant level is low in the expansion tank.

Low level: U = 24 V

Cooling system, description, page 1:25

15

Make-contact (closing switch) water in fuel (B760) sends a ground signal to Control unit, engine (D794) if there is too much water in the fuel prefilter. Control unit, frame (D797-1) is used to supply voltage for the signal.

Water in fuel: U = 0 V

Make-contact (closing switch) water in fuel, description (engine alternative Yuchai YC6A240-30), page 1:22

16

Control unit, engine (D794) sends engine data and warning messages on the CAN bus.



17

Control unit, frame (D797-1) sends lamp information on the CAN bus.



18

Control unit KID (D795) shows engine data via display figures.

-

Section 11 Common electrics, group 11.5.3.12 Control unit, KID

19

Control unit KIT (D790-2) activates warning lamps when necessary.

-


20

Sensor fuel level (B757) sends a voltage signal proportional to the fuel level in the tank to Control unit, frame rear (D797-R).

U = 0.5-4.5 V

Sensor, fuel level, description, page 1:22

Lower voltage than 0.5 V and higher voltage than 4.5 V is used to detect faults in cable harnesses and controls.

D20: Diagnostic menu, see section 8 Control system, group 8.4.3.7 CAB, menu 7

D14: Diagnostic menu, see section 8 Control system, group 8.4.6.6 ENGINE, menu 6, 8.4.6.7 ENGINE, menu 7, 8.4.6.8 ENGINE, menu 8, 8.4.6.9 ENGINE, menu 9 and 8.4.6.10 ENGINE, menu 10

21

The frame control unit (D797-1) transmits fuel level on the CAN bus.



22

Control unit KID (D795) shows the fuel level in the operating menu for the engine.

-



VDCT01.02GB

1:6

1 Engine – Engine

Pos

Explanation

Signal description

Reference

23

If the rotation speed of the output shaft is so high that it corresponds with the limit for the machine's speed limitation then Control unit, cab (D790-1) sends reduce engine speed on the CAN bus.



24

Control unit, engine (D794) limits the engine speed.

-


VDCT01.02GB


1 Engine – Engine

1:7

Engine alternative Cummins QSB6.7 function description

,

°C .

rpm kph

0 I

P

bar

II III

10

D5

1,5

<°

D10

D1

D14 3, 12, 14, 20

D794

D790-1

17 D12

D11

11, 19

2,6 D790-2

D797-1

D795

15, 18

D7 D16

D4

H2O

SENSORS

4

D8

13

16

8

015016

9 7

M

Pos

Explanation

Signal description

Reference

1

The ignition key lock sends a voltage signal to Control unit, cab (D790-1) when the ignition key is turned to position 1 or preheating mode.

U = 24 V


2

Cab control unit (D790-2) sends ignition on over the CAN bus. If the key is turned to the preheating mode, then preheating is also sent on the CAN bus.



3

If preheating has been activated with the start key or automatically, then the engine control unit (D794) feeds voltage to the preheating relay and through this also the preheating coil (E800).

U = 24 V


4

The preheating coil heats the primary air to the engine.

-


5

The ignition key lock sends a voltage signal to Control unit KIT (D790-2) when the ignition key is turned to start position.

U = 24 V


Control unit KIT (D790-2) sends a start signal on the CAN bus.

-

6

D1: Diagnostic menu, see section 8 Control system, group 8.4.1.5 CAN/POWER, menu 5 and 8.4.6.4 ENGINE, menu 4




VDCT01.02GB

1:8

1 Engine – Engine

Pos

Explanation

Signal description

Reference

7

The starter motor is controlled by the engine control unit (D794) through starter relays and receives signals from the cab control unit KCU (D790-1) over the CAN bus.

U = 24 V

Starter motor, description, page 1:31

The starter motor cranks the engine.

-

8


Starter motor, description, page 1:31 D8: Diagnostic menu, see section 8 Control system, group 8.4.6.5 ENGINE menu 5

9

The engine's sensor sends signals to Control unit, engine (D794) that controls the injectors so the engine starts.

-


10

The accelerator pedal sends a voltage signal proportional the depression to Control unit, cab (D790-1).

U = 0.2-4.8 V

Accelerator pedal, replacement, page 1:20

Lower voltage than 0.2 V and higher voltage than 4.8 V is used to detect malfunction in cable harnesses and controls.


Control unit, cab (D790-1) sends a message with the rpm request on the CAN bus.




-

11

12

D11: Diagnostic menu, see section 8 Control system, group 8.4.6.1 ENGINE menu 1 Section 11 Common electrics, group 11.5.3.10 Control unit, engine D11: Diagnostic menu, see section 8 Control system, group 8.4.6.1 ENGINE menu 1

13

Make-contact (closing switch) coolant level sends a voltage signal to Control unit, engine (D794) if the coolant level is low in the expansion tank.

U = 24 V

Cooling system, description, page 1:25

14

Control unit, engine (D794) sends engine data and warning messages on the CAN bus.



15

Control unit KID (D795) shows engine data via display figures.

-


16

Sensor fuel level (B757) sends a voltage signal proportional to the fuel level in the tank to Control unit, frame (D797-1).

D14: Diagnostic menu, see section 8 Control system, group 8.4.6.6 ENGINE, menu 6, 8.4.6.7 ENGINE, menu 7, 8.4.6.8 ENGINE, menu 8 and 8.4.6.9 ENGINE, menu 9

R = 0-70 ohm

Sensor, fuel level, description, page 1:22

A warning message appears on the display if the amount of fuel in the tank is less than 15% for more than 40 seconds.


17

The frame control unit (D797-1) transmits fuel level on the CAN bus.



18

Control unit KID (D795) shows the fuel level and the machine speed in the operating menu for the engine.

-


VDCT01.02GB


1 Engine – Engine

1:9

Pos

Explanation

Signal description

Reference

19

If the rotation speed of the output shaft is so high that it corresponds with the limit for the machine's speed limitation then Control unit, cab (D790-1) sends reduce engine speed on the CAN bus.



20

Control unit, engine (D794) limits the engine speed.

-


Engine alternative Yuchai YC6A240-30, component placement 2

1

3 4 14 13

5

12

6

8 9

014622

11

10

7

Engine alternative Yuchai YC6A240-30, left-hand side (in the machine's direction of travel) 1.

Make-contact (closing switch), low coolant level (B759)

2.

Expansion tank

3.

Thermostat housing

4.

Connection radiator outlet

5.

Coolant pump

6.

Connection cab heating

7.

Drain radiator

8.

Connection radiator inlet

9.

Oil filter

10. Relay, starter motor (K360) 11. Starter motor (M654) 12. Connection exhaust system 13. Turbocharger 14. Air cleaner connection


VDCT01.02GB

1:10

1 Engine – Engine

1 2 3 4 5

10

8

7

6

Engine alternative Yuchai YC6A240-30, right-hand side (in the machine's direction of travel) 1.

Filling point engine oil

6.

Control unit, engine (D794)

2.

Connection intercooler

7.

Fuel filter

3.

Relay preheating (K312)

8.

Connection intercooler

4.

Preheating coil (E8000)

9.

Fuel pump

5.

Oil dipstick engine

10. Alternator

VDCT01.02GB


014641

9

1 Engine – Engine

1:11

Engine alternative Cummins QSB6.7, component placement 4 3 2 5

1

6

10

7

015097

8 9 Engine alternative Cummins QSB6.7, left side (in machine's direction of travel) 1.

Oil dipstick engine

6.

Connections cab heating

2.


7.

Coolant inlet

3.

Outlet exhaust system

8.

Oil filter

4.

Outlet coolant to radiator

9.

Starter motor

5.

Alternator

10. Crankcase ventilation


VDCT01.02GB

1:12

1 Engine – Engine

6 5 4

3 2 1

14

13

12

7 8 9 015096

11 10 Engine alternative Cummins QSB6.7, right side (in machine's direction of travel) 1.

Alternator

8.

Air inlet

2.

Outlet coolant to radiator

9.

Engine control unit (D794)

3.

Turbo air inlet

10. Drain engine oil

4.

Turbo air outlet

11. Vibration damper (rubber)

5.

Oil dipstick engine

12. Fan drive

6.


13. Water pump

7.

Fuel filter

14. Drive belt tensioner

VDCT01.02GB


1 Engine – Engine

1:13

Components on the machine, component placement 1

2

0 P

3

I

5

4

II III

6

12

11

10

9

014697

7

8

1.

Accelerator pedal (B690)

7.

Control unit, transmission (D793)

2.

Ignition key lock (S150)

8.

Fuel tank

3.

Control unit KIT (D790-2)

9.

Sensor fuel level (B757)

4.

Control unit, KID (D795)

10. Control unit, frame front (D797-1)

5.

Control unit, cab (D790-1)

11. Water in fuel sensor (B760)

6.

Diagnostic socket drive-train

12. Fuel pre-filter


VDCT01.02GB

1:14

1 Engine – Engine

Engine and transmission, separation (engine alternative Yuchai YC6A240-30) Separation 1

Machine in service position, see section B Safety.

2

Attach hoisting equipment to the engine.

3

Disconnect the requisite hoses and cables before separating engine and transmission.

NOTE Drain and collect liquids before detaching hoses.

VDCT01.02GB

4

Use a jack to secure the transmission.

5

Remove the cover washer on the clutch housing so that the flex plate's attaching bolts are accessible.


1 Engine – Engine

1:15

6

Remove the cover washer.

7

Rotate the engine so that the bolts in the flex plate can be removed.

8

Remove the screws for the flex plate. The flex plate has eight fastening points against for the flywheel on the engine.

9

Take up the slack in the hoisting equipment.

NOTE Do not lift the engine. 10 Remove the bolts between engine and transmission. 11 Loosen the engine and transmission brackets. 12 Withdraw the engine rearwards to separate it from the transmission.

Assembly 13 Rotate the engine so that the holes in the flywheel are just in front of the attachment points on the flex plate. The flex plate has eight fastening points against for the flywheel on the engine. 14 Fit the bolts to the engine mounts and transmission brackets. Tighten to a torque of: Engine mount, 330 Nm. Transmission bracket, 280 Nm. 15 Connect the engine to the transmission. 16 Fit the bolts between engine and transmission. Tighten to a torque of: M12: 100–120 Nm. M14: 140–160 Nm. 17 Fit the flex plate's attaching bolts. Tighten to a torque of 40 Nm.

NOTE The engine must be loosened from the engine mounts and separated from the transmission to remove a dropped bolt. Secure the bolt in the socket when installing. 18 Fit the cover plate in front of the flywheel.


VDCT01.02GB

1:16

1 Engine – Engine

19 Fit the cover plate on the clutch housing. 20 Remove the hoisting equipment from the engine. 21 Remove the jack from underneath the transmission. 22 Connect the requisite hoses and cables for the engine and transmission. Check and fill fluids as required.

VDCT01.02GB


1 Engine – Engine

1:17

Engine, replacement (engine alternative Cummins QSB6.7 ) Separation 1


2

Attach hoisting equipment to the engine.

3

Disconnect the requisite hoses and cables before separating engine and transmission. If the engine is replaced the cooling unit must be removed.

NOTE 009088

Drain and collect liquids before detaching hoses. Remove the radiator.

5

Use a jack to secure the transmission.

6

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

7

Remove the screws in the flex plate through the hole under the cover plug.

008314

4

NOTE Turn the engine over to access each screw on the flex plate. 8

Take up the slack in the hoisting equipment.

008315

NOTE Do not lift the engine or transmission.


VDCT01.02GB

1:18

1 Engine – Engine

9

Remove the bolts between the engine and the transmission.

10 Remove the screws in the engine brackets. 11 Carefully detach the transmission from the engine. 12 Withdraw the engine rearwards to separate it from the transmission. 008275

13 Lift the engine away.

Assembly 14 Move the engine mount to the new engine. Tighten to a torque of 115 Nm (oiled screw).

NOTE Beware of balance before the engine is lifted.

NOTE If the flex plates are damaged during engine replacement, they must be replaced.

008301

15 Apply lubricating grease to the converter connection - both on the engine and the transmission.

007769

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

Transmission guide stud

VDCT01.02GB


1 Engine – Engine

1:19

17 Lift the engine into place. Guide the stud through the flywheel and out through the hole in the flywheel housing. 18 Install the screws which fix the transmission and engine, but do not tighten the screws fully. Leave about a millimetre between the engine and transmission to facilitate installation of the screws for the flex plate/flywheel.

008319

19 Remove the stud through the hole in the flywheel housing.

20 Fit the screws that secure the flex plate by the flywheel in two steps. The first step without tightening the screws, then rotate the flywheel a further turn. Tighten to a torque of 35 Nm (oiled screw).

NOTE 008315

Turn the engine over to access each screw on the flex plate.

NOTE The engine must be loosened from the engine mounts and separated from the transmission to remove a dropped bolt. Secure the bolt in the socket when installing. 21 Fit the bolts that secure the transmission and engine.

008275

Tighten to a torque of 52 Nm (oiled screw).

22 Measure and check that the engine is centred in the frame. 23 Fit the screws in the engine bracket. Tighten to a torque of 169 Nm (oiled screw). 24 Fit the cover plug in front of the flywheel. 25 Remove the hoisting equipment from the engine. 26 Remove the jack from underneath the transmission.

007796

27 Connect the requisite components, hoses and cables for the engine and transmission. Check and fill fluids as required. 28 Bleed air from the engine's fuel system before starting.


VDCT01.02GB

1:20

1 Engine – Controls and instruments

1.1 Controls and instruments 1.1.1 Ignition Ignition key lock, description P

No function.

0

Stop position. Everything switched off, the key can be removed.

I

Operating position. Voltage to all electrical functions. The control units for engine and transmission are now ready to be started. The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.1.4 CAN/POWER, menu 4.

II

Preheating position. The preheating is controlled automatically by the Engine control unit (D794).

III

Start position. Engagement of starter motor for engine start.

0 P

NOTE

I

The machine is equipped with an electric restart interlock, which prevents engagement of the starter motor when the engine is rotating.

II

000317

III

Condition for starter motor to engage is that the transmission is in neutral position and that the engine isn't already running. The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.6.4 ENGINE, menu 4.

1.1.2 Accelerator Accelerator pedal, replacement

1.

Brake pedal

2.

Accelerator

1


2

Pull one edge of the cover away to facilitate access to the accelerator pedal.

3

Disconnect the cable harness from the connector.

4

Unscrew the connector from the accelerator pedal.

5

Replace the accelerator pedal.

6

Fit in the reverse order.

7

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

Accelerator pedal, calibration See section 8 Control system, group 8.5.2.3 Calibrate DRIVE-TRAIN. VDCT01.02GB


1 Engine – Fuel system

1:21

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

1.2.1 Fuel tank Fuel tank, description The fuel tank is located on the left-hand side of the machine.

3 2

015051

1

1.

Sensor fuel level

2.

Filling point fuel

3.

Fuel tank


VDCT01.02GB

1:22

1 Engine – Sensor fuel level

1.2.2 Sensor fuel level Sensor, fuel level, description Fuel tank sensor (B757) is placed on the front of the fuel tank.

3

Sensor fuel level (B757) sends a voltage signal proportional to the fuel level in the tank to Control unit, frame (D797-1). The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.3.7 CAB, menu 7.

2

015051

1

1.

Sensor fuel level

2.

Filling point fuel

3.

Fuel tank

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

014134

Make-contact (closing switch) water in fuel (B760) sends a ground signal to Control unit, Engine (D794) when the filter should be drained. The contact voltage is fed in parallel on the signal line of Control unit (D797-F) across a resistor (a so-called "pull up" voltage).

Make-contact (closing switch) water in fuel, (engine alternative Yuchai YC6A240-30)

VDCT01.02GB


1 Engine – Air intake and exhaust outlet

1:23

1.6 Air intake and exhaust outlet 1.6.1 Air cleaning system Air cleaning system, description The air cleaning system consists of an air cleaner with filter, filter indicator, pipes and hoses. There are two filters in the air cleaner that purify the air and a dust reservoir that collects larger particles. The dust reservoir can be emptied without opening the air cleaner.

2 3

008040

1

Air cleaning system, overview 1.

Dust reservoir

2.

Air cleaner

3.

Filter indicator

Combustion in the engine requires air. Free unobstructed flow for fresh air and exhaust gases is essential for efficient engine operation. Particles are collected in the filter material when the air filters clean the air to the engine. Over time, a great deal of particle matter is collected and the filter does not let through sufficient air for efficient combustion, the filter must then be changed. The filter indicator measures the negative pressure on the engine side of the filter. When the filter is clogged the negative pressure is higher and the indicator indicates that it is time to replace the filter. As an option the machine can be equipped with a raised air intake.

1.6.3 Exhaust system Exhaust system, description The exhaust system is mounted in the chassis. Heat protection is fitted between the engine and exhaust system to protect cables, etc. A flex pipe between the turbo and silencer takes up engine movement. On the outside of the machine, there is heat protection fitted over the exhaust system.

1

WARNING Hot exhaust system! Risk of burn injuries! Never touch the turbo, silencer or catalytic converters when the machine is running or just after it has been turned off!

3

014700

2

1.

End pipe

2.

Silencer

3.

Exhaust pipe


VDCT01.02GB

1:24

1 Engine – Intercooler

1.6.4 Intercooler Intercooler, description The charge air is cooled by an air-air intercooler in the upper part of the cooling unit. See also Cooling system, description, page 1:25.

1 2 4

014686

3

1.

Intercooler

2.

Transmission oil cooler

3.

Radiator

4.

Condenser AC

VDCT01.02GB


1 Engine – Cooling system

1:25

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

Coolant pump

•

Expansion tank

•

Thermostat

•

Cooling fan

•

Radiator

•

Engine oil cooler

•

Intercooler

Engine cooling work as follows: 1.

Coolant is circulated through the cylinder head, engine block and oil cooler by the coolant pump.

2.

The thermostat directs the heated coolant back to the coolant pump or through the radiator.

3.

The cooling fan blows air through the radiator.

4.

When the coolant is colder than the thermostat opening temperature the thermostat directs it back through the engine. When the coolant is warmer than the thermostat opening temperature the thermostat directs it through the radiator and then back to the coolant pump.

5.

The expansion tank allows the coolant to expand without escaping from the engine.

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

1 2 4

•

Engine coolant.

•

Transmission oil (cooled in its own part of the cooling unit), see also section 2 Transmission, group 2.6.3 Oil cooler.

•

Charge air (cooled in the upper part of the cooler unit), see also Intercooler, description, page 1:24.

See also Cooling system, description, page 1:25.

3

014686

For more information, see supplier documentation, engine.

1.

Intercooler

2.


3.

Radiator

4.

Condenser AC


VDCT01.02GB

1:26

1 Engine – Cooling fan

1.7.5 Cooling fan Cooling fan, description The cooling fan is located on the engine water pump at the rear of the engine. The fan is powered by the engine via the drive belts and pushes cooling air through the cooling unit.

1.7.7 Coolant Coolant, changing (engine alternative Yuchai YC6A240-30)

NOTE Read the safety instructions for coolant before starting work, see section B Safety. 1


2

Open the hood.

3

Remove the cap on the expansion tank.

4

Place a receptacle under the radiator and engine. (The cooling system holds about 40 l.)

5

Drain the cooling system.

014698

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

Drain cock coolant radiator. 6

Connect a hose to the drain cock on the engine and route the other end to the receptacle.

7

Open the drain cock on the engine.

8

Once all the coolant has drained out, close drain cocks.

Drain cock coolant engine, the illustration shows the tap closed.

VDCT01.02GB


1 Engine – Coolant

9

1:27

Fill the new premixed coolant of the correct type in the expansion tank. For volume and quality, see section F Technical data.

A

CAUTION Different types of coolant may not be mixed. Risk of engine damage and damage to the cooling system if different types of coolant are mixed. When changing and topping up coolant, the same type of coolant must be used as was used before.

B 10 Switch on the system voltage and start the engine. 11 Set cab heating to max.

014191

12 Run the engine to operating temperature so the thermostat opens and coolant is pumped around the whole system. Do not operate the machine.

C A

Position for coolant reservoir (expansion tank)

B

Filling point

C

Sight glass, level check

13 Check the level in the expansion tank, fill if necessary. 14 Close the hood. 15 Check the coolant level again after 10 operating hours.


VDCT01.02GB

1:28


Coolant, replacement (engine alternative Cummins QSB6.7 )

NOTE Read the safety instructions for coolant before starting work, see section B Safety. 1


2

Open the hood.

3

Remove the cap on the expansion tank.

4

Place a receptacle under the radiator and engine. (The cooling system holds about 40 l.)

5

Drain the cooling system.

014698

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

Open the drain on the engine.

7

Once all the coolant has drained out, close drain cocks.

015538

6

Drain point coolant.

VDCT01.02GB



8

1:29

Fill the new premixed coolant of the correct type in the expansion tank. For volume and quality, see section F Technical data.

A


B 9

Switch on the system voltage and start the engine.

10 Set cab heating to max. 11 Run the engine to operating temperature so the thermostat opens and coolant is pumped around the whole system.

014191

12 Check the level in the expansion tank, fill if necessary.

C 1.

Position for coolant reservoir (expansion tank)

2.

Filling point

3.

Sight glass, level check

13 Close the hood. 14 Check the coolant level again after 10 operating hours.


VDCT01.02GB

1:30

1 Engine – Control system, engine

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

VDCT01.02GB


1 Engine – Start/stop

1:31

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

1.11.2 Stopping device Stopping device, description The engines have electrically regulated injectors that stop delivering fuel when the voltage is cut off, which means that the engine stops. The engine can only be stopped by turning off the ignition via the ignition key lock.

NOTE The battery disconnector must not be used for emergency stop! For more information, see supplier documentation, engine. Automatic engine shutdown is available as an option. This means that the engine shuts off automatically after 3-30 minutes (depending on customer setting) if the machine is stationary at idle.


VDCT01.02GB

1:32

VDCT01.02GB


2:1

2 Transmission

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


VDCT01.02GB

2:2

VDCT01.02GB


2 Transmission – Transmission

2:3

2 Transmission Transmission, general Component supplier documentation The workshop manual only describes components and work descriptions that concern installation in the machine. For descriptions and instructions for the transmission's components and systems, refer to the relevant supplier documentation. References to supplier documentation are only provided in exceptional cases. If information about a component is not found, the component supplier documentation should be used.

Transmission, function description

F R

1 23

5

D 23 6,24

D 1

D 1

D 5

D 7 9 0 -1

D 7 9 0 -2

D 793

D 794

11,17,19,21,27

2,7

D 795 D 7 9 7 -F

22

20

26

D 10 D 12

D 8

8 P a

D 9

9

D 25

10

P a

25 4

16 15

3

14

18 013852

13 12 Pos

Explanation

Signal description

Reference

1

The gear selector sends a voltage signal to Control unit KIT (D790-2).

Forward, Conn. F: U = 24 V


Reverse, Conn. R: U = 24 V

D1: Diagnostic menu, see section 8 Control system, group 8.4.7.2, TRANSM menu 2 2

3

Control unit KIT (D790-2) transmits the selected direction of travel (forward or reverse) on the CAN bus.


The transmission's oil pump pumps oil when the engine is running.

-

Section 11 Common electrics, group 11.5.3.11 Control unit, KIT D1: Diagnostic menu, see section 8 Control system, group 8.4.7.2, TRANSM menu 2


-

VDCT01.02GB

2:4


Pos

Explanation

Signal description

Reference

4

The transmission's oil filter cleans the oil from impurities.

-

-

5

The accelerator pedal transmits a signal to Control unit, cab (D790-1).

U = 0.5-4.5 V

Section 1 Engine, group 1.1.2 Accelerator pedal D5: Diagnostic menu, see section 8 Control system, group 8.4.6.1 ENGINE menu 1

6

Control unit, cab (D790-1) transmits the desired throttle application on the CAN bus.



7

Control unit KIT (D790-2) sends the selected shifting program on the CAN bus.



8

Sensor, oil pressure transmission (B765) sends a voltage signal proportional to the oil pressure to Control unit, transmission (D793).

Checked by Control unit, transmission, error shown with error code.

Transmission, component location, page 2:8

9

Sensor, turbine speed (B751) sends Control unit, transmission (D793) a pulse signal with frequency proportional to turbine speed.



10

Sensor, oil temperature (B766) sends a voltage signal proportional to the transmission oil temperature to Control unit, transmission (D793).



11

Control unit, transmission (D793) supplies voltage to the solenoid and servo valves in order to obtain the desired function.


Section 11 Common electrics, group 11.5.3.9 Control unit, transmission

12

Solenoid valve clutch forward, (Y630) or Solenoid valve clutch reverse (Y631) is activated to select direction of travel. Solenoid valve clutch gear 1 (Y6067-1), or Solenoid valve clutch gear 2 (Y6069).



13 14 15 16

See also, Actuated valves in selected gear, page 2:5

Engine power is transferred to the transmission's output shaft.

17

Control unit, transmission (D793) controls gear shifting according to selected shifting program.



18

The oil cooler cools the transmission oil. A thermostat senses the oil's temperature and directs the oil back to the transmission if the oil is cold.

-

Oil cooler, description, page 2:17

19

Control unit, transmission (D793) transmits temperature and speed data on the CAN bus.



20

Control unit KID (D795) shows transmission information in operating menus.



21

Sensor, turbine speed (B751) indicates that the machine's speed exceeds the speed limit, sends Control unit, transmission (D793) requests for reduced engine speed on the CAN bus.

-


22

Control unit, engine (D794) reduces the engine speed.

-

Section11 Common electrics, group 11.5.3.10 Control unit, engine

VDCT01.02GB



2:5

Pos

Explanation

Signal description

Reference

23

If the declutch pedal (S220-1) is depressed, it sends a voltage signal to Control unit, cab (D790-1).

U = 24 V

Section 9 Frame, body, cab and accessories, group 9.1 Controls and instruments D23: Diagnostic menu, see section 8 Control system, group 8.4.7.1, TRANSM menu 1

24

Control unit, cab (D790-1) transmits declutch drive on the CAN bus.



25

Make-contact (closing switch) declutch (S220-2) sends a voltage signal to Control unit, frame front (D797-F) if the brake pressure is high enough to allow declutch of the drive.

Brake pressure above 0.2 MPa:

Make-contact (closing switch) declutch, description, page 2:18

Conn 1, U = 24 V

D25: Diagnostic menu, see section 8 Control system, group 8.4.7.1, TRANSM menu 1

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

26

Control unit, frame front (D797-F) sends declutch approved on the CAN bus.


Section 11 Common electrics, group 11.5.3.2 Control unit, frame front

27

Control unit, transmission (D793) supplies voltage to valve block transmission control so that drive is declutched.



Table Actuated valves in selected gear

Y6067-1

Y6069

Gear 1

On

On

Gear 2

Off

On

Gear 3

Off

Off


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2:6


Shifting transmission, function description 21 24

Pa

5 25

10

6

23

7 26

14

9 3

17

11 15

4

18

22

1

13

Rev

8

Fwd

12

1st

2nd

16

19

3rd

20

Pos

Explanation

Signal description

Reference

1

Bottom strainer oil sump, separates particles from the oil before the pumps.

-

-

2

The transmission's oil pump feeds the transmission with control pressure for control of the transmission.

30.4 l/min at 685 rpm

-

3

The oil filter cleans the oil.

-

-

4

The bypass valve in the filter bracket leads the oil past the filter if the resistance through the filter becomes too high.

Opening pressure: 410-450 kPa

-

5

The pressure regulator releases pressure to the torque converter if the pressure becomes too high.

Opening pressure: 2200 kPa

-

6

When the reverse direction of travel is selected Solenoid valve, clutch reverse (Y631) is supplied with voltage. The solenoid valve opens and directs pressure to valve slide clutch reverse.

-


7

Valve slide clutch reverse pressurises drive clutch reverse and modulation valve forward.

-

-

8

Drive clutch reverse locks the transmission in reverse drive when the clutch is pressurised.

-

-

9

Modulation valve forward drains the pressure to drive clutch forward at the same rate as the driving clutch reverse is pressurised.

Drive reverse: 2200-2600 kPa

-

10

When the forward direction of travel is selected Solenoid valve, clutch forward (Y630) is supplied with voltage. The solenoid valve opens and directs pressure to valve slide clutch forward.

-


11

Valve slide clutch forward pressurises drive clutch forward and modulation valve reverse.

-

-

12

Drive clutch forward locks the transmission in forward drive when the clutch is pressurised.

-

-

13

Modulation valve reverse drains the pressure to drive clutch reverse at the same rate as the driving clutch forward is pressurised.

Drive reverse: 2200-2600 kPa

-

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014699

2


2:7

Pos

Explanation

Signal description

Reference

14

Solenoid valve gear selection 1 (Y6067-1) pressurises valve slide gear selection 1.

-


15

Valve slide gear selection 1 pressurises drive clutch gear 1 and cuts off the pressure to the gears.

-

-

16

Drive clutch gear 1 locks the transmission in gear position 1 when the clutch is pressurised.

-

-

17

Solenoid valve gear selection 2 (Y6069) pressurises valve slide gear selection 2.

-


18

Valve slide gear selection 1 pressurises drive clutch gear 1 and cuts off the pressure to the gears.

-

-

19

Drive clutch gear 2 locks the transmission in gear position 2 when the clutch is pressurised.

-

-

20

When no solenoid valve is activated, the drive clutch gear 3 is pressurised and locks the transmission in gear 3 when the clutch is pressurised.

-

-

21

Sensor, oil pressure transmission (B765) sends a voltage signal proportional to the oil pressure in the transmission to Control unit, transmission (D793).

-


22

Sensor, oil temperature (B766) sends a voltage signal proportional to the oil temperature to Control unit, transmission (D793).

-


23

The safety valve leads the oil back to the sump if the pressure to the torque converter becomes too high.

Opening pressure: 900 kPa

-

24

The torque converter transmits the engine's power to the transmission.

-

-

25

The transmission oil cooler cools the oil.

-

-

26

The oil is distributed to different lubrication points in the transmission.

-

-


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2:8


Transmission, component location

1

2

3

15

4

16 14

5

13

6

17 12 11

10

9

8

1.


10. Valve block transmission control

2.

Oil pump transmission

11. Return from the transmission oil cooler

3.

Oil filter transmission

12. Breather filter transmission

4.

Sensor turbine speed (B751)

13. Outlet to transmission oil cooler

5.

Solenoid valve clutch reverse (Y631)

14. Sensor oil temperature (B766)

6.

Solenoid valve clutch gear 1 (Y6067-1)

15. Thermostat

7.

Drain plug and strainer transmission oil

16. Sensor, oil pressure transmission (B765)

8.

Solenoid valve clutch gear 2 (Y6069)

17. Output shaft

9.

Solenoid clutch forward (Y630)

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014685

7

2 Transmission – Controls and instruments

1

2

3

2:9

4

5

11 6

10 7

014694

9 8 1.

Accelerator pedal (B690)

7.

Fuse transmission (F51-3)

2.


8.


3.


9.

Declutch pedal (S220-1)

4.

Multi-function lever (S162)

10. Make-contact (closing switch) declutch (S220-2)

5.


11. Frame control unit (D797-1)

6.

Diagnostic socket drive-train

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

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

F - Forward

•

N - Neutral

•

R - Reverse

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


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2:10

2 Transmission – Torque converter/Clutch system

2.2 Torque converter/Clutch system 2.2.1 Flex plates Flex plates, replacement (engine alternative Yuchai YC6M360-30) For further details about separating the motor and transmission, see section 1 Engine, group 1 Engine and transmission, separating. 1 Machine in service position, see section B Safety. 2

Remove the cover plate.

3

Remove the cover plate and rotate the engine so that each bolt to the flex plate can be removed.

4

Remove the screws for the flex plate.

5

Attach the transmission to an overhead crane.

6

Remove the bolts holding together the transmission and engine.

7

Carefully separate the transmission and engine.

8

Remove the bolts holding the flex plate to the transmission.

9

Replace the flex plate. Tighten the screws fixing the flex plate to the transmission to 40 Nm (oiled screws).

10 Apply lubricating grease to the converter connection - both on the engine and the gearbox. Insert a stud into one of the nuts on the flexible plate as a guide when the engine is installed. 11 Place the screws that secure the gearbox and engine in position without tightening the bolts. 12 Remove the stud and replace the screws that secure the flex plate to the flywheel in two steps. The first step fit the screws without tightening them. Now rotate the flywheel a further turn and tighten the screws with a torque of 35 Nm (oiled screws). 13 Fit the screws that fasten the gearbox and engine and tighten them to 52 Nm (oiled screw). Flex plate attachment.

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2 Transmission – Flex plates

2:11

Flex plates, replacement (engine alternative Cummins QSB6.7 ) For further details about separating the motor and transmission, see section 1 Engine, group 1 Engine and transmission, separating. 1 Machine in service position, see section B Safety. 2

Remove the cover plate.

3

Remove the screws for the flex plate. Rotate the engine for each bolt to the flex plate that has to be removed. Attach the transmission to an overhead crane.

5

Remove the bolts holding together the transmission and engine.

6

Carefully separate the transmission and engine.

7

Remove the bolts holding the flex plate to the transmission.

8

Replace the flex plate. Tighten the screws fixing the flex plate to the transmission to 40 Nm (oiled screws).

9

Apply lubricating grease to the converter connection - both on the engine and the gearbox.

008275

008314

4

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

Flex plate attachment.


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2:12

2 Transmission – Flex plates

10 Place the screws that secure the gearbox and engine in position without tightening the bolts.

008275

11 Remove the stud and replace the screws that secure the flex plate to the flywheel in two steps. The first step fit the screws without tightening them. Now rotate the flywheel a further turn and tighten the screws with a torque of 35 Nm (oiled screws).

NOTE The engine must be loosened from the engine mounts and separated from the transmission to remove a dropped bolt. Secure the bolt in the socket when installing. 12 Fit the screws that fasten the gearbox and engine and tighten them to 52 Nm (oiled screw).

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2 Transmission – Lubrication system

2:13

2.6 Lubrication system Lubrication system, description The transmission lubrication system has the following function: •

Lubricate gear wheels and bearings

•

Apply the clutches in the transmission

•

Cool down the torque converter and the transmission

•

Clean the oil of any impurities with two oil filters.

During operation of the engine, the oil pump draws oil from the transmission's oil sump through a strainer, and it then pumps it through the oil filter to a control valve. The control valve supplies oil at the correct pressure to the transmission's valve housing to activate the clutch plates for FORWARD or REVERSE and gear 1, 2 or 3. The clutch plates require just a small amount of the oil flow supplied by the pump. The remainder of the oil is pumped through the torque converter circuit to the oil cooler and returns to the transmission for lubrication. See also supplier documentation, transmission.

Oil and oil filter, changing

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

NOTE The transmission must not be over-filled! 1

Operate and warm up the transmission oil.

2


3

Remove the drain plug (position 2) and and let the oil drain into the receptacle.

1 4

Remove the strainer (position 3) and clean the strainer cloth. If the strainer cloth has caught metal particles, the cause must be investigated before the transmission is filled with new oil.

3 1.

Oil filter holder

2.

Oil plug

3.

Strainer

014693

2

5

Replace the strainer gasket.

6

When the transmission oil has drained out, fit the strainer (position 3) and the drain plug (position 2). Make sure that the washer for the drain plug is included.

7

Remove the filter holder (position 1) and replace the oil filter. Tighten until it makes contact and then another two-thirds of a turn.


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2:14

2 Transmission – Lubrication system

A

8

B

Fill with new transmission oil through the oil filling orifice (position B) to the mark for low level on the dipstick (position A). For volume and quality, see section F Technical data.

9

Start the engine and allow it to idle for at least two minutes.

10 Check that the transmission oil drain plug is sealed.

014193

11 Check the transmission oil level with the engine running at idle and top up to the marking for low level.

A. Oil dipstick transmission oil B. Oil filling transmission oil 12 Operate and warm up the transmission so that the display shows an oil temperature of approx. 85 ºC. Use the oil temperature operating menu to check transmission oil temperature.

a 000356

b

13 Check the oil level. Fill to the MAX mark.

Operating menu, oil temperature a

Transmission oil temperature

b

Hydraulic oil temperature

Oil level, checking

NOTE Read the safety instructions for oil before working, see section B Safety. The transmission's oil filler pipe and dipstick are located under the engine hood in front of the cab.

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2 Transmission – Oil cooler

A

1

B

2:15

Check the oil level with the engine at idle, transmission in neutral position and at operating temperature (approx. 85 ºC in the display). The dipstick has two markings, MAX and MIN. The oil level should be at MAX. Wipe off the oil dipstick before checking.

NOTE The oil dipstick is long. Wear gloves. 2

Fill transmission oil (position B) if required (for volume and grade, see section F Technical data). Fill - wait a moment - check the oil dipstick.

014193

NOTE

A. Oil dipstick transmission oil

Work carefully when filling transmission oil to prevent other fluids or particles from contaminating the oil. Other fluids or particles in the transmission oil means a risk of transmission damage.

B. Oil filling transmission oil

2.6.3 Oil cooler Oil cooler, description The transmission oil is cooled in a section of the cooler unit. A temperature-controlled bypass valve, which only acts on the transmission oil cooling circuit, is located in a pipe on the underside of the cooler (engine side). The valve closes when the oil starts to reach operating temperature. This means that the oil reaches normal operating temperature more quickly.

1

For more information, see supplier documentation, transmission.

2 4

014686

3

1.

Intercooler

2.

Radiator, transmission oil

3.

Radiator, engine

4.

Condenser (for AC)


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2:16

2 Transmission – Oil cooler

Thermostat transmission oil cooler, replacement

NOTE Read the safety instructions for oil before working, see section B Safety. 1


2

Drain the oil from the transmission, see Oil and oil filter, changing, page 2:13.

3

Loosen the cover plug and remove the thermostat.

4

Check the O-ring and the spring in the bottom, replace as necessary.

5

Fit the new thermostat, and the cover plug.

014550

IMPORTANT It is very important that the thermostat is turned with the temperature bulb facing out as shown.

VDCT01.02GB

6

Fill with transmission oil; see Oil and oil filter, changing, page 2:13.

7

Start the engine and check for leaks.

8

Check the transmission oil level, see Oil level, checking, page 2:14.


2 Transmission – Cooling system

2:17

2.7 Cooling system 2.7.3 Oil cooler Oil cooler, description See Oil cooler, description, page 2:15.


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2:18

2 Transmission – Control system, transmission

2.8 Control system, transmission 2.8.1 Transmission control unit Control unit transmission, general See section 11 Common electrics, group 11.5.3.9 Control unit, transmission and supplier documentation, transmission.

2.8.2 NO (normally open) switch, disengagement Make-contact (closing switch) declutch, description Make-contact (closing switch) declutch (S220-2) detects whether the wheel brakes are pressurised. The make-contact (closing switch) is located on the distribution block for the brake system above the drive axle's differential. The sensor can be checked via the diagnostic menu. See section 8 Control system, group 8.4.7.1 TRANSM, menu 1.

1

10

2

1

3 3

4

5 9

6

8

7

009865

5

1.

Connection brake cooling, return from wheel brake

2.

Connection brake cooling, return to radiator and tank

3.

Connection brake cooling, to wheel brake

4.

Connection brake cooling, from accumulator charging valve

5.

Connection brake cylinder, to wheel brake

6.

Connection brake pressure, from brake valve

7.

Make-contact (closing switch), declutch (S220-2)

8.

Make-contact (closing switch), brake light (S216)

9.

Measuring outlet, brake pressure

10. Measuring outlet, back pressure brake cooling

2.8.3 Transmission cable harness Transmission cable harness, description See section E Schematics.

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3:1

3 Power transmission

Contents 3 Power transmission 3 3.2 3.3

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


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3:2

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3 Power transmission – Power transmission

3:3

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

Propeller shaft, replacement 1


2

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

3

Fit the propeller shaft in position with the coupling upward.

4

Fit the propeller shaft's attaching bolts.

005193

Tightening torque: 98 Nm (oiled bolt). Retighten the attaching bolts after 50 operating hours.


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3:4

3 Power transmission – Drive axle

3.3 Drive axle Drive axle, general Component supplier documentation The workshop manual only describes components and work descriptions that concern installation in the machine. For descriptions and instructions for the drive axle's components and systems, refer to the relevant supplier documentation. References to supplier documentation are only provided in exceptional cases. If information about a component is not found, the component supplier documentation should be used.

Drive axle, replacement

DANGER Drive axle and machine are very heavy. Risk of crushing! It is forbidden to go under a machine which has been lifted by a jack etc. For machine weight, see section F Technical data.

VDCT01.02GB

1

Remove the mast, see section 7 Load handling, group 7.2 Lifting/lowering.

2

Park the machine with blocks behind the steering wheels.

3

Depressurise the hydraulic systems, See section B Safety.

4

Turn the start key to position 0 and switch off the main power.

5

Insert wedges between the steering axle and the frame.



6

3:5

Detach the hydraulic hoses (position 1) and cable harness (position 2) from the distribution block.

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

004501

1

2 1. Hydraulic hoses 2. Cables

7

Remove the cover (position 3) on the parking brake.

8

Loosen the lock nut (position 4) and screw in the screw (position 5), this compresses the brake spring. Screw until the brake pads release from the brake disc. Refit the cover on the parking brake (position 3).

9

Detach the hydraulic hose (position 6) from the parking brake.

004505

3

3. Cover, parking brake

6

NOTE 5

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

004506

4

4. Lock nut 5. Release screw 6. Hydraulic hose, parking brake


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3:6


10 Detach the propeller shaft from the drive axle. Secure the propeller shaft, otherwise there is a risk that it will be pulled apart.

Securing the propeller shaft. 11 Lift the machine so that the wheels are off the ground. 12 Remove the drive wheels from the drive axle. 13 Support the drive axle under the hubs.

CAUTION The drive axle may start to roll. Crushing injury! Make sure that the drive axle does not roll away uncontrollably. Lifting machine 14 Remove the bolts that secure the drive axle in the frame. 15 Lift away the drive axle.

CAUTION The drive axle may start to roll. Crushing injury! Make sure that the drive axle does not roll away uncontrollably.

Attaching bolts drive axle

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3:7

16 Undo the hydraulic hoses on the drive axle.

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

17 Transfer the couplings from the old axle to the new axle.

18 Transfer the parking brake union to the new axle.

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


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3:8


21 Clean the contact surfaces on the drive axle and frame. Also clean the bolts' contact surface on the underside of the drive axle. 22 Remove the nuts for attaching the drive axle, blow clean and refit the nuts. 23 Lift the drive axle into place under the frame.

CAUTION The drive axle may start to roll. Crushing injury! Make sure that the drive axle does not roll away uncontrollably. 24 Lower the frame toward the drive axle. 25 Insert the new screws securing the drive axle in the frame. Tighten to 1530 Nm (oiled screw). 26 Install the drive wheels on the new axle. 27 Rustproof the bolts with suitable paint.

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

1

2

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004501

33 Check for leaks.


4:1

4 Brakes

Contents 4 Brakes 4 Brakes..................................................................................................................4:3 4.1 Controls and instruments .................................................................................4:3 4.1.1 Brake pedal .................................................................................................4:3 4.3 Power-assisted brake system ..........................................................................4:5 4.3.1 Hydraulic oil pump.......................................................................................4:6 4.3.2 Brake oil filter ..............................................................................................4:6 4.3.3 Accumulator charging valve ........................................................................4:7 4.3.4 Accumulator ..............................................................................................4:10 4.3.5 Brake valve ...............................................................................................4:14 4.3.6 Drive axle block .........................................................................................4:18 4.3.7 Break contact (opening switch) brake pressure ........................................4:19 4.3.8 Make-contact (closing switch) brake lights................................................4:21 4.3.9 Wheel brakes ............................................................................................4:24 4.3.10 Pipes and hoses........................................................................................4:26 4.3.12 Valve block brake system..........................................................................4:27 4.5 Parking brake system ....................................................................................4:29 4.5.1 Hydraulic oil pump.....................................................................................4:30 4.5.2 Hydraulic oil filter .......................................................................................4:30 4.5.3 Solenoid valve parking brake ....................................................................4:31 4.5.4 Parking brake unit .....................................................................................4:32 4.5.5 Break contact (opening switch) parking brake ..........................................4:36 4.5.6 Pipes and hoses........................................................................................4:36 4.5.7 Valve block brake system..........................................................................4:36


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4:2

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4 Brakes – Brakes

4:3

4 Brakes 4.1 Controls and instruments 4.1.1 Brake pedal Brake pedal, checking and adjustment 1

Clean the floor round the brake pedal and check that nothing is obstructing the movement of the brake pedal.

2

Check that the brake pedal springs back adequately and that the clearance between brake pedal and brake valve is 1-1.5 mm. If necessary, adjust the brake pedal's stop screw to the correct clearance.

3

Check that the pedal moves smoothly.

4

Lubricate the pedal hinge with "EP2" universal grease.

5

Check that the rubber pad on the brake pedal is intact and that the tread pattern is not worn away. Replace if necessary.

6

Check the brake valve; see Brake valve, checking, page 4:14.

Stop screw for adjusting clearance between brake pedal and brake valve. (The illustration shows a loose brake pedal.)

Lubrication points, brake pedal. (The illustration shows a loose brake pedal.)

Brake pedal, replacement


Switch off the engine and switch off the system voltage.

2

Depressurise the brake and hydraulic systems, see section B Safety.

3

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


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4:4

4 Brakes – Brake pedal

4

Remove the panel around the steering wheel shaft.

NOTE There is a variant available with adjustable steering wheel shaft.

5

Detach the steering valve from the pedal assembly. Secure the steering valve on the cab's underside. Remove the steering valve's attaching bolts. Pull down the valve slightly so that the steering axle releases from the steering valve.

6

Detach the steering wheel shaft from the brake pedal. Undo the bolts and pull the steering wheel shaft up slightly so that the brake pedal can be removed.

7

Detach the declutch pedal from the brake pedal.

8

Remove the brake pedal. Remove the brake pedal's attaching bolt and lift away the brake pedal.

9

Transfer the pedal rubber to the new pedal.

10 Fit the new brake pedal.

Mounting of steering wheel shaft and steering valve in pedal assembly.

Fit the pedal and fit the pedal's attaching bolts. 11 Connect the steering valve to the brake pedal. 12 Connect the brake valve to the brake pedal. 13 Fit the clutch pedal to the brake pedal. 14 Close accumulator drain valve.

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

014619

15 Lubricate and adjust the brake pedal, see Brake pedal, checking and adjustment, page 4:3.

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4 Brakes – Power-assisted brake system

4:5

4.3 Power-assisted brake system Power-assisted brake system, function description

14

D790-2

B P

D11

10, 13

D797-1

T

5

C

9 Pa

11 4

D12 2 C

6

D9

C 12 P a ACK M

LB P

P

T

T

3

P

8 7

015034

1

B Pos

Explanation

Signal description

Reference

1

Hydraulic oil pump for the brakes and steering pumps oil from the hydraulic oil tank.

See the pressure plate on the left-hand frame beam.

Hydraulic oil pump, general, page 4:6

2

Valve block accumulator charging and priority valves direct the pressure to the Valve block brakes when the steering does not require hydraulic power.

-

Accumulator charging valve, description, page 4:7

3

Valve block brakes leads the oil on to accumulators and drive axle block.

-

Valve block brake system, description, page 4:27

4

The accumulators store hydraulic oil pressure.


Accumulator, description, page 4:10

5

The brake valve directs pressure from the accumulators to the brake cylinder proportional to the pressure on the pedal.

-

Brake valve, description, page 4:14

6

Drive axle block distributes the brake pressure to the wheel brakes.

-

Drive axle block, description, page 4:18

7

The brake cylinder compresses the discs in the brake unit which stops the machine.


Wheel brakes, description, page 4:24

8

The wheel brakes brake the machine.

-

Wheel brakes, description, page 4:24


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4:6

4 Brakes – Hydraulic oil pump

Pos

Explanation

Signal description

Reference

9

Make-contact (closing switch) brake light (S216) makes the circuit and sends the voltage signal to the Frame control unit (D797-1) when the brake cylinders are pressurised.


Make-contact (closing switch) brake lights, description, page 4:21

Conn. 1, U = 24 V

D8: Diagnostic menu, see section 8 Control system, group 8.4.5.4 HYD, menu 4

Conn. 2, U = 24 V Brake pressure below 0.2 MPa: Conn. 1, U = 24 V Conn. 2, U = 0 V

10

The frame control unit (D797-1) supplies power to the brake light lamps.

Controlled by control system, error shown with error code.


11

Brake light lamps (H411L and H411R) come on.

U = 24 V

Section 9 Frame, body, cab and accessories, group 9.6.4 Brake lights D11: Diagnostic menu, see section 8 Control system, group 8.4.2.8 LIGHTS, menu 8

12

Break contact (opening switch) brake pressure (S204) breaks the circuit and sends the voltage signal to the Frame control unit (D797-1) if the pressure in the accumulators is low.


Brake pressure NC switch, description, page 4:19

Conn. 1, U = 24 V


Conn. 2, U = 24 V Brake pressure below 11.5 MPa: Conn. 1, U = 24 V Conn. 2, U = 0 V

13

The frame control unit (D797-1) transmits a warning about low brake pressure on the CAN bus.



14

Control unit KIT (D790-2) activates Warning lamp brake pressure.



Hydraulic diagram, see section E Schematics, group 10 Common hydraulics, Hydraulic diagram.

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

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

VDCT01.02GB


4 Brakes – Accumulator charging valve

4:7

4.3.3 Accumulator charging valve Accumulator charging valve, description The accumulator charging valve is located in the valve block accumulator charging and priority valve that is part of the main valve, see section 10 Common hydraulics, group 10.5.4 Main valve. The main valve is located on the lifting beam in front of the gearbox in the engine compartment.

1 2 3

The accumulator charging valve distributes the oil from the hydraulic oil pump brakes and steering between pressure storage and cooling of the wheel brakes. The accumulator charging valve stores pressure by directing the oil to the accumulators. The wheel brakes and 4 hydraulic oil are cooled by oil being directed to the drive axle cooling circuit and then on to the hydraulic system cooler. The accumulator charging valve prioritises charging of the

5 accumulators above cooling. A restriction of the charging means that a small quantity of oil also flows to cooling during accumulator charging. At idle the flow from the pump is so small that all oil flows 6 to pressure storage.

13 12 11

10

9

8

015032

7

Valve block accumulator charging and priority valve (a part of the main valve) 1.

Feed from the hydraulic oil pump brake and steering [P]

2.

Adjuster screw control pressure

3.

Return to filter [D]

4.

Measuring outlet control pressure [LSM]

5.

Connection brake cooling [SPOL]

6.

Connection control valve, pilot pressure [LSO]

7.

Feed control valve [O]

8.

Adjuster screw pressure accumulator charging

9.

Measuring outlet servo pressure [PPM]

There are measuring points on the accumulator charging valve for measuring control pressure (position 4), servo pressure (position 9), accumulator charging pressure (position 10) and pump pressure brakes and steering (position 13). The pressure is individual for each machine and can be found on the pressure plate of the left front wing.

10. Measuring outlet accumulator charging pressure [ACC M] 11. Adjusting screw servo pressure 12. Connection valve block brakes, accumulator charging [ACC] 13. Measuring outlet pump pressure brake and steering [PM]


VDCT01.02GB

4:8


Accumulator charging, checking and adjustment


˚C

Operate and warm up the machine so that the oil in the hydraulic system reaches operating temperature, at least 50 ºC.

2


3


4

Connect a pressure gauge (0-25 MPa) to the accumulator charging pressure measuring outlet on the accumulator charging valve.

5

Start the engine and run it at idle.

6

Close accumulator drain valve.

000475

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1

014653

Operating menu, hydraulic oil temperature

014619

Measuring outlet accumulator charging pressure [ACC M]

Close the accumulator drain valve

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4:9

7

Check that the pressure slowly rises to the specified accumulator charging pressure on the pressure plate.

8

Brake repeatedly and check at which pressure the accumulator charging valve switches to charging.

015021

The valve must switch to charging at 13±0.5 MPa.

Pressure plate, accumulator charging pressure 9

If necessary, adjust the accumulator charging pressure on the valve block accumulator charging and priority valve. Undo the lock nut and adjust the pressure by turning the adjusting screw. Clockwise: reduce pressure.

015028

Anticlockwise: increase pressure.

Adjusting screw, accumulator charging pressure 10 Open the accumulator drain valve so that the accumulators are drained and the valve switches to charging. Close the valve and check the max. pressure again. 11 Repeat steps 5–9 until the pressure is correct. 12 Depressurise the hydraulic systems, See section B Safety.

014618

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

Open the accumulator drain valve.


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4:10

4 Brakes – Accumulator

14 Close accumulator drain valve.

NOTE

014619

Check that the accumulator drain valve is fully closed and tighten the lock ring.


Accumulator charging valve, replacement The accumulator charging valve is not replaced separately, in the event of a fault replace the complete main valve, see section 10 Common hydraulics group 10.5.4 Main valve.

4.3.4 Accumulator Accumulator, description The accumulators store pressure so that there is a pressure reserve in the event of engine or brake system malfunction. The brake system has two parallel-connected accumulators placed on the frame member on the left-hand side of the machine. The accumulators are of the diaphragm type. Each accumulator is divided into two compartments by a diaphragm. One side of the diaphragm is pressurised by nitrogen gas. The other side is pressurised by the hydraulic oil, which compresses the nitrogen gas. At the top of the accumulator, there is a connection for checking nitrogen gas pressure (and for filling nitrogen gas using special filling equipment).

009869

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

Brake system accumulators

Pressurised hydraulic oil from the accumulator is used for the service brake and parking brake systems, and for feeding the servo hydraulic's reducing valve.

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

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4:11

Accumulator, checking


˚C


2


3


4

The accumulators can be tested with separate test equipment or in the machine. Primarily, separate test equipment should be used since it is faster and more accurate.

000475

˚C

1

Test equipment can be ordered from Cargotec.


•

Test with test equipment: continue with step 4.

•

Test in machine: continue with step 6.

Checking with test equipment 5

Remove the accumulators and test them with the test equipment designed for the purpose. The accumulators' gas pressure must match with the pressure plate. Continue with step 17.

015030

6

Pressure plate, gas pressure brake accumulators

Checking in the machine

2

3

7

009871

1

Detach one of the accumulators from the distribution block. Plug the connection on the distribution block with a plug that can withstand high pressure. Plug the connection on the accumulator to protect against impurities.

1.

Clamp

2.

Screw

3.

Distribution block


VDCT01.02GB


8

Connect a pressure gauge (0-25 MPa) to the accumulator charging pressure measuring outlet on the Valve block accumulator charging and priority valve.

9

Turn on the main electric power and start the engine.

014653

4:12

Measuring outlet accumulator charging pressure [ACC M] 10 Close the accumulator charging valve and charge the accumulator until the accumulator charging valve changes to cooling.

NOTE Check that the accumulator drain valve is fully closed and tighten the lock ring. 11 Check that the plug seals properly. 12 Turn off engine.

014619

13 Lower the pressure by means of braking carefully several times while checking the pressure on the pressure gauge.


When the pressure reaches approx. 10 MPa the pressure must decrease immediately to 0 MPa. If the pressure drops immediately when the engine is switched off then the accumulator does not have any precharge pressure. This indicates internal leakage and the accumulator must be replaced. If the pressure can be reduced slowly to a pressure below 10 MPa then the precharge pressure is too low and the accumulator must be replaced or handed over to authorised personnel for maintenance. 14 Depressurise the hydraulic systems, See section B Safety. 15 Mark up and disconnect the tested accumulator. Plug the connections. Connect the other accumulator to the distribution block. 16 Repeat steps 6-13. 17 Depressurise the hydraulic systems, See section B Safety.

Installation and final checking 18 Connect both accumulators to the distribution blocks. If necessary, replace or fill deficient accumulators.

NOTE Check that the seals are intact, clean and in the correct position. 19 Turn on the main electric power and start the engine.

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4:13

20 Close the accumulator drain valve so that the accumulators charge.

NOTE Check that the accumulator drain valve is fully closed and tighten the lock ring. 21 Check that the accumulators' connections are sealed tightly.

014619

22 When the accumulators are fully charged, switch off the engine and turn the start key to position I. 23 Check that at least 8 brake applications (pedal depressions) can be performed before the pressure drops to 10 MPa. At 11.5 MPa the warning lamp for low brake pressure must be switched on.


Accumulator, replacement


2

3

1


2

Switch off the engine and switch off the main electric power.

3


4

Detach the accumulator's clamp and remove the bolt.

5

Detach the accumulator from the distribution block.

1

NOTE

009871

Hold the block firmly so that the other accumulator does not work loose. 6

Bend the clamp away and remove the accumulator.

7

Fit the new accumulator.

1.

Clamp

NOTE

2.

Screw

3.

Distribution block

Check that the seal is intact, clean and fitted in the correct position. 8

Secure the accumulator's clamp and tighten the bolt.

9


NOTE Check that the accumulator drain valve is fully closed and tighten the lock ring. 10 Turn on the main electric power and start the engine. 11 Check that the accumulator's connection is sealed tightly.

014619

12 Check precharging and function, see Accumulator, checking, page 4:11 steps 18-22.



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4:14

4 Brakes – Brake valve

4.3.5 Brake valve Brake valve, description The brake valve, which is located on the underside of the cab underneath the brake pedal, controls the hydraulic pressure to the brakes. A lever transfers pedal force to the valve.

3 2 1

009872

The brake valve is a mechanically activated proportional valve. This means that the resistance in the brake valve increases in proportion to brake pressure. This provides optimum pedal responsiveness and increased safety as the operator senses if no brake pressure is being built up (no resistance in the pedal).

1.

Inlet from accumulator [P]

2.

Return connection [T]

3.

Outlet to brake cylinders [B]

Brake valve, checking


˚C


2


3


4

Connect a pressure gauge (0–25 MPa) to the measuring outlet for brake pressure on the distribution block on the front axle.

000475

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1


VDCT01.02GB



5

4:15


NOTE Check that the accumulator drain valve is fully closed and tighten the lock ring. Start the machine and run it at idle until the accumulators are charged and the accumulator charging valve changes to cooling.

7

Press down the pedal completely and read off the pressure. Compare with the pressure plate on the left-hand frame member.

8

Turn off engine.

9

Depress the pedal fully and keep it pressed down, check the pressure.

014619

6


The brake pressure must correspond with the value specified on the pressure plate and must not decrease from this value for 15 seconds. 10 Release the pedal, the brake pressure must decrease to 0 MPa immediately. Otherwise the brake valve is not sealed and could cause the brakes to remain applied and then overheat during operation. Replace the brake valve if it is not sealed. 11 Depressurise the hydraulic systems, See section B Safety.

015026


Pressure plate, brake pressure 13 Close accumulator drain valve.

NOTE

014619




VDCT01.02GB

4:16


Brake valve, replacement


B

1


2


3

Mark up and detach the hydraulic hoses from the brake valve.

NOTE

T

Plug all connections immediately to protect the brake system from impurities.

P

Secure the brake valve under the cab.

5

Remove the brake valve's attaching bolt.

6

Remove the brake valve.

7

Transfer the connection adapters to the new brake valve.

8

Install the new brake valve.

009875

4

NOTE Remember the spacer ring.

9

B

NOTE

T P

Check that the O-rings are intact, clean and in the correct position. 004795

VDCT01.02GB

Connect the hydraulic hoses to the brake valve in accordance with the marking.

10 Lubricate and adjust the brake pedal, see Brake pedal, checking and adjustment, page 4:3.



4:17


NOTE Check that the accumulator drain valve is fully closed and tighten the lock ring. 12 Turn on the main electric power and start the engine. Let the engine run at idle speed. 13 Test the brakes a couple of times.

014619

14 Check that the brake valve's connections are sealed tightly. 15 Bleed the wheel brakes' brake cylinders, see Wheel brakes, bleeding, page 4:25.



VDCT01.02GB

4:18

4 Brakes – Drive axle block

4.3.6 Drive axle block Drive axle block, description The drive axle block distributes oil flow and brake pressure to the right

1 and left-hand wheel brakes. The drive axle block is fitted on a bracket 2 above the drive axle differential.

10 1

3 The drive axle block has a measuring outlet for brake pressure and for measuring back pressure in the disc brake's cooling circuit.

3

4

5

The drive axle block has a bypass valve which leads oil directly from the cooling circuit intake to the cooling circuit return if the resistance in the axle becomes too great. This protects the wheel brake seals, e.g. when the oil is cold.

5

9

6

8

7 There are two contacts in the drive axle block: brake light NO switch

009876

(216), see Make-contact (closing switch) brake lights, description, page 4:21 and disengagement NO switch, see section 2 Transmission, group 2.8.2 Normally closed (NC) switch, disengagement.

1.

Connection brake cooling, return from wheel brake

2.

Connection brake cooling, return to radiator

3.

Connection brake cooling, to wheel brake

4.

Connection brake cooling, from accumulator charging valve

5.

Connection brake cylinder, to wheel brake

6.

Connection brake pressure, from brake valve

7.

Make-contact (closing switch), declutch (S220)

8.

Make-contact (closing switch), brake light (S216)

9.


10. Measuring outlet, back pressure brake cooling

VDCT01.02GB


4 Brakes – Break contact (opening switch) brake pressure

4:19

4.3.7 Break contact (opening switch) brake pressure Brake pressure NC switch, description 1

2

Break contact (opening switch) brake pressure (S204) detects the pressure in the accumulators. Break contact (opening switch) located on the valve block brake system on the lifting beam in front of the gearbox in the engine compartment. See Valve block brake system, description, page 4:27.

3 4 5

11

When the pressure in the feed circuit is high enough to ensure braking of the machine, the sensor closes an electric circuit. This is used to warn for pressure-drop in the brake system. The sensor's opening pressure is chosen so that there is pressure for at least another 8 brake applications without additional feed from the pump after the lamp has illuminated.

6 7

10 9

Break contact (opening switch) brake pressure (S204) voltage fed by Frame control unit (D797-1). When the pressure increases above the cut-off pressure, the voltage signal to the Frame control unit (D797-1) is cut.

8

015018

The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.5.4 HYD, menu 4.

Valve block brake system 1.

Solenoid valve parking brake (Y642)

2.

Accumulator drain valve

3.

Pressure limiting valve

4.

Connection tank return [T]

5.

Switch (NO), parking brake (S200)

6.

Brake pressure NC switch (S204)

7.

Connection, parking brake caliper [HB]

8.

Connection feed from accumulator charging and priority valve [P]

9.

Connection, accumulators [ACC]

10. Connection brake valve [P] 11. Connection brake valve [T]

Brake pressure NC switch, adjusting


˚C


2


3


000475

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1



VDCT01.02GB

4 Brakes – Break contact (opening switch) brake pressure

4

Connect a pressure gauge (0-25 MPa) to the accumulator charging pressure measuring outlet on the Valve block accumulator charging and priority valve.

5


014653

4:20

Measuring outlet accumulator charging pressure [ACC M]

NOTE

014619



6

Start the engine and fully charge the accumulators (the accumulator charging valve changes to cooling).

7

Stop the engine and turn the start key to position I.

8

Brake several times, stop when the warning lamp for low brake pressure comes on.

9

Read the accumulator charging pressure. The pressure should be approx. 11.5 MPa.

10 If necessary, adjust the warning level by turning the adjusting screw in the rear edge of the sensor, between the contact pins.

NOTE The setting is very sensitive, turn max. 1/4 turn at a time. 11 Repeat steps 6-10 until the warning lamp illuminates at 11.5 MPa. 12 Seal the adjusting screw with locking fluid. 13 Depressurise the hydraulic systems, See section B Safety. 14 Remove the pressure gauge and fit the protective cap on the measuring outlet.

VDCT01.02GB


4 Brakes – Make-contact (closing switch) brake lights

4:21


NOTE

014619



4.3.8 Make-contact (closing switch) brake lights Make-contact (closing switch) brake lights, description Make-contact (closing switch) brake lights controls brake light activation when the machine brakes. The switch is fitted on the drive axle block which is fitted on a bracket above the drive axle differential. Make-contact (closing switch) brake light (S216) is supplied voltage by and sends a voltage signal to Frame control unit (D797-1). When the pressure increases above the closing pressure, a voltage signal is sent to Frame control unit (D797-1).

009878


Make-contact (closing switch) brake light, checking


˚C


2


3

Brake and check that the brake light is switched on.

4


000475

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1



VDCT01.02GB

4:22


5

Connect a pressure gauge (0-25 MPa) to the measuring outlet for brake pressure on the distribution block.

6



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

8

Use the display, go to the diagnostic menu, see section 8 Control system, group 8.4.5.4 HYD, menu 4.

014619

7


BRAKE LIGHT PRESS. indicates status for the brake light switch. 1 = Activated switch (brakes applied). 000144

DIAG HYD 4(6) PRESSURE SWITCHES BRAKE PRESSURE X BRAKE LIGHT PRESS. X DECLUTCH PRESSURE X

9

Depress the brake pedal slowly until the brake light is switched on or the status of the input signal changes. Keep the pedal in this position and check the pressure on the pressure gauge. The status should change and the brake light should be switched on when the pressure is approx. 0.2 MPa.

10 Turn off engine. 11 Depressurise the hydraulic systems, See section B Safety. 12 Remove the pressure gauge and fit the protective cap on the measuring outlet.

VDCT01.02GB



4:23


NOTE

014619




VDCT01.02GB

4:24

4 Brakes – Wheel brakes

4.3.9 Wheel brakes Wheel brakes, description The wheel brakes brake the machine during operation and are fitted on the drive axle between the drive axle housing and hub reduction.

015035

The wheel brake uses so-called Wet disc brakes (WDB). Wet disc brakes require minimal maintenance and have a long service life due to efficient cooling. Maintenance requirements are minimised since oil circulates in the brake system and prevents corrosion.

The wheel brakes have two main parts - disc pack and brake cylinder. The disc pack performs the braking. The brake cylinder presses the discs in the disc pack together during braking.

2

000016

1

Wheel hub and brake, cross-section 1.

Disc pack

2.

Brake cylinder

VDCT01.02GB


4 Brakes – Wheel brakes

4:25

Wheel brakes, bleeding


IMPORTANT Both the brake cylinder and disc brake must be bled after work which involves the brake system being opened or after work on the wheel brake. 1


2

Position a ring spanner on the bleed nipple and connect a transparent hose to the bleed nipple. Route the other end of the hose down into a receptacle.

3

Start the machine and depress the brake pedal, keep the pedal depressed.

4

Open the bleed nipple and allow oil to run out of it until the oil is free of air bubbles.

NOTE The hydraulic hose between the brake pedal and brake is long. So allow at least two litres of oil to pass through the bleed nipple when bleeding to ensure that no air pockets remain in the system.

Bleed nipple, brake cylinder, on top of the drive axle at the wheel hub's inner short side (left-hand side).

5

Close the bleed nipple.

6

Move the spanner and hose and repeat steps 1-5 on the other side.

7

Check the oil level in the brake system, fill if necessary.

Wheel brake, replacement See supplier documentation, drive axle.


VDCT01.02GB

4:26

4 Brakes – Pipes and hoses

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

000008

Braking takes place by means of the brake cylinder pressing together the discs. This creates friction between the discs that are fixed to the axle and those fixed to the hub reduction.

Disc pack

4.3.9.2 Brake cylinder Brake cylinder, description The brake cylinder is integrated in the wheel brake and consists of a metal ring (cylinder) with two seal rings. The seals have lateral support from a bevel on the cylinder and a bevel on the wheel brake housing.

000007

The space between the seal rings is pressurised through a channel in the wheel brake housing. The pressure moves the metal ring sideways and compresses the disc pack.

Brake cylinder

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

VDCT01.02GB


4 Brakes – Valve block brake system

4:27

4.3.12 Valve block brake system Valve block brake system, description Solenoid valve parking brake

1

2

Solenoid valve parking brake

3

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

4


6

The accumulator drain valve (position 2) is located on the valve block brake system and is used to drain the pressure in the accumulators to the tank. The valve opens a connection between the accumulators and the wheel brake's cooling circuit. The oil is drained through the wheel brake to the tank.

7

See section 10 Common hydraulics group 10.2.1 Accumulator drain valve.

5 11

10


9

8

See section 10 Common hydraulics group 10.2.4 Pressure limiting valve.

015018

Break contact (opening switch) parking brake

Valve block brake system

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

Break contact (opening switch) brake pressure See Brake pressure NC switch, description, page 4:19.

1.


2.


3.


4.


5.


6.


7.


8.


9.




VDCT01.02GB

4:28

4 Brakes – Valve block brake system

Valve block brake system, replacement



2

Mark and disconnect the cable harness from the valve block.

3

Mark up and detach the hydraulic hoses from the valve block.

4

Move the components to the new valve and assemble the valve in the reverse order.

5


NOTE

014619



VDCT01.02GB


4 Brakes – Parking brake system

4:29

4.5 Parking brake system Parking brake system, function description

D1

10

1 2

3, 8

9

D790-2

D790-1 D797-1

D4

D7

13

4 C

Pa

C

5

7 GHB HB

P

ACK M

T

6

P

12 015036

11

P Pos

Explanation

Signal description

Reference

1

Switch parking brake (S107) activates the parking brake.

Switch activated:


The switch uses two signals, one for applied and one for released parking brake. Both signals must be correct to enable release of the parking brake.

Conn. 1, U = 24 V Conn. 7, U = 0 V Switch in home position: Conn. 1, U = 0 V


Conn. 7, U = 24 V 2

The cab control unit (D790-1) transmits Activate parking brake on the CAN bus.



3

The frame control unit (D797-1) activates the parking brake solenoid valve (Y642).

U = 24 V

Solenoid valve parking brake, description, page 4:31 D7: Diagnostic menu, see section 8 Control system, group 8.4.5.5 HYD, menu 5

4

Solenoid valve parking brake (Y642) acts on the valve slide which drains pressure in the parking brake's brake caliper to tank.

-

Solenoid valve parking brake, description, page 4:31

5

The brake caliper is drained of pressure and the spring applies the parking brake.

0 MPa

Parking brake unit, description, page 4:32

6

Valve block brake system directs the hydraulic oil to the hydraulic oil tank.

-

Valve block brake system, description, page 4:27


VDCT01.02GB

4:30

4 Brakes – Hydraulic oil pump

Pos

Explanation

Signal description

Reference

7

Break contact (opening switch) parking brake (S200) breaks the circuit and sends the voltage signal to the Frame control unit (D797-1) when the pressure drops.

Applied parking brake:

Break contact (opening switch) parking brake, description, page 4:36

Conn. 1, U = 24 V Conn. 2, U = 0 V Released parking brake:


Conn. 1, U = 24 V Conn. 2, U = 24 V 8

The frame control unit (D797-1) transmits Parking brake applied on the CAN bus.



9

Control unit KIT (D790-2) activates indicator light, parking brake (508).



10

Indicator light parking brake comes on.

-


11

The hydraulic oil pump pumps hydraulic oil from the hydraulic oil tank.

See pressure plate on left frame beam.

Hydraulic oil pump, general, page 4:6

12

Valve block accumulator charging and priority valve directs oil to charging of the accumulators or the brake system's cooling circuit.


Accumulator charging valve, description, page 4:7

13

The accumulators store the oil pressure used when the parking brake is released.


Accumulator, description, page 4:10


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

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

VDCT01.02GB


4 Brakes – Solenoid valve parking brake

4:31

4.5.3 Solenoid valve parking brake Solenoid valve parking brake, description 1

2

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

3 4

The solenoid valve opens a connection between the accumulators and the parking brake caliper on activation. This means that the parking brake caliper is pressurised and the parking brake is released. When the voltage feed to the solenoid valve is cut off, the connection between the accumulators and parking brake caliper is closed. Instead, a connection between the parking brake caliper and tank is opened and the parking brake is applied. This means that the parking brake is applied if the machine becomes de-energised or if the brake system becomes depressurised.

5 11

6 7

10 9

The solenoid valve is supplied with voltage by the frame control unit (D797-1) at activation.

8

015018




2.


3.


4.


5.


6.


7.


8.


9.




VDCT01.02GB

4:32

4 Brakes – Parking brake unit

Solenoid valve parking brake, checking

DANGER The machine may start to roll. Risk of crushing. Block the wheels so that the machine cannot start to roll when the parking brake is released. 1

Start the engine and run the engine at idle until the warning lamp for brake pressure goes out and the accumulator charging valve changes to cooling.

2

Switch off the engine and turn the start key to position I.

3

Release the parking brake with the switch for the parking brake and check that the parking brake's brake caliper releases. The brake caliper should be able to move.

4

Activate the parking brake with the switch for the parking brake and check that the parking brake's brake caliper is applied.

4.5.4 Parking brake unit Parking brake unit, description 3

1

The parking brake unit keeps the machine stationary when parked. The parking brake unit is fitted on the drive axle input shaft between the propeller shaft and drive axle.

2

The parking brake acts on the universal drive shaft via a disc mounted on the drive axle input shaft and a brake calliper with dry brake pads mounted in a bracket on the drive axle.

NOTE

009881

If the hydraulic pressure in the feed circuit drops, a warning is activated before the pressure drops so low that the parking brake is applied. If the parking brake is applied while the machine is in motion, the brake disc and brake pads must be replaced.

1.

Cover

2.

Parking brake caliper

3.

Parking brake disc

VDCT01.02GB



4:33

Parking brake unit, checking and adjustment

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 fully charge the accumulators (the accumulator charging valve changes to cooling).

2

Switch off the engine and turn the start key to position I.

3

Release the parking brake.

4

Check that the parking brake caliper can move on the bracket.

5

Check that the brake disc is free from oil and dirt.

6

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

7

Loosen the lock nut.

8

Adjust the adjusting screw so that the brakes are applied.

9

Turn back the adjusting screw so that the clearance between pad and disc is 0.5±0.1 mm.

10 Tighten the lock nut.

NOTE To avoid turning the adjusting screw as well it must be held still when tightening the lock nut. 11 Refit the cover to the caliper. 12 Test the function of the parking brake.


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4:34


4.5.4.1 Parking brake caliper Brake caliper, description 2

3

4

The brake caliper has a spring section and a hydraulic section. The spring section applies the brake while the hydraulic section is used to release the brake. This means that the parking brake is applied if the brake system loses pressure. This, in turn, means that the machine is braked if a serious fault arises.

5

000020

1

1.

Brake pads

2.

Release cylinder

3.

Thrust spring

4.

Slackening screw

5.

Adjusting washer

4.5.4.2 Parking brake pads Brake pads, description The brake pads consist of a metal plate with friction material (lining).

Brake pads, replacement

DANGER 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.

VDCT01.02GB

1

Machine in service position and wheels blocked, see section B Safety.

2

Remove the cover from the brake caliper.



4:35

3

Loosen the lock nut.

4

Slacken the adjusting screw to release the brake pads.

5

Remove the split pin and undo the nut on one of the attaching bolts holding the parking brake caliper in place.

6

Pull the attaching bolt out so that the brake pads can be angled out and removed.

NOTE The bolt does not need to be removed. 7

Remove the parking brake pads.

8

Clean the brake disc with methylated spirit.

9

Fit new parking brake pads.

10 Press back the attaching bolt. 11 Fit the nut and a new split pin. 12 Adjust the parking brake, see Parking brake unit, checking and adjustment, page 4:33.

4.5.4.3 Parking brake disc Brake disc, description The brake disc is fitted on the drive axle input shaft. The drive axle's gear ratio amplifies the braking force.


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4:36

4 Brakes – Break contact (opening switch) parking brake

4.5.5 Break contact (opening switch) parking brake Break contact (opening switch) parking brake, description 1

2

Break contact (opening switch) parking brake (S200) detects whether the parking brake is applied or released. The break contact (opening switch) is fitted on the valve block brake system, which is fitted on the lifting beam in front of the transmission in the engine compartment, see Valve block brake system, description, page 4:27.

3 4 5

11

Break contact (opening switch) parking brake (S200) senses the pressure in the parking brake circuit. When the pressure is so high that the parking brake is released, the sensor opens an electric circuit. This is used to indicate that the parking brake is released.

6

Break-contact (opening switch) parking brake light (S200) is supplied voltage by and sends a voltage signal to Frame control unit (D797-1). When the pressure increases above the cut-off pressure, the voltage signal to the Frame control unit (D797-1) is cut.

7

10 9

8


015018

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



2.


3.


4.


5.


6.


7.


8.


9.




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

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5:1

5 Steering

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


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5:2

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5 Steering – Steering

5:3

5 Steering 5.2 Power assisted system Power assisted system, function description

C3

2

3

P LS

C1

T

L R

O

P

LSO

2 4 015017

1

Pos

Explanation

Signal description

Reference

1

Hydraulic oil pump brake and steering pumps oil to the Valve block accumulator charging and priority valve.


Section 10 Common hydraulics, group 10.4.1 Gear pump with fixed displacement

2

Valve block accumulator charging and priority valve gives priority to the oil feed to the control valve over accumulator charging and cooling to the brakes.


Priority valve, description, page 5:4

3

The steering wheel is turned and acts on the steering valve\qs input shaft.

-

Steering valve, description, page 5:7

-

Steering cylinder, description, page 5:9

The control valve directs oil pressure from the hydraulic oil pump brake and steering to the steering cylinder. 4

The steering cylinder turns the wheels.


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


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5:4

5 Steering – Priority valve

5.2.2 Priority valve Priority valve, description The priority valve is located in the valve block accumulator charging and priority valve that is part of the main valve, see section 10 Common hydraulics, group 10.5.4 Main valve. The main valve is located on the lifting beam in front of the gearbox in the engine compartment. The priority valve divides the oil flow from the hydraulic oil pump brake and steering so that there is always oil to the steering valve. The remaining flow goes to the brake system and to the hydraulic oil's cooling circuit.

1 2 3

The priority valve is load sensing and pilot pressure compensating.

4 Load sensing means that the valve adapts the control signal to the

5

steering valve's consumption. Pilot pressure compensating means that the priority valve compensates for the pressure drop between the priority valve and steering valve via a separate line.

The priority valve has a built-in pressure limiter on the load signal. The pressure limiter maximises the load signal's pressure.

13

6 12 11

10

9

8

015032

7

1.


2.


3.


4.


5.


6.


7.


8.


9.


10. Measuring outlet accumulator pressure [ACC M] 11. Adjusting screw servo pressure 12. Connection valve block brakes, accumulator charging [ACC] 13. Measuring outlet pump pressure brake and steering [PM]

Control pressure, checking


˚C


2


3


000475

˚C

1


VDCT01.02GB



5:5

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

5

Close the relief valve attachment and the accumulator drain valve.

6

Start the engine and increase engine speed to approx. 1200 rpm.

7

Turn the steering wheel to full lock and check that the control pressure corresponds with the pressure on the pressure plate during the steering movement.

014651

4

014619

Measuring outlet, control pressure [LSM]

015020



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5:6


8

If necessary, adjust the steering pressure on the valve block accumulator charging and priority valve. Undo the lock nut and adjust the pressure by turning the adjusting screw. Clockwise: reduce pressure. Anticlockwise: increase pressure.

9


10 Depressurise the hydraulic systems, See section B Safety.

015029


Adjuster screw, control pressure 12 Close the relief valve attachment and the accumulator drain valve.

NOTE

014619



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5 Steering – Steering valve

5:7

5.2.3 Steering valve Steering valve, description The steering valve is a “closed centre, non-reaction valve” with load signal connection to the priority valve. The load signal generates load-dependent control of oil flow from the priority valve to the steering valve. "Closed centre" means that the steering valve is closed in its neutral position. This is necessary so that signal pressure can be connected to the steering valve.

1

5 4

2

The steering valve consists of a gear pump and a distribution valve. When the steering wheel is turned, oil flows from the main pump over the gear pump to the distribution valve, which directs the oil to the steering cylinder. The gear pump ensures that the oil flow fed to the cylinder is proportional to the steering wheel's turning angle.

3

009887

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

Connections control valve 1.

Steering cylinder left [L]

2.

Pilot pressure [LSO]

3.

Steering cylinder right [R]

4.

Tank return [T]

5.

Pressure feed [O]

Steering valve, replacement



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5:8

5 Steering – Steering valve

1.

Water valve

2.

Steering valve

1


2


3


4

Detach the steering valve from the brake pedal. Remove the steering valve's attaching bolts and lower the control valve.

5

Mark up and detach the hydraulic hoses from the steering valve.

NOTE Plug all connections immediately to protect the brake system from impurities. 6

Remove the steering valve.

7

Transfer the connection adapters to the new steering valve.

NOTE Transfer one connection at a time so that the marking is not mixed up. 8

Connect the hydraulic hoses to the steering valve in accordance with the marking.

NOTE Check that the O-rings are intact, clean and in the correct position. 9

Connect the new steering valve to the brake pedal. Position the steering valve and check that the steering wheel shaft's splines enter straight in the steering valve's slot. Fit the attaching bolts.

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5 Steering – Steering cylinder

5:9

10 Close the relief valve attachment and the accumulator drain valve.

NOTE Check that the accumulator drain valve is fully closed and tighten the lock ring. 11 Turn on the main electric power and start the engine. 12 Check that the connections on the steering valve are sealed tightly.

014619

13 Steer very carefully a few times right - left, to bleed the steering valve and steering cylinder.


5.2.4 Steering cylinder Steering cylinder, description 1

2

The steering cylinder acts on the wheels via the link arms. The steering cylinder is a double-acting hydraulic cylinder.

3

009888

4 1.

Steering cylinder

2.

Shaft

3.

Lock screw

4.

Fastening screw (locked with locking fluid)


VDCT01.02GB

5:10

5 Steering – Steering cylinder

Steering cylinder, replacement


Park the machine with the wheels fully turned so that the steering cylinder can be lifted out to one side.

2


3


4

Detach the link arms from the steering cylinder.

5

Mark up and detach the hydraulic hoses from the steering cylinder.

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

1.

Link arm mounting

2.

Hydraulic connection 6

Remove the steering cylinder's attaching bolts.

7

Replace the steering cylinder. Lift the steering cylinder aside.

NOTE The steering cylinder is heavy, use lifting equipment. 8

Support the new steering cylinder so that the holes in the attaching bolts are lined up directly opposite the holes in the steering axle.

9

Fit and lubricate the steering cylinder attaching bolts. Tighten the bolts crosswise in steps until 680 Nm is achieved.

10 Transfer parts to the new steering cylinder.

NOTE

009889

Check that the O-rings are intact, clean and in the correct position.

Attaching bolts steering cylinder.

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5 Steering – Steering axle cradle

5:11

11 Fit the link arms to the steering cylinder. 12 Connect the hydraulic hoses to the steering cylinder.

NOTE Check that the O-rings are intact, clean and in the correct position.

1.

Link arm mounting

2.

Hydraulic connection 13 Close the relief valve attachment and the accumulator drain valve.


014619

14 Start the engine and check for leaks.


Hydraulic cylinders, repairs See section 10 Common hydraulics, group 10.7.1 Hydraulic cylinders.

5.2.5 Steering axle cradle Steering axle cradle, general See section 6 Suspension, group 6.2.1 Steering axle cradle.

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

1

1.

Link arm


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5:12

5 Steering – Wheel spindle

5.2.7 Wheel spindle Wheel spindle, general See section 6 Suspension, group 6.2.2 Wheel spindle.

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


VDCT01.02GB


6:1

6 Suspension

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


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6:2

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6 Suspension – Suspension

6:3

6 Suspension 6.2 Suspension Bushing steering axle mounting, changing

DANGER Steering axle and machine are very heavy. Risk of crushing! It is forbidden to go under a machine which has been lifted by a jack etc. For machine weight, see section F Technical data. 1


2


3

Support under the steering axle so that it cannot fall over.

4

Attach hoisting equipment to the rear of the machine and take up the slack so that the steering axle's mounts are relieved.

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

Remove the pins holding the steering axle.

6

Lift the machine so that the frame is off the steering axle.

7

Support the machine under the frame.

8

Move the steering axle so that the mountings can be accessed.

NOTE

009890

If necessary, disconnect the cable harness for the sensors on the steering axle.

The illustration shows rear mounting


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6:4

6 Suspension – Steering axle cradle

9

2

Remove the washers that hold the bushing in place.

10 Press out the bushing.

1

11 Clean the bearing surfaces on the steering axle. 12 Press in the new bushing. Grease the bushing to facilitate installation. 13 Fit the washers that hold the bushing in place. 14 Move the steering axle into place under the frame. 15 Lubricate and fit the pins at the steering axle's mounts.

3

16 Remove the lifting equipment from the machine. 010121

4

1.

Steering axle mounting

2.

Rubber bushing

3.

Washers

4.

Screw

6.2.1 Steering axle cradle Steering axle cradle, description 2

3

4

5

The steering axle is pendulum suspended with a double-acting steering cylinder. The design comprises a minimum of moving parts to minimise service points and simplify maintenance. The frame suspension comprises maintenance-free parts.

6

008047

1

Steering axle 1.

Wheel hub

2.

Wheel spindle

3.

Link arm

4.

Steering axle cradle

5.

Steering cylinder

6.

Spindle bolt / - bearing

Steering axle cradle, replacement

DANGER Steering axle and machine are very heavy. Risk of crushing! It is forbidden to go under a machine which has been lifted by a jack etc. For machine weight, see section F Technical data. 1

VDCT01.02GB

Clean the steering axle and its surrounding area.


6 Suspension – Steering axle cradle

6:5

2


3


4


5

Connect the lifting equipment to the rear section of the machine.

6

Tension the lifting equipment, do not lift so much that the wheels are off the ground.

7

Support the machine's rear section.

8

Detach the hydraulic hoses from the steering cylinder.

NOTE Plug all connections immediately to protect the hydraulic system from impurities. 9

Remove the pins holding the steering axle.

10 Lift the machine up so that the frame is lifted away from the axle. 11 Lift out the steering axle.

CAUTION The steering axle may start to roll. Crushing injury! Make sure that the steering axle does not roll away uncontrollably. 12 Adjust the support so that the machine is secured in the new position. 13 Lift the steering axle into place under the frame. 14 Remove the support under the frame. 15 Lower the rear section of the machine. 16 Fit the pins at the steering axle mountings. 17 Connect the hydraulic hoses to the steering cylinder.

NOTE Check that the O-rings are intact, clean and in the correct position. 18 Remove the lifting equipment from the machine.


VDCT01.02GB

6:6

6 Suspension – Wheel spindle

6.2.2 Wheel spindle Wheel spindle, description The wheel spindle is the link between steering axle and wheel hubs which means that the wheels can be turned.

3 2 4 5 1

6 7

8

11 1.

Wheel spindle

2.

Seal ring

3.

Bearing (upper)

4.

Protective ring

5.

Seal ring

6.

Bearing (lower)

7.

Circlip

8.

Shim

9.

Bearing cage

10

009780

9

10. Screw 11. Grease nipple

Spindle bolt bearing, replacement

VDCT01.02GB

1


2

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

3

Remove the steering wheel in question.

4

Clean the wheel spindle and its surrounding area.

5

Detach the link arm from the wheel spindle.

6

Remove the wheel hub and wheel bearing; see Wheel bearing, replacement, page 6:8.


6 Suspension – Wheel spindle

6:7

7

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

8

Detach the bearing cage by screwing a screw into the removal hole.

9

Remove the bearing cage and shim from the wheel spindle.

10 Remove the wheel spindle. 11 Remove the three screws on the top of the steering axle cradle. Press out the upper bearing's outer bearing race by screwing three screws (about 90 mm long) into the holes. 12 Remove the inner bearing races on the upper and lower bearings from the wheel spindle.

002419

13 Remove the outer bearing race on the lower bearing from the bearing cage. 14 From underneath, tap in the outer bearing race of the upper bearing into the steering axle cradle. Use a pipe of a suitable diameter so as not to damage the bearing race. 15 Refit the three screws on the top of the steering axle cradle. 16 Fit upper bearing's inner bearing race, seal ring, guard ring and seal ring as well as the lower bearing's inner bearing race and circlip on the wheel spindle. 17 Fit the wheel spindle. 18 Tap the lower bearing's outer bearing race into the bearing cage. Use a pipe of a suitable diameter so as not to damage the bearing race. 19 Fit the bearing cage. Use a shim to get it in the right position. Tighten the screws. 20 Check that the wheel spindle rotates smoothly and that there is no play on the spindle bearing. If necessary, correct with shims.

NOTE The correct number of shims have been used when it takes at least 200 Nm to move the bearing arrangement to move laterally. If it takes more than 400 Nm for the bearing arrangement to move, it is too hard and the number of shims must be corrected. 21 Lubricate the wheel spindle bearings via the grease nipples. 22 Fit the wheel hub and wheel bearing; see Wheel bearing, replacement, page 6:8. 23 Connect the link arm to the wheel spindle. 24 Fit the wheel.


VDCT01.02GB

6:8

6 Suspension – Wheel hub

25 Remove the support and lower the steering wheel. 26 Test-operate the machine and test the steering. Check also that the machine feels stable when driving straight ahead.

6.2.3 Wheel hub Wheel hub, description The wheel hub holds the wheel in place and allows the wheel to rotate.

2

3

1 4 5 6

7 8 9 008595

10 11

1.

Wheel hub

2.

Wheel bolt

3.

Wheel nut

4.

Hub cap

5.

Spacer

6.

Nut

7.

Washer

8.

Bearing

9.

Screw

10. Bearing 11. Seal ring

Wheel bearing, replacement

VDCT01.02GB

1

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

2

Remove the steering wheel in question.



6:9

3

Clean the hub cover and its surrounding area.

4

Remove the hub cover.

5

Wipe away grease from hub cover and hub nut. Handle it as environmentally hazardous waste.

6

Secure the hub with a lifting strap. Route the lifting strap over the hub and around a wheel bolt. Fit a clamp and nut to secure the lifting strap. Use manual forklift, pallet forks or similar to lift the hub.

7

Bend up the locking washer's tabs, remove the lock nut and locking washer.

8

Tension the lifting equipment so that the hub is unloaded.

9

Remove the hub nut.

10 Lift the hub out from the spindle. Remove the outer bearing's inner race and pull the hub from the axle.


VDCT01.02GB

6:10


11 Remove the inner bearing from the wheel spindle.

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

NOTE Fit the outer races with the larger diameter outward.

16 Fit a new seal on the inside with the seal lip turned out. Press in a new seal in the hub. Use a suitable round plate, the seal does not tolerate impacts from a hammer.

NOTE Turn the seal correctly.

17 Fit the inner bearing's inner race and rollers on the wheel spindle. Pack the bearing with universal grease "EP2".

VDCT01.02GB



6:11

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

19 Fit the hub on the wheel spindle.

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

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

Angle tighten the nut 45º.


VDCT01.02GB

6:12


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

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

VDCT01.02GB


6 Suspension – Tyres and rims

6:13

6.3 Tyres and rims Tyres and rims, safety

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


VDCT01.02GB

6:14

6 Suspension – Tyres and rims

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

VDCT01.02GB


6 Suspension – Tyres

6:15

6.3.1 Tyres Tyres, description The tyres are the point of contact between the machine and the ground, and they absorb unevenness and provide suspension. The drive axle is subject to major forces during operation. If each tyre's rolling circumference differs, the stresses on the drive axle increase. For this reason it is important that the tyres on the drive axle have equal wear and correct air pressure.

009892

Spare and replacement tyres must be from a manufacturer approved by Cargotec.

009893

Front wheels

Rear wheels

Tyres, changing

DANGER Changing tyres is complicated and dangerous work. EXTREME DANGER! Leave tyre work to authorised personnel/tyre company. The rims must be checked when tyres are changed. See Maintenance manual DCT 80-90.


VDCT01.02GB

6:16

6 Suspension – Rim

6.3.2 Rim Rim, description 1

2

3

The rim is split to make it possible to fit a tyre. The rim consists of the following parts.

4

•

Rim

•

Rim bead seat

•

Rim edge

•

Lock ring

6

1.

Rim

2.

Lock ring

3.

Rim edge

4.

Tapered rim

5.

Wheel nut

6.

Wheel bolt

VDCT01.02GB

009899

5


6 Suspension – Nut, washer and clamp

6:17

6.3.3 Nut, washer and clamp Nut, washer and clamp, description 1

2

3

The rim is attached to the wheel hub with nuts.

4

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

6

1.

Rim

2.

Lock ring

3.

Rim edge

4.

Tapered rim

5.

Wheel nut

6.

Wheel bolt

009899

5


VDCT01.02GB

6:18

6 Suspension – Nut, washer and clamp

Wheel bolt, replacement

VDCT01.02GB

1


2

Raise the machine with a jack positioned under the steering axle.

3

Remove the steering wheel; see Maintenance manual DCT 80-90.

4

Knock out the bolt with a sledge hammer.

5

Replace the bolt.


7:1

7 Load handling

Contents 7 Load handling 7 Load handling .....................................................................................................7:3 7.1 Controls and instruments .................................................................................7:4 7.1.1 Control levers ..............................................................................................7:4 7.1.2 Switch, lock twistlock...................................................................................7:5 7.1.3 Switch, spreading 20\q-40\q........................................................................7:6 7.1.4 Switch, stop at 30\q .....................................................................................7:6 7.1.13 Switch, automatic spreading .......................................................................7:7 7.2 Lift and lower....................................................................................................7:8 7.2.1 Hydraulic oil pump.....................................................................................7:10 7.2.3 Pressure reducer....................................................................................... 7:11 7.2.5 Control valve, lift and tilt ............................................................................7:14 7.2.7 Lift cylinder ................................................................................................7:15 7.2.9 Mast ..........................................................................................................7:16 7.2.10 Mast position sensor .................................................................................7:25 7.2.11 Trolley........................................................................................................7:26 7.2.13 Pipes and hoses........................................................................................7:30 7.2.14 Accumulator lift..........................................................................................7:30 7.2.15 Hydraulic oil filter .......................................................................................7:30 7.4 Side shift ........................................................................................................7:31 7.4.1 Hydraulic oil pump.....................................................................................7:32 7.4.2 Control valve, attachment .........................................................................7:33 7.4.3 Side shift cylinder ......................................................................................7:37 7.4.5 Trolley........................................................................................................7:37 7.4.7 Relief valve, attachment ............................................................................7:39 7.4.8 Pipes and hoses........................................................................................7:39 7.4.9 Lift, tilt and attachment control valve .........................................................7:40 7.4.10 Hydraulic oil filter .......................................................................................7:40 7.5 Spreading (positioning) ..................................................................................7:41 7.5.1 Hydraulic oil pump.....................................................................................7:47 7.5.2 Control valve, attachment .........................................................................7:48 7.5.3 Spreading cylinder ....................................................................................7:49 7.5.4 Spreader beam .........................................................................................7:49 7.5.5 Main beam, side lift attachment.................................................................7:51 7.5.6 Position sensor, spreading ........................................................................7:56 7.5.7 Buzzer, automatic spread 20'-40' ..............................................................7:56 7.5.8 Pipes and hoses........................................................................................7:56 7.5.9 Relief valve, attachment ............................................................................7:56 7.5.10 Lift, tilt and attachment control valve .........................................................7:56 7.5.11 Hydraulic oil filter .......................................................................................7:57 7.7 Tilt ..................................................................................................................7:58 7.7.1 Hydraulic oil pump.....................................................................................7:59 7.7.5 Control valve, lift and tilt ............................................................................7:60 7.7.6 Load retention valve ..................................................................................7:61 7.7.7 Tilt cylinder ................................................................................................7:61 7.7.8 Mast ..........................................................................................................7:62 7.7.9 Pipes and hoses........................................................................................7:62 7.7.10 Hydraulic oil filter .......................................................................................7:62 7.8 Levelling.........................................................................................................7:63 7.9 Load carrier....................................................................................................7:64 7.9.1 Twistlocks ..................................................................................................7:64 7.10 Other functions...............................................................................................7:75 7.10.1 Container counter......................................................................................7:75


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7:2

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7 Load handling – Load handling

7:3

7 Load handling Position sensor, checking and adjustment The machine has several position sensors in the following locations. 1.

Mast position sensor (B7211-2), see Mast position sensor, description, page 7:25.

2.

Alignment sensors B7203L and B7203R), see Sensor, alignment, description, page 7:71 and Alignment sensor, checking and adjusting, page 7:71.

3.

Locked twistlocks sensors (B7205LL and B7205RL), see Sensor, twistlocks, description, page 7:72 and Twistlocks sensor, checking and adjusting, page 7:73.

4.

Damping sensor (B769L, B769R, B777L and B777R), see Position sensor spreading, description, page 7:56.

1

2 3

015079

4

Position sensor overview

Spacing check Machine in service position, see section B Safety.

2

Check that the sensor in question is free of damage and dirt.

3

Check that the distance between the sensor and the indicator is 5±1 mm.

4

Adjust if necessary.

C-C

1

5±1 mm

009632

5±1 mm

Adjusting position sensor - indicator


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7:4

7 Load handling – Controls and instruments

7.1 Controls and instruments 7.1.1 Control levers Control lever, description A

B

The control lever (S815) is used to control the mast and attachment. The lever sends voltage signals to the Cab control unit (D790-1).

C

The control lever has three potentiometer-controlled functions and three on/off functions. A. Side shift (S815-P3) Side shift left is activated when the potentiometer is pushed in on the left-hand side. Side shift right is activated when the right-hand side is pushed in. See Side shift, function description, page 7:31.

D

The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.9.1 ATTACH, menu 1. B. Spreading out (S815-T1.1) and Spreading in (S815-T1.2) Pressing the right switch activates spreading out and pressing the left switch activates spreading in. See Spreading, function description, page 7:41.

E

D

The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.9.3 ATTACH, menu 3.

C

015080

C. Lifting/lowering (S815-P1) Lifting/lowering is controlled by moving the control lever forward (lowering) or rearward (lifting). See Lifting/lowering, function description, page 7:8. The signal can be checked from the diagnostic menu, see section 8 Control system, group 8.4.8.1 ELSERV, menu 1. D. Tilt (S815-P2) Tilt is controlled by moving the control lever to the right (tilt out) or left (tilt in). See Tilt, function description, page 7:58. The signal can be checked from the diagnostic menu, see section 8 Control system, group 8.4.8.1 ELSERV, menu 1. E. Lock/open the twistlocks (S815-T2) on full alignment The twistlocks are alternately opened/locked when the switch is activated if the conditions are met. See Twistlocks, function description, page 7:64. The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.9.5 ATTACH, menu 5.

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7 Load handling – Switch, lock twistlock

7:5

Linear control levers, description

The load handling functions are controlled with fingertip-controlled linear levers. The control levers are supplied voltage by and send a signal to the cab control unit (D790-1).

C

A. Lift/lower (R8071-P1). Lifting/lowering is controlled by moving the control lever forward (lowering) or rearward (lifting). See Lifting/lowering, function description, page 7:8.

D

The signal can be checked from the diagnostic menu, see section 8 Control system, group 8.4.8.1 ELSERV, menu 1. B. Tilt (R8072-P2). Tilt is controlled by moving the control lever forward (tilt out) or backward (tilt in). See Tilt, function description, page 7:58. The signal can be checked from the diagnostic menu, see section 8 Control system, group 8.4.8.1 ELSERV, menu 1. C. Side shift (R8073-P3). Side shift is controlled by moving the lever forward (left) or backward (right). See Side shift, function description, page 7:31.

E

The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.9.1 ATTACH, menu 1. 014181

B

It is not possible to use side shift on the side lift attachment if the attachment is in its max or min position. D. Emergency stop switch E. Opening locked twistlocks, attachment (S1002). Pull the switch sideways to open the twistlocks if the conditions for this are met. See Twistlocks, function description, page 7:64. The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.9.5 ATTACH, menu 5.

7.1.2 Switch, lock twistlock Switch lock twistlocks, description (linear control levers)

Switch (green) for locking twistlocks (S1003). The switch is momentary in position 2. Position 1 - Twistlocks are locked automatically when alignment with the load occurs. The parking brake must be OFF. 009907

A

Position 0 - Twistlock locking not activated. Position 2 - Twistlocks are locked manually. Button springs back. Twistlocks are opened with the switch on the control lever, see Linear control levers, description, page 7:5. The switch is supplied power by and sends a voltage signal to the cab control unit (D790-1). The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.9.5 ATTACH, menu 5.


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7:6

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

7.1.3 Switch, spreading 20\q-40\q Switch spreading 20'-40', description (linear control levers)

009910

Switch (green) for spreading between 20'-40' (S1012). Spreading stops in the position it is in when the switch is released. The switch is momentary. This function is used to adapt the attachment to the width of the containers. Position 0 - Spreading not activated. Position 1 - Spreading out activated. Spreading's outer end position is at 40'. Position 2 - Spreading in activated. Spreading's inner end position is at 20'. The switch is supplied power by and sends a voltage signal to the cab control unit (D790-1). The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.9.3 ATTACH, menu 3.

7.1.4 Switch, stop at 30\q Switch stop at 30', description (linear control levers)

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

009909

35 30-

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The switch is supplied power by and sends a voltage signal to the cab control unit (D790-1). The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.9.3 ATTACH, menu 3.


7 Load handling – Switch, automatic spreading

7:7

7.1.13 Switch, automatic spreading Switch automatic spreading, description (linear control levers)

009908

Switch (green) for automatic spreading between 20'-40' (S1004). When the switch is pressed down spreading automatically goes to the next position (20, 30 or 40 feet) if spreading is activated with the control lever. This switch is used to activate automatic spreading. Position 0 - Automatic spreading not activated. Position 1 - Automatic spreading activated. Spreading is activated with the switch for spreading 20'-40'. The switch is supplied with voltage from and sends a voltage signal to the cab control unit (D790-1) when the switch is activated. The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.9.3 ATTACH, menu 3.

WARNING Risk of crushing and damage to the product! Automatic spreading is stopped by activating spreading in the opposite direction or deactivating the function with the switch.


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7:8

7 Load handling – Lift and lower

7.2 Lift and lower Lifting/lowering, function description Condition

Reference value

Reference

Control breaker

Not activated

Section 11 Common electrics, group 11.5.1.4 Emergency stop switch voltage

Twistlocks

Locked or unlocked, not intermediate position

Twistlocks, description, page 7:64

Alignment

Mast down: no contact

Sensor, alignment, description, page 7:71

1b

D3

1a D1

D790-1 D797-1

2, 3, 5

D794

6

7, 15

4 D7

D14 14 8

C

12, 16

12, 16

P2

13

10

A

015074

9

11 Pos

Explanation

Signal description

Reference

1a

The lifting/lowering control lever (R8071-P1) sends the cab control unit (D790-1) a voltage signal proportional to lever movement.

U = 0.5-4.5 V

Linear control levers, description, page 7:5

Lower: U = <2.5 V Lift: U = >2.5 V 0.5 V is the fastest lowering speed and 4.5 V is the fastest lift speed. Lower voltage than 0.5 V and higher voltage than 4.5 V is used to detect faults in cable harnesses and controls.

1b

The control lever (S815-P1) sends the cab control unit (D790-1) a voltage signal proportional to lever movement.

US815-P1 = 0.5-4.5 V Lower: US815-P1 = <2.5 V Lift: US815-P1 = >2.5 V 0.5 V is the fastest lowering speed and 4.5 V is the fastest lift speed. Lower voltage than 0.5 V and higher voltage than 4.5 V is used to detect faults in cable harnesses and controls.

2

The cab control unit (D790-1) sends the frame control unit (D797-1) a lift/lower request via the CAN bus.

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D1: Diagnostic menu, see section 8 Control system, group 8.4.8.1 ELSERV, menu 1

Control lever, description, page 7:4 D1: Diagnostic menu, see section 8 Control system, group 8.4.8.1 ELSERV, menu 1


7 Load handling – Lift and lower

Pos

7:9

Explanation

Signal description

Reference

Cab control unit (D790-1) voltage feeds the control breaker relay lifting and lowering (K3007).

U = 24 V


4

Control breaker relay lifting and lowering (K3007) makes the ground connection between Frame control unit (D797-1) and Solenoid valve lift (Y6005) and Solenoid valve lower(Y6004).

-

Section 11 Common electrics, group 11.5.1.4 Emergency stop switch voltage (15E)

5

Control unit, cab (D790-1) transmits a request for increased engine speed on the CAN bus.



6




7

The frame control unit (D797-1) controls the current proportionally to the lever movement to the solenoid valve lift mast (Y6005) or the Solenoid valve lower (Y6004).

I = 380–650 mA


8

Solenoid valve lift (Y6005) or Solenoid valve lower (Y6004) pressurises lift, tilt and the attachment control valve's lift spool with servo pressure.

-

Lift, tilt and attachment control valve, description, page 7:14

9

Hydraulic oil pump load handling feeds the lift, tilt and attachment control valve with hydraulic pressure.


Section 10 Common hydraulics, group 10.4.1 Gear pump

10

The lift, tilt and attachment control valve's lift spool change position and then pressurise the lift cylinders and accumulator lifting/lowering.

-


11

Accumulator lift equalizes the pressure surges that occur in the lift cylinders when the machine is running.

-

Accumulator lift, description, page 7:30

12

The lift cylinders are pressurised and the mast is lifted or lowered.

-

Lift cylinder, description, page 7:15

3

D3: Diagnostic menu, see section 8 Control system, group 8.4.1.6 CAN/POWER, menu 6

D7: Diagnostic menu, see section 8 Control system, group 8.4.8.3 ELSERV, menu 3 and 8.4.8.4 ELSERV, menu 4

Lift The oil is led by a non-return valve past the restrictor to the lifting cylinders' piston side. Lower The oil passes through a restrictor back to the lift, tilt and attachment control valve. 13

The oil filter cleans the return oil from the lift cylinders before it is collected in the hydraulic oil tank.

-

Section 10 Common hydraulics group 10.6.7 Hydraulic oil filter.

14

Damping

UB771/1 = 5 V

When the mast is approx. 50 cm from its topmost position, damping is activated.

UB771/2 = 0 V

Mast position sensor, description, page 7:25

UB771/3 = 0.5-4.5 V

The mast position sensor (B7211-2) sends the frame control unit (D797-1) a voltage signal proportional to the lift height. The control unit then transmits a damping request on the CAN bus.


Section 11 Common electrics, group 11.5.3.3 Frame control unit D14: Diagnostic menu, see section 8 Control system, group 8.4.8.15 ELSERV, menu 15.

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7:10

Pos 15

16

7 Load handling – Hydraulic oil pump

Explanation

Signal description

Reference

The frame control unit (D797-1) reduces the control current to the lift solenoid valve (Y6005) or the lower solenoid valve (Y6004).

-


Lift speed decreases.

-

D7: Diagnostic menu, see section 8 Control system, group 8.4.8.3 ELSERV, menu 3 and 8.4.8.4 ELSERV, menu 4 Lift cylinder, description, page 7:15 Hydraulic diagram, see section E Schematics, group 10 Common hydraulics, Hydraulic diagram

7.2.1 Hydraulic oil pump Hydraulic oil pump, general See section 10 Common hydraulics, group 10.4.1 Gear pump with fixed displacement.

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7 Load handling – Pressure reducer

7:11

7.2.3 Pressure reducer Pressure reducer, description The pressure reducer is located in the valve block accumulator charging and priority valve that is part of the main valve, see section 10 Common hydraulics, group 10.5.6 Main valve. The main valve is located on the lifting beam in front of the gearbox in the engine compartment. The pressure reducer reduces the oil pressure from the Hydraulic oil pump brake and steering to the servo pressure lift, tilt and attachment control valve, see Lift, tilt and attachment control valve, description, page 7:14.

1 2 3 4

5 13

6 12 11

10

9

8

015032

7

1.


2.


3.


4.


5.


6.


7.


8.


9.


10. Measuring outlet accumulator pressure [ACC M] 11. Adjusting screw servo pressure 12. Connection valve block brakes, accumulator charging [ACC] 13. Measuring outlet pump pressure brake and steering [PM]


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7:12


Servo pressure, check


˚C

Operate and warm up the machine so that the hydraulic oil reaches operating temperature, 50 ºC.

2


3


4

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

5

Close the relief valve attachment and the accumulator drain valve.

6


000475

˚C

1

014652


014619

Measuring outlet, servo pressure [PPM]


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7:13

Check that the servo pressure corresponds with the pressure on the pressure plate.

8

If necessary, adjust the servo pressure on the valve block accumulator charging and priority valve.

015022

7

Pressure plate, servo pressure

Undo the lock nut and adjust the pressure by turning the adjusting screw. Clockwise: reduce pressure. Anticlockwise: increase pressure. 9


10 Depressurise the hydraulic systems, See section B Safety.

015027


Adjusting screw, servo pressure 12 Close the relief valve attachment and the accumulator drain valve.

NOTE

014619




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7:14

7 Load handling – Control valve, lift and tilt

7.2.5 Control valve, lift and tilt Lift, tilt and attachment control valve, description Lift slide

Lift, tilt and attachment control valve controls the speed and direction of the lift and tilt and feeds pressure to the attachment control valve. Control valve lift, tilt and attachment is a part of the main valve, see section 10 Common hydraulics, group 10.5.4 Main valve. The main valve is located on the lifting beam in front of the gearbox in the engine compartment.

1 2 3

The valve has three sections, one for the lift function, one for the tilt function and one to pressurise the control valve attachment. The sections have many similarities, but are described separately under the respective function. For tilt, see Lift, tilt and attachment control valve, description, page 7:60, for attachment see Lift, tilt and attachment control valve, description, page 7:40. Electric solenoid valves control the flow from the valve.

015081

4

1.

Solenoid valve, lower (Y6004)

2.

Solenoid valve, lift (Y6005)

3.

Connection left lift cylinder

4.

Connection right lift cylinder

The control valve is proportionally controlled by solenoid valves. This means that both volume and direction of the flow from the valve can be adjusted and that the valve also sends a control signal to the variable pumps. Electrically controlled pressure reducing valves (solenoid valves) convert electric current into a low hydraulic pressure that is proportional to the current, so-called servo pressure. The servo pressure acts on the spring-centred control slide in the control valve for the function in question and thereby controls the main flow. The speed of the function is controlled by means of the flow being regulated in proportion to the lever movement.

Lift slide The lift slide controls the direction and flow of the oil to the lift cylinder.

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

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

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7 Load handling – Lift cylinder

7:15

7.2.7 Lift cylinder Lift cylinder, description The lift cylinders lift and lower the inner mast which runs in the outer mast. The lower part of the lift cylinders is fastened to the outer mast, while its upper part is fastened to the inner mast, one on the right and one on the left side of the mast. The lift cylinder is fastened in the mast with nuts in the bottom and a washer and screw in the top.

009916

The lift cylinders are connected in parallel and are fed from one section of the lift, tilt and attachment control valve, see Lift, tilt and attachment control valve, description, page 7:14. On the piston side there is a built-in load control valve. The load control valve consists of a restrictor and a non-return valve. The non-return valve directs oil past the restrictor when lifting and forces the oil to pass through the restrictor when lowering. This limits the lowering speed.



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7:16

7 Load handling – Mast

7.2.9 Mast Mast, description 1

The mast which has a clear view design lifts the load. The trolley runs in the mast, which in turn holds the side lift attachment.

2

The lower part of the mast is fastened to the frame with two shafts in both of the double lugs on the front of the frame. The mast is also fastened in the frame with two tilt cylinders. The mast consists of an outer mast and an inner mast manufactured in high-strength steel with a minimum number of welds to provide maximum strength. The inner mast runs in the outer mast and is lifted and lowered with the lift cylinders. Between the inner and outer masts are mast wheels and slide plates that guide the inner mast in the outer mast and reduces the friction between the mast parts.

3

The lower part of the lifting cylinders is fastened to the outer mast, while its upper part is fastened to the inner mast. When the oil is pushed into the lift cylinders the cylinders' piston rods are pushed out and the inner mast is lifted. The chain, which is attached to the trolley (and in the outer frame), runs over chain wheels in the top of the inner mast. In this way even the trolley is lifted at the same time as the inner mast.

4

Hydraulic hoses and cables for the trolley and side lift attachment functions run along the left side.

CAUTION

009918

The mast and its component parts are tested under harsh operating conditions and environments to ensure a long and trouble-free life.

1.

Inner mast

2.

Lifting eye

3.

Outer mast

4.

Lift cylinder

Despite these efforts, problems can arise due to neglected maintenance, improper handling, malfunction or damage to a mast wheel, mast or trolley. For example, lamination or pitting could occur on the mast beam flange. This most often occurs on the inner mast, but could also occur on the outer mast. Repairs to the mast may only by performed on the flanges on the outer and inner mast beams according to special instructions, see Flanges on outer and inner mast beam, repair, page 7:23.

Mast, removing


NOTE It is possible to remove the trolley and the side lift attachment as a unit.

VDCT01.02GB

1

Remove the side lift attachment; see Side lift attachment, removing, page 7:52.

2

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



7:17

Connect the lifting equipment to the lifting lugs at the top of the mast in a secure manner.

4

Start the engine and tilt the mast forwards as far as possible.

5

Turn off engine.

6

Turn the start key to position I and activate the hydraulic functions to depressurise the hydraulic system.

7


8

Mark up and disconnect the hydraulic connections of the lift cylinders.

009974

3

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

009980

9

10 Mark up and release the hydraulic connections on the front plate on the mast. Let the oil drain out.

NOTE

009981


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


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7:18


12 Fasten one of the tilt cylinders in the lifting equipment (overhead crane). 13 Release the tilt cylinder from the mast. Remove the cylinder shaft. If necessary, use the threaded hole and a puller to press the shaft out. Start the engine and retract the cylinder so that it comes loose from the mounting in the mast. Turn off engine. Save the circlips. Refit the shaft in the tilt cylinder. Lower the cylinder onto a block of wood. Then slacken and remove the lifting equipment (overhead crane).

009984

Repeat the procedure for the other cylinder.

009979

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

15 Release the mast from the chassis.

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

009983

Risk of personal injury!

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7:19

009985

16 Lift aside the mast.

009975

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


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7:20


Mast, installing

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

2


3


4

Connect lifting equipment to the mast in a secure manner so the mast does not tip when lifted.

5

The shafts and bearing surfaces must be checked before the mast is refitted for deep grooves/scratches, fibres must not protrude above the bearing surface. If there are signs of damage, the shaft/bearing must be replacement.

009975

1

NOTE The mast is attached to the machine's frame with strong shafts which run in maintenance-free bearings. It is extremely important that bearing surfaces are absolutely clean when the mast is installed. 009977

The shafts and bearings mentioned above must NEVER be lubricated with oil or grease. Check that seals are intact and clean. 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

6

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7:21

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

8

Fasten the shafts with bolts and lock nuts.

9

Start the engine and tilt the mast forwards as far as possible.

009978

7

10 Turn off engine. 11 Turn the start key to position I and activate the hydraulic functions to depressurise the hydraulic system.

009979

12 Turn the start key to position 0 and switch off the main power.

009982

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

14 Connect the tilt cylinders to the mast. If necessary, adjust the cylinders' stroke so that the cylinders pull the mast straight. This is done by slackening the screws and turning the piston with a hook spanner. Tighten the screws to 136 Nm.

009996

Fit the shafts and lock with circlips.


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7:22


15 Lubricate the connectors with contact grease and join them up.

009981

16 Remove the plugs and connect the mast's hydraulic hoses on the machine's front panel.

17 Remove the plugs and connect the hydraulic hoses to the lift cylinders. 18 Turn on the power supply and start the engine. 19 Check that the hydraulic connections are sealed tightly. 20 Check the mast functions. 21 Fit the trolley; see Trolley, installing, page 7:27.

009980

22 Fit the side lift attachment; see Side lift attachment, installing, page 7:54.

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7:23

Flanges on outer and inner mast beam, repair

NOTE Read the safety instructions for oil before working, see section B Safety. If the surface of the flanges has started to break down into small flakes, this can be repaired so that the mast can still be used. This is rectified by first grinding down the attacked surfaces and then "run-in" the surface. 1 Machine in service position, see section B Safety. 2


3

Removing the mast, please refer to Mast, removing, page 7:16.

4

Separate the outer and inner mast.

5

Clean the mast components.

6

Grind the affected surfaces with a belt sander until the surface is smooth and bright. Start with grit size 36-40 and finish with 60-80. Grind in the longitudinal direction of the beam.

010127C

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 Cargotec. 7

Apply a thin layer of slide grease to the sliding surfaces of the outer mast and reassemble the inner and outer masts.

8

Apply a thin layer of slide grease to the sliding surfaces of the inner mast and fit the mast on the machine; see Mast, installing, page 7:20.

9

Fit the trolley; see Trolley, installing, page 7:27.

Mast beam size 250 mm.

10 Lift and lower the mast as follows to check its function. Lift and lower the mast 20 times with 50% of the maximum load at the right centre of gravity distance. Lift and lower the mast 20 times with 75% of the maximum load at the right centre of gravity distance. Lift and lower the mast 20 times with the maximum load at the right centre of gravity distance. 11 Check that contact surfaces look normal. If not, contact Cargotec.


VDCT01.02GB

7:24


Slide plates in inner mast, adjusting

NOTE If the slide plate extends less than 3 mm from the holder, replace it. 1

Lubricate the inner sliding surfaces of the outer mast with a thin layer of slide grease.

2

Lift the inner mast 200 mm.

3

Adjust the slide plate in the bottom part of the outer mast so that it lies against or has no more than 0.5 mm play to the outer mast. Use a suitable number of shims in the rear and front of the slide plate so that the slide plate lies evenly against the entire sliding surface. Raise the mast to its end position and check that the slide plates do not pinch too hard against the sliding surface.

010152

4

Slide plates in outer mast, adjusting

NOTE If the slide plate extends less than 3 mm from the holder, replace it. 1

Lubricate the outer sliding surfaces of the inner mast with a thin 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. Raise the mast to its end position and check that the slide plates do not pinch too hard against the sliding surface.

010130

5

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7 Load handling – Mast position sensor

7:25

Mast wheel, adjusting 1

1

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

NOTE Check that the cover washer is centred on the clamping screw.

2 2

3

Screw in the clamping screw (position 5) so that the wheel is completely locked.

NOTE

4

Rotate the mast wheel while tightening the clamping screw.

5 3

6 7

Loosen the clamping screw until the wheel rotates, slightly slowly. Turn the clamping screw so that the next hole for the tubular pin fits.

NOTE Check that there is clearance between the mast wheel and the mast beam. Lock the clamping screw with the spring pin.

010126

4

1.

Impeller

2.

Circlip

3.

Cover washer

4.

Spring pin

5.

Clamping screw

6.

Inner bearing

7.

Outer bearing

7.2.10 Mast position sensor Mast position sensor, description Mast position sensor (B7211-2) activates damping when lifting when the mast approaches its upper end position. The position sensor sends a signals to the Frame control unit (D797-1) when the mast approaches the end position. The signal can be checked from the diagnostic menu, see section 8 Control system, group 8.4.8.15 ELSERV, menu 15. For checking and adjusting, see Position sensor, checking and adjustment, page 7:3.


VDCT01.02GB

7:26

7 Load handling – Trolley

7.2.11 Trolley Trolley, description The trolley holds the side lift attachment and runs along the inner mast with slide plates and mast wheels. The attachment can be shifted sideways ±600 mm with a hydraulic cylinder that sits between the attachment and trolley.

2

Also located on the trolley are the Attachment control unit (D791-1), attachment control valve and buzzer automatic spreading 20'-40'

1

)

(

3

See also Side shift cylinder, description, page 7:37.

3 1.

Side shift cylinder

2.

Control valve, attachment

3.

Slide plates

4.

Mast wheels

013589

4

Trolley, removing


Remove the side lift attachment; see Side lift attachment, removing, page 7:52.

2

Connect lifting equipment to the trolley in a secure manner.

3

Disconnect the main power supply.

4

Disconnect the trolley cable by undoing the lock plate screws.

009995

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

VDCT01.02GB



5

7:27

Mark up and disconnect the carriage's hydraulic connections. Let the oil run out.

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

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.

009987

6

10 Lower the mast again. 11 Lift aside the trolley. Put it on blocks and supports to prevent damage to the cylinders.

013591

12 Undo the lifting equipment (travelling crane).

Trolley, installing

NOTE Read the safety instructions for oil before working, see section B Safety. Park the machine with the mast vertical.

2

Raise the mast high enough to position the carriage in the inner mast and lift it into place.

3

Run down the mast so the trolley fastens in the inner mast. Stop the mast in a position where the chains can be attached to the trolley. Fit the chain tensioners and adjust and fasten with the nuts.

4

Lower the carriage as far as possible.

5

Turn off engine.

6


7


013591

1


VDCT01.02GB

7:28


Remove the plugs and connect the mast's hydraulic hoses and the carriage wiring.

009987

8

9

Connect the trolley cable. Lubricate the connectors with contact grease and connect them Fasten the wiring with the lock plate.

10 Fit the side lift attachment; see Side lift attachment, installing, page 7:54. 11 Turn on the power supply and start the engine. 12 Check that the hydraulic connections are sealed tightly.

009995

13 Check the trolley functions.

VDCT01.02GB



7:29

Slide plates in trolley, adjusting and, if necessary, replacing 1


NOTE Minor adjustment to the clearance between the trolley and inner mast is possible without removing the trolley.

A

2

If the slide plate extends less than 3 mm from the holder, replace it.

3

Use a gauge in the centre of the beam to measure the interior width of the inner mast.

4

Use a sliding calliper to measure the external measurements between the trolley slide plates.

013593

B

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

C

013648

D

Measure the exterior measurements between the trolley slide plates (C and D).


VDCT01.02GB

7:30

7 Load handling – Pipes and hoses

5

Adjust trolley clearance by removing the screws and adding or removing shims. a.

2

If the width at A and B is the same: Adjust C and D to be equal to or max. 0.5 mm more than A.

1

b.

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

c.

If A is less than B: Adjust C to be equal to or max. 0.5 mm more than A.

1

2 1.

Screws

2.

Shim

013648

Adjust D to be equal to or max. 0.5 mm less than B. 6

Lubricate the inner sliding surfaces of the inner mast with a thin layer of slide grease.

7

Fit the trolley; see Trolley, installing, page 7:27.

8

Lift the trolley all the way up and check that the slide plates do not clamp too hard against the sliding surfaces.

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


7.2.14 Accumulator lift Accumulator lift, description 1

2

014672

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

1.

Accumulator brake system

2.

Accumulator lift

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

VDCT01.02GB


7 Load handling – Side shift

7:31

7.4 Side shift Side shift, function description Condition

Reference value

Reference

Control breaker

Not activated


1a D1

1b

D790-1 D797-1

2 D791-1

3

7

D7 D3

C

4

8

P2 P2

5

11

9

A

6

T2 A

B

015076

10

Pos

Explanation

Signal description

Reference

1a

The side shift control lever (R8073-P3) sends the cab control unit (D790-1) a voltage signal proportional to lever movement.

U = 0.5-4.5 V


Left: U = <2.5 V

D1: Diagnostic menu, see section 8 Control system, group 8.4.9.1 ATTACH, menu 1

Right: U = >2.5 V 0.5 V is the highest left side shift speed and 4.5 V is the highest right side shift speed. Lower voltage than 0.5 V and higher voltage than 4.5 V is used to detect faults in cable harnesses and controls.

1b


US815-P3 = 0.5-4.5 V

Control lever, description, page 7:4

Right: US815-P3 = <2.5 V


Left: US815-P3 = >2.5 V 0.5 V is the highest right side shift speed and 4.5 V is the highest left side shift speed. Lower voltage than 0.5 V and higher voltage than 4.5 V is used to detect faults in cable harnesses and controls.

2

Control unit, cab (D790-1) transmits side shift left or right on the CAN bus.



3

The frame control unit (D797-1) activates the solenoid valve for main pump relief (Y6062-2).

U = 24 V

Section 11 Common electrics, group 11.5.3.2 Frame control unit D3: Diagnostic menu, see section 8 Control system, group 8.4.5.6 HYD, menu 6


VDCT01.02GB

7:32


Pos

Explanation

Signal description

Reference

4

Solenoid valve, relief main pump (Y6062-2) pressurises the attachment spool in the lift, tilt and attachment control valve with servo pressure.

-


5




-

6

The control valve lift, tilt and attachment's attachment slide changes position and pressurises the control valve attachment.

-


7

The attachment control unit (D791-1) activates the solenoid valve for side shift left (Y6020) or the solenoid valve for side shift right (Y6021).

U = 24 V

Section 11 Common electrics, group 11.5.3.5 Control unit, attachment

8

The solenoid valve for side shift left (Y6020) or the solenoid valve for side shift right (Y6021) pressurises the side shift spool in the attachment control valve.

-

Attachment control valve, description, page 7:33

9

The control valve's side shift slide changes position and pressurises the side shift cylinder.

-


10

The side shift cylinder pushes in the main beam sideways in relation to the trolley.

-

Side shift cylinder, description, page 7:37

11


-


D7: Diagnostic menu, see section 8 Control system, group 8.4.9.11 ATTACH, menu 11 and group 8.4.9.12 ATTACH, menu 12

Hydraulic diagram, see section E Schematics, group 10 Common hydraulics, Hydraulic diagram


VDCT01.02GB


7 Load handling – Control valve, attachment

7:33

7.4.2 Control valve, attachment Attachment control valve, description Side shift slide

1

2

3

Control valve attachment controls the hydraulic functions on the attachment. The control valve is located up on the trolley. Solenoid valves control the flow from the valve.

4

The control valve is an electro-hydraulically controlled, proportional and pressure-compensated directional control valve. Electrically controlled solenoid valves convert current to servo pressure. The servo pressure controls the spring-centred valve slides, which control pressure and flow for the function in question. The valve slides have a flow limit so that several functions can be used simultaneously. This enables them to control the main flow.

5 10 6

The control valve has built-in supply of pilot pressure. This means that the valve has built-in pressure reduction which converts feed pressure to servo pressure for the various functions. Supply of pilot pressure is common for all functions. This reduces pressure variations due to long hoses and reduces the number of hoses to the valve.

9 7 8

The attachment control valve is fed by lift, tilt and attachment control valve, see Lift, tilt and attachment control valve, description, page 7:40.

015084

The control valve has the following sections:

1.

Solenoid valve, side shift right (Y6021)

2.

Solenoid valve, lock twistlock (Y6040)

3.

Solenoid valve spreading in left (Y6019L)

4.

Solenoid valve spreading in right (Y6019R)

5.

Solenoid valve spreading out right (Y6018R)

6.

Solenoid valve spreading out left (Y6018L)

7.

Solenoid valve, open twistlock (Y6039)

8.

Solenoid valve, side shift left (Y6020)

9.

Connection, feed from hydraulic oil pump (P)

10. Connection return to tank (T)

•

Side shift

•

Spreading right extension beam, see Attachment control valve, description, page 7:48

•

Spreading left extension beam, see Attachment control valve, description, page 7:48

•

Twistlocks, see Attachment control valve, description, page 7:67

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

Solenoid valve, side shift left The solenoid valve for side shift left controls pressure to the side shift spool so that the side shift spool opens and pressurises the side shift cylinder. Solenoid valve, side shift left is controlled electrically by Solenoid valve, side shift left (Y6020), which is activated by Control unit, attachment (D791-1). The solenoid valve directs servo pressure to the side shift slide in proportion to the control current to the solenoid valve. The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.9.11 ATTACH, menu 11.

Solenoid valve, side shift right The solenoid valve for side shift right controls pressure to the side shift spool so that the side shift spool opens and pressurises the side shift cylinder. Solenoid valve, side shift is controlled electrically by Solenoid valve, side shift right (Y6021), which is activated by Control unit, attachment (D791-1). The solenoid valve directs servo pressure to the side shift slide in proportion to the control current to the solenoid valve. The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.9.12 ATTACH, menu 12. Workshop Manual DCT 80-90

VDCT01.02GB

7:34


Control valve attachment, replacement



2


3

Remove the attaching bolts and lift away the plate fitted over the control valve.

4

Mark and disconnect the hydraulic hoses from the control valve.

NOTE Plug all connections immediately to protect the hydraulic system from impurities. Mark and disconnect the cable harness from the control valve.

013595

5

VDCT01.02GB



7:35

6

Remove the attaching bolts and lift away the valve. Place the valve on a clean and protected surface.

7

Transfer the connection adapters to the new control valve.


NOTE 013596

Transfer one connection at a time so that the marking is not mixed up. 8

Mark up the solenoid valves on the new control valve.

9

Lift the valve into place and fit the attaching bolts.

10 Connect the cable harness to the control valve according to the marking. 11 Connect the hydraulic hoses to the control valve in according to the marking.

NOTE Check that the O-rings are intact, clean and in the correct position. 12 Turn on the main electric power and start the engine. 13 Check that the valve\qs hydraulic connections are sealed. 14 Check that the attachment is working.

CAUTION Air in the hydraulic system may cavitate and result in product damage. Activate the steering carefully and operate at the lowest possible speed a couple of times to avoid cavitation. 15 Check the oil level in hydraulic oil tank with all hydraulic cylinders in the retracted position. The oil level should be at the top of the sight glass. Top up if necessary.

CAUTION Do not overfill! Leakage and environmental damage! Check the hydraulic oil level with all hydraulic cylinders fully retracted.


VDCT01.02GB

7:36


Control valve attachment, checking hydraulic pressure


˚C

Operate and warm up the machine so that the hydraulic oil reaches operating temperature, at least 50 ºC.

2

Turn off engine.

3


4

Connect a pressure gauge (0-25 MPa) to the feed pressure measuring outlet on the control valve attachment.

5

Start the engine and run at max. revs. Activate a hydraulic function on the attachment and read the pressure gauge. The pressure must correspond with the pressure plate.

6

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

000475

˚C

1

015085


015025

Measuring outlet, feed pressure control valve, attachment

VDCT01.02GB


7 Load handling – Side shift cylinder

7:37

7.4.3 Side shift cylinder Side shift cylinder, description

013598

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


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


VDCT01.02GB

7:38


Slide plates between trolley and attachment, adjustment 1

1

Park the machine with the attachment lowered as far as possible and spreading run all the way in.

2


3

Clean and measure the thickness of the lower slide plates.

NOTE The thickness of the slide plate should be at least 10 mm. 4

Replace the lower slide plates, if necessary, by loosening the attachment's mounting.

5

Unload the tension from the slide plate in question. The pressure can be relieved from the slide plates by raising the outer edge of the side lift attachment or inserting wedges to alter the position of the side lift attachment in the trolley.

6

Remove the slide plate and fit a new one. Repeat with the other lower slide plates (4 plates).

7

Reassemble the attachment's mounting.

3

013681

2 3 The illustration shows the slide plates between the attachment and trolley. 1.

Upper slide plates

2.

Lower slide plates

3.

Attachment's fastening

VDCT01.02GB


7 Load handling – Relief valve, attachment

1

2

8

3

7:39

Clean and measure the thickness of the upper slide plates. The upper slide plates can be replaced and adjusted using shims when the attachment is in position in the trolley.

NOTE The thickness of the slide plate should be at least 10 mm. 9

Remove the counterhold.

10 Loosen the slide plate's attaching bolt slightly so that the slide plate releases from the carriage.

4

11 Insert the required number of shims to remove the play between attachment and carriage. Alternatively replace the slide plate.

013682

12 Refit the counterhold and tighten the attaching bolt that secures the slide plate.

The illustration shows the slide plates between the trolley and attachment. 1.

Upper slide plates

2.

Shim

3.

Counterhold

4.

Screw

13 Check the play between side lift attachment and the trolley. The play should be less than 1 mm with all slide plates fitted. Use more shims to adjust any play.

NOTE Do not use too thick shims. Too little play increases wear on the slide plates.

NOTE Check that the attaching bolts for all slide plates are tightened. 14 Check that the sliding surface is clean and lubricate the sliding surface on the side lift attachment. 15 Start the machine and side shift the attachment to its end positions. Check that the play between the trolley and the attachment is sufficient along the whole attachment and that no metallic contact occurs. Adjust as necessary, using the shims.

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



VDCT01.02GB

7:40

7 Load handling – Lift, tilt and attachment control valve

7.4.9 Lift, tilt and attachment control valve Lift, tilt and attachment control valve, description Attachment slide


1

The attachment control valve is fed through a separate section in the lift, tilt and attachment control valve. The solenoid valve hydraulic pressure attachment (Y6062-2) is also activated when attachment functions are activated. See also Lift, tilt and attachment control valve, description, page 7:14.

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

2

1.

Solenoid valve hydraulic pressure attachment (Y6062-2)

2.

Connection feed pressure control valve, attachment

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


VDCT01.02GB


7 Load handling – Spreading (positioning)

7:41

7.5 Spreading (positioning) Spreading, function description Condition

Reference value

Reference

Control breaker

Not activated


Twistlocks

Unlocked or bypass activated


1a

D1 2

D790-1 D797-1 D3

4

C

D791-1

3

D13

7, 14, 19

D8

D9 9, 20

8, 15

C

D18

P2 P2

5

23

A

6

T2 B

A

A

B

10, 16, 21 18

13 11, 17

015077

1b

Section 8 Control system, group 8.2.2 Bypass

12, 22

Pos

Explanation

Signal description

Reference

1a

The switch for spreading 20'-40' (S1012) sends a voltage signal to the cab control unit (D790-1).

U = 24 V

Switch spreading 20'-40', description (linear control levers), page 7:6

The control lever (S815-T1.1 and S815-T1.2) sends a voltage signal to the cab control unit (D790-1).

Spreading: US815-T4 = 24 V


Out: US815-T1.2 = 24 V


1b


In: US815-T1.1 = 24V 2

The cab control unit (D790-1) transmits spreading in or out on the CAN bus.



3


U = 24 V


4


-


5





-


VDCT01.02GB

7:42


Pos

Explanation

Signal description

Reference

6


-


7

The attachment control unit (D791-1) activates the Solenoid valve spreading out left (Y6018L) and Solenoid valve spreading out right (Y6018R) or Solenoid spreading in left (Y6019L) and Solenoid valve spreading right (Y6019R).

I = 350–600 mA


The solenoid valve for spreading out left (Y6018L) or the solenoid valve for spreading in left (Y6019L) pressurises the left spreader spool in the attachment's control valve.

-

The solenoid valve for spreading out right (Y6018T) or the solenoid valve for spreading in right (Y6019T) pressurises the right spreader spool in the attachment's control valve.

-

10

The control valve's spreader spools change position and direct pressure to the spreader cylinders.

-


11

Left spreader cylinder pushes left spreader beam in or out in the attachment.

-

Spreading cylinder, description, page 7:49

12

Right spreader cylinder pushes right spreader beam in or out in the attachment.

-


13

The sensor for end position 20'-40' left (B769L) sends a voltage signal to the attachment control unit (D791-1).

Sensor directly opposite indicator plate: U > 24 V

Position sensor spreading, description, page 7:56

The attachment control unit (D791-1) reduces the control current to the solenoid valve for spreading out left (Y6018L) or the solenoid valve for spreading in left (Y6019L).

-

The solenoid valve for spreading out left (Y6018L) or the solenoid valve for spreading in left (Y6019L) reduces the pressure to the left spreader spool in the attachment's control valve.

-

16

The control valve's spreading slide left changes position and lowers the pressure on the left spreading cylinder.

-


17

Spreader speed decreases.

-


18

The sensor for end position 20'-40' right (B769R) sends a voltage signal to the attachment control unit (D791-1).

Sensor directly opposite indicator plate: U = 24 V


8

9

14

15

VDCT01.02GB

D8–D9: Diagnostic menu, see section 8 Control system, group 8.4.9.17 ATTACH, menu 17 – 8.4.9.20 ATTACH, menu 20

Attachment control valve, description, page 7:33 D8: Diagnostic menu, see section 8 Control system, group 8.4.9.17 ATTACH, menu 17 and 8.4.9.18 ATTACH, menu 18 Attachment control valve, description, page 7:33 D9: Diagnostic menu, see section 8 Control system, group 8.4.9.19 ATTACH, menu 19 and 8.4.9.20 ATTACH, menu 20

D13: Diagnostic menu, see section 8 Control system, group 8.4.9.6 ATTACH, menu 6 Section 11 Common electrics, group 11.5.3.5 Control unit, attachment D8: Diagnostic menu, see section 8 Control system, group 8.4.9.17 ATTACH, menu 17 and 8.4.9.18 ATTACH, menu 18 Control valve attachment, replacement, page 7:34 D8: Diagnostic menu, see section 8 Control system, group 8.4.9.17 ATTACH, menu 17 and 8.4.9.18 ATTACH, menu 18




7:43

Pos

Explanation

Signal description

Reference

19

The attachment control unit (D791-1) reduces the control current to the solenoid valve for spreading out right (Y6018R) or the solenoid valve for spreading in right (Y6019R).

-


The solenoid valve for spreading out right (Y6018R) or the solenoid valve for spreading in right (Y6019R) reduces the pressure to the right spreader spool in the attachment's control valve.

-

21

The control valve's spreading slide right changes position and lowers the pressure on the right spreading cylinder.

-


22

Spreader speed decreases.

-


The hydraulic oil filter cleans the return oil from the lift cylinders before it is collected in the hydraulic oil tank.

-


20

23

D9: Diagnostic menu, see section 8 Control system, group 8.4.9.19 ATTACH, menu 19 and 8.4.9.20 ATTACH, menu 20 Control valve attachment, replacement, page 7:34 D9: Diagnostic menu, see section 8 Control system, group 8.4.9.19 ATTACH, menu 19 and 8.4.9.20 ATTACH, menu 20



VDCT01.02GB

7:44


30-foot stop, function description Condition

Reference value

Reference

Control breaker

Not activated


Twistlocks



2b

Section 8 Control system, group 8.2.2 Bypass

D1

2a

D2 1 35

30-

D791-1

3

4,7,9,11

D5 D8

4,7

4,7

5

6

8

30'

30'

014803

D790-1

10

Pos

Explanation

Signal description

Reference

1

The switch for stop at 30' (S1004) sends a voltage signal to the cab control unit (D790-1).

Switch in on position:

Switch stop at 30', description (linear control levers), page 7:6

Conn. 1: U = 0 V Conn. 5: U = 24 V


Switch in off position: Conn. 1: U = 24 V Conn. 5: U = 24 V 2a

2b


U = 24 V DC


The control lever (S815-T1.2) sends a voltage signal to the Cab control unit (D790-1).

Spreading: US815-T4 = 24 V


Out: US815-T1.2 = 24 V



In: US815-T1.1 = 24V 3

Control unit, cab (D790-1) sends spreading 30' on the CAN bus.



4

Spreading is activated in the same way as the normal spreading steps 3–14.

-

Spreading, function description, page 7:41

5

When the left spreader beam approaches the 30' mark, the sensor for 30' end position left (B777L) sends a voltage signal to the attachment control unit (D791-1).



When the right spreader beam approaches the 30' mark, the sensor for 30' end position left (B777R) sends a voltage signal to the attachment control unit (D791-1).


6

VDCT01.02GB



Position sensor spreading, description, page 7:56 D5: Diagnostic menu, see section 8 Control system, group 8.4.9.6 ATTACH, menu 6


7:45

Pos

Explanation

Signal description

Reference

7

The attachment control unit (D791-1) dampens the speed in the same way as in normal spreading, steps 17–22.

-


8

When the left spreader beam is at the 30' mark, the sensor for 20'-40' end position (B769L) sends a voltage signal to the attachment control unit (D791-1).



9

The attachment control unit (D791-1) cuts off the current to the solenoid valve for spreading out left (Y6018L) or the solenoid valve for spreading in left (Y6019L).

U=0V


10

When the right spreader beam is at the 30' mark, the sensor for 20'-40' end position (B769R) sends a voltage signal to the attachment control unit (D791-1).



The attachment control unit (D791-1) cuts off the current to the solenoid valve for spreading out right (Y6018R) or the solenoid valve for spreading in right (Y6019R).

U=0V

11


D8: Diagnostic menu, see section 8 Control system, group 8.4.9.5 ATTACH, menu 5 Attachment control valve, description, page 7:33



VDCT01.02GB

7:46


Automatic spreading 20-40 foot, function description

Condition

Reference value

Reference

Control breaker

Not activated


Twistlocks



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

1a

3

D10

10

D11

D8

8

D795

D790-1 4, 5, 8

11

D791-1

9

D5

7

D13

6

13

D9

D12

9

12

Pos

Explanation

Signal description

Reference

1a.


U = 24 V DC


The control lever (S815-T1.1 and S815-T1.2) sends a voltage signal to the cab control unit (D790-1).

Spreading: US815/T4 = 24 V


Out: US815/T1.2 = 24 V


1b


In: US815/T1.1 = 24 V 2

The switch for automatic spreading 20'-40' (S1012-2) sends a voltage signal to the cab control unit (D790-1).

Switch in on position: US199-2/2 = 0 V US199-2/5 = 24 V

Switch automatic spreading, description (linear control levers), page 7:7 D2: Diagnostic menu, see section 8 Control system, group 8.4.9.3 ATTACH, menu 3

Switch in off position: US199-2/2 = 24 V US199-2/5 = 24 V 3

The cab control unit (D790-1) transmits "automatic spreading out" or "automatic spreading in" on the CAN bus.



4

The attachment control unit (D791-1) activates spreading the same way as in steps 3-14 of normal spreading.

-


5

The attachment control unit (D791-1) activates the automatic spreading buzzer (H9003).

Buzzer active: U = 24 V

Buzzer automatic spreading 20'-40', description, page 7:56

VDCT01.02GB



009347

1b

2

D2

D1


7:47

Pos

Explanation

Signal description

Reference

6

Buzzer automatic spreading (H9003) generates acoustic warning signal.


Buzzer automatic spreading 20'-40', description, page 7:56

7

When automatic spreading is active, the KID control unit (D795) activates the Automatic Spreading event menu.

-


8

When the left spreader beam



approaches the 20', 30' ( ) or 40' mark, the sensor for 20'–40' end position left (B769L) sends a voltage signal to the attachment control unit (D791-1), which activates damping for the left spreader beam the same way as in steps 16-22 of normal spreading. 9

When the right spreader beam approaches the 20', 30' ( ) or 40' mark, the sensor for 20'–40' end position right (B769R) sends a voltage signal to the attachment control unit (D791-1), which activates damping for the right spreader beam the same way as in steps 16-22 of normal spreading.

10

When the left spreader beam is at the 20', 30' ( ) or 40' mark, the sensor for end position 30' left (B777L) sends a voltage signal to the attachment control unit (D791-1).

11

12



30-foot stop, function description, page D9: Diagnostic menu, see section 8 Control system, group 8.4.9.6 ATTACH, menu 6


Position sensor spreading, description, page 7:56 D10: Diagnostic menu, see section 8 Control system, group 8.4.9.6 ATTACH, menu 6

I = 0 mA

When the right spreader beam is


The attachment control unit (D791-1) cuts off the control current the solenoid valve for spreading out right (Y6018R) or the solenoid valve for spreading in right (Y6019R).

Spreading, function description, page 7:41 7:44

The attachment control unit (D791-1) cuts off the current to the solenoid valve for spreading out left (Y6018L) or the solenoid valve for spreading in left (Y6019L).

at the 20', 30' ( ) or 40' mark, the sensor for end position 30' right (B777R) sends a voltage signal to the attachment control unit (D791-1). 13

30-foot stop, function description, page 7:44

Section 11 Common electrics, group 11.5.3.5 Control unit, attachment D11: Diagnostic menu, see section 8 Control system, group 8.4.9.17 ATTACH, menu 17 and 8.4.9.18 ATTACH, menu 18 Position sensor spreading, description, page 7:56 D12: Diagnostic menu, see section 8 Control system, group 8.4.9.6 ATTACH, menu 6

I = 0 mA

Section 11 Common electrics, group 11.5.3.5 Control unit, attachment D13: section 8 Control system, group 8.4.9.19 ATTACH, menu 16 and 8.4.9.20 ATTACH, menu 20 Hydraulic diagram, see section E Schematics, group 10 Common hydraulics, Hydraulic diagram



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7:48


7.5.2 Control valve, attachment Attachment control valve, description Spreader slide

2

1

3

Spreading is controlled by two identical sections in the attachment control valve, one for the right spreader beam and one for the left spreader beam. Both beams are controlled in the same way, which is why they are described together below. For a more detailed description of the valve and component locations, see Attachment control valve, description, page 7:33.

4

5

Spreader slide The valve slides control the direction and speed of the spreading. Each valve slide is controlled by two solenoid valves, one for spreading out and one of spreading in.

10 6

Solenoid valve for spreading out

9 7

The solenoid valves for spreading out control the pressure to the spreader slides so that they open and pressurises the spreader cylinders.

8

015084

Solenoid valve, spreading out left (Y6018L) and solenoid valve, spreading out right (Y6018R) are activated by the attachment control unit (D791-1). The solenoid valve controls the servo pressure to spreader slide proportionally toward the control current.

1.


2.


3.


4.


5.


6.


7.


8.


9.



The signal can be checked with diagnostic menu. •

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

•

Right: section 8 Control system, group 8.4.9.19 ATTACH, menu 19

Solenoid valve for spreading in The solenoid valves for spreading in control the pressure to the spreader slides so that they open and pressurises the spreader cylinders. Solenoid valve, spreading in left (Y6019L) and solenoid valve, spreading in right (Y6019R) are activated by the attachment control unit (D791-1). The solenoid valve controls the servo pressure to spreader slide proportionally toward the control current. The signal can be checked with diagnostic menu. •

Left: section 8 Control system, group 8.4.9.18 ATTACH, menu 18

•

Right: section 8 Control system, group 8.4.9.20 ATTACH, menu 20

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

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7 Load handling – Spreading cylinder

7:49

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

014816

Openings in the sides of the spreader beams and the attachment's main beam make it possible to access the spreader cylinders for maintenance purposes.

7.5.4 Spreader beam Spreader beam, description The spreader beams are the part of the attachment that grips the container Two spreader beams run in the main beam. The spreader beams are pushed in and out by the hydraulic cylinders.

014737

The spreader beam houses twistlocks. See Twistlocks, function description, page 7:64.

Spreader beam slide plates, adjusting/replacing Park the machine with the attachment lowered as far as possible and spreading extended approx. 1000 mm.

2


013683

1000 mm

1


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7:50

7 Load handling – Spreader beam

3

Unscrew the nuts and bolts (position 1) that secure the slide plates.

013684

1

4

Remove the slide plates and shims from the main beam.

013685

Lift the extension section slightly so that the slide the plates are unloaded.

013686

Right side

Left side

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7 Load handling – Main beam, side lift attachment

5

7:51

Refit the slide plates, add a sufficient number shims under the slide plates so that the play between the slide plates and the main beam is 1-3 mm both laterally and vertically. This corresponds to the measurements X + (1-3) mm and Y + (1-3) mm internally between the slide plates.

NOTE Do not use too thick shims. Too little play increases wear on the slide plates.

NOTE Check that the attaching bolts for all slide plates are tightened. Start the machine and check the spreading functioning. Try to lift a container and then check the spreader beams' play again on the attachment's main beam.

013687

6

013688

Right side

Left side

7.5.5 Main beam, side lift attachment Side lift attachment's main beam, description

014817

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


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Side lift attachment, removing


NOTE It is possible to remove the trolley and the side lift attachment as a unit. Park the machine with the mast vertical and the attachment in its lowest position.

2

Turn off engine.

3

Connect lifting equipment (overhead crane) to the attachment in a secure manner.

4

Start the engine and lift slightly with the lifting equipment (overhead crane). Let the machine stand with the ignition on for a while.

5

Turn off engine.

6

Detach the side shift cylinder from the attachment.

014819

1

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

013654

Save the circlips. Refit the shaft in the cylinder.

Fasten the side shift cylinder.

8


9


009997

7

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7:53

10 Mark up and detach hydraulic connections from the side lift attachment and the side shift cylinder.

NOTE

009952


11 Detach the cable harness of the attachment from the attachment control unit. Undo the connectors and protect the terminals by lubricating them with contact grease. Then loosely insert the connectors. Remove the cable harness clamping ring.

12 Loosen the attachment's mounting unit in the trolley.

013680

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


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7:54


Side lift attachment, installing


Park the machine with the mast vertical.

2

Lower the trolley to its lowest position.

3

Turn off engine.

4


5


6

Lift the side lift attachment into place.

7

Fit the lifting carriage's front panels to fix the side lifting attachment in position.

8

Check that the side lift attachment runs correctly in the trolley; see Slide plates between trolley and attachment, adjustment, page 7:38.

9

Clean and apply a layer of lubricating grease to the side shift cylinder shaft prior to installation.

013680

Lifting points side lift attachment

10 Connect the side shift cylinder to the side lift attachment. Align the side shift cylinder, press in the shaft and secure with the circlips.

NOTE

013654

Use an anti-recoil plastic or copper mallet.

VDCT01.02GB

If necessary, detach the hydraulic connections on the side shift cylinder to make it possible to adjust cylinder length.



7:55

11 Attach the cable harness of the attachment to the attachment control unit. Lubricate the connectors with contact grease and join them up. Fasten the wiring with clamps.

12 Remove plugs and connect hydraulic hoses for the side lift attachment and side shift cylinder using the markings as a guide. 13 Turn on the power supply and start the engine. 14 Check that the hydraulic connections are sealed tightly.

009952

15 Check the functions of the side lift attachment.

16 Check the oil level in hydraulic oil tank when all hydraulic cylinders are in the retracted position. The oil level should be at the top of the sight glass. Top up if necessary.



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7:56

7 Load handling – Position sensor, spreading

7.5.6 Position sensor, spreading Position sensor spreading, description 3

4

The spreading position sensors indicate the position of the spreader beams. The position sensors are used to control spreading so that the twistlocks fit the container. The position sensors are located under the protective plate at the rear of the attachment's main beam.

5

Sensor end positions 20' and 40' (B769R and B769L) indicate the end positions for 20 and 40-feet containers. The sensors detect the spreader beams' end positions by means of two indicator plates on top of the spreader beams. The sensor is used to activate damping.

1 2 4

2 1.

Sensor, end position 20' and 40'

2.

Sensor end position 30'

3.

Indicator plate 20'

4.

Indicator plate 30'

5.

Indicator plate 40'

With the 30 feet stop option, two extra sensors are fitted, Sensor end position 30' (B777R and B777L), and two indicator plates. The sensor is used to activate 30-foot stop.

3

1

013676

5

The sensors are supplied power by and send a 24 V signal to Control unit, attachment (D791-1) when the indicator plates pass the sensor. Indicator plates on the spreader units are mounted so that the sensors generate a signal when the spreader unit passes the sensor. The indicator plates and the position of the sensors are designed so that the distance between the spreaders becomes 20' (30') and 40'. The signals can be checked via the diagnostic menu. See section 8 Control system, group 8.4.9.6 ATTACH, menu 6.

Position sensor, checking and adjustment See Position sensor, checking and adjustment, page 7:3.

7.5.7 Buzzer, automatic spread 20'-40' Buzzer automatic spreading 20'-40', description

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


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

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

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7 Load handling – Hydraulic oil filter

7:57



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7:58

7 Load handling – Tilt

7.7 Tilt Tilt, function description Condition

Reference value

Reference

Control breaker

Not activated


1b

1a

D3

D1

D790-1 D797-1

4

2, 3 5

D5 9

6 C P2

11

A

B

8

9

10 Pos 1a

015075

7

10

Explanation

Signal description

Reference

The tilt control lever (R8072-P2) sends the cab control unit (D790-1) a voltage signal proportional to lever movement.

U = 0.5-4.5 V


Out: U = <2.5 V


In: U = >2.5 V 0.5 V is the highest tilt out speed and 4.5 V is the highest tilt in speed. Lower voltage than 0.5 V and higher voltage than 4.5 V is used to detect faults in cable harnesses and controls. 1b


US815-P2 = 0.5-4.5 V


In: US815-P2 <2.5 V


Out: US815-P2 = >2.5 V 0.5 V is the highest tilt in speed and 4.5 V is the highest tilt out speed. Lower voltage than 0.5 V and higher voltage than 4.5 V is used to detect faults in cable harnesses and controls. 2

The cab control unit (D790-1) transmits tilt in or tilt out on the CAN bus.



3

Cab control unit (D790-1) voltage feeds control breaker relay tilt (K3002).

U = 24 V

Section 11 Common electrics, group 11.5.3.2 Frame control unit D5: Diagnostic menu, see section 8 Control system, group 8.4.1.6 CAN/POWER, menu 6

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Pos

7:59

Explanation

Signal description

Reference

4

Control breaker relay tilt (K3002) makes the ground connection between Frame control unit (D797-1) and to Solenoid valve tilt in (Y6011) and Solenoid valve tilt out (Y6010).

-

Section 11 Common electrics, group 11.5.1.4 Emergency stop switch voltage (15E)

5

The frame control unit (D797-1) controls the current proportionally to the lever movement to Solenoid valve tilt in (Y6011) or Solenoid valve tilt out (Y6010).

I = TDB mA


6

The solenoid valve for tilt in (Y6011) or the solenoid valve for tilt out (Y6010) pressurises the tilt spool in the lift, tilt and attachment control valve.

-


7

The hydraulic oil pumps pump oil from the hydraulic oil tank.



8

The control valve's tilt spool changes position and pressurises the load retention valve.

-


9

The load retention valve opens and directs the pressure on to the tilt cylinders.

-

Load holding valve, description, page 7:61

10

The tilt cylinders angle the mast in relation to the frame.

-

Tilt cylinder, description, page 7:61


-

11

D5: Diagnostic menu, see section 8 Control system, group 8.4.8.5 ELSERV, menu 5 and 8.4.8.6 ELSERV, menu 6

Mast, description, page 7:16 Section 10 Common hydraulics group 10.6.7 Hydraulic oil filter.




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7:60

7 Load handling – Control valve, lift and tilt

7.7.5 Control valve, lift and tilt Lift, tilt and attachment control valve, description Tilt slide

1


2

Tilt is controlled by a separate section of the lift, tilt and attachment control valve. See also Lift, tilt and attachment control valve, description, page 7:14. For more information about tilting, see Tilt, function description, page 7:58.

Tilt slide

3 1.

Solenoid valve, tilt in (Y6011)

2.

Solenoid valve, tilt out (Y6010)

3.

Connection rod side tilt cylinders

4.

Connection piston side tilt cylinders

015082

4

When the solenoid valves are activated, the tilt spool is pressurised and controls the direction and flow of oil from the hydraulic oil pumps to the tilt cylinders.

Solenoid valve, tilt out On machines with electric servo, the solenoid valve tilt out is controlled electrically with Solenoid valve tilt out (Y6010) which is activated by the Frame control unit option (D797-1). The solenoid valve directs servo pressure to the tilt spool which is proportional to the control current to the solenoid valve. The signal can be checked from the diagnostic menu, see section 8 Control system, group 8.4.8.6 ELSERV, menu 6.

Solenoid valve, tilt in On machines with electric servo, the solenoid valve tilt in is controlled electrically with Solenoid valve tilt in (Y6011) which is activated by the Frame control unit option (D797-1). The solenoid valve directs servo pressure to the tilt spool which is proportional to the control current to the solenoid valve. The signal can be checked from the diagnostic menu, see section 8 Control system, group 8.4.8.5 ELSERV, menu 5.

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7 Load handling – Load retention valve

7:61

7.7.6 Load retention valve Load holding valve, description

009929

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

Load retention valve

7.7.7 Tilt cylinder Tilt cylinder, description The tilt cylinders sit between the mast and the frame and angle the mast in relation to the machine.

1

3 1.

Tilt cylinder

2.

Mast

3.

Lower mast mounting in frame

009930

2



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



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7 Load handling – Levelling

7:63

7.8 Levelling Mechanical levelling, function description

014021

Mechanical levelling means that the twistlock fasteners can spring out and adjusts the height of the twistlocks according to the incline of the container to be lifted. This means that the machine can handle loads on an uneven surface, up to ± 3° angle.


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7 Load handling – Load carrier

7.9 Load carrier 7.9.1 Twistlocks Twistlocks, description The container is held in place on the side lift attachment with two twistlocks. Twistlocks are controlled with Switch twistlocks. A section of the attachment control valve pressurises two parallel-connected cylinders, one on each side of side lift attachment. Each hydraulic cylinder actuates a linkage that turns a twistlock. Four position sensors, two on each side of the side lift attachment, detect the position of the linkage and indicates whether the twistlocks are open or locked. Indicator lamps on the side lift attachment and in the cab, and a mechanical indicator on the side lift attachment shows the status of the twistlocks. A contact pin and a sensor by each twistlock indicates when the attachment is in contact with the container. This is used to control when the twistlocks can be actuated. An indicator light on the side lift attachment and one in the cab indicate when the side lift attachment is fully aligned. An event menu shows which twistlocks is aligned (1 - 2). Both twistlocks must be aligned in order to actuate the twistlocks.

Twistlocks, function description Condition

Reference value

Reference

Control breaker

Not activated


Alignment

Full alignment or bypass activated

1

Twistlocks, description, page 7:69 Section 8 Control system, group 8.2.2 Bypassing

D1

2b 2a D2

3

D8

8

7, 20 D790-1

D790-2

D797-1

D795 D791-1

9

D17

13

C

D5

5, 12, 18

D12

C

6, 19

17

4

16

P2

21

P2

A

T2

B

A

11

14

VDCT01.02GB

15

16 D17


17

D4

4

015078

10

7 Load handling – Twistlocks

7:65

Pos

Explanation

Signal description

Reference

1

The switch for locking the twistlocks (S1003) (automatic mode) sends a voltage signal to the cab control unit (D790-1).

U = 24 V

Switch lock twistlocks, description (linear control levers), page 7:5

The switch for opening the twistlocks (S1002) sends a voltage signal to the cab control unit (D790-1) for twistlock opening.

U = 24 V

2a

D1: Diagnostic menu, see section 8 Control system, group 8.4.9.5 ATTACH, menu 5 Switch lock twistlocks, description (linear control levers), page 7:5 D2: Diagnostic menu, see section 8 Control system, group 8.4.9.5 ATTACH, menu 5

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

US815/T2 = 24 V

The control lever (S815-T2) sends a voltage signal to the cab control unit (D790-1) for twistlock opening.

Control lever, description, page 7:4 D2: Diagnostic menu, see section 8 Control system, group 8.4.9.3 ATTACH, menu 3

If Switch, lock twistlocks (S1003) is in manual position then no signal is required from the control lever to open twistlocks. 3

Control unit, cab (D790-1) transmits "open twistlocks" or "lock twistlocks" on the CAN bus.


Section 11 Common electrics, group 11.5.3.1 Control unit, cab.

4

The alignment left sensor (B7203L) and alignment right sensor (B7203R) detect position and send a voltage signal to the attachment control unit (D791).



The attachment control unit (D791-1) activates the alignment indicator light on the mast's lamp panel and sends alignment on the CAN bus.

U = 24 V


6

Control unit KID (D795) activates the event menu for alignment.

-


7

Control unit KID (D790-2) activates the indicator light for alignment on the cab's light panel.

-


8


U = 24 V


9


-


10

The load handling hydraulic oil pump pumps oil from the hydraulic oil tank to the lift, tilt and attachment control valve with hydraulic pressure.


Section 10 Common hydraulics, group 10.4.2 Axial piston pump with variable displacement

11


-


12

The attachment control unit (D791-1) activates the "open twistlocks" solenoid valve (Y6039) or the "lock twistlocks" solenoid valve (Y6040).

U = 24 V


The "open twistlocks" solenoid valve (Y6039) or the "lock twistlocks" solenoid valve (Y6040) pressurises the twistlock spool with servo pressure.

-

5

13







VDCT01.02GB

7:66


Pos

Explanation

Signal description

Reference

14

The twistlock spool of the control valve changes position and pressurises the lock cylinders via the overcentre valve.

-


15

The overcentre valve prevents the uncontrolled opening or closing of the twistlocks.

-

Twistlock overcentre valve, description, page 7:68

16

The lock cylinders rotate the twistlocks.

-

Lock cylinder, description, page 7:68

17

The "unlocked twistlocks" sensor (B7204 L and R) or the "locked twistlocks" sensor (B7205 L and R) sends a signal to the attachment control unit (D791-1).


Sensor, twistlocks, description, page 7:72

The attachment control unit (D791-1) voltage feeds the unlocked twistlocks indicator light (H562) or the locked twistlocks indicator light (H563) on the mast's lamp panel and sends unlocked twistlocks or locked twistlocks information on the CAN-bus.

U = 24 V


19

Control unit KID (D795) activates the event menu for twistlocks.



20

Control unit KIT (D790-2) supplies voltage to Indicator light "unlocked twistlocks" or Indicator light "locked twistlocks" on the cab lamp panel.



21


-


18




7.9.1.1 Hydraulic oil pump Hydraulic oil pump, general See section 10 Common hydraulics, group 10.4.1 Gear pump with fixed displacement.

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7:67

7.9.1.2 Control valve, attachment Attachment control valve, description Twistlocks slide, description

1

2

3

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

4

Twistlocks slide, description

5

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

10 6

"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.

9 7 8

Solenoid valve locked twistlocks (Y6040) is activated by the attachment control unit (D791-1). The solenoid valve guides servo pressure to the twistlock spool. The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.9.9 ATTACH, menu 9.

015084

"Open twistlocks" solenoid valve, description

1.


2.


3.


4.


5.


6.


7.


8.


9.


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


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


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7:68


7.9.1.3 Twistlock overcentre valve Twistlock overcentre valve, description

014805

The overcentre valve prevents the uncontrolled opening or closing of the twistlocks. The valve is located to the left of the attachment control valve on the trolley.

7.9.1.4 Lock cylinder Lock cylinder, description

014806

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


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7:69

7.9.1.5 Lock mechanism Lock mechanism, description The lock mechanism transfers the force of the lock cylinders to the twistlocks. Two lock mechanisms, one in the right and one in the left spreader beam, actuate the twistlocks. The lock mechanism runs in the corner box.

1 3

2

014807

The lock mechanism consists of a rotary plate with a linkage bearing at which the lock cylinder is attached. The rotary plate rotates the twistlocks.

1.

Linkages

2.

Rotary plate

3.

Lock cylinder mount

7.9.1.6 Twistlocks Twistlocks, description 1

2

3

WARNING Dropped load. Extreme danger!

5 1.

Unlocked twistlock sensor

2.

Sensor, alignment

3.

Locked twistlock sensor

4.

Lift pin

5.

Alignment pin

4

014716

Twistlocks hold the load during load handling and therefore it is of the utmost importance that twistlocks are checked according to instructions and are replaced at the slightest sign of damage or wear.

Twistlocks secure the load and are located out in the corners of the spreader beam's longitudinal section. Twistlocks are manufactured from high-strength steel in accordance with international standards. The lift pins are marked with serial numbers. Twistlocks are connected pairs via a linkage system to a hydraulic cylinder which in turn is controlled via a section in the attachment's control valve. Inductive sensors send signals when the twistlocks are locked and unlocked, respectively.


VDCT01.02GB

7:70


Twistlocks, replacement 1


2


3

Clean the twistlocks and the surrounding area.

4

Slacken the screws on the clamp holding the twistlocks in place.

5

Hold the twistlocks while removing the clamp halves.

WARNING Dropped component. Risk of pinch injury or product damage. 014821

Twistlock weighs approx. 30 kg. 6

Remove the clamp halves and lift away the twistlock.

7

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

NOTE Remember the washer. 8

Check the positions of the parts and that the twistlocks can move.

9

Tighten the screws of the clamp halves.

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

014821

13 Check that the twistlocks are working.

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7:71

7.9.1.7 Sensor, alignment Sensor, alignment, description The alignment sensors (B7203L and B7203R) detect when the attachment has contact with the container. Two inductive position sensors are used to indicate alignment. The sensor senses the position of a spring pin which is pressed in when the attachment has contact up against the container. The sensor is located behind the pin. The position of the sensor can be adjusted so that it gives a signal when the pin is pressed in and the head is level with the lower edge of the spreader beam. The clearance between the attachment and the container's corner boxes means the sensors stop sending signals when the attachment is lifted. The sensors are supplied power and send a 24 V signal to the attachment control unit (D791-1) when the indicator pin is pressed in.

1 1.

Sensor, alignment

2.

Alignment pin

2

014813


1 Right side 1.

Sensor, alignment

2.

Alignment pin

2

014717

Alignment sensor, checking and adjusting 1

Check that the alignment pins in the corner boxes can move up and down freely. The alignment pins must spring down when they are not loaded.

2

Check that the sensor is free of damage and dirt.

3

Turn the start key to position I and check that the LED on the sensor is unlit.

4

Lower the attachment onto a container and check that the alignment indicator light comes on.

5

Lift the container a little bit so that the alignment indicator light goes out.

6

With the container lifted, check how much alignment pin movement is needed to detect contact (LED on the sensor lights). The movement should be 3–4 mm.


VDCT01.02GB

7:72


2

If necessary, slacken the lock nut and screw the sensor in/out until the distance between the sensor and the alignment pin is 5±1 mm.

014718

7

1

Left side 1.

Sensor, alignment

2.

Alignment pin

7.9.1.8 Sensor twistlocks Sensor, twistlocks, description Twistlock sensors (B7204L, B7204R, B7205L and B7205R) detect when the twistlocks are locked or unlocked. Four inductive position sensors, two in each spreader beam, detect the position of the lock mechanism. Both sides function in the same way independently of one another. An indicator plate is fitted on the lock mechanism by the lock cylinder. When the lock mechanism is in the position that locks the twistlocks, one of the sensors sends a signal to Control unit, attachment (D791-1). When the lock mechanism is in the position that unlocks the twistlocks, the second sensor sends signal to Control unit, attachment (D791-1). No signals are sent if the lock mechanism stops midway. The sensors are supplied power by and send a 24 V signal to Control unit, attachment (D791-1) when the indicator plate is in front of the sensor.

1 1.


2.


VDCT01.02GB

2

014809




7:73

Twistlocks sensor, checking and adjusting 1

Check that the sensors are free of damage and dirt.

2

If necessary, slacken the lock nut and screw the sensor in/out until the distance between the sensor and the indicator plate is 5±1 mm.

3

Check that the "twistlocks open" indicator light is lit.

4

Lower the attachment over a container and lock the twistlocks.

5

Check that the LED on the "locked twistlock" sensor is lit.

1

2

014719

If necessary, slacken the lock nut and screw the sensor in/out until the distance between the sensor and the indicator plate is 5±1 mm.

Right side 1.


2.


2

1

Check that the "twistlocks locked" indicator light is lit.

014720

6

Left side 1.


2.



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

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

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

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

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7 Load handling – Other functions

7:75

7.10 Other functions 7.10.1 Container counter Container counter, function description

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

Condition

Reference value

Reference

Control breaker

Not activated


D1 1, 4, 7 10

D790-1

D795

D797-1

D791-1

3,6,9 D5

D2 5

015086

2,8

Pos

Explanation

Signal description

Reference

1

The attachment is positioned over a container with the functions 7.2 Lifting/lowering, 7.4 Side shift and 7.5 Spreading

-

Lifting/lowering, function description, page 7:8 Side shift, function description, page 7:31 Spreading, function description, page 7:41 D1: Diagnostic menu, see section 8 Control system, group 8.4.8.1 ELSERV, menu 1 and 8.4.8.1 ELSERV, menu 2.

2

Alignment sensors left and right (B7203L and B7203R) voltage signal to the attachment control unit (D791-1).



3

Control unit, attachment (D791-1) sends alignment on the CAN bus.



4

Twistlocks are rotated to the locked position and are closed with the 7.9.1 Twistlocks function.

-

Twistlocks, function description, page 7:64

5

The sensor for locked twistlocks left (B7205L) and sensor for locked twistlocks right (B7205R) send a voltage signal to the attachment control unit (D791-1).


Sensor, twistlocks, description, page 7:72




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7 Load handling – Container counter

Pos

Explanation

Signal description

Reference

6

Control unit, attachment (D791-1) sends locked twistlocks on the CAN bus.



7

The container is lifted with the function 7.2 Lifting/lowering.

-

Lifting/lowering, function description, page 7:8

8

Alignment sensors left and right (B7203L and B7203R) make and send a voltage signal to the attachment control unit (D791-1).

U=0V


9

Control unit, attachment (D791-1) sends no alignment on the CAN bus.



10

If the twistlocks remain locked for 8 seconds then Control unit, cab (D790-1) adds one lift to the container counter.

-


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8:1

8 Control system

Contents 8 Control system 8 Control system ...................................................................................................8:3 8.1 Controls and instruments .................................................................................8:4 8.1.10 Error code menu .........................................................................................8:4 8.2 Monitoring ........................................................................................................8:7 8.2.2 Bypass ........................................................................................................8:7 8.2.3 Speed limitation...........................................................................................8:7 8.2.4 Service indicator..........................................................................................8:8 8.4 Diagnostics ......................................................................................................8:9 8.4.1 CAN/POWER ............................................................................................ 8:11 8.4.2 LIGHTS .....................................................................................................8:25 8.4.3 CAB ...........................................................................................................8:37 8.4.4 CLIMATE ...................................................................................................8:45 8.4.5 HYD...........................................................................................................8:51 8.4.6 ENGINE ....................................................................................................8:55 8.4.7 TRANSM ...................................................................................................8:62 8.4.8 ELSERV ....................................................................................................8:69 8.4.9 ATTACH ....................................................................................................8:76 8.4.10 OLS ...........................................................................................................8:89 8.4.11 EXTRA ......................................................................................................8:89 8.5 Setup..............................................................................................................8:95 8.5.1 Initiation .....................................................................................................8:95 8.5.2 Calibration ............................................................................................... 8:112


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8 Control system – Control system

8:3

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

Monitoring

•

Error codes

•

Diagnostics

•

Setup

•

Software

Monitoring functions describe the machine's monitoring functions that warn the operator or limit the machine's functions in the event of any dangerous situations. Error codes notify operators and mechanics when malfunctions have been detected. Diagnostic test is tool for performing service and troubleshooting with menus in the machine's display. Settings is the tool for setting and adapting the machine's functions. The software creates the functions in the control system.


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8 Control system – Controls and instruments

8.1 Controls and instruments 8.1.10 Error code menu Error code menu, description The control and monitoring system's display is divided into four fields where the information is shown (see figure to the left).

C D

E 000389

B

•

Field B: Error code level is shown with a symbol.

•

Field C: Shows error code.

•

Field D: Shows type of error.

•

Field E: Indicates which function is affected by error code.

•

Book symbol means that information is available in the operator's manual.

Field B: Error code level The control and monitoring system gives error code information in three levels which are indicated with a symbol in the lower left corner (B) on the display unit. •

C

Indicates a serious malfunction that may jeopardise the operator's safety or cause machine failure. The error code must be attended to immediately. Stop working with the machine and contact service immediately.

E

The error code is shown automatically on the display.

000350

D

•

C D

Stop

Warning Indicates malfunction in machine that should be taken care of as soon as possible. After the finished work shift with the machine, contact service as soon as possible.

E 000351


•

Information to the operator that something should be taken care of as soon as possible, e.g., defective light bulb. Take action to fix the cause of the error code as soon as possible. See section 6 Inspection and maintenance in the operator's manual.

C E

The error code is stored in the error code list under operating menu for service.

000352

D

Information

Field C: Error code number


C D

The control and monitoring system gives error codes from three sub-systems:

E

• 000389

B

Shown with error code number XXX on display. •

D

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Engine: Shown with error code number XXX/YY on display.

XX/YY

NOTE 001343

B

Machine:

If several error codes come from the engine, the error code level is shown for the most serious error code.


8 Control system – Error code menu

• XXX/YY

8:5

Transmission: Shown with error code number XX/YY on display.

D 001344

B

Field D: Type of error

1

4

2

5


3

6

1.

Temperature too high/too low.

2.

Incorrect signal to solenoid valve.

3.

Incorrect hydraulic pressure.

4.

Incorrect sensor signal.

5.

Incorrect signal from control.

6.

Incorrect signal to bulb.

7.

Incorrect signal, for example, open circuit.

000396

7


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8 Control system – Error code menu

Field E: Affected function

1

4

7

2


3

5

6

8

9

1.

Attachment

2.

Rotation of attachment

3.

Side shift, attachment

4.

Length adjustment attachment

5.

Levelling

6.

Twistlocks

7.

Forks up/down

8.

Tilt forks

9.

Side shift forks

10. Spreading forks

10

11

11. Rotation forks

12

12. Overload protection 13. Hydraulic functions 14. Brake system

13

14

15. Steering

15

16. Engine 17. Transmission 18. Central lubrication

16

17

18

19. Control unit 20. Hardware-related error 21. Cab 22. Air conditioning

19

20

21

23. Fuel system 24. Headlights 25. Windscreen wipers

22

23

26. Battery voltage

24

27. Bulb for lighting

26

27 010153

25

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8 Control system – Monitoring

8:7

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

locking and opening of twistlocks without complete alignment

•

20'-40' spreading with locked twistlocks

•

lowering a load with alignment on side lift attachment.

•

manual control of the recirculation damper for ECC or ECH.

•

release of parking brake in the event of parking brake switch malfunction

•

output signal to solenoid valves with active error codes.

•

the machine shifts to neutral as no one is sitting in the driver's seat.

DANGER Bypassing the safety systems results in a risk of tipping. Use at your own risk. Extreme hazard to personal health and risk of property damage! Only use the bypass of safety systems in emergency situations.

8.2.3 Speed limitation Speed limitation, description

Speed limitation prevents the machine's speed from exceeding the preset value by limiting gear position and engine speed. Machine speed is limited when: •

the emergency stop switch is activated.

•

load not in transport position during transport. Maximum speed is 5 km/h.

•

constant speed limitation is set.

Speed limitation is set via the initiation menu, see section 8 Control system, group 8.5.1.4 INIT DRIVE-TRAIN, menu 9.


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8 Control system – Service indicator

8.2.4 Service indicator Service indicator, resetting


2

Navigate first to the service menu and press Enter.

3

Enter the code to reset the service indicator.

000056

1

Code is obtained from Cargotec Support.

1 23 4 5 000060

NOTE The code determines which service menu is activated (Service, Diagnostic test, Initiation or Calibration). 4

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Reset the service indicator by pressing Enter. NEXT SERVICE is changed to indicated interval. To change duration of the service interval, set the desired interval with the plus or minus key.

004908

SERVICE INTERVALL NEXT SERVICE XXXXh SERVICE INTERVALL STORED XXXXh PRESENT XXXXh


8 Control system – Diagnostics

8:9

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

Voltage feed and communication for the Control system, CAN/POWER, description, page 8:11.

•

Lighting, LIGHTS, description, page 8:25.

•

Cab functions, CAB, description, page 8:37.

•

Air conditioning, CLIMATE, description, page 8:45.

•

Hydraulic functions, HYD, description, page 8:51.

•

Engine ENGINE, description, page 8:55.

•

Transmission, TRANSM, description, page 8:62.

•

Functions for electric servo, ELSERV, description, page 8:69.

•

Attachment functions, ATTACH, description, page 8:76.

•

Optional functions, EXTRA, description, page 8:89 –

Optional functions, OPT, description, page 8:90


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8 Control system – Diagnostics

Diagnostic menu, description Diagnostic tests show how the control units interpret input signals as well as which signals that the control units send. DIAG

Indicates that diagnostic tests are selected.

CAB

Indicates which menu group is selected, these groups are: CAN/POWER, description, page 8:11. LIGHTS, description, page 8:25. CAB, description, page 8:37. CLIMATE, description, page 8:45. HYD, description, page 8:51. ENGINE, description, page 8:55. TRANSM, description, page 8:62. ELSERV, description, page 8:69. ATTACH, description, page 8:76. OLS, description, page 8:89. EXTRA, description, page 8:89.

2

Number of current menu. Every menu group consists of several menus in a loop.

(X)

Total number of menus in the group. The number of menus depends on the equipment fitted to the machine. For this reason, number of menus is indicated with (X) in this manual.

Variable

The signal that is measured. Different signals are designated in different ways: SWITCH: a digital input signal, e.g. a switch. OUTPUT: a digital output signal, e.g. feed to a motor. INPUT: an analogue input signal, e.g. from a sensor. REFERENCE: status for an analogue output signal. REQUIRED: triggered output signal for a control current FEEDBACK: either feedback signal from a motor or measured current on the minus side for an analogue output signal.

Signal value

Measurement value or status for the signal for variable. On the same row there are different types that are interpreted in different ways. SWITCH: 1 or 0 where 1 means closed circuit. OUTPUT: two characters where the first number is 1 if the output signal is active. The second number is status for the circuit, 1=circuit OK, 0=open circuit or short circuit. INPUT: numerical value corresponding to the signal. REFERENCE: two characters where the first number is 1 if the input signal is active. The second number is status for the circuit, 1=circuit OK, 0=open circuit or short circuit. REQUIRED: numerical value corresponding to the signal. FEEDBACK: numerical value corresponding to the signal.

Menu heading

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Description of the function for which the menu reads signals.


8 Control system – CAN/POWER

8:11

8.4.1 CAN/POWER CAN/POWER, description This group handles redundant voltage feed to control units and CAN bus communication. Confirm selections with function key for Enter. 005263

DIAGNOSIS CAN/POWER LIGHTS CAB CLIMATE HYD ENGINE TRANSM ELSERV ATTACH OLS EXTRA

8.4.1.1 CAN/POWER, menu 1 PRESENT REDCAN STATUS, COMMUNICATION MODE Description: Indicates communication status for the redundant CAN bus. Circuit diagram: Circuit CANBUS ground group 11.6_1 005266

DIAG CAN/POWER 1(X) PRESENT REDCAN STATUS COMMUNICATION MODE X NUMBERS OF UNITS X SEGMENT ERROR X

Contact: Function: 11.6.2 Redundant CAN bus Signal value: 3

OK.

2

Segment check.

0

Error.

PRESENT REDCAN STATUS, NUMBER OF UNITS Description: Indicates the number of control units, excluding Cab control unit (D790-1) which should be on the current machine. The number is dependent on the installed options. Circuit diagram: Circuit CANBUS ground group 11.6_1 005266


Contact: Function: 11.6.2 Redundant CAN bus Signal value: X

Number of nodes that should be in the machine. Number of nodes depends on installed options.


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PRESENT REDCAN STATUS, SEGMENT ERROR Description: Indicates if there is open circuit on the redundant CAN bus and if there is, where the first open circuit is. If there is open circuit, it is indicated with a number that corresponds to the defective segment on the redundant CAN bus. 005266


Circuit diagram: Circuit CANBUS ground group 11.6_1 Contact: Function: 11.6.2 Redundant CAN bus Signal value: 0

No open circuits.

>0

If X is separated from 0, the first segment is indicated as missing contact. A 1 means that the first segment is defective, that is, that contact between first and second control unit is cut off. To see which control units are installed on the machine along with their order, use diagnostic menu CAN/POWER, menu 2, see PRESENT REDCAN STATUS, CONNECTED CITIES, page 8:12.

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

DIAG CAN/POWER 2(X) PRESENT REDCAN STATUS CONNECTED CITIES D797-1 D797-2 XX D795 D791-1 XX

Contact: D795: K1:10, K1:11, K1:12 and K1:13 D797-1, D791-1: K2:2, K2:3, K2:4 and K2:5 Function: 11.5.3.2 Frame control unit (D797-1), 11.5.3.5 Attachment control unit, 11.5.3.12 KID control unit, 11.6.2 Redundant CAN bus. Signal value:

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1

Communication with the node is OK.

0

No communication and/or there is some node error.



8:13

8.4.1.3 CAN/POWER, menu 3 PRESENT OPTION KDU Description: Indicates which optional control units should be present on the machine and if they have working communication with the cab KCU control unit (D790-1).

KDU D797-2 KDU D791-1

XY XY

007183

DIAG CAN/POWER 3(X) PRESENT OPTION KDU

Circuit diagram: Circuit CANBUS ground group 11.6_1, Circuit Attachment DCF90-100/45E 11.6_1 Contact: Function: 11.6.2 Redundant CAN bus Signal value: 00

The control unit is not installed on the machine.

10

The control unit is installed on the machine but there is no communication with the cab control unit (D790-1).

11

The control unit is installed on the machine and there is communication with the cab control unit (D790-1).

8.4.1.4 CAN/POWER, menu 4 PRESENT DRIVE-TRAIN CAN BUS STATUS, ENGINE Description: Indicates status for engine in the drive-train's CAN bus. Circuit diagram: Circuit CANBUS ground group 11.6_1, Circuit Attachment DCF90-100/45E group 11.6_1, Circuit engine QSB6.7 group 1.0_2E1, Circuit Yuchai YC6A240-30 group 1.0_1A1 005269

DIAG CAN/POWER 4(X) PRESENT DRIVE-TRAIN CAN BUS STATUS ENGINE X TRANSMISSION X

Contact: Cummins QSB6.7 to D794/46 and 37

: CAN J1939 from D790-1/K13:1 and K13:2

Yuchai YC6A240-30: CAN J1939 from D790-1/K13:1 and K13:2 to D794/1:34 and 1:35 Function: 11.6.3 CAN bus drive-train Signal value: 1


0


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


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PRESENT DRIVE-TRAIN CAN BUS STATUS, TRANSMISSION Description: Indicates status for transmission in the drive-train's CAN bus. Circuit diagram: Circuit CAN-BUS ground group 11.6_1, circuit Transmission group 2.0_1, Circuit Yuchai YC6A240-30 group 1.0_1A2 005269

DIAG CAN/POWER 4(X) PRESENT DRIVE-TRAIN CAN BUS STATUS ENGINE X TRANSMISSION X

Connection: CAN J1939 from D790-1/K13:1 and K13:2 to D793/22 and D793/23 Function: 11.6.3 CAN bus drive-train Signal value: 1


0


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

8.4.1.5 CAN/POWER, menu 5 IGNITION, KEY IN Description: Indicates if ignition is switched on (key in ignition key lock).

5(X) X XY XY

Circuit diagram: Circuit power group 11.5_3 007126

DIAG CAN/POWER IGNITION KEY IN RELAY K315-1 RELAY K315-2

Connection: signal from S150/15 to digital in D790-1/K11:1 Function: 11.5.1.3 Ignition voltage Signal value:

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1

Input signal active.

0

No signal.



8:15

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

5(X) X XY XY

Circuit diagram: Circuit power 11.5_3 007126


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 and open circuit in the circuit.

01

Normal mode function off. No output signal, circuit OK. It can also be a short circuit as this is only detected when the output signal is active.

10

Output signal active, short-circuiting.

11

Normal mode function on. Output signal active, circuit OK. It can also be an open circuit as this can only be detected when the output signal is missing.

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

5(X) X XY XY

Circuit diagram: Circuit power 11.5_3 007126


Connection: output signal from D790-1/K10:16 to K315-2 Function: 11.5.1.3 Ignition voltage (15) Signal value: 00


01


10

Output signal active, short-circuiting.

11


8.4.1.6 CAN/POWER, menu 6 EMERGENCY STOP, SW Description: Indicates if switch, emergency stop switch, is activated. Circuit diagram: Circuit power control breaker group 11.5_6 Connection: signal from S250/2 to digital in D790-1/K8:4 007127

DIAG CAN/POWER 6(X) EMERGENCY STOP, SW X RELAY K3009-1 XY FEEDBACK X RELAY K3009-2 XY

Function: 11.5.1.4 Emergency stop switch voltage (15E) Signal value: 1


0

No signal.


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EMERGENCY STOP, RELAY K3009-1 Description: Status for control current to relay K3009-1, for emergency stop switch voltage, 15E voltage. Circuit diagram: Circuit power control breaker group 11.5_6 007127


Connection: signal from D790-1/K10:11 to K3009-1/86 Function: 11.5.1.4 Emergency stop switch voltage (15E) Signal value: 00


01


10

Output signal active, short circuit.

11


EMERGENCY STOP, FEEDBACK Description: Feedback signal from control breaker relay (K3009-1), indicates that relay is working normally. Circuit diagram: Circuit power control breaker group 11.5_6 007127


Contact: Signal from K3009-1/87 via F58-3/8 to digital in D790-1/K11:13 Function: 11.5.1.4 Emergency stop switch voltage (15E) Signal value: 1


0

No signal.

EMERGENCY STOP, RELAY K3009-2 Description: Status of the control current to the control breaker relay (K3009-2), Control breaker relay lifting/lowering (K3007) and Control breaker relay tilt (K3002),15E-voltage. Circuit diagram: Circuit power control breaker group 11.5_6 007127


Contact: signal from D790-1/K10:12 to K3009-2/86, K3002/86 and K3007/86. Function: 11.5.1.4 Emergency stop switch voltage (15E) Signal value: 00


01


10


11


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8:17

8.4.1.7 CAN/POWER, menu 7 790-1 CAB, POWER Description: Ignition voltage (15) to Control unit, cab (D790-1). Circuit diagram: Circuit power group 11.5_1, 11.5_4

005271

DIAG CAN/POWER 7(X) 790-1 CAB POWER XX.XXV 5V REF X.XXV

Connection: 15-voltage from K315-1/87 via F54/4 and F58-5/1, F58-5/2 to D790-1/K1:2, D790-1/K1:3 and D790-1/K1:4 Function: 11.5.1 Voltage feed Signal value: XX.XXV = voltage on the connection. The signal value should be 22-30 V (battery voltage).

790-1 CAB, 5V REF

005271

Description: Reference voltage 5 V to controls in cab.

DIAG CAN/POWER 7(X) 790-1 CAB POWER XX.XXV 5V REF X.XXV

Circuit diagram: Circuit climate group 9.4_1, 9.4_2 (contact 1, 2), Circuit drivetrain engine group 1.0_1 (contact 3), Circuit electric servo levers 7.0_1 (contact 4), Circuit electric servo joystick 7.0_2 (contact 5) Contact: 1.

signal from digital out D790-1/K4:5 to Y672/10 and Y673/10

2.

signal from digital out D790-1/K5:11 to S118/1, S139/1 and S117/1

3.

signal from digital out D790-1/K5:13 to B690-1/1

4.

signal from digital out D790-1/K7:2 to R8071/1, R8072/1, R8073/1

5.

signal from digital out D790-1/K7:2 to S815/P1, S815/P2

Function: 9.4 Heating, ventilation and air conditioning (contact 1 and 2); 1 Engine and 2 Transmission (contact 3); 7 Load handling (contact 4 and 5) Signal value: X.XXV = 5.00 V, Important that the signal value is stable (not varying).


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8.4.1.8 CAN/POWER, menu 8 790-1 CAB, 24V SENSOR SUPPLY Description: 24 V voltage feed to components in cab. Circuit diagram:

005275

DIAG CAN/POWER 8(X) 790-1 CAB 24V SENSOR SUPPLY XY 24V SUPPLY,RPM>500 XY

1.

Circuit wiper group 9.5_1

2.

Circuit drivetrain transmission group 2.0_1, Circuit extra equipment group 9.1_1, Circuit seat heating group 9.3_1, Circuit working lights 20-40 group 9.6_1, Circuit working lights truck 9.6_2, Circuit working lights mast 9.6_3, Circuit lighting group 9.6_4 and Circuit wiper group 9.5_1

3.

-

4.

-

5.

Circuit twistlock group 7.9_1, circuit 20-40, 30-35 stop group 7.5_1, circuit over height group 7.9_4, circuit horn servo panel group 9.7_4, circuit power control breaker group 11.5_6, circuit brake system group 4.0_1, circuit 20-40 opt. group 7.5_3, circuit bypass group 8.2_1 and circuit extra equipment group 9.1_1

6.

-

7.

-

8.

Circuit alarm, audible signals group 9.7_1

9.

Circuit wiper group 9.5_1

10. Circuit wiper group 9.5_1 Contact: 1.

signal from digital out D790-1/K4:14 to M650-1/53a

2.

signal from digital out D790-1/K5:1 to S105-1/5, S105-2/5, S105-3/5, S143/5, S100/5, S110/5, S199-1/5, S199-3/5, S199-4/5 and S220-1/1

3.

signal from digital out D790-1/K6:13 not connected

4.


5.

signal from digital out D790-1/K8:16 to S1002/2, S1003/4, S1003/3, S1004/5, S149-3/2, S250/1, S107/5, S1012/3, S1012-2/5, S1031/3, S1005/5, and S199-2/5

6.


7.


8.

signal from digital out D790-1/K11:12 to S230/2

9.

signal from digital out D790-1/K12:1 to M650-2/53a

10. signal from digital out D790-1/K12:3 to M650-3/53a Function: 1.

9.5.5 Wiper motor front

2.

2.0 Transmission, 9.3 Seat, 9.6 Lighting

3.

-

4.

-

5.

11.5.1.4 Emergency stop switch voltage; 4.5 Parking brake system; 8.2.2 Bypassing; 9.10.4 Tiltable cab/Hydraulic sliding cab; 7.5 Spreading; 7.8 Levelling; 7.9.1 Twistlocks

6.

-

7.

-

8.

9.3.14 Sensor operator in seat

9.

9.5.7 Wiper motor rear

10. 9.5.6 Wiper motor roof

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8:19

Signal value: 01

Normal mode function off. No output signal. It can also be a short circuit in the circuit as errors can only be detected when the output signal is active.

10

Output signal active, short circuit. It can also be an open circuit as this cannot be detected.

11

Normal mode function on. Output signal active, circuit OK or open circuit. Open circuit cannot be detected.


VDCT01.02GB

8:20


790-1 CAB, 24V SUPPLY,RPM>500 Description: Voltage feed when engine speed is higher than 500 rpm. Circuit diagram: Circuit hour meter group 9.1_2, Circuit air suspension seat group 9.3_2 005275

DIAG CAN/POWER 8(X) 790-1 CAB 24V SENSOR SUPPLY XY 24V SUPPLY,RPM>500 XY

Connection: signal from digital out D790-1/K10:9 to P708/+ and K358/86 Function: 9.3.6 Compressor air-suspension seat, 11.1.1 Hour meter Signal value: 00


01


10


11


8.4.1.9 CAN/POWER, menu 9 795 DISPLAY, RED. POWER Description: Redundant voltage to Control unit KID (D795).

RED.POWER

LE X

9(X) RI X

Circuit diagram: Circuit canbus ground group 11.6_1 Contact: 005276

DIAG CAN/POWER 795 DISPLAY

LE: redundant feed from D790-1/K11:10 to D795/K1:8 RI: redundant feed from D790-1/K11:8 to D795/K1:7 Function: 11.5.1.2 Redundant voltage feed of control units Signal value: 1

Feed active.

0

No feed.

8.4.1.10 CAN/POWER, menu 10 797-1 FRAME, POWER Description: Ignition voltage (15) to the frame control unit (D797-1). Circuit diagram: Circuit power group 11.5_1 and 11.5_4

005277

DIAG CAN/POWER 10(X) 797-1 FRAME POWER XX.XXV RED.POWER LE X RI X POWER 2 X

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

VDCT01.02GB



8:21

797-1 FRAME, RED. POWER Description: Redundant voltage to frame control unit (D797-1). Circuit diagram: Circuit canbus ground group 11.6_1 Contact: 005277


•

LE: redundant feed from D790-1/K11:7 to D797-1/K2:7

•

RI: redundant feed from D790-1/K11:9 to D797-1/K2:8

Function: 11.5.1.2 Redundant voltage feed of control units Signal value: 1

Feed active.

0

No feed.

797-1 FRAME, POWER 2 Description: Battery voltage to the frame control unit (D797-1). Circuit diagram: Circuit power group 11.5 and 11.5_4

005277


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 NOT USED This menu is not used.

XXXXXXX

X(X)

008793

NOT USED

8.4.1.12 CAN/POWER, menu 12 793 TRANSMISSION, POWER Description: Battery voltage (30) to Control unit, transmission (D793). Circuit diagram: Circuit power group 11.5_1, circuit drivetrain gearbox group 2.0_1, circuit Yuchai YC6A240-30 group 1.0_1A2 005279

DIAG CAN/POWER 12(X) 793 TRANSMISSION POWER XX.XXV IGNITION POWER XX.XXV SENSOR SUPPLY XX.XXV

Connection: 30-voltage from F54/2 via F58-1/5 to D793/45 Function: 11.5.1.1 Battery voltage (30) Signal value: XX.XXV = voltage on the connection. The signal value should be 22-30 V (battery voltage).


VDCT01.02GB

8:22


793 TRANSMISSION, IGNITION POWER Description: Ignition voltage (15) to Control unit, transmission (D793). Circuit diagram: Circuit Yuchai YC6A240-30 group 1.0_1A2, Circuit drivetrain gearbox group 2.0_1, Circuit power group 11.5_1 005279


Connection: 15 voltage from K315/87 via F54/4 and F58-2/6 to D793/20, D793/60 and D793/21 Function: 11.5.1.3 Ignition voltage (15) Signal value: XX.XXV = voltage on the connection. The signal value should be 22-30 V (battery voltage).

793 TRANSMISSION, SENSOR SUPPLY

005279

This menu row is not used.



XXXXXXX

X(X)

008793

NOT USED


XXXXXXX

X(X)

008793

NOT USED

8.4.1.15 CAN/POWER, menu 15 791-1 ATTACHMENT, EME POWER Description: Voltage feed to Control unit, attachment (D791-1). Circuit diagram: Attachment DCF90/100-45E group 11.5_1, Circuit power control breaker group 11.5_6 005282

DIAG CAN/POWER 15(X) 791-1 ATTACHMENT(OPT) EME POWER XX.XXV RED.POWER LE X RI X EME POWER 2 X

Connection: 15E voltage from K3009-1/87 via K3009-2/87, F58-3/1 to D791-1/K2:1, K2:9, K2:10, K2:11 Function: 11.5.1.4 Emergency stop switch voltage (15E) Signal value: XX.XXV = Voltage on the connection. The signal value should be 22-30 V (battery voltage).

VDCT01.02GB



8:23

791-1 ATTACHMENT, RED. POWER Description: Redundant voltage feed to Control unit, attachment (D791-1).

005282


Circuit diagram: Circuit CANBUS ground group 11:6_1, Circuit CANBUS KDU opt. group 11.6_2B, Attachment DCF90/100-45E group 11.6_1 Contact: LE: redundant voltage feed to D791/K2:7 RI: redundant voltage feed to D791/K2:8 Function: 11.5.1.2 Redundant voltage feed of control units Signal value: 1

Feed active.

0

No feed.

791-1 FRAME, EME POWER 2 Description: Emergency stop switch voltage (15E) to attachment control unit (D791-1). Circuit diagram: Circuit 11.5_5 005282


Connection: 15E voltage from K3009-1/87 via K3009-2/87, F58-3/1 to D791-1/K2:11 Function: 11.5.1.4 Emergency stop switch voltage (15E) Signal value: 1

Feed active.

0

No feed.

8.4.1.16 CAN/POWER, menu 16 791-1 ATTACHMENT (OPT), 24V SENSOR SUPPLY Description: Voltage feed to sensors connected to the attachment control unit (D791-1). Circuit diagram: Circuit diagram: Attachment DCF90/100-45E group 7.5_3, 7.9_2, 11.5_2 005283

DIAG CAN/POWER 16(X) 791-1 ATTACHMENT (OPT) 24V SENSOR SUPPLY XY 5V REF X.XXV

Connection: digital out from 791-1/K1:10 to B769L, B769R, B777L, B777R, B7203L, B7203R, B7204L, B7204R, B7205LL and B7205LR Function: 7.5.6 Spreading position sensor, 7.9.1.7 Alignment position sensor, 7.9.1.8 Twistlocks sensor Signal value: 00


01


10


11



VDCT01.02GB

8:24


791-1 ATTACHMENT (OPT), 5V REF

005283


DIAG CAN/POWER 16(X) 791-1 ATTACHMENT (OPT) 24V SENSOR SUPPLY XY 5V REF X.XXV

8.4.1.17 CAN/POWER, menu 17 REDCAN STATUS CHECK Description: Control function from the redundant CAN bus. Cab control unit (D790-1) performs a segment check to verify that all control units are in contact and are connected in the correct order. The control system indicates the fault by numbering the cables between the control units (segments) from 1 onwards. Segment 1 is always between cab control unit (D790 -1) and the next Control unit. The last segment is always between Control unit KID (D795) and Control unit, cab (D790-1). The segments in between vary depending on machine configuration.

SEGMENT ERROR

D790-1 CAN L

D791

CAN R

CAN L

CAN R

Circuit diagram: Circuit CANBUS ground group 11.6_1, Circuit diagram attachment DCF90/100-45E group 11.6_1

D797-1

CAN R

1 4

X

005284

DIAG CAN/POWER 17(X) REDCAN STATUS CHECK PRESS ENTER

CAN L

CAN R

2

Contact: -

3

Function: 11.6.2 Redundant CAN bus

CAN L

015052

D795 Segment numbering with maximum number of control units.

VDCT01.02GB

Signal value: 0

No errors.

>0

X > 0, the number indicates defective segment. Use the circuit diagram to find the defective segment.


8 Control system – LIGHTS

8:25

8.4.2 LIGHTS LIGHTS, description This group covers lighting. Confirm selections with function key for Enter.

005285


8.4.2.1 LIGHTS, menu 1 MAIN LIGHT, SWITCH Description: Signal from headlights switch.

1(X)

Circuit diagram: Circuit lighting group 9.6_4

X

Connection: signal from S100/1 to digital in D790-1/K6:5 005286

DIAG LIGHTS MAIN LIGHT SWITCH

Function: 9.6.1 Headlights. Signal value: 1


0

No signal.

8.4.2.2 LIGHTS, menu 2 PRESENT OUTPUT SIGNAL, SIDE LIGHTS Description: Voltage feed to side running lights.

DIAG LIGHTS 2(X) PRESENT OUTPUT SIGNAL XY XY

005287

SIDE LIGHTS REAR LIGHTS

Circuit diagram: Circuit lighting group 9.6_5 and 9.6_6 Connection: digital out from D797-1/K1:2 to H416-1, H416-2, H417-1 and H417-2 Function: 9.6.2 Running lights Signal value: 00


01


10


11



VDCT01.02GB

8:26


PRESENT OUTPUT SIGNAL, REAR LIGHTS Description: Voltage feed to tail lights.

DIAG LIGHTS 2(X) PRESENT OUTPUT SIGNAL XY XY

Connection: digital out from D797-1/K1:33 to H412L and H412R 005287

SIDE LIGHTS REAR LIGHTS

Circuit diagram: Circuit lighting group 9.6_6

Function: 9.6.3 Tail lights Signal value: 00


01


10


11


8.4.2.3 LIGHTS, menu 3 HEAD LIGHTS, SWITCH Description: Lighting headlights front, switch.

3(X) X XY XY

Circuit diagram: Circuit lighting group 9.6_4 Connection: from S162:56A to digital in D790-2/K3:9 005288

DIAG LIGHTS HEAD LIGHTS SWITCH HEAD LE/RI DIMMED LE/RI

Function: 9.6.1 Headlights Signal value: 1


0

No signal.

HEADLIGHTS, HEAD LE/RI Description: Voltage feed to headlights, high beam.

3(X) X XY XY

Circuit diagram: Circuit lighting group 9.6_5 Connection: digital out from D797-1/K1:15 to E402L-1 and E402R-1 005288




01


10


11


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8:27

HEADLIGHTS, DIMMED LE/RI Description: Voltage feed to headlights, low beam.

3(X) X XY XY

Circuit diagram: Circuit lighting group 9.6_5 Connection: digital out from D797-1/K1:28 to E400L and E400R 005288




01


10


11


8.4.2.4 LIGHTS, menu 4 PRESENT INPUT SIGNAL, HAZARD SWITCH Description: Signal from switch, flashing hazard lights (Hazard). Circuit diagram: Circuit blinkers & hazard group 9.6_7 Connection: signal from S109/1 to digital in D790-1/K5:6 005289

DIAG LIGHTS 4(X) PRESENT INPUT SIGNAL HAZARD SWITCH X FLASH.SW. LE X RI X

Function: 9.7 Signalling system Signal value: 1


0

No signal.

PRESENT INPUT SIGNAL, FLASH.SW. Description: Signal from switch, direction indicators. Circuit diagram: Circuit blinkers & hazard group 9.6_7 Contact: 005289

DIAG LIGHTS 4(X) PRESENT INPUT SIGNAL HAZARD SWITCH X FLASH.SW. LE X RI X

•

LE: signal from S161/6 to digital in D790-2/K8:8

•

RI: signal from S161/1 to digital in D790-2/K8:9

Function: 9.6 Lighting system Signal value: 1


0

No signal.


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8:28


8.4.2.5 LIGHTS, menu 5 PRESENT OUTPUT SIGNAL HAZARD/FLASHER, LEFT F/R Description: Voltage feed to direction indicator, left-hand side. Circuit diagram: Circuit blinkers & hazard group 9.6_7 Connection: digital out from D797-1/K1:30 to H422 and H426 005290

DIAG LIGHTS 5(X) PRESENT OUTPUT SIGNAL HAZARD/FLASHER LEFT F/R XY RIGHT F/R XY

Function: 9.6.6 Direction indicators, 9.6.7 Flashing hazard lights (Hazard) Signal value: 00


01


10


11


PRESENT OUTPUT SIGNAL HAZARD/FLASHER, RIGHT F/R Description: Voltage feed to direction indicator, right-hand side. Circuit diagram: Circuit blinkers & hazard group 9.6_7 Connection: digital out from D797-1/K1:31 to H423 and H427 005290

DIAG LIGHTS 5(X) PRESENT OUTPUT SIGNAL HAZARD/FLASHER LEFT F/R XY RIGHT F/R XY

Function: 9.6.6 Direction indicators, 9.6.7 Flashing hazard lights (Hazard) Signal value: 00


01


10


11


VDCT01.02GB



8:29

8.4.2.6 LIGHTS, menu 6 ROTATION BEACON, SWITCH Description: Signal from switch, revolving beacon.

6(X) X XY

Circuit diagram: Circuit lighting group 9.6_4 Connection: from S110/1 to digital in D790-1/K6:4 005291

DIAG LIGHTS ROTATION BEACON SWITCH OUTPUT

Function: 9.6.8 Revolving beacon Signal value: 1


0

No signal.

ROTATION BEACON, OUTPUT Description: Voltage feed to revolving beacon.

6(X) X XY

Circuit diagram: Circuit lighting group 9.6_4 Connection: digital out from D790-1/K2:5 to H428 005291

DIAG LIGHTS ROTATION BEACON SWITCH OUTPUT

Function: 9.6.8 Revolving beacon Signal value: 01

Normal mode function off. No output signal. It can also be a fault in the circuit as errors can only be detected when the output signal is active.

10

Output signal active, short circuit or open circuit.

11

Normal mode function on. Output signal active, circuit OK.

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

DIAG LIGHTS 7(X) PRESENT INPUT SIGNAL BRAKE LGT SWITCH X REVERSE LGT SIGNAL X

Function: 4.3.8 Make-contact (closing switch) brake lights Signal value: 1


0

No signal.


VDCT01.02GB

8:30


PRESENT INPUT SIGNAL, REVERSE LGT SIGNAL Description: Signal from Control unit, transmission (D793) when reverse gear is activated. Circuit diagram: Circuit Lighting group 9.6 005292

DIAG LIGHTS 7(X) PRESENT INPUT SIGNAL BRAKE LGT SWITCH X REVERSE LGT SIGNAL X

Contact: Function: 9.6.5 Back-up lights Signal value: 1

Input signal active. Output signal "reverse gear active" from Control unit, transmission (D793).

0

No signal.

8.4.2.8 LIGHTS, menu 8 PRESENT OUTPUT SIGNAL, BRAKE LGT Description: Voltage feed to brake lights. Circuit diagram: Circuit lighting group 9.6_6 Contact: 005293

DIAG LIGHTS 8(X) PRESENT OUTPUT SIGNAL BRAKE LGT LE XY RI XY REV. LGT LE XY RI XY REVERSE ALARM XY

•

LE: digital out from D797-1/K1:7 to H411L

•

RI: digital out from D797-1/K1:9 to H411R

Function: 9.6.4 Brake lights Signal value: 00


01


10


11


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8:31

PRESENT OUTPUT SIGNAL, REV. LGT Description: Voltage feed to back-up lights. Circuit diagram: Circuit lighting group 9.6_6 Contact: 005293


•

LE: digital out from D790-1/K2:6 to E405L

•

RI: digital out from D790-1/K2:7 to E405R

Function: 9.6.5 Back-up lights Signal value: 00


01


10


11


PRESENT OUTPUT SIGNAL, REVERSE ALARM Description: Voltage feed to reverse alarm. Circuit diagram: Circuit back-up alarm group 9.7_2 Connection: digital out from D797-1/K1:10 to H965 005293


Function: 9.7.5 Reverse alarm Signal value: 00


01


10


11


8.4.2.9 LIGHTS, menu 9 CAB LIGHT, MANUAL SWITCH Description: Signal from switch, lighting cab.

9(X) X X XXX

Circuit diagram: Circuit interior lighting group 9.6_8 Connection: signal from D790-2/K8:11 to digital in D790-1/K11:2 005294

DIAG LIGHTS CAB LIGHT MANUAL SWITCH DOOR SWITCH OUTPUT



0

No signal.


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8:32


CAB LIGHT, DOOR SWITCH Description: Signal from break contact (opening switch) door.

9(X) X X XXX

Circuit diagram: Circuit interior lighting group 9.6_8

005294


Connection: signal from S266-LE or S266-RI (connected in parallel) to digital in D790-1/K11:3 Function: 9.10.2 Doors Signal value: 1


0

No signal.

CAB LIGHT, OUTPUT Description: Voltage feed to interior lighting cab.

9(X) X X XXX

Circuit diagram: Circuit interior lighting group 9.6_8 Connection: digital out from D790-1/K11:6 to E434-1 005294


Function: 9.6.11 Interior lighting Signal value: XXX = 0-255 = 0-24 V (255 means 24 V which corresponds to battery voltage).

8.4.2.10 LIGHTS, menu 10 WORKING LIGHT MAST, SWITCH Description: Signal from switch for working light, mast. Circuit diagram: Circuit working light mast group 9.6_3 Connection: signal from S105-3/1 to digital in D790-1/K6:3 005295

DIAG LIGHTS 10(X) WORKING LIGHT MAST SWITCH X OUTPUT LE/RI XY



0

No signal.

WORKING LIGHT MAST, OUTPUT Description: Voltage feed to working light, mast. Circuit diagram: Circuit working light mast group 9.6_3 Connection: digital out from D797-1/K1:1 to E404L-1 and E404R-1 005295

DIAG LIGHTS 10(X) WORKING LIGHT MAST SWITCH X OUTPUT LE/RI XY

Function: 9.6.9 Working light, mast Signal value: 00


01


10


11


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8:33

8.4.2.11 LIGHTS, menu 11 WORKING LIGHT EXTRA OUTPUT, D797-1 C1 P42

Description: Voltage feed to auxiliary working light. 005296

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

Circuit diagram: Circuit working light option group 9.6_9 Connection: digital out from D797-1/K1:42 to E404L-4 and E404R-4 Function: 9.1.4 Switch for working light, front wing, 9.1.5 Switch for working light, attachment, 9.1.6 Switch for working light, mast Signal value: 00


01


10


11


WORKING LIGHT EXTRA OUTPUT, D797-2 C1 P42

005296


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

8.4.2.12 LIGHTS, menu 12 WORKING LIGHT CAB, SWITCH Description: Signal from switch, working lights cab roof

DIAG LIGHTS 12(X) WORKING LIGHT CAB SWITCH X 20' XY 40' XY

Connection: signal from S105-1/1 to digital in D790-1/K6:10 005297

OUTPUT

Circuit diagram: Circuit working lights 20-40 group 9.6_1



0

No signal.


VDCT01.02GB

8:34


WORKING LIGHT CAB, OUTPUT Description: Control of relays for power supply to working lights cab roof.

DIAG LIGHTS 12(X) WORKING LIGHT CAB SWITCH X 20' XY 40' XY

005297

OUTPUT

Circuit diagram: Circuit working lights 20-40 group 9.6_1 Contact: •

20': digital out from D790-1/K7:8 to K3017-2. K3017-2 voltage feeds E406L-2 and E406R-2

•

40': digital out from D790-1/K10:8 to K3017-1. K3017-1 voltage feeds E406L-1 and E406R-1

Function: 9.6.10 Work light cab Signal value: 00


01


10


11


8.4.2.13 LIGHTS, menu 13 WORKING LIGHT ATTACH, SWITCH Description: Signal from switch, working lights attachment Circuit diagram: Circuit working lights truck group 9.6_2 Connection: signal from S105-2/1 to digital in D790-1/K6:2 008895

DIAG LIGHTS 13(X) WORKING LIGHT ATTACH SWITCH X OUTPUT LE XY RI XY

Function: 9.6 Lighting system Signal value:

VDCT01.02GB

1


0

No signal.



8:35

WORKING LIGHT ATTACH, OUTPUT Description: Voltage feed to working light, attachment. Circuit diagram: Attachment DCF 90/100/100-45E group 9.6_1 Contact: 008895

DIAG LIGHTS 13(X) WORKING LIGHT ATTACH SWITCH X OUTPUT LE XY RI XY

•

LE: digital out from D791-1/K1:1 to E404UL (and E404L

•

RI: digital out from D791-1/K1:15 to E404UR (and E404R

) )

Function: 9.6.12 Work light attachment Signal value: 00


01


10


11



VDCT01.02GB

8:36


8.4.2.14 LIGHTS, menu 14 SWITCH LIGHTS, OUTPUT

OUTPUT

14(X) XXX

005300

DIAG LIGHTS SWITCH LIGHTS

Description: Voltage feed to background lighting in switches, panels and keys. Circuit diagram: Circuit brake system group 4.0_1, circuit 20-40, 30-35 stop group 7.5_1, circuit twistlock group 7.9_1, circuit extra equipment group 9.1_1, circuit seat heating group 9.3_1, circuit climate system group 9.4_1, circuit working lights 20-40 group 9.6_1, circuit working lights truck group 9.6_2, circuit working light mast group 9.6_3, circuit lighting group 9.6_4, circuit blinkers & hazard group 9.6_7 Contact: output signal from D790-1/K6:1 to S117, S118, S139 output signal from D790-1/K6:2 to S105-2 output signal from D790-1/K6:3 to S105-3 output signal from D790-1/K6:4 to S110 output signal from D790-1/K6:5 to S100 output signal from D790-1/K6:6 to S143 output signal from D790-1/K6:7 to S199-4 output signal from D790-1/K6:8 to S199-3 output signal from D790-1/K6:9 to S199-1 output signal from D790-1/K6:10 to S105-1 output signal from D790-1/K8:10 to S1004 output signal from D790-1/K8:12 to S1003 output signal from D790-1/K8:13 to S107 output signal from D790-1/K8:14 to S199-2 output signal from D790-1/K8:15 to S1012 output signal from D790-1/K5:5 to S109 Function: 9.6.11 Interior lighting Signal value: 50

Means 4-5 V.

170

Means 15-16 V.

8.4.2.15 LIGHTS, menu 15 NOT USED This menu is not used.

XXXXXXX

X(X)

008793

NOT USED

VDCT01.02GB


8 Control system – CAB

8:37

8.4.3 CAB CAB, description This group covers functions in the cab. Confirm selections with function key for Enter.

005301


8.4.3.1 CAB, menu 1 WASHER, SWITCH Description: Signal from gear and multi-function lever switch washer.

1(X) X XY XY

Circuit diagram: Circuit wiper group 9.5_1 Connection: signal from S162/53C to digital in D790-2/K3:4 005541

DIAG CAB WASHER SWITCH OUTPUT FRONT OUTPUT REAR ROOF

Function: 9.5 Wiper/washer system Signal value: 1


0

No signal.

WASHER, OUTPUT FRONT Description: Voltage feed to windscreen washer motor.

1(X) X XY XY

Circuit diagram: Circuit wiper group 9.5_1 Connection: digital out from D790-1/K10:13 to M651-1 and M651-2 005541


Function: 9.5.4 Washer motor and reservoir Signal value: 01


10


11



VDCT01.02GB

8:38


WASHER, OUTPUT REAR ROOF

1(X) X XY XY

005541


Description: Grounding of motor washer roof and rear window. The motor is supplied with voltage parallel with Motor windscreen washing, activation is controlled by controlling grounding of the motor. The motor is grounded at windscreen washing if the wiper motor roof or rear window is activated. Circuit diagram: Circuit wiper group 9.5_1 Connection: PWM out D790-1/K5:4 to M651-2 Function: 9.5.4 Washer motor and reservoir Signal value: 00


01


10


11


8.4.3.2 CAB, menu 2 FRONT WIPER, SWITCH (1-3) Description: Signal from multi-function lever, switch wiper function.

2(X) X XY X

Circuit diagram: Circuit wiper group 9.5_1 Contact: 005542

DIAG CAB FRONT WIPER SWITCH (1-3) OUTPUT FEEDBACK

X = 1 Interval slow: signal from S162/J1 to digital in D790-2/K3:6 X = 2 Interval less slow: signal from S162/J2, digital in D790-2/K3:7 X = 3 Interval continuous: signal from S162/53, digital in D790-2/K3:8 Function: 9.5 Wiper/washer system Signal value:

VDCT01.02GB

1

Long interval.

2

Normal interval.

3

Continuous operation.



8:39

FRONT WIPER, OUTPUT Description: Voltage feed to wiper front.

2(X) X XY X

Circuit diagram: Circuit wiper group 9.5_1 Connection: digital out from D790-1/K2:1 to M650-1/53 005542


Function: 9.5.5 Wiper motor front Signal value: 01


10


11


FRONT WIPER, FEEDBACK Description: Signal from motor wiper front, indicates when the wiper sweep is completed.

2(X) X XY X

Circuit diagram: Circuit wiper group 9.5_1 005542


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 (home position).

8.4.3.3 CAB, menu 3 REAR WIPER, SWITCH Description: Status of rear window wiper switch on Control unit KIT (D790-2).

3(X) X XY X

Circuit diagram: 005543

DIAG CAB REAR WIPER SWITCH OUTPUT FEEDBACK

Contact: Function: 9.5 Wiper/washer system Signal value: 1

Input signal active. Key for continuous/interval pressed down.

0

No signal.


VDCT01.02GB

8:40


REAR WIPER, OUTPUT Description: Voltage feed to direction windscreen wiper rear.

3(X) X XY X

Circuit diagram: Circuit wiper group 9.5_1 Connection: digital out from D790-1/K2:4 to M650-2/53 005543


Function: 9.5.7 Wiper motor rear Signal value: 01


10


11


REAR WIPER, FEEDBACK Description: Signal from motor windscreen wiper rear, indicates when the wiper sweep is completed.

3(X) X XY X



Connection: signal from M650-2/31b to digital in D790-1/K12:2 Function: 9.5.7 Wiper motor rear Signal value: 1


0


8.4.3.4 CAB, menu 4 ROOF WIPER, SWITCH Description: Signal from switch, wiper roof.

4(X) X XY X

Circuit diagram: Contact: 005544

DIAG CAB ROOF WIPER SWITCH OUTPUT FEEDBACK

Function: 9.5 Wiper/washer system Signal value:

VDCT01.02GB

1

Input signal active. Key for continuous/interval pressed down.

0

No signal.



8:41

ROOF WIPER, OUTPUT Description: Voltage feed to wiper roof.

4(X) X XY X

Circuit diagram: Circuit wiper group 9.5_1 Connection: digital out from D790-1/K10:14 to wiper motor M650-3/53 005544


Function: 9.5.6 Wiper motor roof Signal value: 00


01


10


11


ROOF WIPER, FEEDBACK Description: Signal from motor wiper roof, indicates when the wiper sweep is completed.

4(X) X XY X



Connection: signal from M650-3/31B to digital in D790-1/K12:4 Function: 9.5.6 Wiper motor roof Signal value: 1


0


8.4.3.5 CAB, menu 5 HORN, SWITCH Description: Signal from switch, horn.

5(X) X X XY

Circuit diagram: Circuit alarm, audible signals group 9.7_1 Connection: signal from S162/H to digital in D790-2/K3:2 005545

DIAG CAB HORN SWITCH SWITCH 2 OUTPUT

Function: 9.7 Signalling system Signal value: 1


0

No signal.


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8:42


HORN, SWITCH 2

5(X) Description: Signal from horn switch on hydraulic control panel.

X X XY

005545


Circuit diagram: Circuit horn servo panel group 9.7_4 Connection: signal from S149-3 to digital in D790-1/K9:10 Function: 9.7 Signalling system Signal value: 1


0

No signal.

HORN, OUTPUT Description: Voltage feed to horn.

5(X) X X XY

Circuit diagram: Circuit alarm, audible signals group 9.7_1 and circuit compressor horn group 9.7_3 005545


Connection: digital out D790-1/K11:11 to H850 ( horn, signal to relay K3016/86)

for compressor

Function: 9.7.1 Horn Signal value: 01


10


11


8.4.3.6 CAB, menu 6 BUZZER Description: Voltage feed to buzzer for alarm indication panel, feed.

6(X) XY X X X

Circuit diagram: Circuit alarm, audible signals group 9.7_1 Connection: digital out from D790-2/K8:4 to H853/1 005546

DIAG CAB BUZZER SWITCH SEAT ALARM OP

Function: 9.3 Seats, 1 Engine, 8.2.1 Overload protection Signal value: 00


01


10


11


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8:43

SWITCH SEAT Description: Signal from Sensor, operator-in-seat.

6(X) XY X X X

Circuit diagram: Circuit alarm, audible signals group 9.7_1 Connection: signal from S230/1 to D790-1/K11:14 005546


Function: 9.3.14 Sensor operator in seat 1

Input signal active. Operator in seat.

0

No signal. No operator in seat.

ALARM

6(X) XY X X X

Description: Status for alarm indication panel, warning from control system. Circuit diagram: 005546


Contact: Function: 8.1.2 Information display 1

Conditions for activation of buzzer from seat switch and parking brake are fulfilled

0

Conditions for activation of buzzer are not fulfilled.

OP

6(X) XY X X X

005546



8.4.3.7 CAB, menu 7 FUEL, SENSOR VALUE Description: Signal from sensor fuel level.

7(X) XXXohm XXX

Circuit diagram: Circuit drivetrain engine group 1.0_1 Connection: analogue rheostat signal from B757 to D797-1/K2:15 009182

DIAG CAB FUEL SENSOR VALUE PROC

Function: 1.2.2 Sensor fuel level Signal value: XXXohm = Current resistance value from sensor fuel level in ohm.

FUEL, PROC Description: The control system's interpretation of the signal from sensor, fuel tank.

7(X) XXXohm XXX


DIAG CAB FUEL SENSOR VALUE PROC

Contact: Function: 1.2.2 Sensor fuel level Signal value: XXX = 0-100 = 0-100% = Fuel volume in tank.


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8.4.3.8 CAB, menu 8 SEAT HEATER, SWITCH

8(X) Description: Signal from switch, seat heating.

X XY

Circuit diagram: Circuit seat heating group 9.3_1 005548

DIAG CAB SEAT HEATER SWITCH OUTPUT

Connection: signal from S143/1 to digital in D790-1/K6:6 Function: 9.3 Seat Signal value: 1


0

No signal.

SEAT HEATER, OUTPUT Description: Voltage feed to seat heating relay.

8(X) X XY

Circuit diagram: Circuit seat heating group 9.3_1 Connection: digital out from D790-1/K10:7 to K383/86 005548

DIAG CAB SEAT HEATER SWITCH OUTPUT

Function: 9.3.3 Heating coil Signal value: 00


01


10


11


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8 Control system – CLIMATE

8:45

8.4.4 CLIMATE CLIMATE, description This group covers the cab's air conditioning. Confirm selections with function key for Enter.

005302


8.4.4.1 CLIMATE, menu 1 PRESENT INPUT SIGNAL, REQUIRED TEMP Description: Set value for desired temperature. Circuit diagram: Circuit climate system group 9.4_1 Connection: signal from S117/3 to analogue in D790-1/K5:8 005549

DIAG CLIMATE 1(X) PRESENT INPUT SIGNAL REQUIRED TEMP XXX PRESENT TEMP XXX WATER VALVE FEEDB. XXX

Function: 9.4 Heating, ventilation and air conditioning Signal value: XXX = 160-280 = 16-28 ºC = Preset temperature shown in tenths of degrees and adjusted in increments of half degrees (200 = 20 ºC). Test by increasing or decreasing temperature with the temperature switch on the panel.

PRESENT INPUT SIGNAL, PRESENT TEMP Description: Signal from sensor cab temperature. Circuit diagram: Circuit climate system group 9.4_1 Connection: signal from B775-1/2 to input D790-1/K4:8 005549


Function: 9.4.17 Sensor cab temperature Signal value: XXX = Cab's interior temperature in tenths of degrees (200 = 20 ºC).

PRESENT INPUT SIGNAL, WATER VALVE FEEDB. Description: Water valve's position (opening in percent). Circuit diagram: Circuit climate system group 9.4_2 Connection: signal from Y673/9 to analogue in D790-1/K10:4 005549


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

CLIMATE COIL COOLANT AMBIENT DE-ICE

2(X) XXX XXX XXX XXX

Description: Temperature of the air out from the fan. The sensor is fitted in the air distributor. Circuit diagram: Circuit climate system group 9.4_1 005550

DIAG TEMP TEMP TEMP TEMP

Connection: signal from B775-2 to input D790-1/K4:10 Function: 9.4.16 Sensor, temperature outlet fan Signal value: XXX = Temperature of the air blown into the cab in tenths of degrees (200 = 20 ºC).


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TEMP COOLANT



Description: Coolant temperature, temperature of the engine's coolant. Signal is retrieved from the engine via CAN bus drive-train. Circuit diagram: Circuit climate system group 9.4_1 and 9.4_2 005550


Connection: from engine via CAN bus, see PRESENT INPUT SIGNAL, COOLANT TEMP, page 8:59. Function: 1.7 Cooling system Signal value: XXX = Engine temperature in tenths of degrees (200 = 20 ºC).

TEMP AMBIENT



Description: Outdoor temperature. Heat radiation from engine and sun may affect the value since the sensor is fitted on the rear of the cab roof. Circuit diagram: Circuit climate system group 9.4_1 005550


Connection: signal from B774/2 to input D790-1/K4:9 Function: 9.4.18 Sensor ambient temperature Signal value: XXX = Outdoor temperature in tenths of degrees (200 = 20 ºC).

TEMP DE-ICE Description: Temperature in refrigerant circuit.



Circuit diagram: Circuit climate system group 9.4_1 Connection: signal from B775-3/2 to input D790-1/K4:11 005550


Function: 9.4.12 Sensor temperature refrigerant Signal value: XXX = Refrigerant temperature in tenths of degrees (200 = 20 ºC).

8.4.4.3 CLIMATE, menu 3 PRESENT INPUT SIGNAL, PRESSURE SWITCH Description: Signal from refrigerant pressure switch.

DIAG CLIMATE 3(X) PRESENT INPUT SIGNAL PRESSURE SWITCH X

Circuit diagram: Circuit climate system group 9.4_1

005551

Connection: signal from S246/2 to digital in D797-1/K1:40 Function: 9.4.10 Pressure switch Signal value:

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1

Input signal active. Press OK.

0

No signal, too high or too low pressure.



8:47

8.4.4.4 CLIMATE, menu 4 PRESENT INPUT SIGNAL, WATER VALVE Description: Signal from water valve, the voltage is a measure of the position. Circuit diagram: Circuit climate system group 9.4_2 005552

DIAG CLIMATE 4(X) PRESENT INPUT SIGNAL WATER VALVE XX.XXV DRAUGHT VALVE XX.XXV

Connection: signal from Y673/9 to analogue in D790-1/K10:4 Function: 9.4.5 Water valve Signal value: XX.XXV = 0.50 - 4.50 V

PRESENT INPUT SIGNAL, DRAUGHT VALVE Description: Signal from the engine to the air distributor. The voltage is a measure of the damper's position. Circuit diagram: Circuit climate system group 9.4_2 005552

DIAG CLIMATE 4(X) PRESENT INPUT SIGNAL WATER VALVE XX.XXV DRAUGHT VALVE XX.XXV

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 Description: Signal from switch, temperature. Voltage when the switch is pressed in the voltage level indicates increase or decrease of the temperature. Circuit diagram: Circuit climate system group 9.4_1 005553

DIAG CLIMATE 5(X) PRESENT INPUT SIGNAL REQUIRED TEMP XX.XXV REQ. DRAUGHT XX.XXV REQ. FAN SPEED XX.XXV

Connection: signal from S117/3 to analogue in D790-1/K5:8 Function: 9.4 Heating, ventilation and air conditioning Signal value: XX.XXV ~ 2.4 / 0 / 5.0 V = Increase / - / decrease

PRESENT INPUT SIGNAL, REQ. DRAUGHT Description: Signal from switch, air distribution, voltage when switch is pressed in. The voltage level indicates change of air control against windscreen (up) or floor (down). The damper's position changes in steps between windscreen - floor. 005553


Circuit diagram: Circuit climate system group 9.4_1 Connection: signal from S139/3 to analogue in D790-1/K5:9 Function: 9.4 Heating, ventilation and air conditioning Signal value: XX.XXV ~ 2.4 / 0 / 5.0 V = Up / - / down.

PRESENT INPUT SIGNAL, REQ. FAN SPEED Description: Signal from switch, fan speed, switch controls increase or decrease of fan speed. Speed is adjustable steplessly. The voltage level indicates if the speed should be increased or decreased. Circuit diagram: Circuit climate system group 9.4_1 005553


Connection: signal from S118/3 to analogue in D790-1/K5:7 Function: 9.4 Heating, ventilation and air conditioning Signal value: XX.XXV ~ 2.4 / 0 / 5.0 V = Increase / - / decrease.


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8.4.4.6 CLIMATE, menu 6 PRESENT OUTPUT SIGNAL, FAN SPEED Description: Current control of fan motor, speed is controlled with PWM-control of grounding (of fan motor). Circuit diagram: Circuit climate system group 9.4_2 005554

DIAG CLIMATE 6(X) PRESENT OUTPUT SIGNAL FAN SPEED XXX RECIRKULATION XY COMPRESSOR XY

Connection: analogue out from D790-1/K2:2 to M657/31 Function: 9.4.3 cab fan. Signal value: XXX = 0-255 = Fan speed (255 = max. fan speed).

PRESENT OUTPUT SIGNAL, RECIRCULATION Description: Voltage feed to motor for fresh air and recirculation damper. Circuit diagram: Circuit climate system group 9.4_2 005554


Connection: digital out from D790-1/K2:3 to M612 Function: 9.4.2 Fresh air and recirculation damper Signal value: 01


10


11


PRESENT OUTPUT SIGNAL, COMPRESSOR Description: Voltage feed of AC compressor's electromagnetic clutch. Controls cut-in and cut-out of the compressor. Two outputs are connected in parallel to handle the current intensity. Circuit diagram: Circuit climate system group 9.4_2 005554


Connection: digital out from D797-1/K1:25 and D797-1/K1:29 to M645 Function: 9.4.7 Compressor Signal value: 00


01


10


11


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8:49

8.4.4.7 CLIMATE, menu 7 OUTPUT WATER VALVE, CLOCKWISE Description: Voltage feed to water valve, for opening. The valve is connected to an H-bridge. The signal can only be diagnosed when the valve's position changes. The valve's opening and closing is controlled by the air conditioning's software depending on desired temperature, outside temp. cab temperature and coolant temperature, so it may be difficult to determine whether the valve is working as it should.

DIAG CLIMATE 7(X) OUTPUT WATER VALVE CLOCKWISE XY XY ANTI-CLOCKWISE XY XY


24V

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


01

Normal mode function off.

005555

No output signal, circuit OK. It can also be a short circuit as this is only detected when the output signal is active.

0V

H-bridge

10


11


OUTPUT WATER VALVE, ANTI-CLOCKWISE Description: Voltage feed to water valve, for closing. The valve is connected to an H-bridge. The signal can only be diagnosed when the valve's position changes. The valve's opening and closing is controlled by the air conditioning's software depending on desired temperature, outside temp. cab temperature and coolant temperature, so it may be difficult to determine whether the valve is working as it should.

DIAG CLIMATE 7(X) OUTPUT WATER VALVE CLOCKWISE XY XY ANTI-CLOCKWISE XY XY


24V

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

H-bridge

00


01


005555

0V

Signal value: motor runs anticlockwise row 1: 00 11, row 2: 11 11

10


11



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8:50


8.4.4.8 CLIMATE, menu 8 OUTPUT DRAUGHT VALVE, CLOCKWISE Description: Voltage feed to motor for the air distributor, rotation clockwise. Is connected to an H-bridge. Signal can only be diagnosed when the air distributor's position changes.

DIAG CLIMATE 8(X) OUTPUT DRAUGHT VALVE CLOCKWISE XY XY ANTI-CLOCKWISE XY XY

Circuit diagram: Circuit climate system group 9.4_2 Connection: digital out from D790-1/K4:3 via R5 to Y672/5 and from D790-1/K4:4 via R6 to Y672/6

24V

Function: 9.4.14 Air distributor Signal value: motor runs clockwise row 1: 11 11, row 2: 00 11

M


01


005556

0V

00

10


11


H-bridge

OUTPUT DRAUGHT VALVE, ANTI-CLOCKWISE Description: Voltage feed to the motor for the air distributor, rotation anticlockwise. The motor is connected to an H-bridge. The signal can only be diagnosed when the air distributor's position changes.

DIAG CLIMATE 8(X) OUTPUT DRAUGHT VALVE 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 anticlockwise row 1: 00 11, row 2: 11 11

M

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01


005556

0V

H-bridge

00

10


11



8 Control system – HYD

8:51

8.4.5 HYD HYD, description This group covers the hydraulic functions. Confirm selections with function key for Enter.

005303


8.4.5.1 HYD, menu 1 HYDRAULIC OIL, TEMP Description: Signal from sensor hydraulic oil temperature.

1(X) XXX XY X

Circuit diagram: Circuit cooling hydraulic oil group 10.6_1 Connection: signal from B776/1 to temperature in D797-1/K2:13 010070

DIAG HYDRAULIC HYDRAULIC OIL TEMP FAN SET OUTPUT + -

Function: 10.6.4 Sensor hydraulic oil temperature Signal value: XXX = Temperature in tenths of degrees (200 = 20 ºC).

HYDRAULIC OIL, FAN Description: Voltage feed cooling fan hydraulic oil.

1(X) XXX XY X

Circuit diagram: Circuit cooling hydraulic oil group 10.6_1 Connection: digital out from D797-1/K1:14 to M668/1 010070


Function: 10.6.3 Cooling fan Signal value: 01


10


11


HYDRAULIC OIL, SET OUTPUT +/Description: Functionality test of hydraulic oil cooling fan.

1(X) XXX XY X

Circuit diagram: Circuit cooling hydraulic oil group 10.6_1

010070


Connection: digital out from D797-1/K1:14 to M668/1 is activated or deactivated with +/Function: 10.6.3 Cooling fan Signal value:

8.4.5.2 HYD, menu 2 NOT USED This menu is not used.

XXXXXXX

X(X)

008793

NOT USED


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XXXXXXX

X(X)

008793

NOT USED

8.4.5.4 HYD, menu 4 PRESSURE SWITCHES, BRAKE PRESSURE Description: Signal from break contact (opening switch) brake pressure. Circuit diagram: Circuit brake system group 4.0_1 007240

DIAG HYDRAULIC 4(X) PRESSURE SWITCHES BRAKE PRESSURE X BRAKE LIGHT PRESS. X DECLUTCH PRESSURE X

Connection: signal from S204/2 to analogue in D797-1/K1:13 Function: 4.3.7 Normally open (NO) switch, brake pressure Signal value: 1


0

No signal.

PRESSURE SWITCHES, BRAKE LIGHT PRESSURE Description: Signal from make-contact (closing switch) brake lights. Circuit diagram: Circuit lighting group 9.6_5 Connection: signal from S216/2 to digital in D797-1/K1:20 007240


Function: 4.3.8 Make-contact (closing switch) brake lights Signal value: 1


0

No signal.

PRESSURE SWITCHES, DECLUTCH PRESSURE Description: Signal from break contact (opening switch) declutch. Circuit diagram: Circuit drivetrain gearbox group 2.0_1 Connection: signal from S220-2/2 to analogue in D797-1/K1:27 007240


Function: 2.8.2 Normally closed (NC) switch, disengagement Signal value:

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1


0

No signal.



8:53

8.4.5.5 HYD, menu 5 P-BRAKE, SWITCH Description: Signals from switch parking brake. Two signals, one for released parking brake and one for applied parking brake. Both signals must be valid to enable release of parking brake.

5(X) X/Y X XY

Circuit diagram: Circuit brake system group 4.0_1 007241

DIAG HYDRAULIC P-BRAKE SWITCH FEEDBACK SWITCH VALVE

Connection: signal from S107/1 to digital in D790-1/K8:13 and from S107/7 to digital in D790-1/K8:5 Function: 4.5 Parking brake system Signal value: 1/0

Open, parking brake released.

0/1

On, parking brake applied.

P-BRAKE, FEEDBACK SWITCH Description: Signal from break contact (opening switch) parking brake.

5(X) X/Y X XY

Circuit diagram: Circuit brake system group 4.0_1 007241


Connection: signal from S200/2 to analogue in D797-1/K1:41 Function: 4.5.5 Normally open (NO) switch, parking brake Signal value: 1


0

No signal.

P-BRAKE, VALVE Description: Voltage feed to Solenoid valve parking brake.

5(X) X/Y X XY

Circuit diagram: Circuit brake system group 4.0_1 Connection: digital out from D797-1/K1:34 to solenoid valve Y642/1 007241


Function: 4.5.3 Solenoid valve parking brake Signal value: 00


01


10


11



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8:54



XXXXXXX

X(X)

008793

NOT USED


XXXXXXX

X(X)

008793

NOT USED

8.4.5.8 HYD, menu 8 PRESENT OUTPUT SIGNAL, PRESSURE TO ATTACHM. VALVE Description: Voltage feed to solenoid valve for main pump relief (pressurised attachment). Circuit diagram: circuit disengage. hydr pump group 10.4_1 010074

DIAG HYDRAULIC 8(X) PRESENT OUTPUT SIGNAL PRESSURE TO ATTACHM. VALVE XY SET OUTPUT + X

Connection: digital out from circuit disengage hydraulic pump group D797-1/K1:35 to solenoid valve Y6062-2 Function: 10.4.2 Axial piston pump with variable displacement Signal value: 1

Output signal active.

0

No output signal.

PRESENT OUTPUT SIGNAL, PRESSURE TO ATTACHM, SET OUTPUT +/Description: Begin sending or cut off hydraulic pressure to the attachment. Circuit diagram: circuit disengage. hydr pump group 10.4_1 010074

DIAG HYDRAULIC 8(X) PRESENT OUTPUT SIGNAL PRESSURE TO ATTACHM. VALVE XY SET OUTPUT + X

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:

VDCT01.02GB

1


0

No output signal.


8 Control system – ENGINE

8:55

8.4.6 ENGINE ENGINE, description This group covers the engine functions. Confirm selections with function key for Enter.

005306


8.4.6.1 ENGINE, menu 1 PRESENT INPUT SIGNAL, ACCELERATOR Description: Signal from accelerator pedal. Circuit diagram: Circuit drivetrain engine group 1.0_1 Connection: signal from B690-1/2 to analogue in D790-1/K6:11 006866

DIAG ENGINE 1(X) PRESENT INPUT SIGNAL ACCELERATOR X.XXV REQUIRED SPD PROC XXX REQUIRED SPD RPM XXXX

Function: 1 Engine Signal value: X.XXV = 0.50-4.50 V

PRESENT INPUT SIGNAL, REQUIRED SPD PROC Description: Required engine speed (in percent) which is sent from Control unit, cab (D790-1) to Control unit, engine (D794) via CAN bus drive-train. Circuit diagram: 006866


Contact: Function: 1.9 Control system, engine Signal value: XXXX = 0-100%

PRESENT INPUT SIGNAL, REQUIRED SPD RPM Description: Required engine speed (in percent) which is sent from Control unit, cab (D790-1) to Control unit, engine (D794) via CAN bus drive-train. Circuit diagram: 006866


Contact: Function: 1.9 Control system, engine Signal value: XXXX = 0-2010 rpm

8.4.6.2 ENGINE, menu 2 PRESENT INPUT SIGNAL, ENGINE SPEED EDC Description: Engine speed from Control unit, engine (D794) to Control unit, cab (D790-1) via CAN bus drive-train. Actual value for engine speed. Circuit diagram: 005308

DIAG ENGINE 2(X) PRESENT INPUT SIGNAL ENGINE SPEED EDC XXXX ENGINE SPEED TCU XXXX

Contact: Function: 1.9.2 Sensor engine rpm Signal value: XXXX = Active speed in rpm.


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DIAG ENGINE 2(X) PRESENT INPUT SIGNAL ENGINE SPEED EDC XXXX ENGINE SPEED TCU XXXX

005308

PRESENT INPUT SIGNAL, ENGINE SPEED TCU

Description: Engine speed from Transmission control unit (D793) to Cab control unit (D790-1) via CAN bus drivetrain. Actual value for engine speed. Only used on machines with engine alternative Cummins QSB6.7. Circuit diagram: Contact: Function: 2.2.5 Sensor engine speed and oil temperature transmission Signal value: XXXX = active speed in rpm.

8.4.6.3 ENGINE, menu 3 PRESENT INPUT SIGNAL, PRESENT TORQUE Description: Actual torque from Control unit, engine (D794). Percentage torque use of engine's capacity. Circuit diagram: 005309

DIAG ENGINE 3(X) PRESENT INPUT SIGNAL PRESENT TORQUE XXX REQUIRED TORQUE XXX PRES TORQUE @ RPM XXX

Contact: Function: 1.9 Control system, engine Signal value: XXX = 0-100%


005309

PRESENT INPUT SIGNAL, REQUIRED TORQUE

Description: Requested torque from cab control unit (D790-1) to engine control unit (D794). Only used on machines with engine alternative Cummins QSB6.7. Circuit diagram: Contact: Function: 1.9 Control system, engine Signal value: XXXX = 0-100%

PRESENT INPUT SIGNAL, PRES TORQUE @ PPM

Description: Available torque at current engine speed. Only used on machines with engine alternative Cummins QSB6.7. 005309


Circuit diagram: Contact: Function: 1.9 Control system, engine Signal value: XXXX = 0-100%

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8:57

8.4.6.4 ENGINE, menu 4 PRESENT INPUT SIGNAL, PREHEAT SWITCH

009282


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

PRESENT INPUT SIGNAL, CRANK ENGINE SWITCH Description: Signal from ignition key lock, start position. Circuit diagram: Circuit power group 11.5_3, Circuit drivetrain engine group 1.0_1 009282


Connection: signal from S150/50 to digital in D790-2/K2:1 Function: 1 Engine, 1.11 Start and stop Signal value: 1


0

No signal.

PRESENT INPUT SIGNAL, D+ Description: Signal from alternator, indicates if alternator supplies current.

009282


Circuit diagram: Circuit Yuchai YC6A240-30 group 1.0_1A1, circuit engine QSB6.7 group 1.0_2E1 and circuit drivetrain engine group 1.0_1 Connection: from G660/D+ to digital in D797-1/K2:16 Function: 11.4.1 Alternator Signal value: 1


0

No signal.

8.4.6.5 ENGINE, menu 5 PRESENT OUTPUT SIGNAL, PREHEAT Description: Status for preheating of induction air. Only used on machines with engine alternative Yuchai YC6M360-30. Circuit diagram: Connection: controlled by engine's control system 015098

DIAG ENGINE 5(X) PRESENT OUTPUT SIGNAL PREHEAT X CRANK ENGINE X CRANK ENGINE WIRE XY

Function: 1.10.1 Preheating Signal value: 1


0

No output signal.


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8:58


PRESENT OUTPUT SIGNAL, CRANK ENGINE Description: Status for start signal to Engine control unit (D794) via the CAN-bus. Circuit diagram: Connection: controlled by engine's control system 015098


Function: 1.11 Start and stop Signal value: 1


0

No output signal.

PRESENT OUTPUT SIGNAL, CRANK ENGINE WIRE Description: Status for voltage feed to the Starter relay (K360). Circuit diagram: Circuit drivetrain engine group 1.0_1, Circuit Yuchai YC6A240-30 group 1.0_1A1 and Circuit engine QSB6.7 group 1.0_2E1 Connection: digital out D797-1/K1:32 to K360/86

015098


Function: 1.11 Start and stop Signal value: 01


10


11


8.4.6.6 ENGINE, menu 6 PRESENT INPUT SIGNAL, OIL PRESSURE Description: Engine oil pressure. CAN bus message from Control unit, engine (D794) to Control unit, cab (D790-1). Circuit diagram: see supplier documentation, engine 000153

DIAG ENGINE 6(10) PRESENT INPUT SIGNAL OIL PRESSURE XXX BOOST PRESSURE XXX

Contact: Function: 1.8 Lubrication system Signal value: XXX = 10 corresponds to 100 kPa.

PRESENT INPUT SIGNAL, BOOST PRESSURE Description: Boost pressure. CAN bus message from Control unit, engine (D794) to Control unit, cab (D790-1). Circuit diagram: see supplier documentation, engine 000153

DIAG ENGINE 6(10) PRESENT INPUT SIGNAL OIL PRESSURE XXX BOOST PRESSURE XXX

Contact: Function: 1.6 Air intake and exhaust outlet Signal value: XXX = 10 corresponds to 100 kPa.

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8:59

8.4.6.7 ENGINE, menu 7 PRESENT INPUT SIGNAL, OIL TEMP Description: Engine oil temperature. CAN bus message from Control unit, engine (D794) to Control unit, cab (D790-1). Circuit diagram: see supplier documentation, engine. 009284

DIAG ENGINE 7(X) PRESENT INPUT SIGNAL OIL TEMP XXX COOLANT TEMP XXX INTAKE MAIN.TEMP XXX

Contact: Cummins QSB6.7 : signal from "Oil pressure/temperature sensor" sleeve 4 to Control unit, engine (D794) "Sensor connector" sleeve 42 Yuchai YC6A240-30: Function: 1 Engine Signal value: XXX = 200 corresponds to 20 ºC.

PRESENT INPUT SIGNAL, COOLANT TEMP Description: Coolant temperature. CAN bus message from Control unit, engine (D794) to Control unit, cab (D790-1). Circuit diagram: see supplier documentation, engine 009284


Contact: Function: 1.7 Cooling system Signal value: XXX = 200 corresponds to 20 ºC.

PRESENT INPUT SIGNAL, INTAKE MAIN.TEMP Description: Charge air temperature. CAN bus message from Control unit, engine (D794) to Control unit, cab (D790-1). Circuit diagram: see supplier documentation, engine 009284


Contact: Function: 1.6 Air intake and exhaust outlet Signal value: XXX = 200 corresponds to 20 ºC.

8.4.6.8 ENGINE, menu 8 PRESENT EDC ERROR, NO. OF ACT ERROR Description: Number of active error codes from Control unit, engine (D794). Circuit diagram: 009279

DIAG ENGINE 8(X) PRESENT EDC ERROR NR OF ACT ERROR XX SPN XXXX FMI XX

Contact: Function: 1.9 Control system Signal value: XX = number of active error codes.


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8:60


PRESENT EDC ERROR, SPN Description: SPN number for the first error code from Control unit, engine (D794). SPN indicates the malfunction area, i.e. what component or signal is defective. Error codes are shown with SPN/FMI in the error code menus. 009279


Circuit diagram: Contact: Function: 8.3 Error codes Signal value: XXXX = error code number. Use the error code list; see section D Error codes.

PRESENT EDC ERROR, FMI Description: FMI number for the first error code from the Control unit, engine (D794). FMI indicates error type, e.g. short circuit or low value. Error codes are shown with SPN/FMI in the error code menus. Circuit diagram: 009279


Contact: Function: 8.3 Error codes Signal value: XX = fault type number. Use the error code list; see section D Error codes.

8.4.6.9 ENGINE, menu 9 FUEL CONSUMPTION, MOMENTARILY l/h Description: Current fuel consumption in litres/hour.

9(X)

Circuit diagram: -

XXX

Contact: 009280

DIAG ENGINE FUEL CONSUMTION MOMENTARILY l/h

Function: 1.2 Fuel system Signal value: XXX = fuel consumption in l/h.

8.4.6.10 ENGINE, menu 10 PRESENT INPUT SIGNAL, PRE-HEAT FEEDBACK Description: Signal from Control unit, engine (D794) which indicates that preheating is active. Only used on machines with engine alternative Yuchai YC6A240-30.

013919

DIAG ENGINE 10(X) PRESENT INPUT SIGNAL PRE-HEAT FEEDBACK X WATER IN FUEL SW. X COOLANT LEVEL SW. X

Circuit diagram: Circuit Yuchai YC6A240-30 group 1.0_1A1, circuit mast sensor OLS group 8.2_3 Connection: signal from D794/1:38 to D797-1/K1:36 Function: 1.6 Air intake and exhaust outlet Signal value:

VDCT01.02GB

1

No signal

0

Input signal active. (Indication that preheating is activated by Control unit, engine (D794) is active.)



8:61

PRESENT INPUT SIGNAL, WATER IN FUEL SW. Description: Signal from Control unit, engine (D794) which indicates that there is too much water in the fuel filter. Only used on machines with engine alternative Yuchai YC6A240-30.

013919


Circuit diagram: Circuit Yuchai YC6A240-30 group 1.0_1A1, circuit mast sensor OLS group 8.2_3 Connection: signal from D794/1:39 to D797-1/K1:37 Function: 1.2 Fuel system Signal value: 1

No signal

0

Input signal active. (Indication that there is too much water in the fuel filter.)

PRESENT INPUT SIGNAL, COOLANT LEVEL SW. Description: The signal from the make-contact (closing switch) coolant level (B759), which indicates that the coolant level is low. Only used on machines with engine alternative Yuchai YC6A240-30. Circuit diagram: Circuit Yuchai YC6A240-30 group 1.0_1A1 013919


Connection: signal from B759/2 to digital in D797-1/K1:12 Function: 1.7 Cooling system Signal value: 1

No signal

0

Input signal active. Coolant level is low.


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8:62

8 Control system – TRANSM

8.4.7 TRANSM TRANSM, description This group covers transmission functions. Confirm selections with function key for Enter.

005324


8.4.7.1 TRANSM, menu 1 PRESENT INPUT SIGNAL, BRAKE PEDAL

005325


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

PRESENT INPUT SIGNAL, DECLUTCH SWITCH Description: Signal from declutch pedal. Circuit diagram: Circuit drivetrain gearbox group 2.0_1 Connection: signal from S220-1/2 to digital in D790-1/K6:14 005325


Function: 2 Transmission Signal value: 1

Input signal active. Declutch pedal depressed.

0

No signal.

PRESENT INPUT SIGNAL, DECLUTCH PRESS SW. Description: Signal from break contact (opening switch) declutch (pressure switch). Circuit diagram: Circuit drivetrain gearbox group 2.0_1 005325


Connection: signal from S220-2/2 to digital in D797-1/K1:27 Function: 2.8.2 Normally closed (NC) switch, disengagement Signal value:

VDCT01.02GB

1


0

No signal.



8:63

8.4.7.2 TRANSM, menu 2 SWITCHES, FORWARD Description: Signal from gear and multi-function lever (forward).

2(X) X X X

Circuit diagram: Circuit drivetrain gearbox group 2.0_1 Connection: signal from S162/F to digital in D790-2/K3:11 005326

DIAG TRANSM. SWITCHES FORWARD REVERSE SHIFT MODE


Input signal active. Travel direction forward selected.

0

No signal.

SWITCHES, REVERSE Description: Signal from gear and multi-function lever (reverse).

2(X) X X X

Circuit diagram: Circuit drivetrain gearbox group 2.0_1 Connection: signal from S162/R to digital in D790-2/K3:12 005326



Input signal active. Travel direction reverse selected.

0

No signal.

SWITCHES, SHIFT MODE Description: Signal from switch, shifting program. Status on CAN bus from Control unit KIT (D790-2). The switches are integrated in Control unit KIT (D790-2).

2(X) X X X



Contact: Function: 2 Transmission Signal value: 1

Shifting program 1 selected.

2

Shifting program 2 selected.

4

Automatic shifting selected.

8.4.7.3 TRANSM, menu 3 PRESENT VALUE, FORWARD Description: Status for forward direction of travel from Control unit, transmission (D793). Indicates if forward drive is activated in the transmission.

3(X) X X X


DIAG TRANSM. PRESENT VALUE FORWARD REVERSE GEAR

Contact: Function: 2.8 Control system, transmission Signal value: 1

Output signal for travel direction forward active.

0

No output signal.


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8:64


PRESENT VALUE, REVERSE Description: Status for rearward direction of travel from Control unit, transmission (D793). Indicates if rearward drive is activated in the transmission.

3(X) X X X




Output signal for travel direction reverse active.

0

No output signal.

PRESENT VALUE, GEAR Description: Current gear, status from Control unit, transmission (D793). Shows which gear is activated in the transmission.

3(X) X X X



Function: 2.8 Control system, transmission Contact: Signal value: X = current gear.

8.4.7.4 TRANSM, menu 4 OPERATING STATE, AUT/MAN MODE Description: Shows which shifting program is selected automatic or manual.

4(X) X X X


DIAG TRANSM. OPERATING STATE AUT/MAN MODE WARNING OPERATING MODE


Automatic.

0

Manual.

OPERATING STATE, WARNING Description: Warning for serious malfunction in transmission from Control unit, transmission (D793).

4(X) X X X



Contact: Function: 2.8 Control system, transmission Signal value:

VDCT01.02GB

1

Active error.

0

No errors.



8:65

OPERATING STATE, OPERATING MODE Description: Operating mode status for Control unit, transmission (D793), also shown in control unit display.

4(X) X X X




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 Description: Status for transmission function during operation, shifting in progress. Active during shifting. Circuit diagram: 005329

DIAG TRANSM. 5(X) OPERATING STATE SHIFT IN PROGRESS X FAULT X OLD FAULT X


Shifting in progress.

0

No activity.

OPERATING STATE, FAULT Description: Status for transmission's function during operation, active error codes present. Circuit diagram: 005329



Active error code.

0

No error codes.


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8:66


OPERATING STATE, OLD FAULT Description: Status for transmission's function during operation, there are inactive error codes that have not been acknowledged. Circuit diagram: 005329



There are inactive error codes that have not been acknowledged.

0

No unacknowledged error codes.

8.4.7.6 TRANSM, menu 6 NOT USED This menu is not used.

XXXXXXX

X(X)

008793

NOT USED


XXXXXXX

X(X)

008793

NOT USED


XXXXXXX

X(X)

008793

NOT USED


XXXXXXX

X(X)

008793

NOT USED

VDCT01.02GB



8:67


XXXXXXX

X(X)

008793

NOT USED


XXXXXXX

X(X)

008793

NOT USED


XXXXXXX

X(X)

008793

NOT USED

8.4.7.13 TRANSM, menu 13 ACT ERROR AREA Description: Indicates malfunction area active error, first part of the error code. In the event of several error codes, the most serious error code is shown. Circuit diagram: 005337

DIAG TRANSM. 13(X) ACT ERROR AREA XXX TYPE XXX NUMBER OF OCCU. XXXXX TIME AGO XXXXX

Contact: Function: 2.8 Control system, transmission Signal value: XXX = First part of error code; see section D Error codes

TYPE Description: Indicates type of active error. Circuit diagram: Contact: 005337


Function: 2.8 Control system, transmission Signal value: XXX = Second part of error code.


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8:68


NUMBER OF OCCU. Description: Number of times active errors have occurred. Circuit diagram: Contact: 005337


Function: 2.8 Control system, transmission Signal value: XXXXX = Number of times active errors have occurred.

TIME AGO Description: When latest active error occurred. Circuit diagram: Contact: 005337


Function: 2.8 Control system, transmission Signal value: XXXXX = Operating time in hours since latest error

8.4.7.14 TRANSM, menu 14 MANUAL GEAR SHIFT, GEAR Description: Manual control of the transmission with the plus and minus keys. The menu can be used to rule out mechanical malfunctions in the transmission's gear control.

DIAG TRANSM. 14(X) MANUAL GEAR SHIFT X


GEAR (+/-)

Contact: Function: 2.8 Control system, transmission Signal value: X = Selected gear.

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8 Control system – ELSERV

8:69

8.4.8 ELSERV ELSERV, description

This group covers electric servo functions. Confirm selections with function key for Enter. 005400


8.4.8.1 ELSERV, menu 1 PRESENT INPUT SIGNALS, P1 Description: Signal from control lever P1. Circuit diagram: Circuit electric servo levers group 7.0_1, circuit electric servo joystick group 7.0_2 005401

DIAG ELSERVO 1(X) PRESENT INPUT SIGNALS P1 XX.XXV P2 XX.XXV P3 XX.XXV

Connection: signal from R8071/3 (S815/8) to analogue in D790-1/K7:3 Function: 7.1.1 Control levers Signal value: XX.XXV = 0.50 - 4.50 V. 2.5 V in zero position.

PRESENT INPUT SIGNALS, P2 Description: Signal from control lever P2. Circuit diagram: Circuit electric servo levers group 7.0_1, circuit electric servo joystick group 7.0_2 005401



PRESENT INPUT SIGNALS, P3 Description: Signal from control lever P3. Circuit diagram: Circuit electric servo levers group 7.0_1, circuit electric servo joystick group 7.0_2 005401



8.4.8.2 ELSERV, menu 2 NOT USED This menu is not used.

XXXXXXX

X(X)

008793

NOT USED


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8:70


8.4.8.3 ELSERV, menu 3 OUTPUT LIFT, REFERENCE Description: Status for control current to control valve (solenoid valve, lift mast).

3(X) XY XXXmA XXXmA

Circuit diagram: Circuit lift/lower electric servo group 7.2_1 005403

DIAG ELSERVO OUTPUT LIFT REFERENCE REQUIRED VALUE FEEDBACK

Contact: digital output from D797-1/K1:4 to Y6005/1 Function: 7.2.5 Control valve, lift and tilt Signal value: 00

No output signal, PWM off.

10


11

Output signal active, circuit OK.

NOTE Depending on different types of PWM connections, the following is also possible: XY = 01 No output signal, PWM off.

OUTPUT LIFT, REQUIRED VALUE Description: Reference value for control current to control valve (solenoid valve, lift mast).

3(X) XY XXXmA XXXmA



Connection: output signal reference value out from D797-1/K1:16 to Y6005/2 Function: 7.2.5 Control valve, lift and tilt Signal value: XXX = Current value in mA for controlling solenoid valve.

OUTPUT LIFT, FEEDBACK Description: Current value for control current to control valve (solenoid valve, lift mast).

3(X) XY XXXmA XXXmA



Connection: output signal, actual value out from D797-1/K1:16 to Y6005/2 Function: 7.2.5 Control valve, lift and tilt Signal value: XXX = Measured current value in mA.

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8:71

8.4.8.4 ELSERV, menu 4 OUTPUT LOWER, REFERENCE Description: Status for control current to control valve (solenoid valve, lower mast).

4(X) XY XXXmA XXXmA


DIAG ELSERVO OUTPUT LOWER REFERENCE REQUIRED VALUE FEEDBACK

Contact: digital output from D797-1/K1:4 to Y6004/1 Function: 7.2.5 Control valve, lift and tilt Signal value: 00


10


11



OUTPUT LOWER, REQUIRED VALUE Description: Reference value for control current to control valve (solenoid valve, lower mast).

4(X) XY XXXmA XXXmA




OUTPUT LOWER, FEEDBACK Description: Current value for control current to control valve (solenoid valve, lower mast).

4(X) XY XXXmA XXXmA





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8:72


8.4.8.5 ELSERV, menu 5 OUTPUT TILT IN, REFERENCE Description: Status for control current to control valve (solenoid valve, tilt in).

5(X) XY XXXmA XXXmA

Circuit diagram: Circuit tilt electric servo group 7.7_1 005405

DIAG ELSERVO OUTPUT TILT IN REFERENCE REQUIRED VALUE FEEDBACK

Connection: digital out from D797-1/K1:5 to Y6011/1 Function: 7.7.5 Control valve, lift and tilt Signal value: 00


10


11



OUTPUT TILT IN, REQUIRED VALUE Description: Reference value for control current to control valve (solenoid valve, tilt in).

5(X) XY XXXmA XXXmA




OUTPUT TILT IN, FEEDBACK Description: Current value for control current to control valve (solenoid valve, tilt in).

5(X) XY XXXmA XXXmA




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8:73

8.4.8.6 ELSERV, menu 6 OUTPUT TILT OUT, REFERENCE Description: Status for control current to control valve (solenoid valve, tilt out). Circuit diagram: Circuit tilt electric servo group 7.7_1 005406

DIAG ELSERVO 6(X) OUTPUT TILT OUT REFERENCE XY REQUIRED VALUE XXXmA FEEDBACK XXXmA

Connection: digital out from D797-1/K1:5 to Y6010/1 Function: 7.7.5 Control valve, lift and tilt Signal value: 00


10


11



OUTPUT TILT OUT, REQUIRED VALUE Description: Reference value for control current to control valve (solenoid valve, tilt out). Circuit diagram: Circuit tilt electric servo group 7.7_1 005406


Connection: output signal, reference value out from D797-1/K1:19, to solenoid valve Y6010/1 Function: 7.7.5 Control valve, lift and tilt Signal value: XXX = Current value in mA for controlling solenoid valve.

OUTPUT TILT OUT, FEEDBACK Description: Current value for control current to control valve (solenoid valve, tilt out). Circuit diagram: Circuit tilt electric servo group 7.7_1 005406


Connection: output signal, actual value out from D797-1/K1:19 to solenoid valve Y6010/2 Function: 7.7.5 Control valve, lift and tilt Signal value: XXX = Measured current value in mA.


XXXXXXX

X(X)

008793

NOT USED


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8:74



XXXXXXX

X(X)

008793

NOT USED


XXXXXXX

X(X)

008793

NOT USED


XXXXXXX

X(X)

008793

NOT USED


XXXXXXX

X(X)

008793

NOT USED


XXXXXXX

X(X)

008793

NOT USED

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8:75

8.4.8.13 ELSERV, menu 13 PRESENT INPUT SIGNALS, SPREADER Description: Signal from switch for spreading the attachment. Circuit diagram: Circuit electric servo joystick group 7.0_2 Contact: 007128

DIAG ELSERVO 13(X) PRESENT INPUT SIGNALS SPREADER IN X OUT X PISTOL X UNLOCK TW X

IN: Signal from S815/14 to digital in D790-1/K7:14 (spreading in) OUT: Signal from S815/16 to digital in D790-1/K7:13 (spreading out) Function: 7.1.1 Control lever Signal value: 1


0

No signal.

PRESENT INPUT SIGNALS, PISTOL

007128



PRESENT INPUT SIGNALS, UNLOCK TW Description: Signal from control lever to unlock twistlock. Circuit diagram: Circuit electric servo joystick group 7.0_2 Contact: Signal from S815/20 to digital in D790-1/K7:15 007128


Function: 7.1.1 Control lever Signal value: 1


0

No signal.


XXXXXXX

X(X)

008793

NOT USED


XXXXXXX

X(X)

008793

NOT USED


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8:76

8 Control system – ATTACH

8.4.9 ATTACH ATTACH, description This group covers attachment functions. Confirm selections with function key for Enter.

005339


8.4.9.1 ATTACH, menu 1 PRESENT INPUT SIGNALS, P3 Description: Signal from control lever P3. Circuit diagram: Circuit electric servo levers group 7.0_1, circuit electric servo joystick group 7.0_2 005416

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


PRESENT INPUT SIGNALS, P4

005416



PRESENT INPUT SIGNALS, P7

005416



8.4.9.2 ATTACH, menu 2 PRESENT INPUT SIGNALS, P5 This menu row is not used.

005417

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

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8:77

8.4.9.3 ATTACH, menu 3 PRESENT INPUT SIGNALS, SPREADER Description: Signals from switch for spreading the attachment. Circuit diagram: Circuit 20-40, 30-35 stop group 7.5-1, circuit electric servo joystick group 7.0_2 005418

DIAG ATTACHMENT 3(X) PRESENT INPUT SIGNALS SPREADER IN X OUT X AUTO 20/40 X 30/35 STOP X

Contact: IN: Signal from S1012/1 (S815/14) to digital in D790-1/K7:14 (spreading in) OUT: Signal from S1012/7 (S815/16) to digital in D790-1/K7:13 (spreading out) Function: 7.1.3 Switch, spreading 20'-40', 7.1.1 Control lever Signal value: 1


0

No signal.

PRESENT INPUT SIGNALS, AUTO 20/40

Description: Signal from switch automatic spreading 20/40. Circuit diagram: Circuit 20-40 opt. group 7.5_3 005418


Connection: from S1012-2/1 to digital in D790-1/K8:11 Function: 7.5 Spreading Signal value: 1


0

No signal.

PRESENT INPUT SIGNALS, 30/35 STOP

Description: Signal from switch for stop at 30'/35'. Circuit diagram: Circuit 20-40, 30-35 stop group 7.5-1 005418


Connection: from S1004/1 to digital in D790-1/K8:10 Function: 7.5 Spreading Signal value: 1


0

No signal.

8.4.9.4 ATTACH, menu 4 PRESENT INPUT SIGNALS, PISTOL This menu row is not used.

PISTOL

X

007130

DIAG ATTACHMENT 4(X) PRESENT INPUT SIGNALS


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8.4.9.5 ATTACH, menu 5 PRESENT INPUT SIGNALS, LOCK CONT Description: Signal from switch, lock twistlocks. Circuit diagram: Circuit Twistlock group 7.9_1 Contact: Signal from S1003 to digital in D790-1/K8:12 010079

DIAG ATTACHMENT 5(X) PRESENT INPUT SIGNALS LOCK CONT X UNLOCK CONT X

Function: 7.9.1 Twistlocks Signal value: 1


0

No signal.

PRESENT INPUT SIGNALS, UNLOCK CONT Description: Signal from control lever to open twistlocks. Circuit diagram: Circuit Twistlock group 7.9_1 Contact: Signal from S1002 to digital in D790-1/K7:15 010079

DIAG ATTACHMENT 5(X) PRESENT INPUT SIGNALS LOCK CONT X UNLOCK CONT X

Function: 7.1.1 Control levers Signal value: 1


0

No signal.

8.4.9.6 ATTACH, menu 6 PRESENT INPUT SIGNALS, LOW SPEED 20/40 Description: Signal from spreading position sensor for end position damping 20'/40' right or left. Circuit diagram: Attachment DCF90/100-45E group 7.5_3 010080

DIAG ATTACHMENT 6(X) PRESENT INPUT SIGNALS LE RI LOW SPEED 20/40 X X 30/35 STOP X X

Connection: from inductive sensor B769L to digital in D791/K1:12 or from inductive sensor B769R to digital in D791/K1:40 Function: 7.5.6 Position sensor spreading Signal value: 1


0

No signal.

PRESENT INPUT SIGNALS, 30/35 STOP Description: Signal from position sensor for end position 30' right or left. Circuit diagram: Attachment DCF90/100-45E group 7.5_3 010080

DIAG ATTACHMENT 6(X) PRESENT INPUT SIGNALS LE RI LOW SPEED 20/40 X X 30/35 STOP X X

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:

VDCT01.02GB

1


0

No signal.



8:79

8.4.9.7 ATTACH, menu 7 PRESENT INPUT SIGNALS, ALIGNMENT LE RI Description: Signals from right and left alignment sensors. Circuit diagram: Attachment DCF90/100-45E group 7.9_5A, 7.9_4 Contact: LE: signal from B7203L to digital in D791/K1:27

010093

DIAG ATTACHMENT 7(X) PRESENT INPUT SIGNALS ALIGNMENT LE RI X X

RI: signal from B7203R to digital in D791/K1:26 Function: 7.9.1.7 Alignment sensor Signal value: 1


0

No signal.

8.4.9.8 ATTACH, menu 8 PRESENT INPUT SIGNAL LE RI, LOCKED CONT Description: Signals from sensors locked twistlock right and left. Circuit diagram: Attachment DCF90/100-45E group 7.9_2 Contact: LE: Signal from B7205LL to analogue in (used as digital) D791/K1:23

010082

DIAG ATTACHMENT 8(X) PRESENT INPUT SIGNALS LE RI LOCKED CONT X X UNLOCKED CONT X X

RI: Signal from B7205RL to analogue in (used as digital) D791/K1:24 Function: 7.9.1.8 Twistlocks sensor Signal value: 1


0

No signal.

PRESENT OUTPUT SIGNAL LE RI, UNLOCKED CONT Description: Signals from sensors open twistlock right and left. Circuit diagram: Attachment DCF90/100-45E group 7.9_2 Contact: LE: Signal from B7204L to analogue in (used as digital) D791-1/K1:22

010082

DIAG ATTACHMENT 8(X) PRESENT INPUT SIGNALS LE RI LOCKED CONT X X UNLOCKED CONT X X

RI: Signal from B7204R to analogue in (used as digital) D791-1/K1:41 Function: 7.9.1.8 Twistlocks sensor Signal value: 1


0

No signal.


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8:80


8.4.9.9 ATTACH, menu 9 PRESENT OUTPUT SIGNAL, LOCK CONT Description: Voltage feed to control valve attachment, locked twistlock. Circuit diagram: Circuit Twistlock group 7.9_1 010083

DIAG ATTACHMENT 9(X) PRESENT OUTPUT SIGNAL LOCK CONT XY UNLOCK CONT XY

Connection: digital out from D791/K1:7 to Y6040/1 Function: 7.9.1.2 Attachment control valve Signal value: 00


01


10


11


PRESENT OUTPUT SIGNAL, UNLOCK CONT Description: Voltage feed to control valve attachment, open twistlock. Circuit diagram: Circuit Twistlock group 7.9_1 Connection: digital out from D791/K1:9 to Y6039/1 010083

DIAG ATTACHMENT 9(X) PRESENT OUTPUT SIGNAL LOCK CONT XY UNLOCK CONT XY

Function: 7.9.1.2 Attachment control valve Signal value: 00


01


10


11


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8:81

8.4.9.10 ATTACH, menu 10 PRESENT OUTPUT SIGNAL, IND. LOCKED CONT Description: Voltage feed, indicator light for locked twistlocks - located on carriage. Circuit diagram: Circuit attachment DCF90/100-45E group 11.5_2, 7.9_3A 010084

DIAG ATTACHMENT 10(X) PRESENT OUTPUT SIGNAL IND. LOCKED CONT XY IND. UNLOCKED CONT XY IND. ALIGNMENT XY

Connection: digital out from D791/K1:29 to H563/1 Function: 7.9.1 Twistlocks Signal value: 00


01


10


11


PRESENT OUTPUT SIGNAL, IND. UNLOCKED CONT Description: Voltage feed, indicator light for unlocked twistlocks located on carriage. Circuit diagram: Circuit attachment DCF90/100-45E group 11.5_2, 7.9_3A 010084




01


10


11



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8:82


PRESENT OUTPUT SIGNAL, IND. ALIGNMENT Description: Voltage feed, alignment indicator light - located on carriage. Circuit diagram: Circuit attachment DCF90/100-45E group 11.5_2, 7.9_3A 010084




01


10


11


8.4.9.11 ATTACH, menu 11 OUTPUT SIDE SHIFT LE, REFERENCE Description: Status for control current to attachment control valve for side shift left. Circuit diagram: Circuit attachment DCF90/100-45E group 7.4_1 010088

DIAG ATTACHMENT 11(X) OUTPUT SIDESHIFT LE REFERENCE XY REQUIRED VALUE XXX FEEDBACK XXX

Connection: digital out from D791-1/K1:32 to Y6020/1 Function: 7.4.2 Control valve attachment Signal value: 00


10


11



OUTPUT SIDE SHIFT LE, REQUIRED VALUE Description: Reference value for control current to attachment control valve for output signal, side shift left. Circuit diagram: Circuit attachment DCF90/100-45E group 7.4_1 010088


Connection: output signal reference value out from D791-1/K1:18 to Y6020/2 Function: 7.4.2 Control valve attachment Signal value: XXX = Current value in mA for controlling solenoid valve.

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8:83

OUTPUT SIDE SHIFT LE, FEEDBACK Description: Current value for control current to attachment control valve for side shift left. Circuit diagram: Circuit attachment DCF90/100-45E group 7.4_2 010088


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 Description: Status for control current to attachment control valve for side shift right. Circuit diagram: Circuit attachment DCF90/100-45E group 7.4_1 010089

DIAG ATTACHMENT 12(X) OUTPUT SIDESHIFT RI REFERENCE XY REQUIRED VALUE XXX FEEDBACK XXX

Connection: digital out from D791/K1:33 to Y6021/1 Function: 7.4.2 Control valve attachment Signal value: 00


10


11



OUTPUT SIDE SHIFT RI, REQUIRED VALUE Description: Reference value for control current to attachment control valve for output signal, side shift right. Circuit diagram: Circuit attachment DCF90/100-45E group 7.4_1 010089


Connection: output signal reference value out from D791-1/K1:18 to Y6021/2 Function: 7.4.2 Control valve attachment Signal value: XXX = Current value in mA for controlling solenoid valve.

OUTPUT SIDE SHIFT RI, FEEDBACK Description: Current value for control current to attachment control valve for side shift right. Circuit diagram: Circuit attachment DCF90/100-45E group 7.4_1 010089


Connection: output signal, actual value out from D791-1/K1:18 to Y6021/2 Function: 7.4.2 Control valve attachment Signal value: XXX = Measured current value in mA.


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8:84


8.4.9.13 ATTACH, menu 13 NOT USED This menu is not used.

XXXXXXX

X(X)

008793

NOT USED


XXXXXXX

X(X)

008793

NOT USED


XXXXXXX

X(X)

008793

NOT USED


XXXXXXX

X(X)

008793

NOT USED

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8:85

8.4.9.17 ATTACH, menu 17 OUTPUT SPREAD LE OUT, REFERENCE Description: Status for control current to attachment control valve for spreading, left side out. Circuit diagram: Attachment DCF90/100-45E group 7.5_1 010087

DIAG ATTACHMENT 17(X) OUTPUT SPREAD LE OUT REFERENCE XY REQUIRED VALUE XXX FEEDBACK XXX

Connection: digital out from D791/K1:3 to Y6018L/1 Function: 7.5.2 Control valve attachment Signal value: 00


10


11



OUTPUT SPREAD LE OUT, REQUIRED VALUE Description: Reference value for control current to attachment control valve for output signal spreading left side out. Circuit diagram: Attachment DCF90/100-45E group 7.5_1 010087


Connection: output signal, reference value out from D791/K1:16 to Y6018L/2 Function: 7.5.2 Control valve attachment Signal value: XXX = Current value in mA for controlling solenoid valve.

OUTPUT SPREAD LE OUT, FEEDBACK Description: Current value for control current to attachment control valve for spreading, left side out. Circuit diagram: Attachment DCF90/100-45E group 7.5_1 010087


Connection: output signal, actual value out from D791/K1:16 to Y6018L/2 Function: 7.5.2 Control valve attachment Signal value: XXX = Measured current value in mA.


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8.4.9.18 ATTACH, menu 18 OUTPUT SPREADER LE IN, REFERENCE Description: Status for control current to attachment control valve for spreading, left side in. Circuit diagram: Attachment DCF90/100-45E group 7.5_1 010090

DIAG ATTACHMENT 18(X) OUTPUT SPREADER LE IN REFERENCE XY REQUIRED VALUE XXX FEEDBACK XXX

Connection: digital out from D791/K1:2 to Y6019L/1 Function: 7.5.2 Control valve attachment Signal value: 00


10


11



OUTPUT SPREADER LE IN, REQUIRED VALUE Description: Reference value for control current to attachment control valve for output signal spreading left side in. Circuit diagram: Attachment DCF90/100-45E group 7.5_1 010090


Connection: output signal, reference value out from D791/K1:16 to Y6019L/2 Function: 7.5.2 Control valve attachment Signal value: XXX = Current value in mA for controlling solenoid valve.

OUTPUT SPREADER LE IN, FEEDBACK Description: Current value for control current to attachment control valve for spreading, left side in. Circuit diagram: Attachment DCF90/100-45E group 7.5_1 010090


Connection: output signal, actual value out from D791/K1:16 to Y6019L/2 Function: 7.5.2 Control valve attachment Signal value: XXX = Measured current value in mA.

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8:87

8.4.9.19 ATTACH, menu 19 OUTPUT SPREAD RI OUT, REFERENCE Description: Status for control current to attachment control valve for spreading, right side out. Circuit diagram: Attachment DCF90/100-45E group 7.5_1 010091

DIAG ATTACHMENT 19(X) OUTPUT SPREAD RI OUT REFERENCE XY REQUIRED VALUE XXX FEEDBACK XXX

Connection: digital out from D791/K1:5 to Y6018R/1 Function: 7.5.2 Control valve attachment Signal value: 00


10


11



OUTPUT SPREAD RI OUT, REQUIRED VALUE Description: Reference value for control current to attachment control valve for output signal spreading right side out. Circuit diagram: Attachment DCF90/100-45E group 7.5_1 010091


Connection: output signal, reference value out from D791/K1:17 to Y6018R/2 Function: 7.5.2 Control valve attachment Signal value: XXX = Current value in mA for controlling solenoid valve.

OUTPUT SPREAD RI OUT, FEEDBACK Description: Current value for control current to attachment control valve for spreading, right side out. Circuit diagram: Attachment DCF90/100-45E group 7.5_1 010091


Connection: output signal, actual value out from D791/K1:17 to Y6018R/2 Function: 7.5.2 Control valve attachment Signal value: XXX = Measured current value in mA.


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8.4.9.20 ATTACH, menu 20 OUTPUT SPREADER RI IN, REFERENCE Description: Status for control current to attachment control valve for spreading, right side in. Circuit diagram: Attachment DCF90/100-45E group 7.5_1 010092

DIAG ATTACHMENT 20(X) OUTPUT SPREADER RI IN REFERENCE XY REQUIRED VALUE XXX FEEDBACK XXX

Connection: digital out from D791/K1:4 to Y6019R/1 Function: 7.5.2 Control valve attachment Signal value: 00


10


11



OUTPUT SPREADER RI IN, REQUIRED VALUE Description: Reference value for control current to attachment control valve for output signal spreading right side in. Circuit diagram: Attachment DCF90/100-45E group 7.5_1 010092


Connection: output signal, reference value out from D791/K1:17 to Y6019R/2 Function: 7.5.2 Control valve attachment Signal value: XXX = Current value in mA for controlling solenoid valve.

OUTPUT SPREADER RI IN, FEEDBACK Description: Current value for control current to attachment control valve for spreading, right side in. Circuit diagram: Attachment DCF90/100-45E group 7.5_1 010092


Connection: output signal, actual value out from D791/K1:17 to Y6019R/2 Function: 7.5.2 Control valve attachment Signal value: XXX = Measured current value in mA.

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8 Control system – OLS

8:89

8.4.9.21 ATTACH, menu 21 PRESENT OUTPUT SIGNAL, BUZZER AUTO 20-40

Description: Voltage feed to buzzer, automatic spreading 20'-40'.

BUZZER AUTO 20-40

Circuit diagram: Attachment DCF90/100-45E group 7.5_2

XY

009181

DIAG ATTACHMENT 21(X) PRESENT OUTPUT SIGNAL

Connection: digital out from D791/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


11


8.4.10 OLS OLS, description

005436

This menu is not used.


8.4.11 EXTRA EXTRA, description

This menu consists of optional functions: 005440


•

Reversible driver's seat, VBFS

•

Joystick control or mini-wheel, EL-STEERING

•

External attachment, EXT-ATTACH

•

Freelift, FREELIFT

•

Cab tipping, MOVE-CAB

•

Auxiliary equipment, OPT

•

Inputs and outputs, control units, I/O

•

Remote machine interface, RMI

Confirm selections in the main menu with function key for Enter.

8.4.11.1 VBFS VBFS, description

008904


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


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8 Control system – EXTRA

8.4.11.2 EL-STEERING EL-STEERING, description

008911



8.4.11.3 EXT-ATTACH EXT-ATTACH, description

007625



8.4.11.4 FREELIFT FREELIFT, description

008912



8.4.11.5 MOVE-CAB MOVE-CAB, description

008913



8.4.11.6 OPT OPT, description This group covers a number of options.

VDCT01.02GB

Confirm selections with function key for Enter.

008914




8:91

OPT, menu 1 OPTION SWITCH, S199-1

OPTION SWITCH, S199-1 Description: Signal from switch S199-1. Circuit diagram: Circuit extra equipment group 9.1_1 005488

DIAG OPTION 1(X) OPTION SWITCH S199-1 X S199-4 X S199-2 X S199-3 X

Connection: signal from S199-1/1 to digital in D790-1/K6:9 Function: Signal value:

OPTION SWITCH, S199-2


0

No signal.



1




0

No signal.



1




0

No signal.



1

Connection: signal from S199-4/1 to digital in D790-1/K6:7 Function: Signal value: 1


0

No signal.


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OPT, menu 2 PRESENT OUTPUT SIGNAL CENTRAL LUBRICATION, FRAME

PRESENT OUTPUT SIGNAL CENTRAL LUBRICATION, FRAME Description: Voltage feed to central lubrication of frame. 005489

DIAG OPTION 2(X) PRESENT OUTPUT SIGNAL CENTRAL LUBRICATION FRAME XY ATTACHMENT XY

Circuit diagram: Circuit std. opt. group 9.0_1 and circuit central lubrication group 9.14_1 Connection: digital out from D797-1/K1:42 to M693-1/1 Function: 9.14.1 Pump unit Signal value: 00


01


10


11


PRESENT OUTPUT SIGNAL CENTRAL LUBRICATION, ATTACHMENT

PRESENT OUTPUT SIGNAL CENTRAL LUBRICATION, ATTACHMENT Description: Voltage feed to central lubrication of attachment. 005489

DIAG OPTION 2(X) PRESENT OUTPUT SIGNAL CENTRAL LUBRICATION FRAME XY ATTACHMENT XY

Circuit diagram: Attachment DCF90/100-45E group 9.14_1 Connection: digital out from D791-1/K1:14 to M693/1 Function: 9.14.1 Pump unit Signal value:

VDCT01.02GB

01


10


11




8:93

OPT, menu 3 PRESENT OUTPUT SIGNAL, D797-1 C1 P42

PRESENT OUTPUT SIGNAL, D797-1 C1 P42

DIAG OPTION 3(X) PRESENT OUTPUT SIGNAL D797-1 C1 P42 XY

Description: Voltage feed from D797-1/K1:42.

005490

Circuit diagram: Connection: digital out D797-1/K1:42 Function: Signal value: 00


01


10


11


OPT, menu 4 This menu row is not used.

OPT, menu 5 PRESENT OUTPUT SIGNAL, D791-1 C1 P14

PRESENT OUTPUT SIGNAL, D791-1 C1 P14 Description: Voltage feed from D791-1/K1:14. Circuit diagram: 005492

DIAG OPTION 5(X) PRESENT OUTPUT SIGNAL D791-1 C1 P14 XY D791-1 C1 P28 XY

Connection: digital out from D791-1/K1:14 Function: Signal value: 01


10


11



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PRESENT OUTPUT SIGNAL, D791-1 C1 P28

PRESENT OUTPUT SIGNAL, D791-1 C1 P28 Description: Voltage feed from D791-1/K1:28. Circuit diagram: 005492

DIAG OPTION 5(X) PRESENT OUTPUT SIGNAL D791-1 C1 P14 XY D791-1 C1 P28 XY

Connection: digital out from D791-1/K1:28 Function: Signal value: 00


01


10


11


8.4.11.7 I/O I/O, description

015099


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

8.4.11.8 RMI RMI, description

VDCT01.02GB

007657




8 Control system – Setup

8:95

8.5 Setup Setup, general Settings are built-in functions to adapt the functions to the unique machine individual. Settings are performed via menus in the display. Settings are divided into initiation and calibration.

Initiation Initiation, which involves setting start and stop currents for the steering and hydraulic functions, is performed before the machine is used in work. This is carried out in order to compensate for mechanical and electrical tolerances (variations between different machines).

Calibration Calibration is performed after the machine has started to be used for work, after replacement of control units, and in certain cases, service or replacement of components. Calibration is performed so that certain functions shall function properly and show correct values.

8.5.1 Initiation Initiation, description 1

4

DANGER

1(X) The settings influence the functions. Adjustments may impair the function.

XXXmA XXXmA

3

008891

INIT ELSERVO START CURRENT LIFT STORED VALUE PRESENT VALUE

2

If uncertain, contact Cargotec Service.

Example of initiation menu, start current for lift function. 1.

Menu group

NOTE

2.

Menu number. The number of menus depends on the equipment fitted to the machine. For this reason, number of menus is indicated with (X) in this manual.

Initiation does not need to be performed in one process but each step can be performed separately, independently of other steps.

3.

Signal value

4.

Actual variable

In order that hydraulic functions shall work satisfactorily and safely, certain values must be set to operate the machine, this is known as initiation. Initiation consists of several menus grouped according to functions. Each individual menu sets a specific variable. The menus are similar in structure and use a common terminology explained here:

PRESENT Displays the stored value when the menu is opened. Adjust the value with the plus and minus keys. Store the set value with the Enter key. Go to the next menu with the arrow keys. Go back with the R-key. STORED

STORED

I [mA]

States the stored value for the current variable.

1

3 t [s] 1.

Max. current (END CURRENT)

2.

Damping (PROC DAMPING)

3.

Start current (START CURRENT)

006299

2


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8 Control system – Initiation

START CURRENT Specifies the start current to the solenoid valve for the selected function. The start current is the lowest current that can be actuated. In practice, it controls how slowly a function can be operated. On functions with analogue control/activation (controllable), e.g. lift, this is the current that is triggered when the lever leaves the zero position. On certain functions with digital activation (off/on) which are soft-started, this is the current which is triggered immediately the function is activated.

END CURRENT Specifies the max. current to the solenoid valve for the selected function. The max. current is the highest current that can be actuated. In practice, it controls how quickly a function can be operated. On functions with analogue control activation (controllable), e.g. lift, this is the current which is triggered when the lever is in the end position. On certain functions with digital activation (off/on) which are soft-started, this is the current which is triggered after the ramp time when the function is activated. The interval between START CURRENT and END CURRENT is the active range for controlling the solenoid valve.

PROC DAMPING Specifies how much the control current shall be reduced during damping. The interval is specified as 0-100% of the active range between START CURRENT and END CURRENT.

Function

Menu

1 Engine, speed limitation

INIT DRIVE-TRAIN, menu 9, page 8:110

1 Engine, automatic engine shut-down on idle


1 Engine, automatic engine speed increase for lifting


2 Transmission, starting gear


2 Transmission, speed limitation (gear lock-out)


2 Transmission, automatic engine speed reduction for shift forward - reverse


7.2 Lifting/lowering, lift mast

INIT ELSERVO, menu 1, page 8:98 INIT ELSERVO, menu 2, page 8:98

7.2 Lifting/lowering, lower mast

INIT ELSERVO, menu 3, page 8:99

Comment: The current value is for unladen machines. When loaded, the current value is controlled by the limited lowering speed.

INIT ELSERVO, menu 4, page 8:99

7.4 Side shift

INIT ATTACH, menu 5, page 8:105 INIT ATTACH, menu 6, page 8:105

7.5 Spreading out

INIT ATTACH, menu 9, page 8:106 INIT ATTACH, menu 10, page 8:106 INIT ATTACH, menu 11, page 8:106

7.5 Spreading in

INIT ATTACH, menu 12, page 8:107 INIT ATTACH, menu 13, page 8:107 INIT ATTACH, menu 14, page 8:107

7.7 Tilt

INIT ELSERVO, menu 5, page 8:99 INIT ELSERVO, menu 6, page 8:100

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8:97

Initiate hydraulic function, work instruction To select a hydraulic function to initiate, proceed as follows: All hydraulic functions are initiated in the same way. 1 Navigate to the service menu. Press Enter.

3

Enter the code for initiation.

000056

2


1 23 4 5 000060

NOTE

4

5

Change the current value with the plus and minus keys.

1(X)

NOTE XXXmA XXXmA

Current values can only be adjusted within specific limits. 005494


Select group by scrolling with the arrow keys (1 and 2) and confirm with Enter. Each initiation consists of a sequence of a number of menus. The first menu for the selected initiation opens in the display. Select the desired menu with the arrow keys (1 and 2).

007169

INITIATION ELSERVO ATTACHMENT STEERING DRIVE-TRAIN SLIDING-CAB RETURN

The code determines which service menu is activated (Service, Diagnostic test, Initiation or Calibration).

6

Use the function key for Enter to store the desired current value setting, "STORED".


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8.5.1.1 ELECTRIC SERVO INIT ELSERVO The menu group for this function covers initiation of the electric servo functions for load handling. The settings for lift, lower, tilt in, tilt out are made here. For other load handling functions, see INIT ATTACH, page 8:104. 007169


DANGER The settings influence the functions. Adjustments may impair the function. If uncertain, contact Cargotec Service.

NOTE Initiation does not need to be performed in one process but each step can be performed separately, independently of other steps.

INIT ELSERVO, menu 1 START CURRENT, LIFT

START CURRENT, LIFT

1(X) Description: Start current for activation of solenoid valve, lift mast (Y6005).

XXXmA XXXmA

005494


PRESENT VALUE: indicates the current value for the start current. Adjust the value with the plus and minus keys. Store the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates stored value for start current. Function: 7.2.5 Control valve, lift and tilt Component: Solenoid valve, lift mast (Y6005) Signal value: XXXmA = 0 - 999 mA.

INIT ELSERVO, menu 2 END CURRENT, LIFT

END CURRENT, LIFT

2(X) Description: Control current on full lever actuation for the activation of the solenoid valve for mast lift (Y6005).

XXXmA XXXmA

005495

INIT ELSERVO END CURRENT LIFT STORED VALUE PRESENT VALUE

PRESENT VALUE: indicates the current value for max. current. Adjust the value with the plus and minus keys. Store the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates stored value for max. current. Function: 7.2.5 Control valve, lift and tilt Component: Solenoid valve, lift mast (Y6005) Signal value: XXXmA = 0 - 999 mA.

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8:99

INIT ELSERVO, menu 3 START CURRENT, LOWER

START CURRENT, LOWER

3(X) Description: Start current for activation of solenoid valve, lower mast (Y6004).

XXXmA XXXmA

005496

INIT ELSERVO START CURRENT LOWER STORED VALUE PRESENT VALUE

PRESENT VALUE: indicates the current value for the start current. Adjust the value with the plus and minus keys. Store the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates stored value for start current. Function: 7.2.5 Control valve, lift and tilt Component: Solenoid valve, lower mast (Y6004) Signal value: XXXmA = 0 - 999 mA.

INIT ELSERVO, menu 4 END CURRENT, LOWER

END CURRENT, LOWER

4(X) Description: Control current on full lever actuation for the activation of the solenoid valve for mast lower (Y6004).

XXXmA XXXmA

005497

INIT ELSERVO END CURRENT LOWER STORED VALUE PRESENT VALUE

PRESENT VALUE: indicates the current value for max. current. Adjust the value with the plus and minus keys. Store the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates stored value for max. current. Function: 7.2.5 Control valve, lift and tilt Component: Solenoid valve, mast (Y6004) Signal value: XXXmA = 0 - 999 mA.

INIT ELSERVO, menu 5 START CURRENT, TILT IN

START CURRENT, TILT IN

5(X) Description: Start current for the activation of the solenoid valve for tilt in (Y6011).

XXXmA XXXmA

007139

INIT ELSERVO START CURRENT TILT IN STORED VALUE PRESENT VALUE

PRESENT VALUE: indicates the current value for the start current. Adjust the value with the plus and minus keys. Store the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates stored value for start current. Function: 7.7.5 Control valve, lift and tilt Component: Solenoid valve, tilt in (Y6011) Signal value: XXXmA = 0 - 999 mA.


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INIT ELSERVO, menu 6 END CURRENT, TILT IN

END CURRENT, TILT IN

6(X) Description: Control current on full lever actuation for the activation of the solenoid valve for tilt in (Y6011).

XXXmA XXXmA

007140

INIT ELSERVO END CURRENT TILT IN STORED VALUE PRESENT VALUE

PRESENT VALUE: indicates the current value for max. current. Adjust the value with the plus and minus keys. Store the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates stored value for max. current. Function: 7.7.5 Control valve, lift and tilt Component: Solenoid valve, tilt in (Y6011) Signal value: XXXmA = 0 - 999 mA.

INIT ELSERVO, menu 7 START CURRENT, TILT OUT

START CURRENT, TILT OUT

7(X) Description: Start current for the activation of the solenoid valve for tilt out (Y6010).

XXXmA XXXmA

007141

INIT ELSERVO START CURRENT TILT OUT STORED VALUE PRESENT VALUE

PRESENT VALUE: indicates the current value for the start current. Adjust the value with the plus and minus keys. Store the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates stored value for start current. Function: 7.7.5 Control valve, lift and tilt Component: Solenoid valve, tilt out (Y6010) Signal value: XXXmA = 0 - 999 mA.

INIT ELSERVO, menu 8 END CURRENT, TILT OUT

END CURRENT, TILT OUT

8(X) Description: Control current on full lever actuation for the activation of the solenoid valve for tilt out (Y6010).

XXXmA XXXmA

007142

INIT ELSERVO END CURRENT TILT OUT STORED VALUE PRESENT VALUE

PRESENT VALUE: indicates the current value for max. current. Adjust the value with the plus and minus keys. Store the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates stored value for max. current. Function: 7.7.5 Control valve, lift and tilt Component: Solenoid valve, tilt out (Y6010) Signal value: XXXmA = 0 - 999 mA.

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8:101

INIT ELSERVO, menu 9 START CURRENT, SIDE SHIFT LE/RI

START CURRENT, SIDE SHIFT LE/RI Description: Start current of activation of solenoid valve for side shift left (Y6020) and solenoid valve for side shift right (Y6021). 007143

INIT ELSERVO 9(X) START CURRENT SIDESHIFT LE/RI STORED VALUE XXXmA PRESENT VALUE XXXmA

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

INIT ELSERVO, menu 10 END CURRENT, SIDE SHIFT LE/RI

END CURRENT, SIDE SHIFT LE/RI Description: Control current at full lever actuation for activation of solenoid valve for side shift left (Y6020) and solenoid valve for side shift right (Y6021). 007144

INIT ELSERVO 10(X) END CURRENT SIDESHIFT LE/RI STORED VALUE XXXmA PRESENT VALUE XXXmA

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

INIT ELSERVO, menu 11 START CURRENT, SPREADING IN/OUT

START CURRENT, SPREADING IN/OUT Description: Start current for activation of solenoid valve for spreading in (Y6019) and solenoid valve for spreading out (Y6018). 007145

INIT ELSERVO 11(X) START CURRENT SPREADING IN/OUT STORED VALUE XXXmA PRESENT VALUE XXXmA

PRESENT VALUE: indicates the current value for the start current. Adjust the value with the plus and minus keys. Store the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates stored value for start current. Function: 7.5.2 Control valve attachment Component: Solenoid valve for spreading in (Y6019) and solenoid valve for spreading out (Y6018) Signal value: XXXmA = 0 - 999 mA.


VDCT01.02GB

8:102


INIT ELSERVO, menu 12 END CURRENT, SPREADING IN/OUT

END CURRENT, SPREADING IN/OUT Description: Control current at full lever actuation for activation of solenoid valve for spreading in (Y6019) and solenoid valve for spreading out (Y6018). 007146

INIT ELSERVO 12(X) END CURRENT SPREADING IN/OUT STORED VALUE XXXmA PRESENT VALUE XXXmA

PRESENT VALUE: indicates the current value for max. current. Adjust the value with the plus and minus keys. Store the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates stored value for max. current. Function: 7.5.2 Control valve attachment Component: Solenoid valve for spreading in (Y6019) and solenoid valve for spreading out (Y6018) Signal value: XXXmA = 0 - 999 mA.

INIT ELSERVO, menu 13 START CURRENT, LIFT 2

START CURRENT, LIFT 2

13(X) Description: Start current for activation of solenoid valve, lift trolley (Y6022).

XXXmA XXXmA

007147

INIT ELSERVO START CURRENT LIFT 2 STORED VALUE PRESENT VALUE

PRESENT VALUE: indicates the current value for the start current. Adjust the value with the plus and minus keys. Store the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates stored value for start current. Function: 7.2.5 Control valve, lift and tilt Component: Solenoid valve trolley (Y6022) Signal value: XXXmA = 0 - 999 mA.

INIT ELSERVO, menu 14 END CURRENT, LIFT 2

END CURRENT, LIFT 2

14(X) Description: Control current on full lever actuation for the activation of the solenoid valve for lift trolley (Y6022).

XXXmA XXXmA

007148

INIT ELSERVO END CURRENT LIFT 2 STORED VALUE PRESENT VALUE

PRESENT VALUE: indicates the current value for max. current. Adjust the value with the plus and minus keys. Store the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates stored value for max. current. Function: 7.2.5 Control valve, lift and tilt Component: Solenoid valve trolley (Y6022) Signal value: XXXmA = 0 - 999 mA.

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8:103

INIT ELSERVO, menu 15 START CURRENT, LOWER 2

START CURRENT, LOWER 2

15(X) Description: Start current for activation of solenoid valve, lower trolley (Y6023).

XXXmA XXXmA

PRESENT VALUE: indicates the current value for the start current. Adjust the value with the plus and minus keys. Store the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key.

007149

INIT ELSERVO START CURRENT LOWER 2 STORED VALUE PRESENT VALUE

STORED VALUE: indicates stored value for start current. Function: 7.2.5 Control valve, lift and tilt Component: Solenoid valve, lower trolley (Y6023) Signal value: XXXmA = 0 - 999 mA.

INIT ELSERVO, menu 16 END CURRENT, LOWER 2

END CURRENT, LOWER 2

16(X) Description: Control current on full lever actuation for the activation of the solenoid valve for lower trolley (Y6023).

XXXmA XXXmA

PRESENT VALUE: indicates the current value for max. current. Adjust the value with the plus and minus keys. Store the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key.

007150

INIT ELSERVO END CURRENT LOWER 2 STORED VALUE PRESENT VALUE

STORED VALUE: indicates stored value for max. current. Function: 7.2.5 Control valve, lift and tilt Component: Solenoid valve, lower trolley (Y6023) Signal value: XXXmA = 0 - 999 mA.

INIT ELSERVO, menu 17 DAMP (PROC), LIFT

DAMP (PROC), LIFT

INIT ELSERVO DAMP (PROC) LIFT STORED VALUE PRESENT VALUE

17(X) Description: Percentage damping of control current to solenoid valve for mast lift (Y6005) when the mast reaches max height.

XX XX

PRESENT VALUE: indicates the current value for damping. Adjust the value with the plus and minus keys. Store the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key.

I [mA] 1

STORED VALUE: indicates stored value in percent.

2 t [s] 1.


2.


3.


007151

Function: 7.2.5 Control valve, lift and tilt

3

Component: Solenoid valve, lift mast (Y6005) Signal value: XXX = 0 - 100%. 100% means no damping i.e. max. current. 0% means full damping i.e. start current.


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8.5.1.2 ATTACHMENT INIT ATTACH This function handles initialization of the attachment functions side shift and spreading.

DANGER

007170


The settings influence the functions. Adjustments may impair the function. If uncertain, contact Cargotec Service.


INIT ATTACH, menu 1 NOT USED

XXXXXXX

NOT USED

X(X)

This menu is not used. 008793

NOT USED


XXXXXXX

NOT USED

X(X)


NOT USED


XXXXXXX

NOT USED

X(X)


NOT USED


XXXXXXX

NOT USED

X(X)


NOT USED

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8:105

INIT ATTACH, menu 5 START CURRENT, SIDE SHIFT

START CURRENT, SIDE SHIFT

5(X) Description: Start current of activation of solenoid valve for side shift left (Y6020) and solenoid valve for side shift right (Y6021).

XXXmA XXXmA

005513

INIT ATTACH START CURRENT SIDESHIFT STORED VALUE PRESENT VALUE

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

INIT ATTACH, menu 6 END CURRENT, SIDE SHIFT

END CURRENT, SIDE SHIFT

6(X) XXXmA XXXmA

005514

INIT ATTACH END CURRENT SIDESHIFT STORED VALUE PRESENT VALUE

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


XXXXXXX

NOT USED

X(X)


NOT USED


XXXXXXX

NOT USED

X(X)


NOT USED


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8:106


INIT ATTACH, menu 9 START CURRENT, SPREADER OUT, 20'-40'

START CURRENT, SPREADER OUT, 20'-40'

INIT ATTACH 9(X) START CURRENT SPREADER OUT, 20'-40' STORED VALUE XXXmA PRESENT VALUE XXXmA

Description: Start current for activation of solenoid valve for spreading out left (Y6018L) and solenoid valve for spreading out right (Y6018R). PRESENT VALUE: indicates the current value for the start current. Adjust the value with the plus and minus keys. Store the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key.

I [mA] 1

STORED VALUE: indicates stored value for start current.

2 t [s] 1.


2.


3.


005517

Function: 7.5.2 Control valve attachment

3

Component: Solenoid valve, spreading out 20'-40' (Y6018) Signal value: XXXmA = 0 - 999 mA

INIT ATTACH, menu 10 END CURRENT, SPREADER OUT, 20'-40'

END CURRENT, SPREADER OUT, 20'-40'

INIT ATTACH 10(X) END CURRENT SPREADER OUT, 20'-40' STORED VALUE XXXmA PRESENT VALUE XXXmA

Description: Control current at full lever actuation for activation of solenoid valve for spreading out left (Y6018L) and solenoid valve for spreading out right (Y6018R).

1


2

STORED VALUE: indicates stored value for max. current.

3 t [s]

005518

I [mA]


1.


Component: Solenoid valve for spreading out left (Y6018L) and solenoid valve for spreading out right (Y6018R).

2.


Signal value: XXXmA = 0 - 999 mA

3.


INIT ATTACH, menu 11 DAMP (PROC), SPREADER OUT, 20'-40'

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

INIT ATTACH 11(X) DAMP PROC SPREADER OUT, 20’-40’ STORED VALUE XX PRESENT VALUE XX

Description: Percentage damping of control current to solenoid valve for spreading out left (Y6018L) and solenoid valve for spreading out right (Y6018R) when spreading out approaches 40'.

1


2


3


t [s] 1.


2.


3.


VDCT01.02GB

014600

I [mA]

Component: Solenoid valve for spreading out left (Y6018L) and solenoid valve for spreading out right (Y6018R). Signal value: XXX = 0 - 100%. 100% means no damping, i.e. max. current. 0% means full damping, i.e. start current



8:107

INIT ATTACH, menu 12 START CURRENT, SPREADER IN, 40'-20'

START CURRENT, SPREADER IN, 40'-20'

INIT ATTACH 12(X) START CURRENT SPREADER IN, 40'-20' STORED VALUE XXXmA PRESENT VALUE XXXmA

Description: Start current for activation of solenoid valve for spreading in left (Y6019L) and solenoid valve for spreading in right (Y6019R). PRESENT VALUE: indicates the current value for the start current. Adjust the value with the plus and minus keys. Store the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key.

I [mA] 1

STORED VALUE: indicates stored value for start current.

2 t [s] 1.


2.


3.


005520


3

Component: Solenoid valve for spreading in left (Y6019L) and solenoid valve for spreading in right (Y6019R). Signal value: XXXmA = 0 - 999 mA

INIT ATTACH, menu 13 END CURRENT, SPREADER IN, 40'-20'

END CURRENT, SPREADER IN, 40'-20'

INIT ATTACH 13(X) END CURRENT SPREADER IN, 40'-20' STORED VALUE XXXmA PRESENT VALUE XXXmA

Description: Control current at full lever actuation for activation of solenoid valve for spreading in left (Y6019L) and solenoid valve for spreading in right (Y6019R).

1


2

STORED VALUE: indicates stored value for max. current.

3


t [s]

005521

I [mA]

1.


Component: Solenoid valve for spreading in left (Y6019L) and solenoid valve for spreading in right (Y6019R).

2.


Signal value: XXXmA = 0 - 999 mA

3.


INIT ATTACH, menu 14 DAMP (PROC), SPREADER IN, 40'-20'

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

INIT ATTACH 14(X) DAMP PROC SPREADER IN, 40’-20’ STORED VALUE XX PRESENT VALUE XX

Description: Percentage damping of control current to solenoid valve for spreading in left (Y6019L) and solenoid valve for spreading in right (Y6019R) when spreading in approaches 20'.

1


2


3 t [s] 1.


2.


3.


014704

I [mA]

Function: 7.5.2 Control valve attachment Component: Solenoid valve for spreading in left (Y6019L) and solenoid valve for spreading in right (Y6019R). Signal value: XXX = 0 - 100%. 100% means no damping, i.e. max. current. 0% means full damping, i.e. start current


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8:108


8.5.1.3 STEERING INIT STEERING This menu is not used.

8.5.1.4 DRIVE-TRAIN INIT DRIVE-TRAIN This function covers engine and transmission initiation.

DANGER 007172


The settings influence the functions. Adjustments may impair the function. If uncertain, contact Cargotec Service.


NOTE The machine must be stationary with parking brake applied in order to enable access to the menus. After changes have been made, the ignition must be switched off and then on for the changes to be saved and start to apply.

INIT DRIVE-TRAIN, menu 1 START IN 1:ST

START IN 1:ST

1(X) Description: Setting to get transmission to always start in 1st gear.

XXX XXX

013915

INIT DRIVE-TRN START IN 1:ST 1=YES 0=NO STORED VALUE PRESENT VALUE

PRESENT VALUE: indicates the present speed setting. Change the value using the plus or minus keys. Save the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates saved setting. Function: 2 Transmission Component: Signal value: XXX = 1= yes, XXX = 0 = no

INIT DRIVE-TRAIN, menu 2 NOT USED

XXXXXXX

NOT USED

X(X)


NOT USED

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8:109


XXXXXXX

NOT USED

X(X)


NOT USED


XXXXXXX

NOT USED

X(X)


NOT USED


XXXXXXX

NOT USED

X(X)


NOT USED


XXXXXXX

NOT USED

X(X)


NOT USED


XXXXXXX

NOT USED

X(X)


NOT USED


XXXXXXX

NOT USED

X(X)


NOT USED


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8:110


INIT DRIVE-TRAIN, menu 9 OPTION SPEED LIMIT

OPTION SPEED LIMIT

Description: Setting of speed limitation. 005587

INIT DRIVE-T 9(X) OPTION SPEED LIMIT (km/h) STORED VALUE XXX 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 OPTION HIGHEST GEAR AT SPEED LIMIT

OPTION HIGHEST GEAR AT SPEED LIMIT

005588

INIT DRIVE-T 10(X) OPTION HIGHEST GEAR AT SPEED LIMIT STORED VALUE XXX PRESENT VALUE XXX

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

INIT DRIVE-TRAIN, menu 11 OPTION ENGINE SHUT DOWN

OPTION ENGINE SHUT DOWN

Description: Setting of idle time prior to automatic engine shutdown. 005589

INIT DRIVE-T 11(X) OPTION ENGINE SHUT DOWN AT IDLE (sec) STORED VALUE XXX 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.

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8:111

INIT DRIVE-TRAIN, menu 12 F-R WITHOUT ENGINE SPEED REDUCTION

F-R WITHOUT ENGINE SPEED REDUCTION

005590

INIT DRIVE-T 12(X) F-R WITHOUT ENGINE SPEED REDUCTION STORED VALUE X PRESENT VALUE X

Description: Activation or deactivation of automatic engine speed reduction when changing direction of travel forward - reverse. This makes it possible to change direction of travel without releasing the accelerator pedal. Engine speed drops to that set in menu 3, see INIT DRIVE-TRAIN, menu 3, page 8:109. If no value is set in menu 3, engine speed is reduced to idle speed. PRESENT VALUE: indicates the current setting. Change the value with the plus and minus keys. Save the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates saved setting. Function: 2 Transmission Component: Signal value: X = 1, activated X = 0, deactivated

INIT DRIVE-TRAIN, menu 13 AUTO ENGINE SPEED AT LIFT

AUTO ENGINE SPEED AT LIFT

005591

INIT DRIVE-T 13(X) AUTO ENGINE SPEED AT LIFT STORED VALUE X PRESENT VALUE X

Description: Activation or deactivation of automatic engine speed increase during lift. PRESENT VALUE: indicates the current setting. Change the value with the plus and minus keys. Save the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the R-key. STORED VALUE: indicates saved setting. Function: 1 Engine Component: Signal value: X = 1, activated X = 0, deactivated


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8:112

8 Control system – Calibration

8.5.1.5 SLIDING-CAB NOT USED This menu is not used.

XXXXXXX

X(X)

008793

NOT USED

8.5.2 Calibration Calibration, description Certain functions require calibration in order to operate correctly. The control system has integrated calibrations for these functions. SCALE

SCALE

CALIBRATION

000062


SCALE STEERING DRIVE-TRAIN RETURN

STEERING

STEERING

CALIBRATION

000074



DRIVE-TRAIN

DRIVE-TRAIN

CALIBRATION

This function handles calibration for engine and transmission. The menu loop contains two different calibrations are not linked to each other, see: 000078


Accelerator pedal, calibration, page 8:114


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Calibration menu, explanation

5

4

Calibration menu, explanation

2

The illustration shows an example of a menu, here for the calibration of the centre position for lever joystick control. The table indicates what a description contains (which follows in the next section):

CALIBR STEERING 1(X) STEERING LEVER CENTER POSITION STORED VALUE X.XXV PRESENT VALUE X.XXV

3

008892

1

8:113

1.

Menu group

2.

Sequence number. The number of menus depends on the equipment fitted to the machine. For this reason, number of menus is indicated with (X) in this manual.

3.

Signal value

4.

STORED indicates stored value, PRESENT indicates the current value of the signal to be calibrated

5.

Heading of menu figure

Designation: Example

Description

Variable (position 5): STEERING LEVER CENTRE POSITION

Name of the input signal/control signal affected.

Description: Setting the centre position for lever joystick control (R825).

A short description of what is calibrated and the meaning of the variables.

STORED VALUE: Gives the stored signal value for lever steering control (R825), centre position. PRESENT VALUE: Gives the present signal value for lever steering control (R825), centre position. Function: 5.2 Power-assisted steering system

Name of current function.

Component: Lever joystick control (R825)

Indicates the component whose signal is the basis for calibration.

Calibration, work instructions Calibration consists of a number of menus, the number of menus depends on the function. All menus are similar in structure and therefore the descriptions are similar. To select a function to calibrate, proceed as follows: 1 Navigate to the service menu. Press Enter.

3

Enter the code for calibration.

000056

2


1 23 4 5 000060

NOTE

4

000062

CALIBRATION SCALE STEERING DRIVE-TRAIN RETURN

The code determines which service menu is activated (Service, Diagnostic test, Initiation or Calibration). Select group by scrolling with the arrow keys (1 and 2) and confirm with Enter. Each calibration consists of a sequence of a number of menus. The first menu for the selected calibration opens in the display. Select the next menu with key 1 and 2 (arrow function).


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8:114


8.5.2.3 Calibrate DRIVE-TRAIN Accelerator pedal, calibration 1

Start key in operating position, engine switched off.

DRIVE-TRAIN, menu 1 2

Go into the calibration menus and select DRIVE-TRAIN, menu 1, see Calibration, work instructions, page 8:113. ACCELERATOR, RELEASE THE PEDAL

005532

CALIBR DRIVE-TRN 1(X) ACCELERATOR, RELEASE THE PEDAL STORED VALUE X.XXV PRESENT VALUE X.XXV

Description: setting the accelerator's pedal zero position. STORED VALUE: Indicates current calibrated control value from accelerator pedal (R690-1). PRESENT VALUE: indicates the current signal value from Accelerator pedal (B690-1). Function: 1 Engine Component: Accelerator pedal (B690-1). 3

Release the accelerator pedal.

4

Store the position with function key for Enter.

DRIVE-TRAIN, menu 2

CALIBR DRIVE-TRN 2(X) ACCELERATOR, PRESS THE PEDAL TO FLOOR STORED VALUE X.XXV PRESENT VALUE X.XXV

5

ACCELERATOR, PRESS THE PEDAL TO FLOOR Description: Setting of full-throttle position for Accelerator pedal (B690-1).

00

STORED VALUE: Indicates current calibrated control value from accelerator pedal (R690-1). PRESENT VALUE: indicates the current signal value from Accelerator pedal (B690-1). Function: 1 Engine Component: Accelerator pedal (B690-1).

VDCT01.02GB

6

Press the accelerator pedal down fully and keep it down until the position is stored.

7

Store the position with function key for Enter.


9:1

9 Frame, body, cab and accessories

Contents 9 Frame, body, cab and accessories 9 Frame, body, cab and accessories ...................................................................9:3 9.1 Controls and instruments .................................................................................9:3 9.1.1 Gear selector and multi-function lever.........................................................9:8 9.1.22 Switch, direction indicators..........................................................................9:9 9.2 Safety and emergency equipment .................................................................9:10 9.2.1 Control breaker .........................................................................................9:10 9.2.2 Seat belt ....................................................................................................9:10 9.2.3 Fire extinguisher........................................................................................9:10 9.2.4 Seat buzzer ...............................................................................................9:10 9.3 Seat................................................................................................................ 9:11 9.3.1 Seat cushion .............................................................................................9:14 9.3.2 Back rest cushion ......................................................................................9:15 9.3.3 Heating coil ...............................................................................................9:16 9.3.4 Bumper......................................................................................................9:16 9.3.5 Air suspension...........................................................................................9:17 9.3.6 Compressor air-suspension seat...............................................................9:17 9.3.7 Mechanical seat adjustment......................................................................9:18 9.3.8 Passenger seat .........................................................................................9:18 9.3.9 Arm rest.....................................................................................................9:18 9.3.14 Sensor, operator-in-seat............................................................................9:19 9.4 Heating, ventilation and air conditioning ........................................................9:21 9.4.1 Fresh air filter ............................................................................................9:28 9.4.2 Fresh air filter or recirculation damper.......................................................9:29 9.4.3 Cabin fan ...................................................................................................9:32 9.4.4 Heat exchanger heat .................................................................................9:35 9.4.5 Water valve ...............................................................................................9:38 9.4.6 Sensor, engine temperature ......................................................................9:38 9.4.7 Compressor...............................................................................................9:39 9.4.8 Condenser.................................................................................................9:43 9.4.9 Moisture filter.............................................................................................9:45 9.4.10 Pressure switch .........................................................................................9:45 9.4.11 Expansion valve ........................................................................................9:46 9.4.12 Sensor, temperature refrigerant ................................................................9:48 9.4.13 Heat exchanger, cooling............................................................................9:49 9.4.14 Air distributor .............................................................................................9:50 9.4.15 Defroster nozzles ......................................................................................9:51 9.4.16 Sensor, temperature outlet fan ..................................................................9:52 9.4.17 Sensor cab temperature............................................................................9:53 9.4.18 Sensor, ambient temperature ....................................................................9:54 9.5 Wiper/washer system.....................................................................................9:55 9.5.1 Wiper front.................................................................................................9:55 9.5.2 Wiper roof..................................................................................................9:55 9.5.3 Wiper rear .................................................................................................9:55 9.5.4 Washer motor and reservoir......................................................................9:55 9.5.5 Wiper motor front ......................................................................................9:56 9.5.6 Wiper motor roof .......................................................................................9:57 9.5.7 Wiper motor rear .......................................................................................9:58 9.6 Lighting system ..............................................................................................9:59 9.6.1 Headlights .................................................................................................9:63 9.6.2 Running lights ...........................................................................................9:63 9.6.3 Tail lights ...................................................................................................9:63 9.6.4 Brake lights ...............................................................................................9:63 9.6.5 Back-up lights............................................................................................9:64 9.6.6 Direction indicators....................................................................................9:64 9.6.7 Flashing hazard lights ...............................................................................9:64 Workshop Manual DCT 80-90

VDCT01.02GB

9:2


9.6.8 9.6.9 9.6.10 9.6.11 9.6.12 9.6.14 9.7 9.7.1 9.7.2 9.7.3 9.7.4 9.7.5 9.8 9.9 9.9.1 9.9.2 9.9.3 9.9.4 9.9.5 9.10 9.10.1 9.10.2 9.10.3 9.11 9.11.1 9.11.2 9.11.3 9.11.4 9.11.5 9.11.7 9.11.8 9.11.9 9.12 9.13 9.13.1 9.13.2 9.13.3 9.13.4 9.14 9.14.1 9.14.2 9.14.3 9.15

VDCT01.02GB

Revolving beacon......................................................................................9:64 Working lights, mast ..................................................................................9:64 Working lights, cab ....................................................................................9:66 Interior lighting...........................................................................................9:66 Working lights, attachment ........................................................................9:67 Work lights, front wing ...............................................................................9:67 Signalling system ...........................................................................................9:68 Horn ..........................................................................................................9:70 Flashing hazard lights ...............................................................................9:70 Revolving beacon......................................................................................9:71 Warning parking brake ..............................................................................9:71 Back-up alarm ...........................................................................................9:71 Entertainment and communication ................................................................9:72 Glass/windows/mirrors...................................................................................9:73 Windscreen ...............................................................................................9:74 Side window ..............................................................................................9:76 Roof window..............................................................................................9:79 Rear window .............................................................................................9:79 Rear view mirror ........................................................................................9:79 Cab structure and suspension .......................................................................9:80 Cab frame .................................................................................................9:80 Doors.........................................................................................................9:80 Cab substructure .......................................................................................9:80 Cab interior ....................................................................................................9:81 Instrument and control panels ...................................................................9:81 Interior fittings, plastic ...............................................................................9:82 Interior fittings, textile ................................................................................9:82 Floor covering ...........................................................................................9:82 Insulation ...................................................................................................9:82 Terminal console .......................................................................................9:83 Writing desk...............................................................................................9:83 Reading-lamp ............................................................................................9:83 Chassis ..........................................................................................................9:84 Body structure................................................................................................9:85 Wings ........................................................................................................9:85 Hood engine compartment ........................................................................9:85 Footsteps and hand rail.............................................................................9:85 Counterweights .........................................................................................9:86 Central lubrication ..........................................................................................9:87 Pump unit ..................................................................................................9:89 Distribution block .......................................................................................9:90 Lines..........................................................................................................9:90 Paint/coatings ................................................................................................9:91


9 Frame, body, cab and accessories – Frame, body, cab and accessories

9:3

9 Frame, body, cab and accessories 9.1 Controls and instruments Controls and instruments, overview Overview

Overview

1

2

3

4

5

11

10

15

12

13

12

9

8

7

6 015102

14 1.

Left instrument panel

2.

Gear selector and multi-function lever (S162)

3.

Steering wheel panel

4.

Steering wheel

5.

Switch direction indicators (S161)

6.

Panel for hydraulic functions

7.

Emergency stop switch for hydraulics (S250)

8.

Switch for parking brake (S107)

9.

Control lever (S815)

10. Driver's seat 11. Accelerator pedal (B690) 12. Brake pedals 13. Declutch pedal (S220-1) 14. Electronic box with fuses and relays 15. Hour meter (P708)


VDCT01.02GB

9:4

9 Frame, body, cab and accessories – Controls and instruments

Left-hand instrument panel

Left-hand instrument panel 16. Switch for fan (S118) 17. Switch for heating (S117)

24..28

29 30 31 18. Switch for air distribution (S139) 19. Switch for working lights cab roof (S105-1)

19..23

20. Switch, work lights on carriage and attachment (S105-2)

18 16 Left instrument panel

Auxiliary work lights, carriage and attachment 010907

17

21. Switch for work lights on mast (S105-3) Auxiliary work lights, mast 22. Switch for revolving beacon (S110) 23. Switch for flashing hazard lights (S109) 24. Switch for headlights (S100) 25. Spare 26. Spare 27. Spare 28. Spare 29. Spare 30. Spare 31. Socket 12 VDC

VDCT01.02GB




32

33

35

34

9:5


36

32. Warning lamp, low battery charging 33. Warning lamp for low brake pressure 34. Indicator for active error codes 35. Warning lamp, by-pass of hydraulic functions 36. Not used

37..41

37. Warning lamp, high coolant temperature

49

38. Warning light, low oil pressure engine

42..46

39. Indicator light for preheating

47 48

40. Warning lamp for low coolant level engine 41. Warning lamp for high transmission oil temperature 42. Warning lamp, low fuel level 43. Warning lamp, high temperature hydraulic oil

50

51

52

53

44. Indicator light, high beams 45. Indicator light, travel direction indication 46. Indicator light, parking brake 47. Indicator light, locked twistlock (secured load) 48. Indicator light, alignment (attachment / load) 49. Indicator light, unlocked twistlock (load released) 50. Panel, warning and indicator lights 51. Control system display

64 63 62

54

52. Control system indicator

55

53. Ignition 54. Switch for defroster

61 Steering wheel panel

60

59 58 57

008132

56

55. Switch, windscreen wiper roof, interval 56. Switch, windscreen wiper roof, continuous 57. Switch, interior lighting 58. Switch, windscreen wiper rear, interval 59. Switch, windscreen wiper rear, continuous 60. Control system function keys 61. Travel direction indicator, Forward Neutral Reverse 62. Shifting program A, automatic shifting 63. Shifting program 1, locked to 1st gear 64. Shifting program 2, locked to 2nd gear


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9:6




68

65. Lift/lower (R8071) 66. Tilt (R8072)

70 67. Side shift (R8073) 72

68. Opening the twistlocks (S1002)

74 74 73

69. Switch, horn (S149) 70. Switch for twistlock, automatic/manual locking (S1003) 71. Switch, spreading 20'-40' (attachment) (S1012) 72. Switch for stopping spreading at 30' (attachment) (S1004) 73. Switch, automatic spreading 20'-40' (S1012-2) 74. Switch for bypassing of hydraulic functions (S1005)

8

7

014179

Key for bypassing hydraulic functions

69

Panel for hydraulic functions and control lever

65 66

68

67 7

69 70 71 72

8

74

74

014178

73

Panel for hydraulic functions and linear control levers

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9:7

Operating menus, overview

1

2

3

4

5

8

9

7

6

11

12

13

14

1.

Engine and transmission operating menu

8.

Service operating menu

2.

Engine operating menu

9.

Operating menu heating and air conditioning

3.

Operating menu for oil temperature

10. Operating menu, code lock

4.

Operating menu electrical system

11. Operating menu statistics, operating hours

5.

Operating menu, container counter

12. Operating menu statistics, fuel consumption

6.

Operating menu service interval

13. Operating menu statistics, driving distance

7.

Operating menu statistics

14. Operating menu statistics, lift statistics

Event menus overview

014668

10

Event menus overview Side lift attachment with twistlocks

2

3

4

014669

1

1.

Event menu, twistlock alignment

2.

Event menu twistlocks

3.

Event menu open door

4.

Event menu automatic spreading


VDCT01.02GB

9:8

9 Frame, body, cab and accessories – Gear selector and multi-function lever

9.1.1 Gear selector and multi-function lever Gear selector and multi-function lever, description Movement

2 3

The following functions are handled by the gear and multi-function lever (position 2).

1 0

000338

Movement

Function

Forward/Reverse

Travel direction (for selecting shifting program and travel direction, see section 2 Transmission).

Inward, handle

Washing of windscreen, roof window and rear window.

Rotation

The signal can be checked via the diagnostic menu. see section 8 Control system, group 8.4.3.1 CAB, menu 1 Windscreen wiper, front. 0 – No wiping of front window. If wiper rear or roof are active then these run at slow interval wiping. 1 – Slow interval wiping front window, controls slow interval wiping for roof window and rear window. 2 – Fast interval wiping front window, controls fast interval wiping for roof window and rear window. 3 - Continuous wiping of front window. If wiper rear or roof are active then these run at fast interval wiping. The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.3.2 CAB, menu 2.

Upward

Light signal

Downward

High beam (on/off) With headlights on: The gear selector multi-function lever are used for switching between high and low beam. With headlights off: The gear selector and multi-function lever are used to flash with the headlights.

000339

A

The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.2.3 LIGHTS, menu 3. Inward, button

VDCT01.02GB

Horn (position A). The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.3.5 CAB, menu 5.


9 Frame, body, cab and accessories – Switch, direction indicators

9:9

Gear selector and multi-function lever, replacement 1

Separate the steering wheel panel. 6 attaching bolts and 2 bolts to the steering wheel shaft. Remove the steering wheel, see Steering wheel panel, replacement, page 9:81.

2

Undo the attaching bolts (2 x hexagonal socket bolts).

3

Unplug the connector from Control unit KIT (D790-2).

4

Fit a new lever and refit the steering wheel panel.

9.1.22 Switch, direction indicators Switch, direction indicators, replacement 1


2

Remove the steering wheel and separate the steering wheel panel.

3

Detach the cable harness from the direction indicator.

4

Press together the clips on the direction indicator and detach it from the steering wheel panel.

5

Replace the direction indicator, fitting it in the reverse order.


VDCT01.02GB

9:10

9 Frame, body, cab and accessories – Safety and emergency equipment

9.2 Safety and emergency equipment 9.2.1 Control breaker Emergency stop switch, description See section 11 Common electrics, group 11.5.1.4 Emergency stop switch voltage.

9.2.2 Seat belt Seat belt, description The seat belt is a two or a three-point belt, depending on the type of seat fitted in the machine. The seat belt is mounted on the seat.

9.2.3 Fire extinguisher Fire extinguisher, description

The fire extinguisher is located by the instep on the left-hand frame member or inside the cab. Usage instructions are on the fire extinguisher.

9.2.4 Seat buzzer Seat buzzer, description See 9.3.14 Sensor, operator-in-seat, page 9:19.

VDCT01.02GB


9 Frame, body, cab and accessories – Seat

9:11

9.3 Seat Seat, general There are three versions of the driver's seat: • • •

Seat, description (product alternative Hao Bang), page 9:11 Seat, description (product alternative BE-GE 9200), page 9:12 Seat, description (product alternative BE-GE 9200 air suspension), page 9:13

As an option, the machine can be equipped with a fold-down passenger seat to the left of the operator.

Seat, description (product alternative Hao Bang) The seat's function is to provide the operator with a good sitting position and contribute to a good work environment. The cab's seat has several adjustment options and fulfils high comfort standards.

1

The seat has the following equipment:

2

3

•

mechanical height adjustment

•

seat cushion angling

•

arm rest right

•

two-point seat belt

•

head rest

The seat is equipped with a sensor which detects if there is downward pressure on the seat cushion. This is used to activate the buzzer if the operator leaves the seat without applying the parking brake as well as without putting the transmission in neutral position if leaving the seat.

7

5 4 1.

Head rest

2.

Adjusting arm rest, right

3.

Back rest rake adjustment

4.

Display of weight setting

5.

Seat height adjustment

6.

Seat cushion angle adjustment

7.

Front/rear adjustment

014151

6


VDCT01.02GB

9:12


Seat, description (product alternative BE-GE 9200)

1

The seat's function is to provide the operator with a good sitting position and contribute to a good work environment. The cab's seat has several adjustment options and fulfils high comfort standards.

2


3

4

8

6 7

006825

5

•

mechanical height adjustment

•

arm rest right

•

two-point seat belt

•

seat heating

•

head rest

•

armrest left

The seat is equipped with a sensor that senses the spring deflection of the seat. This is used to activate the buzzer if the operator leaves the seat without applying the parking brake as well as without putting the transmission in neutral position if leaving the seat.

Controls 1.

Adjusting lumbar support

2.


3.

Adjusting arm rest, left

4.


5.

Adjusting suspension position

6.


7.


8.


VDCT01.02GB



9:13

Seat, description (product alternative BE-GE 9200 air suspension)

1

The seat's function is to provide the operator with a good sitting position and contribute to a good work environment. The cab's seat has several adjustment options and fulfils high comfort standards. The air suspension automatically adjusts seat height and suspension to the operator's weight. The air suspension is supplied by a special compressor installed on the underside of the cab.

2 3


4

8

6 7

Controls BE-GE 9200 1.

Adjusting lumbar support

2.


3.

Adjusting arm rest, left

4.


5.

Adjusting suspension position

6.


7.


8.


006826

5

•

air suspension (with external compressor)

•

arm rest right

•

three-point seat belt

•

seat heating

•

armrest left

•

head rest

The seat is equipped with a sensor that senses the spring deflection of the seat. This is used to activate the buzzer if the operator leaves the seat without applying the parking brake as well as without putting the transmission in neutral position if leaving the seat.

Seat, replacement (product alternative BE-GE 9200) 1


2

Slide back the seat to its rear position, remove the front attaching bolts.


VDCT01.02GB

9:14

9 Frame, body, cab and accessories – Seat cushion

3

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


9.3.1 Seat cushion Seat cushion, description The function of the seat cushion is to provide good comfort to the operator. Under the seat cushion is the driver's seat frame and a circuit breaker for the buzzer. There may be a heating coil fitted (

).

For location, see Seat, general, page 9:11.

Seat cushion, replacement (product alternative BE-GE)

5

2

1


2

Loosen the rubber bellows by removing the plastic clips.

3

Unhook the upholstery's rails from the seat frame and remove the upholstery.

4

Remove the padding. If the seat is equipped with seat heater.

4

Unplug the connector for the heating coil before the padding is removed.

NOTE The seat's heating coil is glued to the padding. Exercise caution if the padding is to be replaced but the heating coil is to be re-used, or if only the coil is to be replaced.

3

5

Assemble in reverse order.

006276

1

1.

Plastic clip, rubber bellows

2.

Upholstery

3.

Seat frame

4.

Padding

5.

Heating coil

VDCT01.02GB


9 Frame, body, cab and accessories – Back rest cushion

9:15

9.3.2 Back rest cushion Back rest cushion, description The function of the back rest cushion is to provide good comfort to the operator. Under the back rest cushion is the driver's seat frame. There may be a heating coil fitted (

).

For location, see Seat, general, page 9:11.

Back rest cushion, replacement (product alternative BE-GE) 1


2

Detach the rubber bellows on the rear of the seat by removing the plastic clips and folding down the rubber bellows. See Seat cushion, replacement (product alternative BE-GE), page 9:14.

3

3

Remove the back rest by first removing the attaching bolts on the right and left-hand side of the seat and then remove the attaching bolts for the seat belt on the right and left-hand side of the seat.

4

4

If the seat is equipped with 3-point seat belt. Remove the belt guide by removing the cover and the attaching bolt.

5

If the seat is equipped with arm rests. Remove the arm rest by removing the attaching bolts.

6

5

Position the back rest on the seat and fit the attaching bolts, do not tighten them. Then fit the attaching bolts for the seat belt. Tighten the attaching bolts for the seatbelt with a torque of 42 Nm, then tighten the attaching bolts with a torque of 33 Nm.

7

Cut holes in the upholstery for seat belt and arm rest on the new back rest before arm rest or seat belt is installed.

6

1.

Attaching bolt back rest

2.

Attaching bolt, seat belt

3.

Cover, belt guide

4.

Attaching bolt, belt guide

5.

Arm rest

6.

Attaching bolt, arm rest

2


006278

8

1

If the seat is equipped with 3-point seat belt or arm rest.


VDCT01.02GB

9:16

9 Frame, body, cab and accessories – Heating coil

9.3.3 Heating coil Heating coil, description (product alternative BE-GE)

The function of the heating coil is to warm the back rest and seat cushions in the driver's seat. The heating coil is fitted under the upholstery on the seat. The heating coil (E803) is supplied with voltage upon warm-up by the Cab control unit, (D790-1) via the seat heating relay (K383). The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.3.8 CAB, menu 8.

Heating coil, replacement (product alternative BE-GE)

See Seat cushion, replacement (product alternative BE-GE), page 9:14.

9.3.4 Bumper Bumper, description The bumpers are integrated in the suspension unit in the seat's frame and are self-adjusting, that is, they adjust automatically to the operator's weight.

Bumper, replacement (product alternative BE-GE)

2

1


2

Remove the driver's seat from the frame and lift it out of the machine. See Seat, replacement (product alternative BE-GE 9200), page 9:13.

3

Remove the seat cushion, see Seat cushion, replacement (product alternative BE-GE), page 9:14.

4

Remove the back rest cushion, see Back rest cushion, replacement (product alternative BE-GE), page 9:15.

5

Remove the shock absorber's attaching bolts.

6

Replace the shock absorber.

7

Assemble in reverse order.

3 1.

Bumper

2.

Attaching bolt

3.

Attaching bolt

VDCT01.02GB

006277

1


9 Frame, body, cab and accessories – Air suspension

9:17

9.3.5 Air suspension Air suspension, description (product alternative BE-GE 9200 air suspension)

001621

The air-suspension driver's seat consists of a seat with rubber bellows and compressor. The air suspension is self-adjusting, that is, it adjusts automatically to the operator's weight. The compressor provides air for the suspension unit.

Compressor air-suspension seat

For location, see Seat, description (product alternative BE-GE 9200 air suspension), page 9:13.

9.3.6 Compressor air-suspension seat Compressor air-suspension seat, description (product alternative BE-GE 9200 air suspension)

001621

The compressor is part of the air-suspension driver's seat and is fitted inside the seat's suspension unit.

Compressor air-suspension seat


VDCT01.02GB

9:18

9 Frame, body, cab and accessories – Mechanical seat adjustment

9.3.7 Mechanical seat adjustment Mechanical seat adjustment, description Seat adjustment is all mechanical and is adapted by the operator with different controls in order to obtain a good sitting position. See: •

Seat, description (product alternative BE-GE 9200), page 9:12

•

Seat, description (product alternative BE-GE 9200 air suspension), page 9:13

•

Seat, description (product alternative Hao Bang), page 9:11

9.3.8 Passenger seat Passenger seat, description

001627

The passenger seat is collapsible (vertically), provided with a seat belt and is located on the left-hand side of the driver's seat.

Passenger seat with bracket

9.3.9 Arm rest Armrests, description The armrest is affixed to the back rest and is individually adjustable vertically (around the attachment point). An option there are also arm rests available on the left-hand side.

VDCT01.02GB


9 Frame, body, cab and accessories – Sensor, operator-in-seat

9:19

9.3.14 Sensor, operator-in-seat Sensor, operator-in-seat, description (product alternative Hao Bang) Sensor, operator-in-seat (S230) is fitted under the seat cushion's upholstery and it detects whether the driver's seat is depressed, which indicates to the control system that the driver's seat is occupied. This is used to allow the control system to indicate with Buzzer, operator-in-seat (H853) if the operator leaves the driver's seat without applying the parking brake.

014164

The signal from Sensor, operator-in-seat (S230) is also used to set the transmission in neutral position if the operator leaves the seat. In an emergency situation the machine can be operated by bypassing the safety system. Activate the by-pass switch, select travel direction and drive the machine to the workshop. Speed is limited to 10 km/h.

Sensor, operator-in-seat (S230) (product alternative Hao Bang)

DANGER Bypassing the safety systems results in a risk of tipping. Use at your own risk. Extreme hazard to personal health and risk of property damage! Only use the bypass of safety systems in emergency situations.

Sensor, operator-in-seat (S230) is supplied with voltage by and sends a voltage signal to Control unit, cab (D790-1). The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.3.6 CAB, menu 6.


VDCT01.02GB

9:20

9 Frame, body, cab and accessories – Sensor, operator-in-seat

Sensor, operator-in-seat, description (product alternative BE-GE)

1

2

Sensor, operator-in-seat (S230) is fitted under the seat cushion and it detects whether the driver's seat suspension is depressed, which indicates to the control system that the driver's seat is occupied. This is used to allow the control system to indicate with Buzzer, operator-in-seat (H853) if the operator leaves the driver's seat without applying the parking brake.

008220

The signal from Sensor, operator-in-seat (S230) is also used to set the transmission in neutral position if the operator leaves the seat. In an emergency situation the machine can be operated by bypassing the safety system. Activate the by-pass switch, select travel direction and drive the machine to the workshop. Speed is limited to 10 km/h.

DANGER

Seat, view from below 1.

Sensor, operator-in-seat, (S230) (product alternative BE-GE)

2.

Buzzer (H853)

Bypassing the safety systems results in a risk of tipping. Use at your own risk. Extreme hazard to personal health and risk of property damage! Only use the bypass of safety systems in emergency situations.

Sensor, operator-in-seat (S230) is supplied with voltage by and sends a voltage signal to Control unit, cab (D790-1). The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.3.6 CAB, menu 6.

VDCT01.02GB


9 Frame, body, cab and accessories – Heating, ventilation and air conditioning

9:21

9.4 Heating, ventilation and air conditioning Heating, ventilation and air conditioning, description Heating system (EHC)

The heating system controls heating and ventilation of the cab. The cab can also be equipped with air conditioning (

F

).

The temperature in the cab is thermostat-controlled by Control unit, cab (D790-1). The cab temperature is regulated to the set temperature. The temperature can be set between 16 and 28 °C. The unit is operated with controls on the dashboard panel.

2 4

Heating system (EHC)

D

C E

The heating system (EHC) handles heating and ventilation. (The heating system cannot provide cooling.)

E

The heating system uses heat from the engine's cooling system via a heating coil to heat the ambient air. The fan forces the ambient air through the heating coil on through ducts in the cab interior. It is then directed to the windscreen (defroster) or the feet.

3

Air conditioning (ECC)

6

A

B The climate control system (ECC) is responsible for heating, ventilation, cooling and dehumidifying. The air is heated in the same way as for the heating system (EHC).

G

1 000762

5

During cooling, ambient air is forced through the evaporator, which cools the air. The air can then be directed in the same way as for the heating system.

Outline view, air conditioning 1.

Fluid reservoir/filter dryer with integrated pressure switch

2.

Heating coil and evaporator

3.

Fan

4.

Expansion valve

5.

Condenser

6.

Compressor

A

High-pressure gas

B

High-pressure fluid

C

Low-pressure fluid

D

Low-pressure gas

E

Outdoor air for cab ventilation

F

Heated or cooled air to the cab

G

Outdoor air for eliminating heat

The function of the air conditioning is to: •

heat the air when it is cold

•

dehumidify the air when it is damp

•

clean the air of impurities

•

cool the air when it is hot

•

defrost (defroster function)

IMPORTANT On machines with ECC or AC, it is vital that the engine cooling system is refilled with coolant with the correct concentration of antifreeze. Otherwise there is a risk that the air conditioning system will freeze during usage.


VDCT01.02GB

9:22


Heating, ventilation and air conditioning, function description

2

1

D

°C

6

°C

D

D

D 7

D790-1

D790-2

15

D

M 5

°C

D795

D797-1 16

D

D

25

D

D

4

26

3

D

D794 12 D 22

14 Pa

M 13

D

M D

D 19 18

20 C

23 °C

21

24

17

9

D

M °C

8

11 007690

10

Pos

Explanation

Signal description

Reference

1

Switch, temperature (S117) sends a voltage signal to Control unit, cab (D790-1).

Raise: U = 2.0–2.5 V

Controls and instruments, overview, page 9:3

Unaffected: U = 0-0.5 V Lower: U = 4.5-5.0 V

2

Raise: U = 2.0–2.5 V

Switch, fan (S118) sends a voltage signal to Control unit, cab (D790-1).

Unaffected: U = 0-0.5 V Lower: U = 4.5-5.0 V

3

Switch, air distribution (S139) sends a voltage signal to Control unit, cab (D790-1).

Scroll up: U = 2.0–2.5 V Unaffected: U = 0 V Scroll down: U = 4.5-5.0 V

4

Sensor, cab temperature (B775-1) sends a voltage signal proportional to the temperature to Control unit, cab (D790-1).

VDCT01.02GB

R = 10 kΩ at 25 ºC


D1: Diagnostic menu, see section 8 Control system, group 8.4.4.5, CLIMATE menu 5 Controls and instruments, overview, page 9:3 D2: Diagnostic menu, see section 8 Control system, group 8.4.4.5, CLIMATE menu 5 Controls and instruments, overview, page 9:3 D3: Diagnostic menu, see section 8 Control system, group 8.4.4.5, CLIMATE menu 5 Sensor, cab temperature, description, page 9:53 D4: Diagnostic menu, see section 8 Control system, group 8.4.4.1, CLIMATE menu 1


9:23

Pos

Explanation

Signal description

Reference

5

The outlet fan temperature sensor (B775-2) sends the cab control unit (D790-1) a voltage signal proportional to temperature.

R = 10 kΩ at 25 ºC

Sensor, temperature outlet fan, description, page 9:52

Sensor, ambient temperature (B774) sends a voltage signal proportional to the temperature to Control unit, cab (D790-1).

R = 10 kΩ at 25 ºC

7

Control unit, cab (D790-1) regulates temperature and air distribution with signals from sensors and controls.



8

The engine produces heat while running. It is cooled with the cooling system. The heat from the cooling system is used to heat the cab air.

-

-

9

Control unit, cab (D790-1) controls Water valve (Y673), which routes hot water for heat exchanger heat.

U = 0.5-4.5 V

Water valve, description, page 9:38

6

D5: Diagnostic menu, see section 8 Control system, group 8.4.4.2, CLIMATE menu 2


D9: Diagnostic menu, see section 8 Control system, group 8.4.4.7 CLIMATE, menu 7 and 8.4.4.4 CLIMATE, menu 4

The water valve's opening (%) is fed back to the Control unit, cab (D790-1). This gives information for controlling the water valve's position. 10

Sensor, ambient temperature, description, page 9:54

Sensor, engine temperature, sends a voltage signal proportional to the engine temperature to Control unit, engine (D794).


11

Heat exchanger heat supplies heat to the cab air. The heat is transferred from the engine's cooling system to the cab air.

-

Heat exchanger heat, description, page 9:35

12

Control unit, engine (D794) transmits engine temperature in the cooling system on the CAN bus.



13

Control unit, cab (D790-1) controls Actuator motor, recirculation (M612) which sets the fresh air or recirculation damper in the required position.


Fresh air filter or recirculation damper, description, page 9:29

14

Control unit, cab (D790-1) controls Fan motor (M657), which increases the airflow in the cab.



15

Control unit, cab (D790-1) controls Damper motor (Y672), which sets the air distributor to the required position.

U = 0.5-4.5 V

Air distributor, description, page 9:50

The frame control unit (D797-1) controls AC compressor connection.



D15: Diagnostic menu, see section 8 Control system, group 8.4.4.8 CLIMATE, menu 8 and 8.4.4.4 CLIMATE, menu 4

The air distributor's position is fed back to Control unit, cab (D790-1). This gives information for controlling the air distributor's position. 16

Section 1 Engine




VDCT01.02GB

9:24


Pos

Explanation

Signal description

Reference

17

The frame control unit (D797-1) supplies voltage to the compressor's solenoid valve (645).

U = 24 V

Compressor, description (engine alternative Cummins QSB6.7

), page 9:39

D17: Diagnostic menu, see section 8 Control system, group 8.4.4.6, CLIMATE menu 6 The compressor draws gaseous refrigerant from the evaporator, compresses it, and forces it on to the condenser.

-

19

The condenser cools the refrigerant. The gaseous refrigerant condenses to liquid form and is pumped on in the circuit.

-

Condenser, description, page 9:43

20

The moisture filter absorbs any moisture from the cooling circuit. The fluid reservoir stores the refrigerant.

-

Moisture filter, description, page 9:45

21

The pressure switch (S246) sends a signal to the frame control unit (D797-1) if the pressure in the system becomes abnormally high or low.

U = 24 V

Pressure switch, description, page 9:45

22

The expansion valve adjusts the amount of refrigerant that is let in to the evaporator. If the temperature in the evaporator's outlet pipe increases, the expansion valve increases the flow of refrigerant so that heat dissipation in the evaporator increases.

-

Expansion valve, description, page 9:46

23

Sensor, refrigerant circuit temperature, sends a voltage signal proportional to the temperature to Control unit, cab (D790-1).

R = 10 kΩ at 25 ºC

Sensor, temperature refrigerant, description, page 9:48

24

Heat exchanger, cooling, dissipates heat from the cab air. The heat is transferred from the air to the refrigerant and transforms the refrigerant to a gaseous state.

-

Heat exchanger, cooling, description, page 9:49

25

The defroster switch on Control unit KIT (D790-2) activates the defroster program for the air conditioning for six minutes.



26

Control unit KID (D795) shows the heating and ventilation settings in the display.



18

VDCT01.02GB

Compressor, description (engine alternative Cummins QSB6.7

), page 9:39


D23: Diagnostic menu, see section 8 Control system, group 8.4.4.2, CLIMATE menu 2.



9:25

Heating, ventilation and air conditioning, checking Machine in service position, see section B Safety.

2

Navigate to the service menu and press Enter.

3

Enter the code for diagnostics. Code is obtained from Cargotec Support.

000056

1

NOTE 000060

1 23 4 5

4

Select CLIMATE.

004998


The code determines which service menu is activated (Service, Diagnostic test, Initiation or Calibration).

Menu 1 5

Checking the desired temperature, inside temperature sensor and water valve. REQUIRED TEMP: should be 160 (16.0 ºC) for max. cooling and 280 (28.0 ºC) for max. heating. The setting is changed with the temperature switch.

000132

DIAG CLIMATE 1(8) PRESENT INPUT SIGNAL REQUIRED TEMP XXX PRESENT TEMP XXX WATER VALVE FEEDB. XXX

PRESENT TEMP: shows the temperature inside the cab. This is measured by Sensor, cab temperature (located down to the left on the instrument panel, behind the rubber lead-through). Blowing through the hole should increase the value. WATER VALVE FEEDB. should show 0 (closed) when the requested temperature is 160, and 100 (open) when the requested temperature is 280. The water valve is located under the cab.

Menu 2


2(8) XXX XXX XXX XXX

6

000133


Check of Sensor, temperature outlet fan (B775-2), engine temperature, Sensor, outdoor temperature (B774), and check of Sensor, temperature refrigerant (B775-1). TEMP COIL: temperature that the air has in the air distributor is measured by Sensor, temperature outlet fan (B775-2). TEMP COOLANT: engine temperature that is sent on the CAN bus. TEMP AMBIENT: outdoor temperature that is measured by Sensor, outdoor temperature (B774). TEMP DE-ICE: the cooling circuit's temperature is measured by the refrigerant temperature sensor (B775-1). If the compressor is activated, the value will be low. However, if heat has been selected and the compressor is deactivated, the value will almost be equal to TEMP COIL.


VDCT01.02GB

9:26


Menu 3 7

(Only machines with ECC) Checks that the refrigerant circuit is filled.

006865

DIAG CLIMATE 3(X) PRESENT INPUT SIGNAL PRESSURE SWITCH X OPT DOOR SWITCH X

PRESSURE SWITCH: 0 = not filled, 1 = filled. The sensor is located on the receiver drier which is fitted right rear in the frame.

Menu 4 8

Checks Water valve (Y673) and Air distributor (Y642). WATER VALVE: should work between 1.0-1.24 V and 2.95-3.2 V. This is checked by turning the temperature control and changing the temperature setting from min. to max.

000135

DIAG CLIMATE 4(8) PRESENT INPUT SIGNAL WATER VALVE XX.XXV DRAUGHT VALVE XX.XXV

DRAUGHT VALVE: should work in the range 1.0-4.0 V. The difference between min. and max. should be approx. 1 V. This is checked by changing the air distribution from floor to front window. At the same time, feel with your hand so that air blows through different vents.

NOTE Air to the round panel vents is not controlled by the air conditioning.

Menu 5 9

000136

DIAG CLIMATE 5(8) PRESENT INPUT SIGNAL REQUIRED TEMP XX.XXV REQ. DRAUGHT XX.XXV REQ. FAN SPEED XX.XXV

Checks the switches for temperature, air distribution and fan speed. REQUIRED TEMP: home position U = 0 V; raise U = 2-2.5 V; lower U = 4.5-5 V. REQ. DRAUGHT: home position U = 0 V; against window U = 2-2.5 V; against floor U = 4.5-5 V. REQ. FAN SPEED: home position U = 0 V; raise U = 2-2.5 V; lower U = 4.5-5 V.

Menu 6 10 Checks Cab fan (M657), Fresh air and recirculation damper (M612) and Electromagnetic clutch, compressor (M645) 000137

DIAG CLIMATE 6(8) PRESENT OUTPUT SIGNAL FAN SPEED XXX RECIRKULATION XY COMPRESSOR XY

.

FAN SPEED: increase and decrease fan speed, value should increase from 0 to 255 in steps. RECIRCULATION: press in the Switch, bypass (S1005) (on the panel for load handling functions). When checking, the display should show "11". Check that the damper actually moves as it should by removing the fresh air filter at the front of the climate control system casing and feeling with your hand. (Only machines with ECC) COMPRESSOR: lower the temperature setting to max. cooling, after approx. 45 seconds the compressor will be activated and the display should show "11".

NOTE Compressor activation can only be tested when the engine is running and the system is filled.

VDCT01.02GB



9:27

Menu 7

DIAG CLIMATE 7(8) OUTPUT WATER VALVE CLOCKWISE XY XY ANTI-CLOCKWISE XY XY

11 Checks the direction selector for Water valve (Y673). CLOCKWISE: when the temperature is increased and the water valve opens shows "CLOCKWISE 11 11" and "ANTI-CLOCKWISE 00 11". ANTI-CLOCKWISE: when the temperature is decreased and the water valve closes shows "CLOCKWISE 00 11" and "ANTI-CLOCKWISE 11 11".

24V

NOTE The "ones" are only shown for a moment when the water valve changes position, "zeros" are shown when the valve does not change position. The water valve does not open if the engine temperature is low, or if the outdoor temperature is high.

000138

M

0V

Menu 8

DIAG CLIMATE 8(8) OUTPUT DRAUGHT VALVE CLOCKWISE XY XY ANTI-CLOCKWISE XY XY

12 Checks the direction selector for the air distributor. CLOCKWISE: when the air is directed against the windscreen and the air distributor changes position shows "CLOCKWISE 00 11" and "ANTI-CLOCKWISE 11 11". ANTI-CLOCKWISE: when the air is directed against the feet and the air distributor changes position shows "CLOCKWISE 11 11" and "ANTI-CLOCKWISE 00 11".

24V

NOTE The "ones" are only shown for a moment when the air distributor changes position, "zeros" are shown when the air distributor does not change position.

0V

000139

M


VDCT01.02GB

9:28

9 Frame, body, cab and accessories – Fresh air filter

9.4.1 Fresh air filter Fresh air filter, description The fresh air filter is located under a cover in the external unit for fresh air intake into the cab, in front of the cab fan.

1

004999

2

1 Fresh air intake, cab 1.

Fresh air filter

2.

Fresh air and recirculation damper

VDCT01.02GB


9 Frame, body, cab and accessories – Fresh air filter or recirculation damper

9:29

9.4.2 Fresh air filter or recirculation damper Fresh air filter or recirculation damper, description The damper is controlled electrically and controls the air between fully open for fresh air to recirculation of air. The damper is located in the external unit for fresh air intake into the cab. The signal can be checked via the diagnostic menu, section 8 Control system, group 8.4.4.6 CLIMATE, menu 6.

1

004999

2

1 Fresh air intake, cab 1.

Fresh air filter

2.

Fresh air and recirculation damper


VDCT01.02GB

9:30


Motor, fresh air filter or recirculation damper, replacement

VDCT01.02GB

1


2

Remove the wiper arms.

3

Remove the nuts which hold the wiper motor in the protective plate.

4

Remove the protective plate.

5

Remove the fresh air filter.



9:31

6

Remove the bolts which secure the arm and motor in the plate.

7

Detach the connector from the motor.

8

Replace the motor.

9

Fit in the reverse order. Tighten the wiper arm to torque 16-20 Nm.


VDCT01.02GB

9:32

9 Frame, body, cab and accessories – Cabin fan

9.4.3 Cabin fan Cab fan, description The cab fan is located in the external unit for fresh air intake into the cab. The fan consists of two single fans that are driven by a motor. The signal can be checked via the diagnostic menu, section 8 Control system, group 8.4.4.6 CLIMATE, menu 6.

003209

1

Fresh air intake, cab 1.

Cabin fan

Cab fan, replacement

VDCT01.02GB

1


2




9:33

3

Remove the bolts which hold the wiper motor in the protective plate.

4


5

Detach the washer hose from the protective plate.

6



VDCT01.02GB

9:34


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 torque 16-20 Nm.

VDCT01.02GB


9 Frame, body, cab and accessories – Heat exchanger heat

9:35

9.4.4 Heat exchanger heat Heat exchanger heat, description The heat from the engine's coolant is transferred to the cab via the heat exchanger. The heat exchanger is located behind the fan in the external unit for fresh air intake into the cab.

1, 2

003210

3


Heat exchanger heat

2.

Heat exchanger, cooling

3.

Expansion valve and sensor for refrigerant temperature

Heat exchanger, cooling/heating, replacement

WARNING Personal injury, environmental damage. Read the safety instructions for refrigerant, see section B Safety. 1



VDCT01.02GB

9:36


2

Drain the AC system of R134a refrigerant.

IMPORTANT Working on the air conditioning requires special authorisation.

VDCT01.02GB

3

Detach the AC system hoses and the coolant hoses.

4


5

Remove the nuts which hold the wiper motor in the protective plate.

6


7


8




9

9:37

Remove the plate frame.

10 Remove the cab fan.

11 Remove the heat exchanger cover plate.

12 Detach all fluid inlets and outlets from the heat exchanger. 13 Lift out the heat exchanger carefully. 14 Replace the heat exchanger. 15 Fit in the reverse order. Tighten the wiper arm to 16-20 Nm. 16 Check for leaks and refill the AC-system with refrigerant R134a, using the intended equipment. For volume, see section F Technical data.

IMPORTANT Connection points for cooling hoses.

Working on the air conditioning requires special authorisation.


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9:38

9 Frame, body, cab and accessories – Water valve

9.4.5 Water valve Water valve, description The water valve controls the climate control system's capacity for heating from 0 (closed valve) to 100% (open valve). The water valve is electrically controlled.

010021

The signal can be checked from the diagnostic menu, section 8 Control system, group 8.4.4.1 CLIMATE, menu 1, 8.4.4.4 CLIMATE, menu 4 and 8.4.4.7 CLIMATE, menu 7.

Water valve position under cab floor (from below)

Water valve, replacement

1.

Water valve

2.

Steering valve

1


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


8

Check the coolant level.

9

Run the heating system at the highest setting (fully open valve) to vent air from the system.

9.4.6 Sensor, engine temperature Sensor, engine temperature, description Sensor, coolant temperature, is fitted on the engine and detects engine's coolant temperature. See supplier documentation, engine. The signal can be checked via the diagnostic menu, section 8 Control system, group 8.4.4.2 CLIMATE, menu 2. For location, see section 1 Engine.

VDCT01.02GB


9 Frame, body, cab and accessories – Compressor

9:39

9.4.7 Compressor Compressor, description (engine alternative Yuchai YC6A240-30) 1 The compressor drives the air conditioning by working as a pump. It draws in cold, low-pressure gas from the evaporator, compresses the gas which then becomes warm, and then forces out high-pressure gas to the condenser. The compressor is driven by V-belts directly by the machine's engine. Activation and deactivation of the compressor is handled by an electromagnetic clutch, which is controlled by a thermostat.

3

The signal can be checked via the diagnostic menu, section 8 Control system, group 8.4.4.6 CLIMATE, menu 6.

015087

2

1.

Compressor

2.

Belt tensioner

3.

Drive belt

Compressor, description (engine alternative Cummins QSB6.7 ) 1

3

2

The compressor drives the air conditioning by working as a pump. It draws in cold, low-pressure gas from the evaporator, compresses the gas which then becomes warm, and then forces out high-pressure gas to the condenser. The compressor is driven by V-belts directly by the machine's engine. Activation and deactivation of the compressor is handled by an electromagnetic clutch, which is controlled by a thermostat. The signal can be checked via the diagnostic menu, section 8 Control system, group 8.4.4.6 CLIMATE, menu 6.

5 1.

Rigging screw (belt tensioner)

2.

Compressor

3.

Connections

4.

Screw and nut

5.

Drive belt

009116

4


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9:40


Compressor, changing (engine alternative Yuchai YC6A240-30)

WARNING Personal injury, environmental damage. Read the safety instructions for refrigerant, see section B Safety.

NOTE For tightening torque of refrigerant hoses and pressure switch, see section F Technical data. 1


2



1

3

3

Detach the coolant hoses from the compressor.

4

Loosen the belt tensioner so that the drive belt is released.

5

Undo the hose couplings and detach the hoses from the compressor intake and outlet. Plug the connections immediately to prevent contamination.

6

Remove the bolts which secure the compressor.

7

Drain the oil from the old compressor (through the intake and outlet connections) and the hoses. Measure the oil quantity.

8

Drain the oil from the new compressor.

9

Fill the new compressor with the same quantity of oil as was drained from the old compressor - minimum 0.1 litre.

10 Fit the new compressor and other equipment in reverse order. 11 Check for leaks and refill the AC-system with refrigerant R134a, using the intended equipment. 015087

2

1.

Compressor

2.

Belt tensioner

3.

Drive belt

For volume, see the plate for the climate control system.


NOTE Fill new oil through the compressor's suction connection.

VDCT01.02GB



9:41

Compressor, replacement (engine alternative Cummins QSB6.7 )




2



1

3

2

5 1.

Rigging screw (belt tensioner)

2.

Compressor

3.

Connections

4.

Screw and nut

5.

Drive belt

009116

4

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 compressor intake and outlet. Plug the connections immediately to prevent contamination.

6

Remove the bolts which secure the compressor.

7

Drain the oil from the old compressor (through the intake and outlet connections) and the hoses. Measure the oil quantity.

8

Drain the oil from the new compressor.

9

Fill the new compressor with the same quantity of oil as was drained from the old compressor - minimum 0.1 litre.

10 Fit the new compressor and other equipment in reverse order. 11 Check for leaks and refill the AC-system with refrigerant R134a, using the intended equipment. For volume, see the plate for the climate control system.


NOTE Fill new oil through the compressor's suction connection.


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9:42


Pulley and electromagnetic clutch, replacement There is no need to drain refrigerant from the system before replacement. 1 Machine in service position, see section B Safety. Slacken the belt tensioner and remove the drive belt.

3

Remove the screw from the centre of the pulley.

4

Remove the locking washer and the outer lock ring.

5

Remove the groove.

006263

2

1

006264

2

1.

Lock ring

2.

Locking washer

006265

1

1.

Groove

VDCT01.02GB


9 Frame, body, cab and accessories – Condenser

9:43

Remove the three screws securing the electromagnetic clutch.

7

Remove the clutch coil

8


9

Check the function.

006266

6

006267

1

1.

Electromagnetic clutch

9.4.8 Condenser Condenser, description

The condenser is located on the radiator in the engine compartment. The function of the condenser is to convert the hot, high-pressure gas from the compressor to liquid form. Pipes and cooling fins in the condenser battery absorb the heat, which is dissipated with a fan.

1

The temperature of the refrigerant in the condenser varies from approx. 50 ºC to 70 ºC and the pressure varies between 12 and 14 bar, depending on ambient temperature and airflow through the condenser. When the refrigerant has been condensed to liquid, it is directed on to the fluid reservoir/filter dryer.

2 4

014686

3

1.

Intercooler

2.


3.

Radiator

4.

Condenser


VDCT01.02GB

9:44

9 Frame, body, cab and accessories – Condenser

Condenser, replacement




2


IMPORTANT

1

Working on the air conditioning requires special authorisation.

2 4

014686

3

1.

Intercooler

2.


3.

Radiator

4.

Condenser

VDCT01.02GB

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.

5

Replace the condenser, fitting it in the reverse order.

6

Check for leaks and refill the AC-system with refrigerant R134a, using the intended equipment. For volume, see section F Technical data.



9 Frame, body, cab and accessories – Moisture filter

9:45

9.4.9 Moisture filter Moisture filter, description

NOTE For tightening torque of refrigerant hoses and pressure switch, see section F Technical data. The moisture filter collects the liquid refrigerant, binds moisture, and filters out impurities. The reservoir functions as an expansion tank in the cooling circuit.

1.

Moisture filter

2.

Pressure switch

3.

Sight glass

When the refrigerant has passed through the dryer in the bottom of the fluid reservoir, it rises through a standpipe. Through a sight glass, it is possible to check that there is flow without bubbles and that the system is adequately filled with refrigerant.

9.4.10 Pressure switch Pressure switch, description

NOTE For tightening torque of refrigerant hoses and pressure switch, see section F Technical data. The pressure switch cuts off the current to the compressor's electromagnetic clutch if the pressure in the cooling circuit becomes abnormally high or low. The signal can be checked via the diagnostic menu, section 8 Control system, group 8.4.4.3 CLIMATE, menu 3. 1.

Moisture filter

2.

Pressure switch

3.

Sight glass


VDCT01.02GB

9:46

9 Frame, body, cab and accessories – Expansion valve

Pressure switch, replacement



2

Drain the machine of refrigerant, R134a.


1.

Moisture filter

2.

Pressure switch

3.

Sight glass

3

Detach the connector from the pressure switch.

4

Unscrew the pressure switch from its mounting.

5

Replace the pressure switch.

6



9.4.11 Expansion valve Expansion valve, description

The expansion valve is the part in the circuit that separates the high-pressure side from the low-pressure side. The refrigerant arrives at the expansion valve under high pressure and leaves it under low pressure. After the expansion valve, the refrigerant converts to a gaseous state and is transported to the compressor once again. The amount of refrigerant that passes through the evaporator varies depending on the heat load. The valve works from fully open to fully closed and searches between these for an optimal evaporation point.

VDCT01.02GB


9 Frame, body, cab and accessories – Expansion valve

9:47

Expansion valve, replacement



2

Drain the AC system of refrigerant.

IMPORTANT Working on the air conditioning requires special authorisation. 3

Detach the AC system hoses.

4

Detach the coolant hoses.

5

Remove the heat exchanger for cooling/heating to access the expansion valve, see Heat exchanger, cooling/heating, replacement, page 9:35.

6

Replace the expansion valve.

7


8




VDCT01.02GB

9:48

9 Frame, body, cab and accessories – Sensor, temperature refrigerant

9.4.12 Sensor, temperature refrigerant Sensor, temperature refrigerant, description

Sensor, temperature refrigerant, (position 2) detects the refrigerant temperature in the heat exchanger, cooling. This is used to control the air conditioning. The signal can be checked via the diagnostic menu, section 8 Control system, group 8.4.4.2 CLIMATE, menu 2.

1

2 1.

Sensor cab temperature

2.

Sensor temperature refrigerant

3.

Sensor, temperature outlet fan

005001

3

Sensor, temperature refrigerant, replacement



2

Drain the AC system of refrigerant.


VDCT01.02GB

3

Detach the AC system hoses from the heat exchanger.

4

Detach the coolant hoses from the heat exchanger.

5

Detach the heat exchanger to access the refrigerant temperature sensor, see Heat exchanger, cooling/heating, replacement, page 9:35.

6

Replace the temperature sensor.

7



9 Frame, body, cab and accessories – Heat exchanger, cooling

8

9:49



9.4.13 Heat exchanger, cooling Heat exchanger, cooling, description

Heat exchanger, cooling, consists of pipes and cooling fins. The cab air is cooled as it passes through the heat exchanger, cooling. The heat exchanger is located behind the fan in the external unit for fresh air intake into the cab.

1, 2

003210

3


Heat exchanger heat

2.

Heat exchanger, cooling

3.

Expansion valve and sensor for refrigerant temperature

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

VDCT01.02GB

9:50

9 Frame, body, cab and accessories – Air distributor

9.4.14 Air distributor Air distributor, description The air distributor controls the air between defroster and floor and is located behind the panel inside the cab. The damper is controlled electrically by the control system.

002230

The signal can be checked from the diagnostic menu, section 8 Control system, group 8.4.4.4 CLIMATE, menu 4 and 8.4.4.5 CLIMATE, menu 5 and 8.4.4.8 CLIMATE, menu 8.

Air distributor, replacement

1.

Instrument panel

2.

Steering column adjustment

3.

Lower protective cover

1


2

Remove the dashboard panel.

3

Remove the steering wheel shaft cover.

4

Detach the steering wheel shaft and angle it back against the driver's seat.

5

Remove the lower cover in front of the pedal assembly.

6

Detach the air hoses from the air distributor and detach the connector.

7

Remove the air distributor from its mounting.

8

Replace the air distributor, fitting it in the reverse order.

Air distributor

VDCT01.02GB


9 Frame, body, cab and accessories – Defroster nozzles

9:51

9.4.15 Defroster nozzles Defroster nozzles, description There are a number of fixed defroster nozzles in the cab's interior: at the front of the doors and the defroster for the windscreen. There are also two adjustable air vents (flow and direction) in the instrument panel's outside corners.

001839

There is an air inlet towards the cab's lower part (floor).

Defroster nozzles, replacement 1


2

Remove the air damper manually.

3

Remove the bolts which hold the other part of the defroster nozzle in the dashboard.

4

Detach the air hose from the defroster nozzle.

5

Replace the defroster nozzle.


VDCT01.02GB

9:52

9 Frame, body, cab and accessories – Sensor, temperature outlet fan

9.4.16 Sensor, temperature outlet fan Sensor, temperature outlet fan, description Sensor, temperature outlet fan, detects the temperature of the air that blows out in the defroster nozzles. The air conditioning is controlled by signals from the following sensors:

1

Sensor cab temperature

2.


3.


The signal can be checked via the diagnostic menu, section 8 Control system, group 8.4.4.2 CLIMATE, menu 2.

005001

3 2

1.

Sensor, temperature outlet fan, replacement

1.

Instrument panel

2.

Steering column adjustment

3.

Lower protective cover

1


2


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.

5

Detach the temperature sensor from the air distributor.

6


Air distributor including temperature sensor.

VDCT01.02GB


9 Frame, body, cab and accessories – Sensor cab temperature

9:53

9.4.17 Sensor cab temperature Sensor, cab temperature, description Sensor, cab temperature, detects the temperature of the air in the cab. The signal can be checked via the diagnostic menu, section 8 Control system, group 8.4.4.1 CLIMATE, menu 1.

1

2 Sensor cab temperature

2.


3.


Sensor, cab temperature, replacement 1


2


3

Detach the hose from the temperature sensor.

4

Detach the connector from the temperature sensor.

5

Remove the temperature sensor.

6


7


007985

1.

005001

3


VDCT01.02GB

9:54

9 Frame, body, cab and accessories – Sensor, ambient temperature

9.4.18 Sensor, ambient temperature Sensor, ambient temperature, description Sensor, ambient temperature, detects the temperature of the air outside the cab. The signal can be checked via the diagnostic menu, section 8 Control system, group 8.4.4.2 CLIMATE, menu 2.

Sensor, ambient temperature

Sensor, ambient temperature, replacement

VDCT01.02GB

1


2

Detach the connector from the temperature sensor.

3

Remove the temperature sensor from its mounting in the cab.

4


5



9 Frame, body, cab and accessories – Wiper/washer system

9:55

9.5 Wiper/washer system Wiper/washer system, description The wipers automatically switch off 2 minutes after the operator has left the driver's seat.

9.5.1 Wiper front Wiper front, description The front wiper is the parallel wiper type, i.e. the wiper blade is moved in a constant vertical position over the front window.

9.5.2 Wiper roof Wiper roof, description The roof wiper is the sector wiper type. Wiping angle is approx. 180 degrees.

9.5.3 Wiper rear Wiper rear, description The rear wiper is the sector wiper type. Wiping angle is approx. 180 degrees.

9.5.4 Washer motor and reservoir Washer motor and reservoir, description Washer motors are located on the washer fluid reservoir. There are non-return valves on the lines from the reservoir to the washer nozzles, preventing the washer fluid from draining back in the line between washings. This minimises the time between the activation of the switch for washing and washer fluid spraying on the window. The washer nozzles are mounted on the wiper arms. The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.3.1 CAB, menu 1.


VDCT01.02GB

9:56

9 Frame, body, cab and accessories – Wiper motor front

Washer motor and reservoir, replacement Machine in service position, see section B Safety.

2

Remove the protection over the washer fluid reservoir.

3

Drain the washer fluid from the fluid reservoir.

4

Remove the washer motors from the fluid reservoir.

5

Remove the bolts which secure the fluid reservoir in the cab wall.

6

Replace the washer fluid reservoir. Replace the washer motor, if necessary.

003619

A

1

B

Washer fluid reservoir without protective plate. A

Washer fluid reservoir

B

Washer motors

9.5.5 Wiper motor front Wiper motor front, description The wiper motor drives the wiper for the front window. The wiper arm is mounted on the motor. The motor produces the movement of the wiper. The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.3.2 CAB, menu 2

Wiper motor front, replacement

VDCT01.02GB

1


2


3

Remove the nuts which hold the motor in the protective plate.

4


5


6

Remove the nuts which hold the motor in the cab.

7

Detach the connector from the wiper motor.

8

Replace the motor.

9

Fit in the reverse order. Tighten the wiper arms to torque 16-20 Nm.


9 Frame, body, cab and accessories – Wiper motor roof

9:57

9.5.6 Wiper motor roof Wiper motor roof, description The wiper motor drives the wiper for the roof window. The wiper arm is mounted on the motor. The motor produces the movement of the wiper. The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.3.4 CAB, menu 4.

Wiper motor roof, replacement 1


2

Remove the plastic cover.

3

Detach the washer hose and the connector to the wiper motor.

4

Undo the lock nut securing the wiper arm and disconnect the washer fluid hose.

5

Remove and replace the wiper motor.

6

Fit in the reverse order. Tighten the wiper arm to torque 16-20 Nm.


VDCT01.02GB

9:58

9 Frame, body, cab and accessories – Wiper motor rear

9.5.7 Wiper motor rear Wiper motor rear, description The wiper motor drives the wiper for the rear window. The wiper arm is mounted on the motor. The motor produces the movement of the wiper. The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.3.3 CAB, menu 3.

Wiper motor rear, replacement

VDCT01.02GB

1


2

Remove the panels behind the driver's seat.

3

Remove the screws holding the motor's plastic cover.

4

Detach the connector to the motor.

5

Raise the plastic cover and remove the nut securing the wiper arm. Detach the washer fluid hose.

6

Remove the screws securing the motor and the lock nut on the motor.

7

Replace the wiper motor.

8

Fit in the reverse order. Tighten the wiper arms to torque 16-20 Nm.


9 Frame, body, cab and accessories – Lighting system

9:59

9.6 Lighting system Lighting system, function description The working lights are shut off automatically after 5 minute's idle in order to prevent discharge of the batteries. Extra working lights are shut off after 2 minutes. The lights are activated automatically again when the operator sits in the seat, a gear is selected or the accelerator pedal is pressed.

NOTE It is important that the right type of bulb is used for each area. See section F Technical data.

1

2

3

5

4

D1

D2

D3

D5

D4

8 13

9 10

D13

6

D8 D6

14

17 D17

14 D10

15

16 M

D15 D16

19 D797-1

D790-1 7, 12

D9

D790-2 11

28 D791-1

D18

D20 D21 D22 D23 D24

Pa

18

D25 D29

D30

20

21

22

23

24

25

26

27

D27

29

30

Pos

Explanation

Signal description

Reference

1

The switch for cab roof work lights (S105-1) sends a voltage signal to the cab control unit (D790-1).

Switch in ON position: U = 24 V

D1: Diagnostic menu, see section 8 Control system, group 8.4.2.12 LIGHTS, menu 12

2

Switch, working lights attachment (S105-2) sends a voltage signal to Control unit, cab (D790-1).


D2: Diagnostic menu, see section 8 Control system group 8.4.2.13 LIGHTS, menu 13

3

The switch for mast work lights (S105-3) sends a voltage signal to the cab control unit (D790-1).



4

Switch, headlights (S100) sends a voltage signal to Control unit, cab (D790-1).



5

Switch, revolving beacon (S110) sends a voltage signal to Control unit, cab (D790-1).




VDCT01.02GB

015047

D26

9:60

6


The door NC switch (S266-LE & S266-RI) sends a voltage signal to the cab control unit (D790-1).

Door open: U = 24 V

Interior lighting cab, description, page 9:66

7

Control unit, cab (D790-1) transmits "switch on lights" messages on the CAN bus.



8

Multi-function lever (S162) sends a voltage signal to Control unit KIT (D790-2).

Lever in high beam position: US162/56a = 24 V

Gear selector and multi-function lever, description, page 9:8


D8: Diagnostic menu, see section 8 Control system group 8.4.2.3 LIGHTS, menu 3 9

Lever, direction indicator (S161) sends a voltage signal to Control unit KIT (D790-2).

Right: US161/1 = 24 V


Left: US161/6 = 24 V

10

Switch, interior lighting on Control unit KIT (D790-2) sends a voltage signal to Control unit KIT (D790-2).



11

Control unit KIT (D790-2) sends a "switch on lights" message on the CAN bus.



12

Control unit, cab (D790-1) supplies voltage to the lights in and around the cab.



13

The relay for cab roof work lights (K3017-1 and K3017-2) is activated when the cab roof work lights are activated. It supplies voltage to the cab roof work lights (E406L-1 E406R-1, E406L-2 & E406R-2).

UK3017/30 = 24 V

Working lights, cab, description, page 9:66

UK3017/85 = 0 V Cab roof work lights on: UK3017/86 = 24 V UK3017/87 = 24 V Cab roof work lights off: UK3017/86 = 0 V UK3017/87 = 0 V

14

15

16

The cab roof work lights (E406L-1 E406R-1, E406L-2 & E406R-2) come on when the cab roof work lights are activated.

Light on: U = 24 V

Back-up lights, white (E405L & E405R) are switched on when reverse gear is selected.

Light on: U = 24 V

Revolving beacon (H428) is switched on when the revolving working light is activated.

Light on: U = 24 V

Working lights, cab, description, page 9:66 D14: Diagnostic menu, see section 8 Control system group 8.4.2.12 LIGHTS, menu 12 Back-up lights, description, page 9:64 D15: Diagnostic menu, see section 8 Control system group 8.4.2.8 LIGHTS, menu 8 Revolving beacon, description, page 9:64 D16: Diagnostic menu, see section 8 Control system group 8.4.2.6 LIGHTS, menu 6

17

Interior lighting (E434-1) comes on when a door is opened or if activated when the switch on the KIT control unit (D790-2).

VDCT01.02GB

Light on: U = 24 V


Interior lighting cab, description, page 9:66 D17: Diagnostic menu, see section 8 Control system, group 8.4.2.9 LIGHTS, menu 9


18

The brake light NO switch (S216) sends a voltage signal to the frame control unit (D797-1).

Brake pressure over 0.2 MPa: U = 24 V

9:61

Section 4 Brakes, group 4.3.8 Make-contact (closing switch) brake lights D18: Diagnostic menu, see section 8 Control system group 8.4.2.7 LIGHTS, menu 7

19

The frame control unit (D797-1) supplies voltage to the machine lights.



20

The direction indicators (H422, H423, H426 & H427) come on when they or the warning lights are activated.

Light on: U = 24 V

Direction indicators, description, page 9:64

The running lights (H416-1, H416-2, H417-1 & H417-2) come on together with the headlights.

Light on: U = 24 V

Headlights, low beam (E400L & E400R) are switched on when the headlight is activated.

Light on: U = 24 V

Headlights high beam (E402L-1 & E402R-1) are lit when high beam is activated.

Light on: U = 24 V

Tail lights, red (H412L & H412R) are switched on when the headlight is activated.

Light on: U = 24 V

Brake lights (H411L & H411R) are switched on when the brake is activated.

Light on: U = 24 V

The mast work lights (E404L-1 & E404R-1) come on when activated.

Light on: U = 24 V

21

22

23

24

25

26

D20: Diagnostic menu, see section 8 Control system, group 8.4.2.5 LIGHTS, menu 5 Running lights, description, page 9:63 D21: Diagnostic menu, see section 8 Control system group 8.4.2.2 LIGHTS, menu 2 Headlights, description, page 9:63 D22: Diagnostic menu, see section 8 Control system group 8.4.2.3 LIGHTS, menu 3 Headlights, description, page 9:63 D23: Diagnostic menu, see section 8 Control system, group 8.4.2.3 LIGHTS, menu 3 Tail lights, description, page 9:63 D24: Diagnostic menu, see section 8 Control system group 8.4.2.2 LIGHTS, menu 2 Brake lights, description, page 9:63 D25: Diagnostic menu, see section 8 Control system group 8.4.2.8 LIGHTS, menu 8 Mast working lights, description, page 9:64 D26: Diagnostic menu, see section 8 Control system, group 8.4.2.10 LIGHTS, menu 10

27

The auxiliary mast work lights (E404L-4 & E404R-4) come on when the mast work lights are activated.

Light on: U = 24 V

Mast working lights, description, page 9:64

28

Control unit, attachment (D791-1) supplies voltage to the attachment's lights.



29

The twistlock attachment work lights (E404L-3 & E404R-3) come on when activated.

Light on: U = 24 V

Working lights, attachment, description, page 9:67


D29: Diagnostic menu, see section 8 Control system, group 8.4.2.13 LIGHTS, menu 13 30

The twistlock attachment auxiliary work lights (E404L-5 and E404R-5) come on when activated.

Light on: U = 24 V


Working lights, attachment, description, page 9:67 D30: Diagnostic menu, see section 8 Control system group 8.4.2.11 LIGHTS, menu 11

VDCT01.02GB

9:62


Lighting system, component location The purpose of the lighting is to increase safety during operation and load handling.

NOTE It is important that the right type of bulb is used for each area. See section F Technical data. The machine has the following lights:

4

1

5

6

6

7

9

2

3,8,10 12 24 23

19, 20, 21

17

18

16

15

11, 13, 14

1.

Mast work lights (E404L-1 & E404R-1)

14. Direction indicators, rear (H426 & H427)

2.

Auxiliary mast work lights (E404L-4 & E404R-4)

3.

Relay, cab roof work lights (K3017-1 & K3017-2)

15. Door NC (normally closed) switch (S266-LE & S266-RI)

4.


5.


6.

Interior lighting (E434-1)

7.

Cab roof work lights (E406L-1 & E406R-1)

8.

Auxiliary cab roof work lights (E406L-2 & E406R-2)

014664

22

16. Switch, see Controls and instruments, overview, page 9:3 17. Frame control unit (D797-1) 18. Make-contact (closing switch) brake light (S216) 19. Direction indicators, front (H422 & H423) 20. Running lights, front (H416-1 & H417-1)

9.

21. Headlights, low beam (E400L & E400R)

Revolving beacon (H428)

10. Control unit, cab (D790-1)

Headlights, high beam (E402L-1 & E402R-1)

11. Running lights, rear (H416-2 & H417-2)

22. Control unit, attachment (D791-1)

12. Back-up lights, white (E405L & E405R)

23. Twistlock attachment work lights (E404L & E404R)

13. Tail lights, red (H412L & H412R)

24. Auxiliary carriage work lights (E404L-5 & E404R-5)

Brake lights (H411L & H411R)

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9 Frame, body, cab and accessories – Headlights

9:63

9.6.1 Headlights Headlights, description Headlights are located in the front of the machine to give the operator enhanced vision when operating in darkness, and to provide surrounding traffic and the environment an indication of the machine's position. Headlights have the options of high beam and low beam (for meeting other traffic). Switch between high and low beam with the gear and multi-function lever. The signal travels to Control unit, cab (D790-1). High and low beam signals can be checked from the diagnostic menu, section 8 Control system, group 8.4.2.3 LIGHTS, menu 3.

9.6.2 Running lights Running lights, description The running lights are fitted on the right and left-hand sides of the machine to provide surrounding traffic and the environment an indication of the machine's position and direction of travel. The running lights are controlled by selecting with the headlight switch. The signal travels to Control unit, cab (D790-1). The lights and their signal can be checked from the diagnostic menu, section 8 Control system, group 8.4.2.2 LIGHTS, menu 2.

9.6.3 Tail lights Tail lights, description Tail lights are located in the rear of the machine to provide surrounding traffic and the environment an indication of the machine's position, and a limited enhancement of the view for the operator in darkness. The tail lights are controlled by selecting with the headlight switch. The signal travels to Control unit, cab (D790-1). The lights and their signal can be checked from the diagnostic menu, section 8 Control system, group 8.4.2.2 LIGHTS, menu 2.

9.6.4 Brake lights Brake lights, description The brake lights are fitted on the rear of the machine to provide surrounding traffic and the environment an indication that the machine is braking and consequently slowing down. The brake lights are regulated by brake pedal position (via actuated break contact (opening switch)). The signal travels to Control unit, frame (D797-1), which supplies power to the brake lights. The lights and their signal can be checked from the diagnostic menu, see section 8 Control system, group 8.4.2.7 LIGHTS, menu 7 and 8.4.2.8 LIGHTS, menu 8.


VDCT01.02GB

9:64

9 Frame, body, cab and accessories – Back-up lights

9.6.5 Back-up lights Back-up lights, description The back-up lights are fitted on the rear of the machine to provide surrounding traffic and the environment an indication that the machine is travelling backwards. In addition, this provides the operator enhanced view when operating in darkness. The back-up lights are controlled by direction of travel. Signals are sent via the CAN-bus). The lights and their signal can be checked from the diagnostic menu, see section 8 Control system, group 8.4.2.7 LIGHTS, menu 7 and 8.4.2.8 LIGHTS, menu 8.

9.6.6 Direction indicators Direction indicators, description The direction indicators are located on both the front and rear of the machine to provide surrounding traffic and the environment an indication that the machine is changing direction, i.e. turning. The direction indicators are controlled by the choice made with the direction indicators switch (lever). The signal goes to frame control unit (D797-1). The lights and their signal can be checked from the diagnostic menu, see section 8 Control system, group 8.4.2.4 LIGHTS, menu 4 and 8.4.2.5 LIGHTS, menu 5

9.6.7 Flashing hazard lights Flashing hazard lights, description Flashing hazard lights (Hazard) are used to warn the surroundings, flashing hazard lights activate all direction indicators simultaneously. The flashing hazard lights are controlled by selecting with the switch for flashing hazard lights. The signal travels to Control unit, cab (D790-1). The signal can be checked from the diagnostic menu, see section 8 Control system, group 8.4.2.4 LIGHTS, menu 4 and 8.4.2.5 LIGHTS, menu 5.

9.6.8 Revolving beacon Revolving beacon, description The revolving beacon is located high on the machine's cab. This is used to provide surrounding traffic and the environment an indication that a working vehicle is moving and at work. An indication to bystanders to exercise caution. The revolving beacon is controlled by selecting with the revolving beacon switch. The signal travels to Control unit, cab (D790-1). The lights and their signal can be checked from the diagnostic menu, section 8 Control system, group 8.4.2.6 LIGHTS, menu 6.

9.6.9 Working lights, mast Mast working lights, description Work lights on the mast provide enhanced view when load handling in darkness. The working lights are controlled by selecting with the switch for working lights, mast. The signal travels to Control unit, cab (D790-1). VDCT01.02GB


9 Frame, body, cab and accessories – Working lights, mast

9:65

The lights and their signal can be checked from the diagnostic menu, see section 8 Control system, group 8.4.2.10 LIGHTS, menu 10 and 8.4.2.11 LIGHTS, menu 11 The mast can be equipped with two auxiliary work lights (


).

VDCT01.02GB

9:66

9 Frame, body, cab and accessories – Working lights, cab

Working lights, replacement (product alternative Xenon lights)

DANGER Xenon lights are activated with high voltage. Always switch off the system voltage before working on Xenon lights. Handle the headlight with care since the light is under gas pressure and may explode.

NOTE The Xenon light is filled with different gases and metals. Replaced Xenon headlights should be considered as hazardous waste and should be deposited for recycling.

9.6.10 Working lights, cab Working lights, cab, description

Working lights on the cab provide visibility when handling a load in darkness. The working lights are controlled by selecting with the switch for working lights, cab roof. The signal travels to Control unit, cab (D790-1), which in turn supplies power to the working lights. The lights and their signal can be checked from the diagnostic menu, section 8 Control system, group 8.4.2.12 LIGHTS, menu 12.


See Working lights, replacement (product alternative Xenon lights), page 9:66.

9.6.11 Interior lighting Interior lighting cab, description The interior lighting illuminates the cab when the doors are opened or when activated with the interior lighting switch. There is background lighting in all switches, function keys and rotary controls. This is so that the operator will be able to read their functions and settings in darkness. Brightness is controlled by the plus and minus keys. The lights and their signal can be checked from the diagnostic menu, section 8 Control system, group 8.4.2.9 LIGHTS, menu 9.

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9 Frame, body, cab and accessories – Working lights, attachment

9:67

9.6.12 Working lights, attachment Working lights, attachment, description Working lights on the attachment provide increased visibility when handling a load in darkness. The working lights are controlled by selecting with the switch for working lights, attachment. The signal travels to Control unit, cab (D790-1). The lights and their signal can be checked from the diagnostic menu, section 8 Control system, group 8.4.2.13 LIGHTS, menu 13. The attachment can be equipped with two extra working lights (

).



9.6.14 Work lights, front wing Front wing work lights, lighting Work lights on the front wing provide enhanced view when load handling in darkness. The working lights are controlled by selecting with the switch for working lights, cab roof . The signal travels to Control unit, cab (D790-1). The lights and their signal can be checked from the diagnostic menu, section 8 Control system, group 8.4.2.11 LIGHTS, menu 11.




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9:68

9 Frame, body, cab and accessories – Signalling system

9.7 Signalling system Signalling system, function description

NOTE It is important that the right type of bulb is used for each area. See section F Technical data.

1

2

3

D2 D3

4 6

D17 17

7

D4

D1

15

16

D6

D6 13

14 M D790-1

D14

D797-1

D10 10

11

D18 18 D790-2

5 9

8

D795 D791-1

D11

D12

D21 12

19

20 21

Pos

Description

Signal description

Reference

1

Switch, revolving beacon (S110) sends a voltage signal to Control unit, cab (D790-1).



2

Switch, flashing hazard lights (Hazard) (S109) sends a voltage signal to Control unit, cab (D790-1).



3

Switch, parking brake (S107) sends a voltage signal to Control unit, cab (D790-1).


D3: Diagnostic menu, see section 8 Control system group 8.4.5.4 HYD, menu 4

4

The horn switch (S149-3) sends a voltage signal to the cab control unit (D790-1).



5

Control unit, cab (D790-1) sends messages about activation on the CAN bus.



6

Multi-function lever (S162) sends a voltage signal to Control unit KIT (D790-2).

Signal button pressed in: US162/H = 24 V

Gear selector and multi-function lever, description, page 9:8

Lever, direction indicator (S161) sends a voltage signal to Control unit KIT (D790-2).

Left: US161/6 = 24 V

8

Control unit KIT (D790-2) sends messages about activation on the CAN bus.



9

The frame control unit (D797-1) supplies voltage to the machine lights and buzzers.



7

VDCT01.02GB

D6: Diagnostic menu, see section 8 Control system group 8.4.3.5 CAB, menu 5

Right: US161/1 = 24 V



010027

D13

D15

9 Frame, body, cab and accessories – Signalling system

9:69

Pos

Description

Signal description

Reference

10

The direction indicators (H422, H423, H426 and H427) come on when the warning lights are activated.

Light on: U = 24 V

Direction indicators, description, page 9:64

The reversing lights (E405L and E405R) come on when reverse gear is selected.

Light on: U = 24 V

Back-up alarm (H965) is activated when reverse gear is selected.

Reverse gear selected: U = 24 V

Horn (H850) sounds when the horn is activated.

Horn active: U = 24 V

Revolving beacon (H428) is switched on when the flashing hazard light is activated.

Light on: U = 24 V

Relay loud horn (K3016) is activated when horn is activated.

UK3016/30 = 24 V

Horn, description, page 9:70

UK3016/85 = 0 V


11

12

13

14

15

D10: Diagnostic menu, see section 8 Control system, group 8.4.2.5 LIGHTS, menu 5 Back-up lights, description, page 9:64 D11: Diagnostic menu, see section 8 Control system group 8.4.2.8 LIGHTS, menu 8 Reverse alarm, description, page 9:71 D12: Diagnostic menu, see section 8 Control system group 8.4.2.8 LIGHTS, menu 8 Horn, description, page 9:70 D13: Diagnostic menu, see section 8 Control system group 8.4.3.5 CAB, menu 5 Revolving beacon, description, page 9:64 D14: Diagnostic menu, see section 8 Control 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 the horn is activated.

Horn active: U = 24 V

Horn, description, page 9:70

17

Make-contact (closing switch) operator-in-seat (S230) sends a voltage signal to Control unit, cab (D790-1) when there is a load on the driver's seat.

Operator in seat: U = 24 V

9.3.14 Sensor, operator-in-seat, page 9:19

18

In the event of warnings, Buzzer, cab (H853) is supplied voltage by Control unit KIT (D790-2) to draw the operator's attention to the warning message.



19

In the event of warnings, control unit KID (D795) activates the warning lamp to draw the operator's attention to the warning message.

A clicking sound is audible when then termination resistor is activated.


20

The attachment control unit (D791-1) supplies voltage to the automatic spreading buzzer during automatic spreading.



21

The automatic spreading buzzer (H9003) is activated when automatic spreading 20'-40' is activated.


Section 7 Load handling, group 7.5.10 Buzzer, automatic spreading 20'-40'



NOTE On machines with side lift attachment, an audible signal can also be given with the open twistlock button (S1002) on the panel for hydraulic functions or the open twistlock button on the joystick, provided that the "open twistlocks upon contact" function is not active.


VDCT01.02GB

9:70

9 Frame, body, cab and accessories – Horn

Signalling system, component location The machine has the following signalling systems:

19 18

17

16

15

14

13

2

3 4 5

6

12 10,1 1 9 8

7

014665

1

1.


11. Control unit, cab (D790-1)

2.

Buzzer, cab (H853)

12. Make-contact (closing switch) operator-in-seat (S230)

3.


13. Horn (H850)

4.


5.

Direction indicator lever (S161)

14. Switch, see Controls and instruments, overview, page 9:3

6.

Revolving beacon (H428)

15. Loud horn (H850-1)

7.

Reverse alarm (H965)

16. Frame control unit (D797-1)

8.

Reversing lights (E405L & E405R)

17. Direction indicators, front (H422 & H423)

9.

Direction indicators, rear (H426 & H427)

18. Control unit, attachment (D791-1)

10. Relay loud horn (K3016)

19. Buzzer automatic spreading (H9003)

9.7.1 Horn Horn, description The horn is electromagnetic. Compressed air horn can be selected (

).

001247

The horn is activated from the gear selector and multi-function lever or from the horn switch ( ). The horn is located under the cab (the air horn is located on the front of the cab). The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.3.5 CAB, menu 5.

9.7.2 Flashing hazard lights Flashing hazard lights, description See Flashing hazard lights, description, page 9:64.

VDCT01.02GB


9 Frame, body, cab and accessories – Revolving beacon

9:71

9.7.3 Revolving beacon Revolving beacon, description See Revolving beacon, description, page 9:64.

9.7.4 Warning parking brake Warning parking brake, description If the operator leaves the machine without applying the parking brake, a buzzer sounds to alert the operator, i.e. to ensure the operator applies the parking brake. A sensor in the driver's seat (see Sensor, operator-in-seat, description (product alternative Hao Bang), page 9:19, Sensor, operator-in-seat, description (product alternative BE-GE), page 9:20) indicates to the control system if the operator leaves the seat. The buzzer is located in the steering wheel panel. The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.3.6 CAB, menu 6.

9.7.5 Back-up alarm Reverse alarm, description

When reverse is selected, a warning sound and the back-up lights are activated. This is to give surrounding traffic an indication that the machine is reversing. Indication to bystanders to take caution. An indication to bystanders to exercise caution. The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.2.8 LIGHTS, menu 8.


VDCT01.02GB

9:72

9 Frame, body, cab and accessories – Entertainment and communication

9.8 Entertainment and communication Entertainment and communication, general

The machine is prepared with a connector for customer accessories, see section 11 Common electrics, group 11.5.2.1 Electronic box, cab.

Entertainment and communication, repair

Repairs should be left to authorised personnel.

VDCT01.02GB


9 Frame, body, cab and accessories – Glass/windows/mirrors

9:73

9.9 Glass/windows/mirrors Glass/windows/mirrors, component placement The windows are designed to both enclose the cab and provide the operator with a good view. Toughened glass windows are standard on all trucks. The roof window is a safety detail and is therefore always made of polycarbonate plastic.

C D

The rear view mirrors are of the convex mirror type. There is an interior rear view mirror on all machines. The machine has tinted, toughened glass windows.

A

E

B

A

Side windows

B

Windscreen (front window)

C

Roof window

D

Rear window

E

Front side windows

001512

The following windows may have laminated glass: •

Side windows front, position E

•

Windshield (front window), position B

Silicone adhesive, handling advice The window panes are secured with decor strips adhesive and silicone adhesive.

NOTE The purpose of this instruction is to describe how silicone adhesive 923854.0100 should be handled in connection with replacement of the windscreen and roof window on the Spirit Delta cab. •

Silicone adhesive 923854.0100 is a quick-hardening, two-component silicone adhesive that can withstand temperatures between -50 ºC and +200 ºC. The hardening properties of the adhesive are extremely dependent on the ambient temperature. An increase of 10 ºC cuts hardening time in half. Silicone adhesive 923854.0100 is mixed at a ratio of 1:10 in a static mixer. Change mixer after every interruption that lasts more than 5 minutes. The short setting time means that work has to be planned carefully in order to avoid undesired hardening.

Fixing time: 10-20 minutes at 20 ºC approx. 5 minutes at 60 ºC

Hardening time: approx. 24 hours at 20 ºC approx. 1 hour at 60 ºC Full strength is obtained after 7 days. •

In warm climates, it is advantageous to cool the container to increase hardening time. The silicone adhesive should not be used at temperatures above +75 °C.

•

In cold climates, the hardening time can be shortened by covering the joints so that cooling is prevented. The window pane can be warmed with defroster or cab heater.

•

The recommended storage temperature is between -30 ºC and +20 ºC. Storage in a refrigerator or a colder environment is recommended.


VDCT01.02GB

9:74

9 Frame, body, cab and accessories – Windscreen

9.9.1 Windscreen Windscreen, description The windscreen consists of the front window and side windows. The windscreen is attached to the cab with a decor strip and is glued to the roof window with silicone adhesive. Front and side windows are joined with silicone adhesive to give good all-round visibility from the operator's station. For location see, Glass/windows/mirrors, component placement, page 9:73.

Windscreen, replacement

NOTE Read the handling advice for silicone adhesive before starting work. See Silicone adhesive, handling advice, page 9:73. 1


2

Remove the decor strip.

3

Remove the broken window pane and check that no remains of glass or other particles remain in the window pane's groove on the strip. Cut apart silicone joints with a sharp tool.

NOTE Make sure that no silicone adhesive remains between the window pane and the strip by the window pane's lower front edge. If the roof window is to be replaced, then all bolts must be removed before the silicone adhesive is cut away.

CAUTION Acetone may not come into contact with a roof window made of polycarbonate plastic. Acetone has a chemical effect on the polycarbonate plastic which reduces the roof window's strength.

Removing the decor strip

VDCT01.02GB

4

Clean all surfaces thoroughly. Remove old remains of silicone with a razor blade or similar.

5

Fit masking tape on the inside and outside of the window panes by the surfaces that are to be glued.


9 Frame, body, cab and accessories – Windscreen

1

2

6

3

9:75

When the windscreen or a side window is to be replaced, then the window panes must be adjusted so that the upper edge on the side window has the same height as the upper edge of the cab roof and so that the distance between windscreen and side window. Use spacers against the roof member to ensure that the distances are maintained.

1

006268

1,0 1

1.

Side window

2.

Rubber strip

3.

Cab frame/door opening

006269

Adjusting side window - cab roof

1,0 Adjusting side window - windscreen 1.

Masking tape

7

Fit the decor strip around the whole window pane.

8

Apply silicone adhesive 923854.0100 around the window panes. Make the new joint wider than the old one in order to create a good seam. The silicone should be applied from the outside of the joints, to give a full and smooth joint.

NOTE There must be silicone between the window panes, to avoid contact between the window panes.


VDCT01.02GB

9:76

9 Frame, body, cab and accessories – Side window

9

Remove excess silicone from the outer vertical corners, using a tool made of cardboard. Smooth out the joints on the inside with a finger soaked in water or soapy water.

10 Apply silicone adhesive 923854.0100 between the strip and window pane at the bottom edge of the front corners, so-called top sealing. 11 If the roof window is to be replaced, apply silicone adhesive 923854.0100 by the cab frame (where it was glued earlier). 12 Align the roof window into place and check that there is a uniform distance of one or several millimetres along the window pane's edges and by the protection over the frame's sides. Then tighten the corner bolts for the window pane. 13 Apply silicone adhesive 923854.0100 by the edges and smooth out the joints with a finger, wet with water or soapy water.

006272

IMPORTANT Mark the window panes with "New adhesive. Do not touch".

Cardboard tool template for silicone joint scale 1:1

14 Remove the masking tape immediately after applying adhesive to avoid edge formation. Hardening time is dependent on ambient temperature, plan the change so that downtime is minimised.

9.9.2 Side window Side window, description The side windows are secured in the cab and doors with decor strips. For further details, see Glass/windows/mirrors, component placement, page 9:73.

Side window, replacement

NOTE The method describes a general procedure.

VDCT01.02GB

1


2

Use special tools to detach the decor strip.



9:77

3

Remove the decor strip which runs around the whole window.

4

Carefully remove any remains of glass from the rubber strip.

5

Fit the new window, securing it at the bottom edge.

6

Spray soap solution on the window and rubber strip to facilitate fitting.


VDCT01.02GB

9:78


7

Thread the rubber strip around the whole window; use special tools.

8

Secure the decor strip with a special tool.

9

Pull the decor strip around the whole window.

10 Cut off the decor strip approx. 2 cm too long. 11 Fit the other end of the decor strip edge to edge. 12 Adjust the decor strip so that the correct fit is obtained.

VDCT01.02GB


9 Frame, body, cab and accessories – Roof window

9:79

9.9.3 Roof window Roof window, description The roof window is made of polycarbonate plastic, which is a safety feature for the operator, intended to protect the operator from falling objects. The polycarbonate plastic plate is elastic. Safety is maintained within a temperature interval of 120 ºC to -45 ºC (becomes brittle at -110 ºC, glass conversion temperature 145 ºC). The roof window has a patented surface layer that increases its resistance to wear, UV light and chemicals. The roof window is joined with the windscreen. Joints between the window panes and between roof window and cab are sealed tightly with silicone adhesive. Align a new seal of silicone adhesive when replacing. For location, see Glass/windows/mirrors, component placement, page 9:73.

WARNING The strength of the roof window may be significantly reduced in case of exposure to substances containing aromatic hydrocarbons, ketones, esters, or chlorinated hydrocarbons. Low strength! Danger! Check the surface layer of the roof window and clean only with washer fluid or mild detergent. Rinse thoroughly with lukewarm water afterwards. Replace a damaged roof window that shows cracks or scratches immediately!

Roof window, replacement See Windscreen, replacement, page 9:74, for the general procedure. The roof window is joined with the windscreen. The joint is sealed with silicone. Align a new seal of silicone when replacing.

9.9.4 Rear window Rear window, description The rear window is attached to the cab with a decor strip. For further details, see Glass/windows/mirrors, component placement, page 9:73.

Rear window, replacement See Side window, replacement, page 9:76 for the general procedure.

9.9.5 Rear view mirror Rear view mirror, description The cab has a rear-view mirror located inside the cab as well as exterior mirrors on the outside of the machine. The function of the rear view mirror is to give the operator visibility around the machine.


VDCT01.02GB

9:80

9 Frame, body, cab and accessories – Cab structure and suspension

9.10 Cab structure and suspension Cab structure and suspension, description The cab is mounted in a cab substructure via strong rubber insulators fitted on the underside of the cab. This minimises vibrations from the frame to the cab. There is an insulator at four points, one at each corner. Each insulator mounting has one rubber bushing and one bolt.

1

3 4

003206

2

Cab Spirit Delta 1.

Cab frame

2.

Door

3.

Cab suspension

4.

Cab substructure

9.10.1 Cab frame Cab frame, description The cab frame is made of high-strength steel sheet profiles. The cab is dimensioned to handle impacts and, to some degree, dropped loads. The frame must not be modified!

9.10.2 Doors Doors, description The cab has two doors, the left is the operator's door and the right is the emergency exit. The door has: •

hand rail

•

handle

•

key lock

•

openable window (emergency exit

)

Switches in the doors' locks sense if the door is open. The switch is used to light the interior lighting and warn of an open door. The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.2.9 LIGHTS, menu 9.

9.10.3 Cab substructure Cab substructure, description The cab is mounted on a cab substructure via strong rubber insulators fitted on the underside of the cab. This minimises vibrations from the frame to the cab. The cab substructure is fitted on the machine's chassis (frame) via a mounting. The chassis mounting depends on whether the machine is equipped with a hydraulic tiltable cab.

VDCT01.02GB


9 Frame, body, cab and accessories – Cab interior

9:81

9.11 Cab interior 9.11.1 Instrument and control panels Steering wheel panel, description The steering wheel panel is secured to the steering column and contains warning and indicator lights, display (KID), function keys (KIT) and switches.

Left-hand dashboard panel, description The left-hand dashboard panel is located in the left-hand corner of the cab. It contains rotary controls, switches, and ventilation.

Panel for load handling functions, description The panel is mounted on the driver's seat. The panel includes switches and controls for load handling functions and emergency stop switches to interrupt ongoing load handling functions. On machines equipped with a control lever, it is located next to the panel

.

Steering wheel panel, replacement 1


2

Remove the steering wheel centre cover.

3

Remove the nut and the steering wheel.

4

Remove the bolts on the underside of the steering wheel panel.


VDCT01.02GB

9:82

9 Frame, body, cab and accessories – Interior fittings, plastic

5

Remove the bolts on the top of the steering wheel panel.

6

Unplug the connector from the multi-function levers, ignition key lock, Control unit KIT (D790-2) and Control unit KID (D795).

7

Transfer the components to the new steering wheel cover.

8


9.11.2 Interior fittings, plastic Interior fittings, plastic, description The interior of the cab consists of recyclable material.

9.11.3 Interior fittings, textile Interior fittings, textile, description The interior of the cab consists of recyclable material.

9.11.4 Floor covering Floor covering, description The floor covering is a wear-resistant and recyclable material.

9.11.5 Insulation Insulation, description The cab insulation consists of recyclable material.

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9 Frame, body, cab and accessories – Terminal console

9:83

9.11.7 Terminal console Terminal console, description

008227

The function of terminal desk is to provide a work surface for a computer/terminal. It is located to the right of the steering wheel, easily accessible for the operator.

9.11.8 Writing desk Writing desk, description

008228

The writing desk with a reading lamp is fitted on a jointed bracket to the right in front of the door in the cab. Work orders, etc. can be attached here.

9.11.9 Reading-lamp Reading lamp, description

The reading lamp is fitted on a jointed bracket to the right in front of the door in the cab.


VDCT01.02GB

9:84

9 Frame, body, cab and accessories – Chassis

9.12 Chassis Chassis, description The frame is a modular construction and consists of front section, rear section and a beam pair. This design provides advantages in terms of rigidity and strength. There are mounting points in the frame for engine, gearbox, drive axle, steering axle, fuel and hydraulic tanks, cab, mast and body parts. The space in the rear section of the frame is used for counterweights, the number of which is adapted to the machine in question. The counterweights are designed to allow as good visibility rearwards as possible. The front wings are bolted into the frame (which has advantages when delivering the machine).

3

5

4

1.

Frame's rear section with counterweights

4.

Bracket for front wings

2.

Engine compartment with mountings for engine and transmission

5.

Cab mounting (4 points)

6.

Steering axle mounting

3.

Frame's front section with drive axle mounting

VDCT01.02GB


6

014666

1

2

9 Frame, body, cab and accessories – Body structure

9:85

9.13 Body structure Body structure, description The body structure's components comprise:

1

014667

2

3 1.

Counterweight

2.

Hood engine compartment

3.

Wings

9.13.1 Wings Wings, description There are wings over the wheels to protect from dirt thrown up by the wheels during operation. The design of the counterweight (see Counterweights, description, page 9:86) acts as a mudguard for the rear wheels. The fenders can be equipped with extra mudguards when the machine's work environment requires such (

).

9.13.2 Hood engine compartment Hood engine compartment, description The machine's engine compartment is protected by a hood. The machine compartment for the transmission and drivetrain/axle is protected by floor plates. The floor plates are secured with fastening bolts. The floor plates are designed for walking on and are ribbed to provide sure footing.

9.13.3 Footsteps and hand rail Footsteps and hand rail, description The cab has footsteps for easy access. There is a hand rail by the cab. Workshop Manual DCT 80-90

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9:86

9 Frame, body, cab and accessories – Counterweights

9.13.4 Counterweights Counterweights, description The machine has counterweights to balance the machine's lift capacity and these may therefore vary in quantity and weight. The counterweights are located at the very back of the frame for maximal leverage. The machine has counterweights in the following locations: •

Under the steering axle

•

Furthest back on the machine there are vertical counterweights secured in the rear edge of the frame; the outer has a towing eye. Between the outer counterweight and frame, there are smaller counterweights whose dimensions and quantity are adapted to balance the machine's lifting capacity.

•

Upper horizontal counterweight. Under the horizontal counterweight, there are smaller counterweights whose dimensions and quantity are adapted to balance the machine's lifting capacity.

DANGER The counterweights are factory fitted and are adapted according to the machine's properties. The machine's operating characteristics are changed! Never change the quantity of counterweights.

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9 Frame, body, cab and accessories – Central lubrication

9:87

9.14 Central lubrication Central lubrication, checking 1

Check that no grease has been forced out through the safety valve (position 2). If grease has been forced out through the safety valve, this means that there is a blockage in the system. Locate the line that is blocked by feeling the connections on the distribution blocks. A blocked hose remains pressurized and the connection will be rigid.

NOTE If several distribution blocks are connected in series, a clogged line will be pressurised all the way to the first distribution block. 2

Turn the start key to position I.

3

Operate the pump manually and check that the indicator pin moves in and out on the distribution block. To operate the pump, loosen the cover and press in the switch for manual operation (position 5). If the indicator pins do not move even when the pump is running, troubleshoot the pump unit.

NOTE The system can be lubricated manually through the grease nipple on the distribution block. Overview central lubrication. Example illustration. 4

1.

Grease nipple, filling point grease

2.

Safety valve

3.

Grease nipple, manual lubrication of system

4.

Indicator pin

5.

Switch, manual operation

Fill grease in the pump unit through the filler nipple, see section F Technical data.


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9:88

9 Frame, body, cab and accessories – Central lubrication

Central lubrication, adjusting lubrication times Test or extra greasing

The central lubrication's pause and run-time must be set after changing, the setting is unique to each machine, depending on the machine's equipment. When changing the new pump unit must be set in the same way as the old one. If the machine does not lubricate properly the running and pause times can be adjusted. The running time is adjusted first, so that all the lubrication points on the machine have time to be lubricated each time. If large amounts of grease are forced out to all lubrication points the pause time can be increased.

NOTE Only adjust one step each time. Small adjustments make a large difference.

Test or extra greasing Central lubrication can be run manually by pressing and holding the button for manual operation for 2 seconds. This starts an extra lubrication cycle.

Example illustration 1.

Pause time setting (red)

2.

Run-time setting (blue)

3.

Manual pump operation

Pause time The pause time is the length of the interval between lubrications. The interval is adjusted in full hours between 1 and 15 hours. The pause time is adjusted with the red dial. Switch position

1

2

3

4

5

6

7

8

9

A

B

C

D

E

F

Pause time [hours]

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

Run-time The run-time is the time that the pump is activated each time. The run-time can be adjusted between 2 and 30 minutes. The pause time is adjusted with the blue dial. Switch position

1

2

3

4

5

6

7

8

9

A

B

C

D

E

F

Run-time [minutes]

2

4

6

8

10

12

14

16

18

20

22

24

26

28

30

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9 Frame, body, cab and accessories – Pump unit

9:89

9.14.1 Pump unit Pump unit, description

The pump unit consists of containers with stirrer, pump housing with built-in motor, timer, pump element, filler nipple, and safety valve. Central lubrication works with lubrication cycles (pause and run-time and read time). There is a circuit board with a timer in the pump. This can be used to set the run and pause time of the pump motor. When the central lubrication works so that the lubrication points are lubricated one by one in series. If there is a blockage in a lubrication point, the pressure will rise and the safety valve will release grease, in addition subsequent lubrication points will not be lubricated.

NOTE The safety valve will force grease out if a lubrication point cannot be lubricated. If a lubrication point is not lubricated, none of the subsequent points will be lubricated. It is therefore very important to check the safety valve.

Example illustration, components central lubrication 1.

Pump unit

2.

Safety valve

3.

Distribution block


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9:90

9 Frame, body, cab and accessories – Distribution block

9.14.2 Distribution block Distribution block, description

The distribution blocks distribute grease from pump unit to the lubrication points or to other distribution blocks. The number of distribution blocks can vary depending on how many (and which) lubrication points are selected. The distribution blocks consist of pistons that proportion grease into each lubrication point. The pistons are powered by the lubricant and have no springs and seals. It is the grease that powers the pistons inside the distributor. The design of the pistons and channels in the distribution block make the pistons move in a predetermined manner. Each piston must have complete its movement before the next piston can move. The pistons are interdependent. It is technically impossible for a connected lubrication point to be missed. If a lubrication point cannot be lubricated, the complete system is blocked and the grease is pressed out through the safety valve.

Example illustration, components central lubrication 1.

Pump unit

2.

Safety valve

3.

Distribution block

There is an indicator pin on the system's first distribution block (i.e. the block closest to the pump unit). If the pin moves back and forth (at the same rate as the piston movement) this indicates that the grease is being pumped through the system. If one distributor block cannot deliver grease to one of its lubrication points, the pin stops and thus the whole system. If there is a blockage in the system, this line will be pressurised from the pump to the stop through all distribution blocks on the circuit. This makes it easy to find a blockage in the system. The blockage can be traced by feeling the distribution blocks' connectors and identifying which connections are rigid. Note that several distribution blocks can be connected in series.

9.14.3 Lines Lines, description

Central lubrication works under very high pressure, only use lines that meet the following specifications.

Main hose

VDCT01.02GB

Diameter

8.4 mm

Explosion pressure

min. 60.0 MPa


9 Frame, body, cab and accessories – Paint/coatings

9:91

9.15 Paint/coatings Paint/coatings, description The machine is painted with an alkyd-based mono-component paint that is applied with a brush or a spray. For paint codes (RAL), see machine card. Check the machine frequently for stone chips, dents and paint scratches, repair them at once to prevent corrosion on the underlying metal. Only use touch-up paint for small stone chips and scratches. More extensive paint damage should be repaired by a paint workshop.

NOTE Before touching up, the surfaces to be touched up must be thoroughly cleaned. Please contact Cargotec for information about other surface treatment and material colours.


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9:92

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10:1

10 Common hydraulics

Contents 10 Common hydraulics 10 Common hydraulics .........................................................................................10:3 10.2 Safety valves..................................................................................................10:3 10.2.1 Accumulator drain valve ............................................................................10:3 10.2.2 Relief valve, attachment ............................................................................10:3 10.2.3 Pressure limiting valve ..............................................................................10:4 10.2.4 Pipes and hoses........................................................................................10:4 10.3 Tanks and accumulators ................................................................................10:5 10.3.1 Hydraulic oil tank .......................................................................................10:5 10.3.2 Accumulator ..............................................................................................10:5 10.3.4 Pipes and hoses........................................................................................10:5 10.4 Pumps............................................................................................................10:6 10.4.1 Gear pump with fixed displacement ..........................................................10:6 10.4.3 Pipes and hoses......................................................................................10:12 10.5 Hoses, pipes and valves ..............................................................................10:13 10.5.1 Pipes and hoses......................................................................................10:13 10.5.4 Main valve ...............................................................................................10:14 10.6 Temperature control, cleaning and hydraulic oil...........................................10:18 10.6.2 Cooler hydraulic oil..................................................................................10:20 10.6.3 Cooling fan ..............................................................................................10:21 10.6.4 Sensor hydraulic oil temperature.............................................................10:21 10.6.5 Bypass valve, cooler ...............................................................................10:23 10.6.6 Breather filter hydraulic oil tank ...............................................................10:24 10.6.7 Hydraulic oil filter .....................................................................................10:24 10.6.8 Hydraulic oil.............................................................................................10:26 10.6.9 Pipes and hoses......................................................................................10:27 10.6.10 Fine filter hydraulic oil..............................................................................10:27 10.7 Other ............................................................................................................10:29 10.7.1 Hydraulic cylinders ..................................................................................10:29


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10:2

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10 Common hydraulics – Common hydraulics

10:3

10 Common hydraulics 10.2 Safety valves 10.2.1 Accumulator drain valve Accumulator drain valve, description

014619

The accumulator drain valve is located on the valve block brake system and is used to drain the pressure in the brake system's accumulators to the tank. See section 4 Brakes, group 4.3.12 Valve block brake system.

Accumulator drain valve, the illustration shows the closing of the valve.

10.2.2 Relief valve, attachment Relief valve attachment, description The relief valve is located on the pressure supply from the lift, tilt and attachment control valve included in the main valve to the attachment control valve. The valve drains the pressure build-up between the lift, tilt and attachment control valve and the attachment control valve to tank. See section 7 Load handling, group 7.4.7 Relief valve attachment.

015019

1

Relief valve, attachment. The illustration depicts an open valve.


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10:4

10 Common hydraulics – Pressure limiting valve

10.2.3 Pressure limiting valve Pressure limiting valve, description 1

2

The pressure limiting valve (position 3) is located on the valve block brake system and protects the brake system against excessive pressure. See section 4 Brakes, group 4.3.12 Valve block brake system.

3 4 5

11

6 7

10 9

015018

8



2.


3.


4.


5.


6.


7.


8.


9.



10.2.4 Pipes and hoses Pipes and hoses, general See Pipes and hoses, general, page 10:13.

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10 Common hydraulics – Tanks and accumulators

10:5

10.3 Tanks and accumulators 10.3.1 Hydraulic oil tank Tank, description 1

2

1

3

2

4

The hydraulic oil tank forms part of the side panel on the right-hand side of the machine. The oil filters for the working hydraulics are fitted inside the tank. These are accessible through hatches on top of the tank.

5

Hydraulic oil is filled directly into the tank through the filler caps on the filter manhole covers. For oil capacity and grade, see section F Technical data. The whole filter unit can be removed to facilitate access for cleaning. There is a drain plug located at the bottom of the tank. The tank is equipped with filtered breather that allows volume changes in the tank, due to temperature variations and use.

008086

The oil level is checked on the sight glass on the tank's side when all hydraulic cylinders are in the bottom position.

1.

Hydraulic oil filter cover

2.

Hydraulic oil filler plug

3.

Sight glass hydraulic oil

4.

Breather filter hydraulic oil tank

5.

Hydraulic oil drain plugs

10.3.2 Accumulator Accumulators, description 1

Brake system accumulators, see section 4 Brakes, group 4.3.4 Accumulator

2

014672

Accumulator lift, see section 7 Load handling, group 7.2.14 Accumulator lift

Accumulators 1.

Brake system accumulators

2.

Accumulator lift

10.3.4 Pipes and hoses Pipes and hoses, general See Pipes and hoses, general, page 10:13. Workshop Manual DCT 80-90

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10:6

10 Common hydraulics – Pumps

10.4 Pumps 10.4.1 Gear pump with fixed displacement Gear pump with fixed displacement, description 6

The hydraulic system is fed by two gear pumps with fixed displacement that are driven via the transmission's power take off. A pump feeds the brakes, steering and cooling circuit, the second feeds load handling.

1

The gear pumps pump oil by the two gears rotating against each other. One gear wheel is driven by the pump's input shaft and the other rotates freely. The gear wheel's movement creates suction between the gear wheels and the housing. Each turn of the gear wheels pumps a specific amount of oil (fixed displacement). The pump's flow varies with the speed of the input shaft. The pump shafts are plain bearing mounted and are lubricated by means of the through flowing oil. There are pressure plates on each side of the pump wheels that seal between the suction and pressure side.

2

5

000660

3 4 1.

Pump housing

2.

Outlet

3.

Drive wheel

4.

Gear cover

5.

Intake

6.

Trailing gear

NOTE It is very important that the clearance between the gears and between the gear and the housing is correct. Clearance that is too small creates wear damage. Clearance that is too large reduces the pump's power output.

Hydraulic oil pump brake and steering

1

The displacement, i.e. how many cubic centimetres of oil that the pump can deliver per pump revolution, differs on the various gear pumps.

Hydraulic oil pump brake and steering

2

Hydraulic oil pump brake and steering feds the servo brakes, parking brake and steering, the residual flow is used for cleaning and cooling. Distribution of the hydraulic power is handled by valve block accumulator charging and priority valve on the main valve, see, Main valve, description, page 10:14.

014671

For a more detailed description of the various functions see:

1.

Hydraulic oil pump for load handling

2.

Hydraulic oil pump for brake pressure, steering

VDCT01.02GB

•

Section 4 Brakes, group 4.3 Servo brake system.

•

Section 4 Brakes, group 4.5 Parking brake system.

•

Section 5 Steering, group 5.2 Power assisted system.

•

Temperature control, cleaning and hydraulic oil, function description, page 10:18.


10 Common hydraulics – Gear pump with fixed displacement

10:7

Hydraulic oil pump, load handling The load handling hydraulic oil pump feeds the load handling functions with hydraulic pressure. The lift, tilt and attachment control valve on the main valve distributes the hydraulic pressure between the various functions, see Main valve, description, page 10:14. For a more detailed description of the various functions see: •

Section 7 Load handling, group 7.2 Lifting/lowering.

•

Section 7 Load handling, group 7.4 Side shift.

•

Section 7 Load handling, group 7.5 Spreading.

•

Section 7 Load handling, group 7.7 Tilt.

•

Section 7 Load handling, group 7.9.1 Twistlocks.

Hydraulic oil pump brake and steering, checking


˚C


2


3

Depressurise the hydraulic systems, see section B Safety.

4

Connect a pressure gauge (0-25 MPa) to the measuring outlet pump pressure brakes and steering on the main valve.

5


000475

˚C

1

014649


Measuring outlet, pump pressure brake and steering [PM]


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10:8


6

Close the accumulator drain valve and check the pump pressure during charging.


014619

Check that the pressure rises to the specified feed pressure on the pressure plate. 7


8

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

9


015023


Pressure plate, pump pressure brakes and steering

NOTE

014619



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10:9

Load handling hydraulic oil pump, checking

˚C


2


3


4

Connect a pressure gauge (0-25 MPa) to the measuring outlet pump pressure load handling on the main valve.

5

Close the accumulator drain valve and the attachment relief valve.

6


000475

˚C

1

014650


014619

Measuring outlet, pump pressure load handling [P2]



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10:10


7

Check that the feed pressure corresponds with the pressure plate.

8

Turn off engine.

9


015024


Pressure plate, feed pressure load handling 11 Close accumulator drain valve.

NOTE

014619



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10:11

Gear pump with fixed displacement, replacement



2


3

Clean the hydraulic oil pumps and the areas around them.

4

Mark up and detach the hydraulic hoses from the pump.


Remove the pump. Remove the attaching bolts, pull the pump forward and lift it away.

6

Transfer the connection adapters to the new pump.

NOTE Check that the O-rings are intact, clean and in the correct position. Fastening screws hydraulic oil pump load handling

7

Check the seal between the pump and transmission, replace if necessary.

8

Fit the pump and check that the pump's splines engage in the shaft in the transmission. Fit the pump fastening screws, use locking fluid to lock the screws and seal the screw holes in the transmission.

9

Connect the hydraulic hoses in accordance with the markings.

NOTE Prefill the pump with oil through the pressure connection before it is put into service. Fastening screws hydraulic oil pump brake and steering

If necessary vent the pump before starting the engine by removing the hoses on the pressure side.



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10:12

10 Common hydraulics – Pipes and hoses

10 Close the accumulator drain valve and the attachment relief valve.

NOTE Check that the accumulator drain valve is fully closed and tighten the lock ring. 11 Turn on the system voltage and start the engine.

014619

12 Check that the hose connections are tight.

Close the accumulator drain valve 13 Check the hydraulic oil level with all hydraulic cylinders fully retracted. Top up if necessary.

NOTE If the pump is replaced due to malfunction, change the oil and filter in the hydraulic system as well.



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10 Common hydraulics – Hoses, pipes and valves

10:13

10.5 Hoses, pipes and valves 10.5.1 Pipes and hoses Pipes and hoses, general Hoses with ORFS couplings are used almost exclusively. For maximum service life and function, the following should be observed when replacing hoses. 1.

To avoid stresses in the connection, there should be a length of straight hose after the connection.

2.

The hose must not be twisted. (A twist of 7% reduces service life by 90%.)

3.

Minimise the number of bends by using correct couplings.

4.

Avoid sharp bends.

5.

Keep the hoses clean internally. Leave the plugs in place as long as possible when installing.

6.

Check the position of the O-rings and tighten to the correct torque, see section F Technical data.

NOTE Straight coupling requires a counterhold wrench to prevent damage to the O-ring. 7. Hose length

The O-rings must not be oiled when fitted.

Hose length

C/L

Hose length is measured on a hose laid out between the sealing surfaces. On angled connections, measure from the sealing surface's centre line [C/L] as illustrated.

Cleanliness The function and service life of hydraulic components depend to a great extent on how clean the hydraulic oil is. It is therefore very important to prevent dirt from entering the brake and hydraulic system.

001015

Some simple advice to keep the hydraulic system clean. •

Always clean the area around a component before starting to work.

•

Plug hose connections immediately after disconnecting. If possible, use correct plugs for the connection type. If plugs are missing, use clean plastic bags and cable ties or tape to seal the connection.

•

Never re-use oil that has been drained from the machine.

•

If possible, filter the oil before pouring it into the machine. Oil barrels often contain impurities.

C/L line for measuring hose length

When filling hydraulic oil, fill through the caps at the hydraulic oil filters in the tank so that the oil is filtered.


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10:14

10 Common hydraulics – Main valve

10.5.4 Main valve Main valve, description 1

2 3 4 5 6

28 7

27

8

26

9 10 11 25 24

12 23 22

13 21

14 20 19

18

17

16

015031

15

1.

Solenoid valve, lower (Y6004)

15. Connection servo valves [PP]

2.

Solenoid valve, lift (Y6005)

16. Measuring outlet servo pressure [PPM]

3.

Adjuster screw max pressure lift

17. Adjusting screw accumulator charging pressure

4.

Solenoid valve hydraulic pressure attachment (Y6012/Y6062)

18. Connection valve block brakes, accumulator charging [ACC]

5.

Solenoid valve, tilt in (Y6011)

19. Measuring outlet accumulator pressure [ACC M]

6.

Solenoid valve, tilt out (Y6010)

20. Adjusting screw servo pressure

7.

Adjuster screw max pressure tilt and attachment

8.


9.


21. Measuring outlet pump pressure brake and steering [PM] 22. Connection tilt cylinders, piston side 23. Connection tilt cylinders, rod side

10. Return to filter [D] 11. Measuring outlet control pressure [LSM] 12. Connection brake cooling [SPOL], to the drive axle block

24. Connection control valve, attachment 25. Connection lift cylinders, piston side 26. Feed hydraulic oil pump load handling [P2]

13. Connection control valve, pilot pressure [LSO]

27. Return to filter [D]

14. Feed control valve [O]

28. Measuring outlet, pump pressure load handling [P2]

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10:15

The main valve comprises lift, tilt and attachment control valve which is integrated with the valve block accumulator charging and priority valve.

Valve block accumulator charging and priority valve Valve block accumulator charging and priority valve controls the hydraulic pressure to the brakes, steering and cooling of the brakes and hydraulic oil. In addition, it supplies the valve block lift, tilt and attachment control valve with servo pressure. Accumulator charging valve The accumulator charging valve is a part of the valve block accumulator charging and priority valve located on the main valve and distributes oil from the hydraulic oil pump brakes and steering between pressure storage and cooling of the wheel brakes. See section 4 Brakes, group 4.3.3 Accumulator charging valve. Priority valve The priority valve is included in the valve block accumulator charging and priority valve located on the main valve. See section 5 Steering, group 5.2.2 Priority valve. Pressure reducer The pressure reducer is included in the valve block accumulator charging and priority valve located on the main valve. See section 7 Load handling, group 7.2.3 Pressure reducer.

Lift, tilt and attachment control valve The control valve is the second part of the main valve and controls the hydraulic pressure to the lift and tilt cylinders and to the attachment control valve. See section 7 Load handling, group 7.2.5 Lift, tilt and attachment control valve, 7.4.9 Lift, tilt and attachment control valve and 7.7.5 Lift, tilt and attachment control valve.


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10:16


Main valve, replacement



2

Depressurise the hydraulic systems, see section B Safety.

3

Place a container tray under the main valve and remove the cover that sits over the main valve.

4

Mark up and detach the hydraulic hoses from the main valve.


Mark up and detach the wiring from the main valve.

6

Remove the fastening screws and lift off the main valve. Place the valve on a clean and protected surface.

7

Transfer the connection adapters to the new main valve.


015103

NOTE Transfer one connection at a time so that the marking is not mixed up.

Main valve 8

Mark up the solenoid valves on the new main valve.

9

Lift the main valve into place and fit the fastening screws.

10 Connect the hydraulic hoses to the main valve in accordance with the marking.

NOTE Check that the O-rings are intact, clean and in the correct position. 11 Connect the cable harness to the main valve in accordance with the marking.

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10:17

12 Close the accumulator drain valve and the attachment relief valve.

NOTE Check that the accumulator drain valve is fully closed and tighten the lock ring. 13 Turn on the main electric power and start the engine. 14 Check that the valve\qs hydraulic connections are sealed. 15 Bleed the brakes, see section 4 Brakes, group 4.3.9 Wheel brakes.

014619

16 Check the steering Activate the steering gradually to bleed the steering's hydraulic circuit.


CAUTION Air in the hydraulic system may cavitate and result in product damage. Activate the steering carefully and operate at the lowest possible speed a couple of times to avoid cavitation. 17 Check that the attachment is working. Activate the lift function, tilt function and the attachment functions gradually to bleed the hydraulic circuits. 18 Check the supply pressure to the brakes and steering, see Hydraulic oil pump brake and steering, checking, page 10:7. 19 Check the supply pressure to the load-handling functions, see Load handling hydraulic oil pump, checking, page 10:9. 20 Check the accumulator charging pressure, see 4 Brakes, group 4.3.3 Accumulator charging valve. 21 Check the brake pressure, see 4 Brakes, group 4.3.5 Brake valve. 22 Check the steering pressure, see 5 Steering, group 5.2.1 Hydraulic oil pump. 23 Check the servo pressure, see 7 Load handling, group 7.2.3 Pressure reducer. 24 Remove the container tray and replace the cover over the main valve. 25 Check the oil level in hydraulic oil tank with all hydraulic cylinders in the retracted position. The oil level should be at the top of the sight glass. Top up if necessary.

CAUTION Do not overfill! Leakage and environmental damage! Check the hydraulic oil level with all hydraulic cylinders fully retracted. 26 Test drive the machine and check that all functions work correctly.


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10:18

10 Common hydraulics – Temperature control, cleaning and hydraulic oil

10.6 Temperature control, cleaning and hydraulic oil Temperature control, cleaning and hydraulic oil, function description The hydraulic system's oil is cooled and purified by it circulating through the wheel brakes, cooler and filters. The cooler has a temperature-regulated electric fan that prevents overheating. Temperature control consists of a hydraulic oil tank, hydraulic oil pump, valve block, hydraulic oil cooler, cooling fan, hydraulic oil filter, fine filter, hydraulic oil temperature sensor and bypass valve. Hydraulic oil pump brakes and steering pumps oil (from the tank) through the brake system's cooling circuit to be cooled in the hydraulic oil cooler. Some of the oil is filtered by the fine filter. An electric cooling fan increases the air flow through the cooler when the temperature needs to be lowered. A bypass valve opens when the oil is cold and leads the oil directly to the tank in order that the resistance through the cooler and filter should not be too high. The bypass valve closes when the oil gets hot and then leads the oil through the cooler and filter instead. The temperature sensor controls fan activation and temperature display. Excess oil from brakes and steering, and the return oil from load handling is filtered by the hydraulic oil filter in the hydraulic oil tank.

10, 16

D795

D790-2 D797-1

D

2

18

15

9, 1 1, 14 4

C SPOL

D

19

P

3

5

7 C 13

17

6

1

8 °C

20

Pos

Explanation

Signal description

Reference

1

Hydraulic oil pump for the brakes and steering pumps oil from the hydraulic oil tank.


Gear pump with fixed displacement, description, page 10:6

2

Valve block accumulator charging and priority valve directs the oil to the steering, charging of the accumulators, hydraulic oil filter or through the hydraulic system's cooling circuit. Excess oil is led to the hydraulic oil filter.

P < 0.3 MPa

See section 4 Brakes, group 4.3.3 Accumulator charging valve

VDCT01.02GB


015037

C

M

12

P2

10 Common hydraulics – Temperature control, cleaning and hydraulic oil

10:19

Pos

Explanation

Signal description

Reference

3

The hydraulic oil filter cleans the oil.

-

Hydraulic oil filter, description, page 10:24

4

Hydraulic oil in the cooling circuit passes through the drive axle block to the wheel brakes.

-

See section 4 Brakes, group 4.3.6 Drive axle block

5

The hydraulic oil cools the wheel brakes.

-

See section 4 Brakes, group 4.3.9 Wheel brakes.

6

A small amount of oil is guided through the fine filter and back to the hydraulic oil tank.

7

The hydraulic oil cooler cools the oil.

-

Hydraulic oil cooler, description, page 10:20

8

The hydraulic oil temperature sensor (B776) sends the frame control unit (D797-1) a voltage signal proportional to the hydraulic oil temperature.

-

Sensor, hydraulic oil temperature, description, page 10:21

The frame control unit (D797-1) transmits oil temperature on the CAN bus.

Checked by the control system, error indicated with error code.

9

Fine filter hydraulic oil, description, page 10:27

D8: Diagnostic menu, see section 8 Control system, group 8.4.5.1 HYD, menu 1 Section 11 Common electrics, group 11.5.3.2 Frame control unit D8: Diagnostic menu, see section 8 Control system, group 8.4.5.1 HYD, menu 1

10

The KID control unit (D795) shows oil temperature in the operating menu hydraulic oil temperature.

-

Section 9 Frame, body, cab and accessories, group 9.1 Controls and instruments.

11

If the hydraulic oil temperature is high, the frame control unit (D797-1) supplies voltage to the Cooling fan (M668).

U = 24 V

Cooling fan, description, page 10:21

12

The cooling fan (M668) increases the airflow through the hydraulic oil cooler, thus increasing cooling output

-

Cooling fan, description, page 10:21

13

If the oil temperature is low or the pressure through the cooler becomes too high, the bypass valve opens and leads the oil past the cooler.

P = 0.2 MPa

Bypass valve, cooler, description, page 10:23

14

If the hydraulic oil temperature is too high, the frame control unit (D797-1) transmits a warning for high hydraulic oil temperature on the CAN bus.

Checked by the control system; error shown with error code.


15

The KIT control unit (D790-2) activates the hydraulic oil temperature warning light.

-

Section 9 Frame, body, cab and accessories, group 9.1 Controls and instruments.

16

The KID control unit (D795) shows the error code on the display.

Checked by the control system; error shown with error code.


17

The hydraulic oil pump load handling pumps oil to lift, tilt and attachment control valve.

-

Gear pump with fixed displacement, description, page 10:6

18

Lift, tilt and attachment control valve leads the return oil from load handling to the hydraulic oil filter.

-

Section 7 Load handling, group7.2.3 Lift, tilt and attachment control valve

19

The hydraulic oil filter cleans the oil.

-

Hydraulic oil filter, description, page 10:24



Hydraulic diagram, see section E Schematics group 10 Common hydraulics, Hydraulic diagram. Workshop Manual DCT 80-90

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10:20

10 Common hydraulics – Cooler hydraulic oil

10.6.2 Cooler hydraulic oil Hydraulic oil cooler, description

009989

The hydraulics use a flow-through cooler with electric cooling fan. The oil is cooled when it passes through the cooler. The cooler is fitted inside the side panel on the right-hand side behind the hydraulic oil tank.

Hydraulic oil cooler, replacement



2

Drain the oil from the hydraulic oil tank, see Hydraulic oil, changing, page 10:26.

3

Mark up and detach the hydraulic hoses from the cooler. Let the oil in the cooler drain into the receptacle.

1

NOTE

2


009990

3

1.

Cooling fan

2.

Hydraulic connections

3.

Radiator

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4

Disconnect the cable harness from the cooling fan.

5

Remove the attaching bolts and lift away the cooler.

6

Transfer the cooling fan to the new cooler.

7

Fit the cooler.

8

Connect the cable harness to the cooling fan.

9

Connect the hydraulic hoses to the cooler.



10 Common hydraulics – Cooling fan

10:21

10 Fill oil in the hydraulic oil tank, see Hydraulic oil, changing, page 10:26. The oil level should be visible in the sight glass.

CAUTION Do not overfill! Leakage and environmental damage! The hydraulic oil level is checked with the boom completely lowered and retracted.

10.6.3 Cooling fan Cooling fan, description The electric cooling fan is drawing. The cooling fan is located at the rear of the cooler. The fan draws air from the machine's outside through the cooler. Openings in the side cover allows air to pass through the cooler. The cooler is supplied with voltage by the frame control unit (D797-1) at activation. The cooling fan is activated when oil temperature is 65 °C in the hydraulic oil tank and the fan is deactivated when oil temperature is 55 °C.

009991


10.6.4 Sensor hydraulic oil temperature Sensor, hydraulic oil temperature, description Sensor, hydraulic oil temperature (B776) detects the temperature of the hydraulic oil. The sensor is fitted on the hydraulic oil tank's rear short side. The sensor detects the oil temperature in the tank, and therefore takes into account the accumulated heat in the hydraulic oil. Because of this, the cooling fan may continue to run after the machine has been parked and switched off provided that the system voltage is not disconnected.

009992

The hydraulic oil temperature sensor (B776) is supplied voltage by the frame control unit (D797-1) and sends the control unit a voltage signal proportional to oil temperature. The signal can be checked via the diagnostic menu. See section 8 Control system, group 8.4.5.1 HYD, menu 1.


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10:22

10 Common hydraulics – Sensor hydraulic oil temperature

Sensor, hydraulic oil temperature, replacement



2


3

Disconnect the cable harness from Sensor, hydraulic oil temperature (B776).

4

Replace Sensor, hydraulic oil temperature (B776).

NOTE Check that the O-rings are intact, clean and in the correct position. Connect the cable harness to the sensor.

6

Fill oil in the hydraulic oil tank, see Hydraulic oil, changing, page 10:26. The oil level should be visible in the sight glass.

009992

5

Sensor, hydraulic oil temperature (B776)


7

1(6) XXX XY

Use the display, go to the diagnostic menu, see section 8 Control system, group 8.4.5.1 HYD, menu 1. TEMP indicates hydraulic oil temperature in ºC. Check that correct temperature is shown.

000141

DIAG HYD HYDRAULIC OIL TEMP FAN Diagnostic menu HYD, menu 1

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10 Common hydraulics – Bypass valve, cooler

10:23

10.6.5 Bypass valve, cooler Bypass valve, cooler, description

009993

The bypass valve protects the cooler against excess pressure and boosts the heating of the hydraulic oil by opening a passage past the cooler directly to the tank if the resistance in the cooler is too great or if the temperature is too low.

Bypass valve

Bypass valve, cooler, replacement


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


3


4

Disconnect the bypass valve from the tank.

NOTE Note how the bypass valve faces; the valve is marked with an arrow.

009993

5

Install the new bypass valve, turning the valve to face the same way as the old one. Use Loctite when fitting the bypass valve.

Bypass valve


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10:24

10 Common hydraulics – Breather filter hydraulic oil tank

6

Fill oil in the hydraulic oil tank, see Hydraulic oil, changing, page 10:26. The oil level should be visible in the sight glass.


10.6.6 Breather filter hydraulic oil tank Breather filter hydraulic oil tank, description

009970

A breather filter of insert type is mounted on the hydraulic oil tank to protect the tank from impurities. On the top of the filter housing is an indicator that shows when the filter is clogged and needs to be changed.

10.6.7 Hydraulic oil filter Hydraulic oil filter, description

009994

The oil in the hydraulic system is cleaned by two return filters fitted inside the hydraulic oil tank. The return oil from the load handling functions and excess oil from brakes and steering goes through the filters back to the hydraulic oil tank.

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10 Common hydraulics – Hydraulic oil filter

10:25

Hydraulic oil filter, replacement


IMPORTANT Ensure cleanliness around the filter and filling point when working on the hydraulic tank. Dirt particles may cause machine damage. 1


2 On machines with a raised cab: Remove the footstep over the covers and clean the covers and the area around them.

2

1

3

2

4

3

Remove the cover plates (position 1) over the hydraulic oil filters.

4

Lift up the filter unit and place it in the receptacle. Let the hydraulic oil drain.

5

Separate the filter unit and remove the filter insert. Handle the filter insert as environmentally hazardous waste. Note the position of the parts.

6

Clean the filter holder's parts. Be especially thorough with the magnetic rod.

7

Fit the new filters and assemble the filter units.

8

Install the filter units and the covers. Tighten the screws crosswise.

008084

1

1.


2.

Filling point hydraulic oil

3.


4.


9 On machines with a raised cab: Refit the footstep over the covers. 10 Check the oil level, see Hydraulic oil, level check, page 10:26. Magnetic rod


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10:26

10 Common hydraulics – Hydraulic oil

10.6.8 Hydraulic oil Hydraulic oil, level check

NOTE The oil level is checked with the mast down and the attachment in the 20-foot position. 1

Machine in service position, section B Safety.

2

Check the oil level in the hydraulic oil tank. The oil level should be in the centre of the sight glass. Top up the oil if necessary. For the oil grade, see section F Technical data.

Hydraulic oil, changing


IMPORTANT Ensure cleanliness around the filter and filling point when working on the hydraulic tank. Dirt particles may cause machine damage.

1

2

1

3

2

4

1


2

Remove the filler cap and pump out the hydraulic oil into a receptacle.

3

When as much oil as possible has been pumped out. Place a receptacle under the hydraulic oil tank's drain plug and drain the last of the hydraulic oil.

4

Fit the drain plug when the oil has drained out.

008084

NOTE 1.


2.

Filling point hydraulic oil

3.


4.


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Make sure that the seal washer for the drain plug is fitted as well. 5

If the hydraulic oil filters are to be changed, change them before filling the tank with oil, see Hydraulic oil filter, replacement, page 10:25.


10 Common hydraulics – Pipes and hoses

6

10:27

Fill new hydraulic oil through the filler holes on the filters' covers. This results in the filtering of the oil that is filled and protects the hydraulic system from impurities. Fill oil until the oil level is in the middle of the sight glass. For volume and quality, see section F Technical data.



10.6.10 Fine filter hydraulic oil Fine filter hydraulic oil, description The fine filter is located behind the hydraulic oil tank on the machine's right-hand side. The filter is connected in parallel with the hydraulic oil cooler. Some of the oil from the cooling circuit passes through the fine filter and then back to the hydraulic oil tank.

009968

The fine filter cleans a smaller amount of oil but with a higher degree of filtration when the machine is running.


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10:28

10 Common hydraulics – Fine filter hydraulic oil

Fine filter hydraulic oil, replacement


IMPORTANT Ensure cleanliness around the filter and filling point when working on the hydraulic tank. Dirt particles may cause machine damage.

VDCT01.02GB

1


2

Remove the cover.

3

Take out a collection vessel.

4

Lift up the filter insert and place it in the receptacle. Let the hydraulic oil drain.

5

Fit the new filter insert and refit the cover over the fine filter.


10 Common hydraulics – Other

10:29

10.7 Other 10.7.1 Hydraulic cylinders Hydraulic cylinders, repairs Fault tracing, leakage

Fault tracing, leakage

CAUTION All fault tracing should be carried out with as low a pressure in the system as possible so that the leakage can be detected. High pressure causes the seals to close tighter, which prevents detection of leaks.

1.

Carefully check the source of the leakage before taking any action. It may be possible to rectify the fault without disassembly.

2.

Check for external leakage: •

At cylinder face end welds

•

At sleeve coupling welds

•

Between cylinder barrel and cylinder head This could be due to a defective O-ring or damaged O-ring sealing surfaces. Both faults can be rectified with the cylinder in situ.

•

Between cylinder head and piston rod This could be due to a damaged piston rod or damaged or worn piston rod seal.

3.

Check for internal leakage. Pressurise the cylinder and check whether the piston sinks back. This could be due to a worn piston seal.

1.

Piston rod

2.

Scraper

3.

Cylinder head

4.

Piston rod seal

5.

O-ring with support ring

6.

Cylinder barrel

7.

Sleeve coupling

8.

Welded cylinder end face

9.

Piston

10. Piston seal, double-acting 11. Example of weld


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10:30

10 Common hydraulics – Hydraulic cylinders

Dismantling of cylinders

CAUTION Before dismantling always check that the piston rod is clean and free from all residual paint. Also check that connections and couplings are free from burrs and impact marks. Make sure that the chamfer up to the chromium surface of the piston rod is free from burrs and residual paint. 1

Remove the cylinder from its mounting and undo the connections.

2

Plug the cylinder connections and hoses without delay.

3

If the cylinder is opened - observe the strictest cleanliness!

Inspection of surfaces Inspect the sealing surfaces. Always bearing mind the function of the seals and the type of sealing surfaces they have. See the following descriptions: •

O-ring groove, internal and external

•

piston rod seal in the cylinder head

•

sealing groove on the piston

•

cylinder barrel surface

•

piston rod surface. The piston rod is chromium plated with a layer thickness of 20-50 my. Slight damage to the chromium plating may not necessarily cause leakage directly.

•

all slide surfaces (dynamic surfaces), e.g. cylinder barrel and piston rod. These are always the hardest to seal.

CAUTION When fitting the cylinder head: Get it absolutely straight. This is best done by hand. Under no circumstances hit it with a mallet of any type. If the cylinder head is fitted crooked, the sealing lip of the piston rod seal could be damaged, making an improper seal. This applies to all types of piston rod seals.

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10:31

Function and removal of the seals Piston rod seal

Piston rod seal

2

The piston rod seal is the seal that sits in the groove in the cylinder head and seals against the piston rod. This seal is very exposed to wear since it is both a dynamic and a static seal, i.e. it seals against a moving surface on the piston rod while the sealing surface with the cylinder head is fixed. There are different types of piston rod seals:

1

3

6

001497

4

5 1.

Hydraulic pressure

2.

Seal lip pressed out toward piston rod

3.

Seal lip pressed inward toward cylinder head

4.

Sealing surface, piston rod

5.

Sealing surface, cylinder head

6.

Screwdriver

•

Single V-seal

•

Pre-stressed V-seal with support ring

•

Compressible seal

The single V-seal has a V-shaped section with two lips that seal in opposite directions. The hydraulic pressure acts in the V-shape, pressing the sealing lips out towards the sealing surfaces on the piston rod and in the cylinder barrel. Even minor damage to the sealing lips can generate large leaks. Examine the sealing lips by carefully using a fingernail to feel around the seal. To remove, use a screwdriver to prise the seal outward and bend it up (see illustration). It is extremely important that the screwdriver is always inserted in the V-shape so that it cannot touch and thereby damage a sealing surface. A mark from a screwdriver on a sealing surface can have a devastating effect and cause major leakage.


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10:32


The pretensioned V-seal also has an O-ring in the seal's V-shaped space. The O-ring creates a strong seal at low hydraulic pressure since the O-ring already presses the sealing lips out toward the sealing surfaces when unloaded. It is just as sensitive to damage as the V-seal. Examine in the same manner. To remove, use a screwdriver to prise the seal outward and bend it up (see illustration). It is extremely important that the screwdriver is always inserted in the V-shape so that it cannot touch and thereby damage a sealing surface. A mark from a screwdriver on a sealing surface can have a devastating effect and cause major leakage.

2 1

3

7

001498

4

6

5 1.

Hydraulic pressure

2.


3.


4.


5.


6.

Screwdriver

7.

O-ring The compressible piston rod seal consists of a solid rubber profile and provides a larger sealing surface than the V-seals. To remove, use a screwdriver to prise the seal outward and bend it up (see illustration). With this type of seal with sealing surfaces that cover so much of the seal groove, it is particularly important that marks are not made with the screwdriver.

2 1 3

3 6

4

001499

5

5 1.

Hydraulic pressure

2.


3.


4.


5.


6.

Screwdriver

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Support ring and O-ring

10:33

Support ring and O-ring The support ring and O-ring combination is used for sealing between two fixed surfaces, such as between cylinder barrel and cylinder head. The purpose of the support ring is to lend rigidity to the O-ring so that it is not deformed. The O-ring is pressed against the support ring and the sealing surface by the hydraulic pressure in the cylinder.

3

When the cylinder head is mounted in the barrel: Take extreme care not to damage the O-ring.

4

1 1.

Hydraulic pressure

2.

O-ring

3.

Support ring

4.


001506

2

Scraper

Scraper

øD+10 1

The purpose of the scraper is to scrape the piston rod clean and prevent impurities from entering the cylinder barrel.

2

The scraper must be fitted with a special fitting tool. This tool must have a greater outer diameter than the scraper so that the press force against the scraper ceases precisely when the scraper is pressed into its position. If the scraper were to be pressed in further, the metal capsule would be deformed (see lower illustration), which would impair the function of the scraper.

4

To prevent the scraper from bottoming in its recess in the cylinder head, the recess is slightly deeper than the width of the scraper.

3 øD 5

001496

6

1.

Correct assembly tool

2.

Scraper, correctly fitted

3.

Cylinder head

4.

Clearance between scraper and bottom of cylinder head recess

5.

Incorrect assembly tool

6.

Deformed scraper


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10:34


A screwdriver can be used for removal. This must always be applied against the outer edge of the scraper (see illustration). Carefully tap the screwdriver down between the scraper and the cylinder head and then prise out the scraper. Polish away any damage to the cylinder head.

1 2

CAUTION No tool may be applied from the inside. This could give rise to burrs on the cylinder head which could in turn damage the piston rod. Burrs may also damage the piston rod seal when fitting the piston. 001551

3

1.

Screwdriver

2.

Scraper

3.

Cylinder head On the single-acting V-seal it is always the long side that seals against the fixed surface and the short side that seals against the moving surface.

2

To remove, use a screwdriver to prise the seal outward and bend it up (see illustration). It is extremely important that the screwdriver is always inserted in the V-shape so that it cannot touch and thereby damage a sealing surface. A mark from a screwdriver on a sealing surface can have a devastating effect and cause major leakage.

1

3

002370

4

6

5 1.

Hydraulic pressure

2.

Seal pressed out toward cylinder barrel

3.

Seal pressed in toward piston

4.

Sealing surface, cylinder barrel

5.

Sealing surface, piston

6.

Screwdriver

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10:35

The seal must always be fitted as a single assembly together with the support ring. Always assemble by hand. No tools should be used as they could easily damage the surface of the piston. To facilitate assembly the seal can be heated in hot water to make it soft.

002950

Lubricate with hydraulic oil.

Double-acting piston seal

5

4

3

Double-acting piston seal

6

1

The double-acting seal functions with pressure from both sides, e.g. in a steering cylinder. All of the interior surface of the cylinder barrel is a sealing surface and it is therefore extremely important that it is completely free from damage. 002951

2 1.

Variable sealing surface to cylinder barrel

2.

Fixed sealing surface with piston

3.

Guide ring

4.

Support ring

5.

Piston head

6.

Cylinder barrel

Exercise caution when fitting the piston in the cylinder barrel, making sure that the seal is not damaged by the cylinder barrel threads.

Dismantling: 1

Remove guide rings and support rings.

2

Move the seal body over to one side of the sealing groove.

3

Press up the material so that there is a gap between seal and piston.

4

Without damaging the surface of the piston - cut off the seal with a knife.

5

Carefully examine the seal to find any damage that could cause leakage. This will be easier if you bend the seal sharply bit by bit and feel over the sealing surface with a fingernail.

Assembly: 1

All double-acting piston seals are of similar design: a middle seal body, then support rings and farthest out guide rings.

2

First fit the seal body, then the support rings and finally the guide rings - all must be done by hand without tools to avoid damage.


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10:36


Repairing the piston rod surface

1

2

A small impact mark on a piston rod may be sufficient to cause leakage. The chromium plating on the piston rod has a thickness of 20-50 micrometres and can be treated to make good minor damage. This may be a satisfactory alternative to costly disassembly. 1 Locate the damage using your fingertips and fingernails.

3

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 damage.

5

It is important to treat small impact marks before disassembly and assembly to avoid damaging the cylinder head.

6

Repairing larger damage on a piston rod: •

fill the damage with weld metal, use chromium or stainless steel electrodes

•

remove all slag completely

•

file the weld down to the same level as the chrome

•

polish evenly using emery cloth.

002952

4

2

1.

Piston rod

2.

Chromium plating

3.

Impact mark

4.

Highly-polished hammer

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10:37

Dismantling the steering cylinders It can prove extremely difficult to extract the piston rod from the cylinder barrel on steering cylinders. This is because the O-ring in the cylinder head fastens in the lock ring groove in the cylinder barrel. It is therefore best to remove the O-ring before trying to withdraw the piston rod from the cylinder. 1 Unscrew the end washer at the cylinder head. 2

Unscrew the connecting nipple for the hydraulic hose.

3

Insert the piston rod with piston crown until the O-ring is visible through the nipple hole.

4

Bend the end of a length of heavy-duty steel wire, piano wire or similar into the shape of a hook. Use this to snag the O-ring.

5

Pull the O-ring up slightly and hold it with a pair of needle-nose pliers.

6

Continue to pull the O-ring out through the hole.

7

Hold the O-ring steady and cut it with a knife.

8

Rotate the piston rod while pulling the O-ring out through the hole.

9

Remove the lock ring from the cylinder barrel.

002953

10 Carefully extract the piston rod from the cylinder barrel.


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10:38

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11:1

11 Common electrics

Contents 11 Common electrics 11 Common electrics ............................................................................................11:3 11.2 Electric protection .......................................................................................... 11:3 11.2.1 Battery disconnector ................................................................................. 11:3 11.2.2 Fuses ........................................................................................................ 11:3 11.2.3 Control breaker ......................................................................................... 11:3 11.3 Batteries......................................................................................................... 11:4 11.3.1 Start battery............................................................................................... 11:4 11.4 Alternator ....................................................................................................... 11:6 11.4.1 Alternator................................................................................................... 11:6 11.5 Distribution of electricity ................................................................................. 11:7 11.5.1 Voltage feed .............................................................................................. 11:7 11.5.2 Electronic box.......................................................................................... 11:14 11.5.3 Control units ............................................................................................ 11:16 11.5.5 Cable harness ......................................................................................... 11:25 11.6 Communication ............................................................................................ 11:34 11.6.1 CAN bus .................................................................................................. 11:34 11.6.2 Redundant CAN bus ............................................................................... 11:36 11.6.3 CAN bus drive-train ................................................................................. 11:38 11.6.4 Communication between PC and machine ............................................. 11:39


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11:2

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11 Common electrics – Common electrics

11:3

11 Common electrics 11.2 Electric protection 11.2.1 Battery disconnector Battery disconnector, description The positive terminals of the batteries connected in series are connected to the machine's electrical system via the battery disconnector. The battery disconnector cuts off all power from the batteries to the machine's electrical system.

A

IMPORTANT Never switch off the voltage with the battery disconnector when the engine is running. This could damage the alternator.

010051

The battery disconnector must not be used as control breaker!

A

Position of battery disconnector

11.2.2 Fuses Fuses, changing When checking and changing the main fuse: 1 Switch off the system voltage (battery disconnector). 2 3

Remove the plastic cover. Check that the fuses are intact. Replace if necessary. The fuses are 25 A or 50 A.

When checking and changing fuses: 1 Switch off the system voltage (battery disconnector). 2

Remove the cover from the electronic box.

3

Check and, if necessary, replace fuses. The fuse plate gives information about each fuse.

11.2.3 Control breaker Emergency stop switch, description See Emergency stop switch voltage (15E), function description, page 11:11.


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11:4

11 Common electrics – Batteries

11.3 Batteries 11.3.1 Start battery Start battery, description The machine's electrical system is supplied by two 12 V batteries connected in series. The negative terminal is connected to the frame. The positive terminal is connected to the battery disconnector. The batteries are charged by the alternator, see Alternator, description (engine alternative Yuchai YC6A240-30), page 11:6 or Alternator, description (engine alternative Cummins QSB6.7

), page 11:6.

WARNING Battery electrolyte contains corrosive sulphuric acid. Risk of corrosive injuries! Health hazard! Use protective glasses and protective gloves when working with the batteries. Immediately remove any electrolyte on bare skin. Wash with soap and plenty of water. If the electrolyte has found its way into your eyes, rinse immediately with lots of water and contact a doctor immediately.

WARNING Risk of explosion! Personal injury! During charging, hydrogen gas forms around the batteries. Sparks could ignite the hydrogen gas, causing an explosion. Disconnect the battery with the battery disconnector.

WARNING Short-circuiting of battery. Risk of explosion! Fire hazard! Risk of personal injury! The battery's terminals must not be connected to each other or to common grounding point (chassis).

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11 Common electrics – Start battery

11:5

Start battery, replacement 1


2

Disconnect the cables from the battery terminals. Start with the negative (minus) cable.

3

Replace the batteries.

4

Connect the cables to the battery terminals. Connect the negative cable last of all.

NOTE Take great care when reconnecting the cables to prevent short circuiting.


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11:6

11 Common electrics – Alternator

11.4 Alternator 11.4.1 Alternator Alternator, description (engine alternative Yuchai YC6A240-30) The alternator generates current during operation and supplies this to the batteries. The alternator produces AC current and has an integrated charge regulator. The alternator is driven by the engine via a belt. Faults are indicated by the warning lamp for low battery charging.

015061

The signal can be checked via the diagnostic menu, section 8 Control system, section 8.4.6.4 ENGINE, menu 4.

Alternator, description (engine alternative Cummins QSB6.7 ) The alternator generates current during operation and supplies this to the batteries. The alternator produces AC current and has an integrated charge regulator. The alternator is driven by the engine via a belt. Faults are indicated by the warning lamp for low battery charging.

010052

The signal can be checked via the diagnostic menu, section 8 Control system, section 8.4.6.4 ENGINE, menu 4.

Alternator, replacement See supplier documentation, engine.

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11 Common electrics – Distribution of electricity

11:7

11.5 Distribution of electricity 11.5.1 Voltage feed 11.5.1.2 Redundant voltage feed of control units Redundant voltage feed of control units, function description 1

2

3

D1

4 D3

D4

D2 D794

D793

+

D8

D790-1

D791

5, 6

8

9 D795

7 D797-1

D790-2

D9

0015056

-

D7

Pos

Explanation

Signal description

Reference

1

The NC switch, operator's door (S 266-LE) or the NC switch, passenger door (S 266-RI) sends a voltage signal to the cab control unit (D790-1) when the door is opened.

U = 24 V

Section 9 Frame, body, cab and accessories, group 9.10.2 Doors

The interior lighting switch of the KIT control unit (D790-2) sends a voltage signal to the cab control unit (D790-1).

U = 24 V

Switch, flashing hazard lights (S109) sends a voltage signal to Control unit, cab (D790-1).

U = 24 V

When the ignition switch (S150) is turned to position I, it sends a voltage signal to the cab control unit (D790-1).

U = 24 V

Control unit, cab (D790-1) activates a hold circuit, which activates the control unit's control logic.

-

2

3

4

5

D1: Diagnostic menu, see section 8 Control system, group 8.4.2.9 LIGHTS, menu 9 or 8.4.11.5 MOVE-CAB, menu 1 Section 9 Frame, body, cab and accessories, group 9.6.12 Interior lighting D2: Diagnostic menu, see section 8 Control system, group 8.4.2.13 LIGHTS, menu 13 Section 9 Frame, body, cab and accessories, group 9.6.7 Flashing hazard lights D3: Diagnostic menu, see section 8 Control system, group 8.4.2.5 LIGHTS, menu 5 Section 9 Frame, body, cab and accessories, group 9.1 Controls and instruments D4: Diagnostic menu, see section 8 Control system, group 8.4.1.5 CAN/POWER, menu 5 Cab control unit, description, page 11:17


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11:8

11 Common electrics – Voltage feed

Pos

Explanation

Signal description

Reference

6

Control unit, cab (D790-1) activates a redundant voltage feed to other control units.

UK11:7 = 24 V

Cab control unit, description, page 11:17

Control unit, cab (D790-1) has 4 outputs for redundant voltage feed while other control units have two inputs for redundant voltage feed. In the event of a malfunction of one voltage feed the control unit is supplied by the other feed. 7

Control unit, cab (D790-1) supplies voltage to the control logic of the other control units via the redundant voltage feed.

8

9

VDCT01.02GB

U

K11:8

= 24 V

UK11:9 = 24 V UK11:10 = 24 V

UK2:7 = 24 V

Frame control unit, description, page 11:18

UK2:8 = 24 V


UK2:7 = 24 V

Control unit, attachment, description, page 11:19

UK2:8 = 24 V


UK2:7 = 24 V

D9: Control unit KID, description, page 11:24

UK2:8 = 24 V

Diagnostic menu, see section 8 Control system, group 8.4.1.9 CAN/POWER, menu 9



11:9

11.5.1.3 Ignition voltage (15) Ignition voltage (15), function description Condition

Reference value

Reference

Battery disconnector

In position 1

Battery disconnector, description, page 11:3

Redundant voltage feed

Activated.

Redundant voltage feed of control units, function description , page 11:7

Redundant CAN bus

Communication established.

Redundant CAN bus, description, page 11:36

1 D1

+ K315-2

2

K315-1 D3

D2

3, 6

7

3

D794

D793 10

4, 5

D10

D8 D790-1

D791

2, 8 9 D790-2

D797-1 015054

D795

D9 Pos

Explanation

Signal description

Reference

1

Switch, flashing hazard lights (S109) sends a voltage signal to Control unit, cab (D790-1).

U = 24 V

Section 9 Frame, body, cab and accessories, group 9.6.7 Flashing hazard lights

When the ignition switch (S150) is turned to position I, it sends a voltage signal to the cab control unit (D790-1).

U = 24 V

Cab control unit (D790-1) voltage feeds the ignition key lock power relay K315-1 and the ignition voltage relay K315-2 in the frame electronic box.

U = 24 V

4

Relay, ignition voltage K315-1 supplies voltage to fuse holder in the cab electronic box and in the frame electronic box.

U = 24 V

-

5

The fuses feed voltage to control units, relays, solenoid valves and other electronic components.

U = 24 V

-

2

3

D1: Diagnostic menu, see section 8 Control system, group 8.4.2.5 LIGHTS, menu 5 Section 9 Frame, body, cab and accessories, group 9.1 Controls and instruments D2: Diagnostic menu, see section 8 Control system, group 8.4.1.5 CAN/POWER, menu 5 Cab control unit, description, page 11:17 D3: Diagnostic menu, see section 8 Control system, group 8.4.1.5 CAN/POWER, menu 5


VDCT01.02GB

11:10


Pos

Explanation

Signal description

Reference

6

Relay, ignition voltage K315-2 supplies voltage to Control unit, engine (D794).

U = 24 V

Control unit, engine, description (engine alternative Yuchaii YC6A240-30), page 11:21. Control unit, engine, description (engine alternative Cummins QSB6.7

), page 11:22.

7

The drive-train's CAN-bus establishes communication.


CAN bus drive-train, description, page 11:38

8

Ignition voltage to Control unit, cab (D790-1).

UK1:2 = 24 V


UK1:3 = 24 V


UK1:4 = 24 V

9

Ignition voltage to the frame control unit (D797-1).

UK2:1 = 24 V

Frame control unit, description, page 11:18

UK2:9 = 24 V


UK2:10 = 24 V 10

Ignition voltage to Control unit, transmission (D793).

VDCT01.02GB

UA1 = 24 V

Control unit, transmission, description, page 11:20 D10: Diagnostic menu, see section 8 Control system, group 8.4.1.12 CAN/POWER, menu 12



11:11

11.5.1.4 Emergency stop switch voltage (15E) Emergency stop switch voltage (15E), function description Condition

Reference value

Reference


Activated.


Ignition voltage

Activated.

Ignition voltage (15), function description, page 11:9

Control breaker

Not activated


D794 D793 D5 K3009-1

-

K3007 6

3, 4

K3009-2

+

K3002

D4 D2

D7 D790-1

D797-1

1, 2, 5 D790-2

015055

D795

7 D791

Pos

Explanation

Signal description

Reference

1

Ignition voltage is activated by the cab control unit (D790-1)


Ignition voltage (15), function description, page 11:9

2

Control unit, cab (D790-1) supplies voltage to Relay, emergency stop switch voltage (K3009-1) in the frame electronic box.

UK3009-1/86 = 24 V


3

Relay, emergency stop switch voltage (K3009-1) supplies voltage to Relay, emergency stop switch voltage (K3009-2) in the frame electronic box.

UK3009-2/87 = 24 V

Electronic box frame, description, page 11:15

4

Relay, emergency stop switch voltage (K3009-1) also sends a voltage signal to the Control unit, cab (D790-1), which verifies that Relay, emergency stop switch voltage (K3009-1) is active but Relay, emergency stop switch voltage (K3009-2) is inactive.

UK3009-1/87 = 24 V



UK3009-2/87= 0 V


This verifies that the emergency stop switch is working. 5

Control unit, cab (D790-1) activates Relay, emergency stop switch voltage (K3009-2) in the electronic box.

UK3009-2/86 = 24 V


Cab control unit, description, page 11:17 D5: Diagnostic menu, see section 8 Control system, group 8.4.1.6 CAN/POWER, menu 6

VDCT01.02GB

11:12


Pos

Explanation

Signal description

Reference

6

Relay, emergency stop switch voltage K3009-2 supplies voltage to the emergency stop switch circuit.

UK3009-2/87 = 24 V


7

The attachment control unit (D791) is voltage fed with emergency stop switch voltage as long as emergency stop switch is not depressed.

Emergency stop switch in home position: UK2:1 = 24 V

Control unit, attachment, description, page 11:19

Attachment control unit D791 is only voltage fed by the emergency stop switch, thus all attachment functions stop if the emergency stop switch is activated.


If the emergency stop switch is pressed, ignition voltage to the cab control unit (D790-1) is cut off, thereby cutting off control current to emergency stop switch voltage relay K3009-1, emergency stop switch voltage relay K3009-2, the tilt relay (K3002) and the lift/lower relay (K3007). The power supply to the control units is cut off and the functions cease.




As an extra safety measure, the cab control unit (D790-1) also transmits the status of the emergency stop switch the CAN bus. Thus, functions are also cut off at the signal level.

002084

Emergency stop switch, checking

VDCT01.02GB

1

Start the machine and active any load handling function.

2

Activate lift.

3

Press in the emergency stop switch and check that the lift movement stops.

4

Reset the emergency stop switch (turn in the direction of the arrows) and check that the lift function is working again.



11:13

11.5.1.5 Voltage converter Voltage converter, description

The voltage converter is located under a protective casing to the left behind the driver's seat. The voltage converter converts 24 volts to 12 volts. 12 V power is available for accessories through a connector in the cab electrical distribution box and through a socket on the instrument panel. Connector X067 in cab electronic box (contains 15-voltage, 30-voltage, ground and 12 V).

Voltage converter, replacement

1


2

Remove the covers behind the driver's seat.

3

Detach the electrical cables from the converter.

4

Remove the voltage converter.

5


The voltage converter is located diagonally behind the driver's seat.


VDCT01.02GB

11:14

11 Common electrics – Electronic box

11.5.2 Electronic box 11.5.2.1 Electronic box, cab Electronic box, cab, description The electronic box is mounted on the rear wall of the cab, on the left. Located there are:

7 6

•

Control unit cab (D790-1).

•

Cab battery voltage circuit fuses for (30), ignition voltage (15) F58-4 and cab ignition voltage circuit fuses (15) F58-5.

•

Buzzer for alarm if, for example, the operator leaves the machine without the parking brake being applied.

•

Connectors.

•

Relays.

• Voltage converter 24 V to 12 V •

Customer accessory connector. Output voltage 24 V, max. 10 A. Connector 9-pin Universal mate-n-lock. For part number see Spare parts catalogue.

1

NOTE

2

This connector is not fitted on the machine if the machine is equipped with voltage converter.

3 4

CAUTION 008693

5

1.


2.

Diagnostic socket, machine

3.

Diagnostic socket CAN Bus drivetrain

4.

Fuse holders for cab battery voltage circuit fuses (30) and the ignition voltage (15) F58 -4 (upper) and cab ignition voltage circuit fuses (15) F58 -5 (lower).

5.

Voltage converter

6.

Termination resistor

7.

Customer accessory connector (X067) 24V/10A and 12V/20A

Customer accessory connector (X067)

3

2

Connector X067 must be used when connecting extra electrical equipment. The use of other connections can lead to overloading of cable harness and product damage.

Customer accessory connector (X067)

1

The connector is designed for customer accessories and contains connections for 24 V. On machines with voltage converter 24 V to 12

4

V there is also a connection for 12 V 014169

Pin 1. 24 V, ignition voltage, 10 A Pin 2. 24 V, battery voltage, 10 A Pin 3. Ground Pin 4. 12 V, ignition voltage, 20 A

VDCT01.02GB


.

11 Common electrics – Electronic box

11:15

11.5.2.2 Electronic box frame Electronic box frame, description The electronic box is fitted on the side of the machine. Also located there are:

5

4 3 2

6

1

•

Circuit fuses.

•

Outlet for programming Control unit, transmission (D793)

•

Main fuses.

•


•

Power relays for voltage feed to the machine's functions.

7

8 9 10 11 015057

12 13 1.

Circuit fuses, battery voltage (30) F58-3

2.

Circuit fuses, ignition voltage (15) F58-2

3.

Circuit fuses, emergency stop switch voltage (15E) F58-3

4.

Diagnostic socket engine, (Engine alternative Yuchai YC6A240-30) (the connector hangs loose in the electronic box)

5.

Main fuses

6.

Terminal block

7.

Circuit fuse transmission control unit (0.5 A) (F51-3)

8.

Tilt in/out relay K3002

9.

Lifting/lowering relay K3007

10. Ignition switch relay K315-2 11. Ignition key lock power relay K315-1 12. Control breaker power relay K3009-1 13. Control breaker power relay K3009-2

1

1

-

007184

1 2 3 4 5 6

1.



VDCT01.02GB

11:16

11 Common electrics – Control units

11.5.3 Control units Control units, location 1

2

3

4

7

6

5

1.

Frame control unit (D797-1)

5.


2.


6.

Engine control unit, Yuchai (D794)

3.


7.

Engine control unit, Cummins (D794)

4.


8.

Control unit, attachment (D791-1)

VDCT01.02GB


014680

8


11:17

11.5.3.1 Control unit, cab Cab control unit, description Control unit, cab (D790-1) is the central control unit of the control system. Control unit, cab (D790-1) sends activation signals to other units, and controls and monitors their functions. It administrates work in the control unit network. The control unit controls the redundant voltage feed and handles communication via a redundant CAN bus and gateway for CAN bus drive-train. Control unit, cab (D790-1) also processes all input signals from cab controls and transmits these signals on the CAN bus.

1

3

4

5 6 000041

2

2 1.

Connection terminals - fan, working lights, windscreen wiper

2.

Connection terminals, other

3.

Light 1, battery voltage

4.

Light 2, redundant voltage feed, redundant CAN bus and power supply

5.

Light 3, communication

6.

Light 4, error indication

Control unit, cab has four indicator lights that indicate the control unit's function. Lamp 1

Green light on when there is battery voltage to the unit. The light is physically controlled by voltage feed to the control unit.

Lamp 2

Flashes green when redundant voltage feed to control units and redundant CAN bus communication are active. No power in the system. Green light when power electronics and 15-voltage are supplied voltage.

Lamp 3

Long single flash yellow during communication with Control unit, display (D795). This is a basic condition of fault tracing. Short single flash yellow during communication with Control unit, engine (D794) and Control unit, transmission (D793). Double flash yellow (short and long flash) during communication with the display and engine or transmission.

Lamp 4

Red light in the event of active error.

Control unit cab, replacement 1


2

Remove the cover from the electronic box.

3

Detach the connectors from Control unit, cab (D790-1).

4

Replace the control unit.

5

Check that the new control unit corresponds with the machine's forklift number (Z-number).

6

Calibrate the new control unit. See section 8 Control system, group 8.5.2.3 Calibrate DRIVE-TRAIN.


VDCT01.02GB

11:18


11.5.3.2 Frame control unit Frame control unit, description The frame control unit (D797-1) processes input data from sensors 1 and sends control signals to relays and solenoid valves.

2 The cab control unit has four indicator lights that indicate the control unit's function.

3

Lamp 1


Lamp 2

Flashes green when one or more of the following is missing: redundant voltage feed left, redundant voltage feed right or 15-voltage.

4

000043

6

Green light when redundant voltage feed left, redundant voltage feed right and 15-voltage are supplied voltage.

5

Lamp 3

1.


2.

Light 2, redundant voltage feed and power supply

3.


4.


5.

Control signals (inputs and outputs)

6.

Power supply (redundant voltage feed for control units, redundant CAN bus) and input data

Single yellow flash during communication with the KID control unit (D795) or cab control unit (D790-1). Double yellow flash during communication with the KID control unit (D795) and the cab control unit (D790-1).

Lamp 4


Frame control unit, replacement

VDCT01.02GB

1


2

Detach the cables from the frame control unit (D797-1).

3


4


5

Check the initiation values for attachment functions; see section 8 Control system, group 8.5.1.1 ELSERVO.

6

The control unit is not calibrated.



11:19

11.5.3.5 Control unit, attachment Control unit, attachment, description The attachment control unit (D791) processes input data from sensors 1 and sends control signals to relays and solenoid valves of the side lift attachment.

2 3

6

Lamp 1


Lamp 2

Flashes green when one or more of the following is missing: redundant voltage feed left, redundant voltage feed right or 15-voltage. Green light when redundant voltage feed left, redundant voltage feed right and 15-voltage are supplied voltage.

000043

4

The cab control unit has four indicator lights that indicate the control unit's function.

5

1.


2.

Light 2, redundant voltage feed and power supply

3.


4.


5.

Control signals (inputs and outputs)

6.

Power supply (redundant voltage feed for control units, redundant CAN bus) and input data

Lamp 3

Single yellow flash during communication with the KID control unit (D795) or cab control unit (D790-1). Double yellow flash during communication with the KID control unit (D795) and the cab control unit (D790-1).

Lamp 4


Control unit, attachment, replacement 1


2

Disconnect the cable harness from the control unit.

3


4


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.


VDCT01.02GB

11:20


11.5.3.9 Transmission control unit Control unit, transmission, description Control unit, transmission TCU (D793) is part of the drive-train control and handles the transmission's function, selection of gear at load and engine speed, etc.

015058

Control unit, transmission TCU (D793) is connected via separate CAN bus communication to the engine, which is connected to Control unit, cab (D790-1). In turn, Control unit, cab (D790-1) sends drive-train information on to other units.

Control unit, transmission, replacement Machine in service position.

2

Disconnect the cable harness from Control unit, transmission (D793).

3


4


5

Calibrate the new control unit; see section 8 Control system, group 8.5.2.3 Calibrate DRIVE-TRAIN and section 2 Transmission, group 2.8 Control system, transmission.

015058

1

VDCT01.02GB



11:21

11.5.3.10 Engine control unit Control unit, engine, description (engine alternative Yuchaii YC6A240-30) Control unit, engine (D794) is part of the drive-train control and handles engine function, fuel injection, etc. Control unit, engine (D794) is connected via separate CAN bus communication to the transmission, which is connected to Control unit, cab (D790-1). In turn, Control unit, cab (D790-1) sends drive-train information on to other units. The control unit is fitted on the engine has no function keys or display. All functions are controlled via the CAN bus and an external control system.

013872

The control unit monitors the following values in order to optimise engine performance.

Engine control unit

•

engine speed

•

camshaft position

•

boost pressure

•

charge air temperature

•

coolant temperature

•

oil pressure

•

oil temperature

•

oil level

•

crankcase pressure

•

water in fuel

•

fuel pressure

•

coolant level

The data gives exact information about the operating conditions and makes it possible for the control unit to, for example, calculate the correct fuel volume and to check the condition of the engine.


VDCT01.02GB

11:22


Control unit, engine, description (engine alternative Cummins QSB6.7 ) The engine control unit (D794) is part of drivetrain control and handles engine function, fuel injection, etc.

1

Engine control unit EDC (D794) is connected via separate CAN bus communication to the transmission, which is connected to Cab control unit (D790-1). In turn, Control unit, cab (D790-1) sends drive-train information on to other units.

2

The control unit is fitted on the engine has no function keys or display. All functions are controlled via the CAN bus and an external control system.

3

The control unit monitors the following values in order to optimise engine performance.

010053

4

•

engine speed

•

camshaft position

•

boost pressure

•

charge air temperature

1.

Connector from Cummins cable harness

•

coolant temperature

2.

Connector XD794-3

•

oil pressure

3.

Connector from Cummins cable harness

•

water in fuel

4.

Connector XD794-3

•

fuel pressure

•

coolant level

The data gives exact information about the operating conditions and makes it possible for the control unit to, for example, calculate the correct fuel volume and to check the condition of the engine.

Control unit, engine, replacement See supplier documentation, engine.

CAUTION Each control unit is individually calibrated to each engine. Control unit replacement between engines must not be done under any circumstances.

VDCT01.02GB



11:23

11.5.3.11 Control unit KIT Control unit KIT, description 1

The KIT control unit (D790-2) handles functions for the gear and multi-function lever, the direction indicator switch and start key positions II and III. It also handles the key panel for the control system and its panel for warning and indicator lights.

2

Control unit KIT (D790-2) has several individual function keys and indicator lights.

000049

See the operator's manual for detailed information on warning and indicator lights and function keys.

1.

Panel, warning and indicator lights

2.

Panel for keys

Control unit KIT, replacement 1


2


3

Detach the KIT control unit (D790-2) from the steering wheel panel.

4

Detach the connector sockets.

5

Remove the warning panel for warning and indicator lights.

6


7

The KIT control unit (D790-2) is not calibrated.


VDCT01.02GB

11:24


11.5.3.12 Control unit KID Control unit KID, description 1

Control unit KID (D795) displays to the operator information sent by the control system, such as speed, in the form of messages, status, error indications, etc.

2

There is an indicator light to the right of the display that is activated with a red light when there is a serious malfunction in the control system. The error code and information are shown on the display.

000051

See the operator's manual for detailed information about the display.

1.

LCD display

2.

Series of diodes that serve as an indicator light for serious malfunction.

Control unit KID, replacement

VDCT01.02GB

1


2


3

Detach the connector from the KID control unit (D795).

4

Detach the KID control unit (D795) from the steering wheel panel.

5


6

The KID control unit (D795) is not calibrated.


11 Common electrics – Cable harness

11:25

11.5.5 Cable harness Connectors, overview The list includes all connectors on the machine with a brief description of their locations and to which functions the signals in them are related.

Contact

Location

Function

X001


Power supply and ground connection Control unit, cab (D790-1)

X002


Front windscreen wiper Heater fan Actuator motor, recirculation Rear window wiper Motor, rotating beacon Back-up lights

X004


Water valve Air distributor Interior temperature sensor Ambient temperature sensor Temperature sensor, outlet fan Sensor, temperature refrigerant Air conditioning sensor Front windscreen wiper motor

X005


Switch, left panel Switch, option Window washer, roof rear Switch flashing hazard lights (Hazard) Setting fan speed Setting temperature Air distribution Fan and recirculation controls Accelerator Alignment bypass

X006


Instrument illumination Switch, working lights Switch, rotating beacon Switch, headlights Switch, option Seat heater Accelerator Declutch pedal

X007


Control lever Twistlock Spreading (positioning)


VDCT01.02GB

11:26


Contact

Location

Function

X008


Switch, spreading Switch, bypass Emergency stop switch Switch parking brake Sensor twistlocks Switch 30-35 stop Switch, aut. 20-40 Switch, option Instrument illumination Switch, electric servo panel

X009


Background illumination, switches Switch, horn

X009-2


Control lever

X010


Sensor, alignment Water valve Horn Relay, seat heating Relay, working lights Hour counter Relay, compressor Control current relay K315-1, K3009-1, K3009-2, K315-2, K3002 and K3007 Front windscreen washing Windscreen wiper, roof

X011


Ignition Break contacts (opening switches), cab doors Interior lighting Redundant feed, cab control unit (D790-1) Horn Break contact (opening switch), seat Feedback relay K3009-1

X012


Windscreen wiper, rear Windscreen wiper, roof

X013


CAN bus RS232

X015


CAN bus Power supply and ground connection Control unit KIT (D790-2)

X016


Ignition

X017


Switch, horn Control, windscreen wipers Control, gear Control, high and low beams

VDCT01.02GB



Contact

Location

Function

X018


Sensor steering wheel movement

11:27

Buzzer Switch, direction indicators Switch, interior lighting

X020


CAN bus RS232 Power supply and ground connection Control unit KID (D795)

X033

Air conditioning

Control, fan Control, temperature Control, air distribution Fan and recirculation controls Instrument illumination

X034

Air conditioning

Heater fan Water valve

X035

Air conditioning

Valve, air distribution Interior temperature sensor Temperature sensor, outlet fan

X036

Air conditioning

Actuator motor, recirculation Sensor, temperature refrigerant

X038

Instrument panel, cab

Accelerator Declutch pedal

X039

Electronic box, cab

Relay, compressor air-suspension seat Switch flashing hazard lights (Hazard) Break contact (opening switch), cab door Actuator motor, recirculation Fan motor, heating Water valve, ECC Air conditioning sensor Ambient temperature sensor

X040

Electronic box, cab

Alignment bypass Window washer, roof/rear Accelerator

X048

Electronic box, cab


X049

Electronic box, cab


X050

Electronic box, cab

RS232 Control unit, cab (D790-1)

X051

Electronic box, cab

Feedback relay K3009-1 Power supply, Control unit, cab (D790-1) CAN bus

X052

Electronic box, cab

CAN bus Control relays K315-1, K3009-1, K3009-2 and K315-2

X054

Electronic box, cab

Interior lighting Back-up lights Revolving beacon


VDCT01.02GB

11:28


Contact

Location

Function

X055

Electronic box, cab

Windscreen wiper, roof Power, CD player Power, COM radio

X056

Electronic box, cab

Revolving beacon Working lights, cab

X057

Electronic box, cab

Windscreen wiper, rear

X058

Electronic box, cab

Motor, windscreen washing Engine heater start inhibitor, bridged

X059

Electronic box, cab

CAN bus

X060

Electronic box, cab

CAN bus Interior lighting Engine heater start inhibitor, bridged

X060A

Extension X060

CAN bus Interior lighting Engine heater start inhibitor, bridged

X061

Electronic box, cab

Ground connection, Control unit, KID (D795) Ground connection, Control unit KIT (D790-2)

X061A

Extension X061

Ground connection, Control unit, KID (D795) Ground connection, Control unit KIT (D790-2)

X062

Electronic box, cab

Horn Compressed air horn Map lighting Cigarette lighter 12V Windscreen wiper, front Heater fan motor Motor, recirculation

X063

Electronic box, cab

Sensor, operator-in-seat Seat heater Compressed-air damped seat

X065

Electronic box, cab

Ambient temperature sensor

X066

Electronic box, cab

Accelerator Interior lighting

X067

Electronic box, cab

X069

Electronic box, cab

Customisation Sensor, twistlock open/closed Twistlock relay Spreading relay

X070

Electronic box, cab

Sensor twistlocks Spreading relay

X072

To Right Behind Seat

Current outlet

X080


Switch, mast/attachment work lights Switch, high beam Switch, rotating beacon Switch, seat heater Switch, seat heater

VDCT01.02GB



Contact

Location

Function

X081


Switch, seat heater

11:29

Switch flashing hazard lights (Hazard) Extra sensors Hour counter X082


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


Horn Switch, spreading Switch, twistlock

X092


Switch, twistlock

X168

Electronic box frame

Power supply attachment control unit

X201


Ground connection and power supply, Control unit, transmission (D793)

X203



X204

Front edge of frame

Mast work lights

X205


CAN bus Control unit, transmission (D793)

X207

Front edge of frame

Sensor, alignment Sensor twistlocks

X209

Front edge of frame

Power supply, cab control unit (D790-1) CAN bus, frame control unit (D797-1) CAN bus, attachment control unit (D791)

X210

Between engine and transmission

Power supply and ground connection Control unit, engine (D794) CAN bus, Control unit, engine (D794) Low coolant level sensor (engine alternative Cummins QSB6.7 D+ alternator (engine alternative Cummins QSB6.7

X211


X212


)

)

42-pin connector to frame control unit (D797-1) Power supply and ground connection, frame control unit (D797-1) CAN bus, frame control unit (D797-1) Temperature hydraulic oil Emergency stop switch voltage Sensor fuel level D+ alternator

X214

Front edge of frame

CAN bus, attachment control unit (D791)

X215


Power supply attachment control unit

X230

Beneath driver's seat

Sensor, operator-in-seat

X235

Front edge of frame

Lift/lower valve Tilt valve Mast valves


VDCT01.02GB

11:30


Contact

Location

Function

X236

Engine

Low coolant level sensor

X240

Front edge of frame

Voltage feed

X241

Front edge of frame

Option

X242

Front edge of frame

Option

X243

Front edge of frame

Low beam rear High beam rear Tail light front

X244

Front edge of frame

Side shift valve Spreading valve Lift, tilt and attachment control valve

X247

Front edge of frame

Brake light forward

X248

Front edge of frame

Mast position sensor

X251

Control unit, transmission (D793), electronic box frame

60-pin connector for Control unit, transmission (D793)

X261


RS232 Control unit, transmission (D793)

X270

Lamp bracket left front

High and low beams Direction indicators Side marker lights

X271

High and low beams

Lamp bracket right front

Direction indicators Side marker lights X272

Tail lights

Lamp bracket left rear

Brake light Direction indicators Side marker lights X273

Lamp bracket right rear

Tail lights Brake light Direction indicators Side marker lights

X275

Tail lights

Rear edge of frame

Brake light Direction indicators Side marker lights Back-up alarm X278

Between engine and transmission

Electromagnetic clutch, compressor Sensor pressure refrigerant Relay, starter motor

X279


Signals, Control unit, engine (D794) CAN bus Drive-train

X280

Engine

Coolant level

X281


Diagnostic socket engine

VDCT01.02GB



Contact

Location

Function

X286

Engine

Resistance, indication preheating active

11:31

Resistance, indication water in fuel X287

Engine

Power supply and ground connection Control unit, engine (D794)

X301

Mast

Mast position sensor

X400

Attachment control unit (D791)

Power supply and ground connection, attachment control unit (D791)

X401


CAN bus, attachment control unit

X403

Carriage middle

Sensor, alignment right side Sensor, twistlocks right side Work lighting, right side

X404

Carriage middle

Sensor, alignment left side Sensor, twistlocks left side Work lighting, left side

X415

Attachment, right side

Indicator light locked twistlocks Indicator light, unlocked twistlocks Indicator light alignment

X421


42-pin connector for Control unit attachment (D791)

X422


Power supply and earth connection, Control unit attachment (D791) CAN bus Control unit attachment option (D791) Emergency stop switch voltage

X425

Carriage middle

Sensor, stop at 30' left Sensor, end position 20'-40' left

X426

Carriage middle

Sensor, stop at 30' right Sensor, end position 20'-40' right

X428

Cab

Revolving beacon

X612

Air conditioning

Actuator motor, recirculation

X645

Engine

Compressor air conditioning

X651

Cab

Motor, windscreen washing

X657

Cab

Heater fan

X660

Engine

Alternator

X690

Cab

Accelerator

X759

Engine

Coolant level

X774

Cab

Ambient temperature

X775

Cab

Temperature sensor, cab, fan, refrigerant

X815

Cab

Power assisted system

X900

Cab

CD player

X901

Voltage converter, cab

Voltage converter 24 V/12 V Socket 24 V


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11:32


Signal types, general The machine's control units use a number of different types of signals to receive signals from sensors and switches and control solenoid valves, lights, etc. The table below describes the different signal types. Signal type

Explanation

Application area

Analogue input signals Rheostat

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 equivalent to temperature and the work range of approx. -40 till 150 °C.

E.g. hydraulic oil temperature sensor and air conditioning temperature sensor.

There are two different resistance curves, one for Control unit, cab (D790-1) and one for the frame and attachment control units. Accuracy is ±0.5 in the interval 0-100 °C (sensor's measurement inaccuracy not included). Outside of the interval 0-100 °C, accuracy is ±2 °C. Voltage

An analogue signal 0-5 V. The work range is 0.5 to 4.5 V.

E.g. accelerator pedal and analogue cab controls (operating lever and heater controls).

A modulated signal between 0 V and system voltage, i.e. 24 V. The work range is 0 to 2 A.

Hydraulics, e.g. lifting/lowering of the boom.

Analogue outputs Current feedback voltage out, PWM

A modulated signal is a digital signal translated to an analogue (continuous) signal adapted for a purpose, such as solenoid valve control. When the slide in a solenoid valve gets hot, resistance drops. This generates a lower current through the valve spool, which can cause the valve's servo pressure to remain constant. An internal ammeter measures current in the circuit and regulates the voltage level in order to maintain the desired current value in the valve spool.

Used when the output signal actuates proportional solenoid valves.

Voltage out, PNP PWM

A modulated signal between 0 V and system voltage, i.e. 24 V. Requires a grounding point as reference.

E.g. interior lighting and background illumination in switches.

Voltage out, reversed polarity, NPN PWM

A modulated signal between 0 V and system voltage, i.e. 24 V. Requires 24 V as reference.

E.g. cab fan.

Digital input signals Digital input signal with pull down and search lighting

Signal in, U < 5 V generates logical zero (0) Signal in, U > 16 V generates logical one (1)

E.g. input signal from a circuit breaker with search lighting.

If there is no signal in, the input is grounded. Digital input signal with pull down

Signal in, U < 5 V generates logical zero (0) Signal in, U > 12 V generates logical one (1) If there is no signal in, the input is grounded.

E.g. position sensors (inductive sensors) and brake pressure (pressure switches).

Bandwidth 300 Hz, i.e. designed for slow sensors. Digital outputs High side driver, 1.5 A

Logical one (1) generates voltage out, U >= 22.5 V Max. load 1.5 A

E.g. side marker lights, solenoid valves.

Open load 0.15 A Max. instantaneous current load, 8 A High side driver, 5 A

Logical one (1) generates voltage out, U >= 22.5 V Max. load 5 A Open load 0.9 A Max. instantaneous current load, 35 A

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E.g. working lights and wiper motors.


11:33

Signal type

Explanation

Application area

High side driver, 10 A

Logical one (1) generates voltage out, U >= 22.5 V

E.g. cooling fan.

Max. load 10 A

This output is only found on the frame and attachment control units.

Open load 1.9 A Max. instantaneous current load, 70 A H-bridge

Logical one (1) generates voltage out, U >= 22.5 V or grounded output, U=0V Max. load 0.5 A

E.g. air conditioning water valve (works in both directions).

Open load 0.15 A Max. instantaneous current load, 8 A The H-bridge works with two outputs in a pair. At logical one (1), one output gives voltage while the other output is grounded. At logical zero (0), the outputs switch voltage levels.


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11:34

11 Common electrics – Communication

11.6 Communication 11.6.1 CAN bus CAN bus, description 2 Communication between the control units takes place using so-called

1

"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 simple technology that is highly reliable (low error frequency), which is a requirement for control signals to be able to regulate systems based on varying conditions and requirements.

120 ohm

120 ohm

CAN specifies:

5

5 3

•

that the signal traffic is carried by "twisted pair" cables.

•

that termination resistors (position 1) are necessary (adapted to cables' impedance) so that the pulse train (position 4) should obtain a sharp signal.

•

that the signal valve is given as the potential difference between the cables, CAN + and CAN - (position 2 and 3).

•

form of signal messages.

U [V]

4 2

000026

3 t [S] Messages are sequential and signal is high (voltage high) or low (voltage low). 1.

Termination resistor (120 ohm)

2.

CAN + (voltage high)

3.

CAN - (voltage low)

4.

Pulse

5.

Control unit

Message

Message

A

B

C

D

E

F G

t [S] Messages are sequential and signal is high (voltage high) or low (voltage low).

000027

There are two types of messages: •

CAN Standard, has identity field of 11 bits

•

CAN Extended, has identity field of 29 bits

CAN works in messages sent in frames of 8 bytes (64 bits). A complete message is approx. 100 bits long. The illustration depicts how a message is structured.

Start bit (B)

A

Length message

B

Start bit

C

Identity field/Priority

D

Control field (length of data segment)

Identity field (C)

E

Data segment

F

Checksum for error detection

Indicates what kind of information the message contains, e.g. measurement information on engine speed.

G

Acknowledge bit

Indicates that the transmission of a frame, i.e. a message, is now beginning.

Does not indicate address to control unit. CAN does not work with addressing. All control units receive messages and send them on.

Control field (D) Indicates how the length of the data segment that follows.

Data segment (E) Contains the information to be conveyed to control units in the network.

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11 Common electrics – CAN bus

11:35

Checksum for error detection (F) Calculates a checksum for the message. This makes it possible for the receiving control unit to detect errors in the sent message.

Acknowledge (G) The transmitting control unit sets a bit to logical one (1) when the message is sent. The first control unit to receive the message sends it on and sets the bit to logical zero (0). Communication

Communication The CAN network consists of control units and segments. The segment (bus) is a twisted pair cable that leads CAN + and CAN signal levels from control unit to control unit.

U [V]

3,5 V

Each control unit measures the potential difference of its two inputs. The potential difference generates logical zero and logical one. The illustration depicts an approved interval according to the standard for potential levels. CAN + has a recommended value of 3.5 V and CAN - has 1.5 V. As a worst case scenario, the potential difference can be only 0.5 V and still be approved. In practice, a potential difference of 2 V is recommended for reliable communication.

0,5 V

1,5 V

Potential levels CAN + and CAN -

000028

t [S]

A pulse train can only be observed using an oscilloscope, NOT with a digital multimeter. When a message is sent, all control units in the network listen. Messages are saved in the control unit and relevant information is processed. The control unit that receives the message first confirms receipt (sets an acknowledge bit). The transmitting control unit then knows that the message has been received by at least one control unit. One control unit at a time sends the message. Other control units listen and wait until the bus is available. If two messages are to be sent simultaneously then the sending of the message with the lowest priority (highest value in identity field) is concluded. This means that messages do not need to be re-sent in the event of a communication conflict but only in the event of a bus error (erroneous message). The CAN bus exchanges around 100 messages per second in the network. Different bus systems can be used e.g. random sending or primary (master) / secondary (slave).

HLP High Layer Protocol CAN only specifies messages and how communication shall take place, i.e. one protocol. In order to manage the network the CAN protocol needs to be supplemented by a HLP which specifies: •

flow control

•

transport of data above a length of 8 bits in 8 bit messages (division)

•

how control units are addressed in the network

•

how bits in the message's data field should be interpreted


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11:36

11 Common electrics – Redundant CAN bus

11.6.2 Redundant CAN bus Redundant CAN bus, description CAN R

D790-1

CAN L

CAN R

D790-2

CAN L

The redundant CAN bus handles communication between all of the machine's control units except Control unit, transmission (D793) and Control unit, engine (D794). These have a separate CAN bus; see CAN bus drive-train, description, page 11:38.

D795 CAN R

CAN L

CAN L

CAN R

D797-1

014682

D791

Outline view, redundant CAN bus

D790-1 CAN L

D791

CAN R

CAN L

1

4

D797-1

CAN R

CAN L

CAN R

2 3

CAN L

009752

CAN R

D795

Redundant CAN bus means that the control units are connected into a network that communicates via a CAN bus (see CAN bus, description, page 11:34) and that there are double communication routes on the network. The network is divided into control units and segments (segments are the cables between the control units). The number of active segments depends on the number of control units the machine has, which depends on the machine's equipment level (options).

Segment numbering starts from the CAN-R (right) connection

D790-1 CAN R

CAN L

CAN R

1 4 CAN R

The network is built on the CAN kingdom principle, which means that one control unit is central and is the master unit. In this case, it is the cab control unit (D790-1). Other control units in the network are secondary (slaves) and handle special areas, e.g. machine components.

D797-1 CAN L

CAN R

2 3

CAN L

D795

015052

CAN L

D791

The control units have two CAN bus connections - CAN L (left) and CAN R (right). The control units are connected to one another in series in a loop.

Segment numbering The redundant CAN bus can handle the loss of a segment. The link is analysed upon start-up. If a segment has a malfunction, messages are sent via another route. If several segments are lost, one or more control units lose communication and work independently, often with significantly limited functionality. CAN bus faults are indicated with an error code and a warning in the display. If several CAN bus segments are faulty, the system only shows an error code for the first faulty out segment.

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11 Common electrics – Redundant CAN bus

11:37

Connection of redundant CAN bus Condition

Reference value

Reference


In position 1

Battery disconnector, description, page 11:3


Activated.


D790-2 S1

D791

S2

1, 6

D790-1

S4

5

D795

D797-1

S3

3 015060

2

4

Pos

Explanation

Signal description

Reference

1

Control unit, cab (D790-1) establishes redundant CAN bus communication by sending a request on the CAN bus via CAN R.



The attachment control unit (D791) sends a response back on the CAN bus via CAN L and sends the request on via CAN R.


2

Termination resistors in the control nodes ensure communication segment by segment. 3

The frame control unit (D797-1) sends a response back on the CAN bus via CAN L and sends the request on via CAN R. Termination resistors in the control nodes ensure communication segment by segment.

4

Control unit KID (D795) sends a response back on the CAN bus via CAN L and sends the request on via CAN R. Termination resistors in the control nodes ensure communication segment by segment.




Diagnostic menu, see section 8 Control system, group 8.4.1.1 CAN/POWER, menu 1 and 8.4.1.2 CAN/POWER, menu 2 Control unit, attachment, description, page 11:19 Diagnostic menu, see section 8 Control system, group 8.4.1.1 CAN/POWER, menu 1 and 8.4.1.2 CAN/POWER, menu 2

Frame control unit, description, page 11:18 Diagnostic menu, see section 8 Control system, group 8.4.1.1 CAN/POWER, menu 1 and 8.4.1.2 CAN/POWER, menu 2

Control unit KID, description, page 11:24 Diagnostic menu, see section 8 Control system, group 8.4.1.1 CAN/POWER, menu 1 and 8.4.1.2 CAN/POWER, menu 2

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11:38

11 Common electrics – CAN bus drive-train

Pos

Explanation

Signal description

Reference

5

The KIT control unit (D790-2) is not connected to the redundant CAN bus. The KIT control unit (D790-2) does not communicate until ignition voltage (15) is activated.


Control unit KIT, description, page 11:23

6

If all control units have responded, the cab control unit (D790-1) deactivates the segment to the attachment control unit (D791).


Diagnostic menu, see section 8 Control system, group 8.4.1.1 CAN/POWER, menu 1 and 8.4.1.2 CAN/POWER, menu 2

If a control unit has not responded, then Control unit, cab (D790-1) uses both CAN L and CAN R to keep communication open and analyses which segment is faulty.

11.6.3 CAN bus drive-train CAN bus drive-train, description 4

The drive-train CAN bus is based on the SAE J1939 standard where selected messages are used to control engine.

6

SAE J1939 is a standard from SAE (Society of Automotive Engineers) for data communication in vehicles. The standard regulates hardware interface, bit times and message composition.

D790-1

3

5

Control units for engine and transmission come from the respective transmission and engine supplier. The machine only uses one model, while there are several engine alternatives. All engine alternatives use the standard and therefore the messages for each engine are structured in the same way. Communication with Control unit, engine (D794) and Control unit, transmission (D793) are separate from the redundant CAN bus.

1 1.

Redundant CAN bus

2.

CAN bus drive-train

3.


4.

Engine

5.


6.

Transmission

VDCT01.02GB

2

000033

The signals can be checked via the diagnostic menu. See section 8 Control system, group 8.4.1.4 CAN/POWER, menu 4.


11 Common electrics – Communication between PC and machine

11:39

11.6.4 Communication between PC and machine Communication between PC and machine, description The machine has three sockets for communication between control units and PC. Two are fitted in electronic box cab and one is in electronic box frame. The diagnostic socket for the engine is loose in electronic box frame.

1

Sockets for programming control units in electronic box cab (position 1) are used for programming the control units in the cab, on the frame and on the attachment.

2

Sockets for CAN bus drive-train in electronic box cab (position 2) are used for communicating with the engine and transmission via CAN bus.

015059

For further details on communication between computer and machine, contact Cargotec.

3 1.

Diagnostic socket, machine

2.

Diagnostic socket CAN bus drive-train

3.

Diagnostic socket engine (loose in electronic box)


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11:40

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D:1

D Error codes

Contents D Error codes D 1 2 8

Error codes ........................................................................................................ D:3 Engine................................................................................................................. D:9 Transmission ................................................................................................... D:59 Control system ................................................................................................ D:95


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D:2

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D Error codes – Error codes

D:3

D Error codes Error codes, explanation The error codes are explained in table form for Engine, Transmission as well as Control system. They are sorted according to error code number. The error code table has the following information:

C

B

B. Error code level (symbol)

E 000389

D

•

Code, error code\qs number, shown in field C on display.

•

Description, explanation of the error code and when it\qs generated.

•

Limitation, in case of certain error codes certain functions are impaired or limited to protect the machine and operator.

•

Action, information of what should be checked to find the cause of the error code.

•

Diagnostic menu, reference to suitable diagnostic menu to rectify the problem, read signal value or check the function.

C. Error code number

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.

D. Error cause (symbol) E. Function (symbol) •

Function group is a reference to which function group the error code is associated. This field is used to search for more information as necessary. The function group can be used to find different types of information. Sections 0-12 contain a description of the function and its components, component location and work instructions for different tasks.


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D:4


Error code menu, description The control and monitoring system's display is divided into four fields where the information is shown (see figure to the left).

C D

E 000389

B

•

Field B: Error code level is shown with a symbol.

•

Field C: Shows error code.

•

Field D: Shows type of error.

•

Field E: Indicates which function is affected by error code.

•

Book symbol means that information is available in the operator's manual.

Field B: Error code level The control and monitoring system gives error code information in three levels which are indicated with a symbol in the lower left corner (B) on the display unit. •

C

Indicates a serious malfunction that may jeopardise the operator's safety or cause machine failure. The error code must be attended to immediately. Stop working with the machine and contact service immediately.

E


000350

D

•

C D

Stop

Warning Indicates malfunction in machine that should be taken care of as soon as possible. After the finished work shift with the machine, contact service as soon as possible.

E 000351


•

Information to the operator that something should be taken care of as soon as possible, e.g., defective light bulb. Take action to fix the cause of the error code as soon as possible. See section 6 Inspection and maintenance in the operator's manual.

C E

The error code is stored in the error code list under operating menu for service.

000352

D

Information



C D

The control and monitoring system gives error codes from three sub-systems:

E

• 000389

B

Shown with error code number XXX on display. •

D

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Engine: Shown with error code number XXX/YY on display.

XX/YY

NOTE 001343

B

Machine:

If several error codes come from the engine, the error code level is shown for the most serious error code.



• XXX/YY

D:5

Transmission: Shown with error code number XX/YY on display.

D 001344

B


1

4

2

5


3

6

1.

Temperature too high/too low.

2.

Incorrect signal to solenoid valve.

3.

Incorrect hydraulic pressure.

4.

Incorrect sensor signal.

5.

Incorrect signal from control.

6.

Incorrect signal to bulb.

7.

Incorrect signal, for example, open circuit.

000396

7


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D:6



1

4

7

2


3

5

6

8

9

1.

Attachment

2.

Rotation of attachment

3.

Side shift, attachment

4.

Length adjustment attachment

5.

Levelling

6.

Twistlocks

7.

Forks up/down

8.

Tilt forks

9.

Side shift forks

10. Spreading forks

10

11

11. Rotation forks

12

12. Overload protection 13. Hydraulic functions 14. Brake system

13

14

15. Steering

15

16. Engine 17. Transmission 18. Central lubrication

16

17

18

19. Control unit 20. Hardware-related error 21. Cab 22. Air conditioning

19

20

21

23. Fuel system 24. Headlights 25. Windscreen wipers

22

23

26. Battery voltage

24

27. Bulb for lighting

26

27 010153

25

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D:7

Reading out error code NOTE In the event of an error code, perform the actions recommended in the error code table to identify the fault. Error codes are stored as active and inactive. Active errors are shown in the error code menu. Always use error code menus for reading error codes, otherwise there is a risk of missing error codes. 1

Turn the start key to position I.

WARNING Risk of machine damage. In the event of error codes of level "WARNING" and "STOP", serious machine damage may result if the engine is started. Do not start the engine until the cause of the error code has been identified or repaired. Navigate to the service menu and press Enter.

3

The safety menu is shown. Hold Enter depressed for at least two seconds.

4

The error code list is shown on the display. An active error code is shown on display where field C shows error code number together with X(Y). X shows sequence number for displayed error code and (Y) shows total number of active error codes.

000056

2

000060

1 23 4 5

001998

Scroll between error codes with key 1 and 2 (arrow function). Error codes disappear from the list when the cause has been remedied.


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D:8


5

C

B

E 000389

D

Note error code number (field C) to avoid forgetting. •

Error code level is shown with a symbol in field B

•

Error code is shown in field C

•

Error cause is shown with a symbol in field D

•

The function affected by the error is shown with a symbol in field E The book symbol is an instruction for the operator to read the operator's manual.

VDCT01.02GB

6

Use the error code tables to find more information about the error code.

7

After the remedial action, check that no active error codes remain for the function in question.


1 Engine – Engine

D:9

1 Engine Error codes engine, general When contacting engine suppliers, use the supplier code. •

Display indicates error code as shown in the machine, in accordance with SAE J1939 in SPN/FMI

•

The supplier code indicates the error code in accordance with the engine manufacturer's specification.

Table Specifications FMI

FMI

Description

SAE-text

0

Too high value.

Data valid, but higher than normal operating range.

1

Too low value.

Data valid, but lower than normal operating range.

2

Incorrect data.

Intermittent or incorrect data.

3

Electrical problem.

Abnormally high voltage or short-circuit to higher voltage.

4

Electrical problem.

Abnormally low voltage or short-circuit to lower voltage.

5

Electrical problem.

Abnormally low current or open circuit.

6

Electrical problem.

Abnormally high current or short-circuit to ground.

7

Mechanical problem.

Incorrect response from mechanical system.

8

Mechanical problem or electrical problem.

Abnormal frequency.

9

Communication error.

Abnormal update rate.

10

Mechanical problem or electrical problem.

Abnormally wide variations.

11

Unknown malfunction.

Non-identifiable malfunction.

12

Component error.

Incorrect unit or component.

13

Incorrect calibration.

Values outside calibration values.

14

Unknown malfunction.

Special instructions.

15

Too high value.

Data valid, but higher than normal operating range. The least serious level

16

Too high value.

Data valid, but higher than normal operating range. Moderately severe level

17

Too low value.

Data valid, but below normal operating range: The least serious level

18

Too low value.

Data valid, but below normal operating range: Moderately severe level

19

Communication error.

Received network data incorrect

20-30 31

Reserved for SAE-assignment FMI is not available or the condition that is identified by the SPN exists.

Not available or condition exists


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D:10

1 Engine – Engine

Error codes engine (engine alternative Yuchai YC6A240-30) Table Error codes Yuchai YC6A240-30

Display

29/2

Supplier code P2135

Connections and components

Diagnostic menu

-

Description

Limitation

Action

Signal from accelerator pedal, signal 2 and 1 do not correspond.

Reduced engine power.

Check the cable harness at the control unit.

D794/1:79 D794/1:80

29/3

P0223

Accelerator pedal, short circuit to voltage.



D794/1:80

-

29/4

P0222

Accelerator pedal, short circuit to ground.



D794/1:80

-

84/0

P0501

Machine speed too high.

Engine speed is limited.

Ease off throttle or select higher gear.

-

-

84/2

P0501

Speed signal unreasonable. Machine speed does not correspond with values from fuel injection and engine speed.


Check the engine speed sensor.

D794/1:71

ENGINE, menu 1

Speed signal wrong. Internal error engine control unit.


-

-

Speed signal wrong.


-

ENGINE, menu 1

-

84/11

84/12

P0510

P0500

Check the speed sensor on the transmission.

Check the engine speed sensor. Check the speed sensor on the transmission. Check the engine speed sensor. Check the speed sensor on the transmission.

91/2

P2135

Signal from accelerator pedal, signal 1 and 2 do not correspond.



D794/1:79 D794/1:80

91/3

P0123

Accelerator pedal, short circuit to voltage.



D794/1:79

-

91/4

P0122

Accelerator pedal, short circuit to ground.



D794/1:79

-

91/7

P2299

Signal from accelerator pedal and brake pedal not consistent.

No limitation.


D794/1:79

-

Sensor pressure fuel filter, unreasonable signal.

No limitation.

Check the cable harness between control unit and sensor.

D794/1:81

95/2

P1017

Check the sensor.

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D794/1:80 -

1 Engine – Engine

Display

95/3

Supplier code P1015

D:11

Description

Limitation

Action

Sensor pressure fuel filter, signal high.

No limitation.



Diagnostic menu

D794/1:81

-

D794/1:81

-

Check the sensor. 95/4

P1016

No limitation.

Sensor pressure fuel filter, signal low.

Check the cable harness between control unit and sensor. Check the sensor.

95/7

P1018

Fuel filter clogged.

No limitation.

Change the fuel filter.

-

-

97/3

P2267

Water-in-fuel sensor (B760), short circuit to voltage.

No limitation.


D794/1:43 – B760/1

ENGINE, menu 10

D794/1:43 – B760/1

ENGINE, menu 10


P2266

Water-in-fuel sensor (B760), short circuit to ground.

No limitation.


97/11

P2269

Water in fuel.

No limitation.

Change the fuel prefilter.

D794/1:43 – B760/1

ENGINE, menu 10

98/2

P250B

Sensor engine oil level, unreasonable signal.

No limitation.


-

-

98/3

P250D

Sensor engine oil level, short circuit to voltage.

No limitation.


-

-

98/4

P250C

Sensor engine oil level, short circuit to ground.

No limitation.


-

-

98/12

P250A

Sensor engine oil level, incorrect signal via CAN bus.

No limitation.

Use diagnostic menu to check communication.

D794/1:34

CAN/POWER, menu 3

D794/1:35

Check the cable harness between Control unit, cab (D790-1) and Control unit, engine (D794). 100/2

P0521

No limitation.

Sensor engine oil pressure, unreasonable signal.


-

ENGINE, menu 6

-

ENGINE, menu 6

-

ENGINE, menu 6

Check the sensor. Check the oil level in the engine. 100/3

P0523

Sensor engine oil pressure, short circuit to voltage.

No limitation.


100/4

P0522

Sensor engine oil pressure, short circuit to ground.

No limitation.



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D:12

Display

100/12

1 Engine – Engine

Supplier code P0520

Description

Limitation

Action

Sensor engine oil pressure, incorrect signal via CAN bus.

No limitation.


Connections and components D794/1:34 D794/1:35

Diagnostic menu

CAN/POWER, menu 3


P0524

Low engine oil pressure.


Check the oil level in the engine.

-

ENGINE, menu 6

D794/2:32 – 36

ENGINE, menu 6

D794/2:34

ENGINE, menu 6

D794/2:34

ENGINE, menu 6

D794/1:34

CAN/POWER, menu 3

Change oil filter. Check the system pressure valves and the safety valve in the lubrication system. Check the sensor. 102/2

102/3

P0236

P0238

Sensor boost pressure and sensor air pressure, unreasonable signal combination.


Sensor boost pressure, short circuit to voltage.


Check the cable harness between control unit and sensor. Check the sensors. Check the cable harness between control unit and sensor. Check the sensor.

102/4

P0237

Sensor boost pressure, short circuit to ground.



102/12

P0235


Sensor boost pressure, incorrect signal via CAN bus.


D794/1:35


105/4

P0098

P0097

Sensor intake temperature, incorrect signal. Short circuit to voltage.

No limitation.

Sensor intake temperature, short circuit to ground.

No limitation.


D794/2:36

ENGINE, menu 7

D794/2:36

ENGINE, menu 7

D794/1:34

CAN/POWER, menu 3

Check the sensor. Check the cable harness between control unit and sensor. Check the sensor.

105/12

P0099

Sensor intake temperature, incorrect signal via CAN bus.

No limitation.

Use diagnostic menu to check communication. Check the cable harness between Control unit, cab (D790-1) and Control unit, engine (D794).

VDCT01.02GB


D794/1:35

1 Engine – Engine

Display

108/2

108/3

Supplier code P2227

P2229

D:13

Description

Limitation

Action

Sensor air pressure and sensor boost pressure, unreasonable signal combination.



Sensor air pressure, short circuit to voltage.



Diagnostic menu

D794/2:32 – 2:36

ENGINE, menu 6

-

-

-

-

D794/1:34

CAN/POWER, menu 3

Check the sensors. Check the cable harness between control unit and sensor. Check the sensor.

108/4

P2228

Sensor air pressure, short circuit to ground.



108/12

P0000


Sensor air pressure, incorrect signal via CAN bus.


D794/1:35


110/3

P0116

P0118

Coolant temperature sensor, the temperature is unreasonable in relation to the oil temperature.


Sensor coolant temperature, short circuit to voltage.



D794/2:15

ENGINE, menu 7

D794/2:15

ENGINE, menu 7

D794/2:15

ENGINE, menu 7

D794/1:34

CAN/POWER, menu 3

Check the sensor.


110/4

P0117


Sensor coolant temperature, short circuit to ground.


110/12

P0115

Sensor coolant temperature, incorrect signal via CAN bus.



D794/1:35

Check the cable harness between Control unit, cab (D790-1) and Control unit, engine (D794).


VDCT01.02GB

D:14

Display

110/15

1 Engine – Engine

Supplier code P0217

Description

Limitation

Action

Coolant temperature too high.

No limitation.



Diagnostic menu

D794/2:15

-

Check that radiator is clean. Check the thermostat. Check the cap on the expansion tank. Check if there is air in coolant system. Check the cable harness between control unit and sensor. Check the sensor. 111/2

P2557

Sensor coolant level, unreasonable signal combination.

No limitation.


-

ENGINE, menu 10

111/3

P2559

Sensor coolant level, short circuit to voltage.

No limitation.


-

ENGINE, menu 10

111/4

P2558

Sensor coolant level, short circuit to voltage.

No limitation.


-

ENGINE, menu 10

111/12

P2556

Sensor coolant level, open circuit.

No limitation.


-

ENGINE, menu 10

132/3

P0101

Mass air flow sensor, signal deviation too high.

No limitation.


-

-

132/3

P0103

Mass air flow sensor, air flow too high.

No limitation.


-

-

132/4

P0101

Mass air flow sensor, signal deviation too low.

No limitation.


-

-

132/4

P0102

Mass air flow sensor, air flow too low.

No limitation.


-

-

157/3

P0193

Sensor fuel pressure, short circuit to voltage.



D794/2:14

-

D794/2:14

-

D794/2:14

-


P0192

Sensor fuel pressure, short circuit to ground.



157/15

P0191

Sensor fuel pressure, signal deviation too high.



VDCT01.02GB


1 Engine – Engine

Display

157/17

Supplier code P0191

D:15

Description

Limitation

Action

Sensor fuel pressure, signal deviation too low.




Diagnostic menu

D794/2:14

-


P2533

Ignition key lock, open circuit.

No limitation.


D794/1:40

-

168/3

P0563

High battery voltage.

No limitation.

Check the voltage feed.

D794/1:2

-

D794/1:2

-

If equipment for assisted start is connected, disconnect it. 168/4

P0562

Low battery voltage.

The engine may be difficult to start.

Check and charge the batteries. Check the cable harness to the control unit. Check alternator, battery and cable harness between battery and alternator.

171/3

P0073

Sensor outdoor temperature, short circuit to voltage.

No limitation.


-

-

171/4

P0072

Sensor outdoor temperature, short circuit to ground.

No limitation.


-

-

171/12

P0071

Sensor outdoor temperature, incorrect signal via CAN bus.

No limitation.


D794/1:34

CAN/POWER, menu 3

D794/1:35


P0113

Sensor intake temperature, high signal.

No limitation.


D794/2:36

ENGINE, menu 7

D794/2:36

ENGINE, menu 7

-

-

-

-


P0112

Sensor intake temperature, low signal.

No limitation.


174/3

P0183

Sensor fuel temperature, short circuit to voltage.

No limitation.


174/4

P0182

Sensor fuel temperature, short circuit to ground.

No limitation.



VDCT01.02GB

D:16

Display

175/3

1 Engine – Engine

Supplier code P0198

Description

Limitation

Action

Sensor engine oil temperature, short circuit to voltage.

No limitation.



Diagnostic menu

-

ENGINE, menu 7

-

ENGINE, menu 7

D794/1:34

CAN/POWER, menu 3


P0197

No limitation.

Sensor engine oil temperature, short circuit to ground.


175/12

P0195

Sensor engine oil temperature, incorrect signal via CAN bus.

No limitation.


D794/1:35


P0196

High oil temperature.

No limitation.

Check the oil level.

-

ENGINE, menu 7

D794/2:09

-

Check coolant temperature and level. 190/7

P0016

No limitation.

Sensor camshaft and sensor crankshaft, unreasonable signal combination.

Check the cable harness between control unit and sensors.

D794/2:23

Check the sensors. 190/11

P0336

Sensor rotation speed crankshaft, irregular signal.

The engine is extremely difficult to start and runs unevenly or stops.


D794/2:23

ENGINE, menu 2

D794/2:09

-

D794/2:23

-

D794/1:34

CAN/POWER, menu 3

Check the sensor.

Reduced engine power. 190/12

P0008

Sensor camshaft rotation speed, signal error.

No limitation.


190/12

P0335

Sensor rotation speed crankshaft, no signal.

The engine is extremely difficult to start and runs unevenly or stops.


Reduced engine power. 520/11

UD13A

520/12

UD13B

CAN bus, communication error.

No limitation.

Use diagnostic menu to check communication. Check the cable harness between Control unit, cab (D790-1) and Control unit, engine (D794).

VDCT01.02GB


D794/1:35

1 Engine – Engine

Display

533/15

Supplier code P0219

D:17

Description

Limitation

Action

Engine speed too high.

No limitation.

Check the fuel pressure.


Diagnostic menu

Engine, menu 2

Check the cable harness between control unit and sensors. Check sensor camshaft rotation speed and sensor crankshaft. 596/2

P0564

No limitation.

Cruise control input, unreasonable signal.


D794/1:31

-

D794/1:64 D794/1:74 D794/1:46

597/2

P0504

The signal from the brake pedal does not correspond with the accelerator pedal.

No limitation.


-

-

597/12

P0571

Brake pedal, incorrect signal via CAN bus.

No limitation.


D794/1:34

CAN/POWER, menu 3

D794/1:35


P0704

Sensor clutch, unreasonable signal.

No limitation.


-

-

598/12

P0704

Sensor clutch, incorrect signal via CAN bus.

No limitation.


D794/1:34

CAN/POWER, menu 3

D794/1:35


P1626

Drive circuit lamp 1, overheating.

No limitation.


-

-

624/2

P162A

Drive circuit lamp 2, overheating.

No limitation.


-

-

624/2

P162E

Drive circuit lamp 3, overheated.

No limitation.


-

-

624/2

P161C

Drive circuit system lamp, overheated.

No limitation.


-

-

624/2

P1632

Drive circuit warning lamp, overheated.

No limitation.


-

-


VDCT01.02GB

D:18

Display

1 Engine – Engine

Supplier code

Description

Limitation

Action


Diagnostic menu

624/3

P1623

Drive circuit lamp 1, short circuit to voltage.

No limitation.


-

-

624/3

P1627


No limitation.


-

-

624/3

P162B


No limitation.


-

-

624/3

P1619

Drive circuit system lamp, short circuit to voltage.

No limitation.


-

-

624/3

P162F

Drive circuit warning lamp, short circuit to voltage.

No limitation.


-

-

624/4

P1624

Drive circuit lamp 1, short circuit to ground.

No limitation.


-

-

624/4

P1628


No limitation.


-

-

624/4

P162C


No limitation.


-

-

624/4

P161A

Drive circuit system lamp, short circuit to ground.

No limitation.


-

-

624/4

P1630

Drive circuit warning lamp, short circuit to ground.

No limitation.


-

-

624/12

P1625

Drive circuit lamp 1, open circuit.

No limitation.


-

-

624/12

P1629


No limitation.


-

-

624/12

P162D


No limitation.


-

-

624/12

P161B

Drive circuit system lamp, open circuit.

No limitation.


-

-

624/12

P1631

Drive circuit warning lamp, open circuit.

No limitation.


-

-

630/2

P062F

No limitation.

-

P062F

Contact Yuchai service.

-

630/4

Internal error engine control unit.

630/12

P062F

VDCT01.02GB


1 Engine – Engine

Display

636/11

636/12

639/12

Supplier code P0341

P0340

UC029

D:19

Description

Limitation

Action

Sensor rotation speed camshaft, irregular signal.

The engine takes longer to start than normal. The engine is running normally once it has started.




No limitation.


Sensor rotation speed camshaft, no signal.

CAN bus (A), electrical problem.


Diagnostic menu

D794/2:09

-

D794/2:09

-

D794/1:34

CAN/POWER, menu 3

Check the sensor.

Check the sensor.

D794/1:35


P1511

Sensor machine speed, incorrect signal form.



D794/1:71

ENGINE, menu 2

D794/1:71

ENGINE, menu 2

D794/1:71

ENGINE, menu 2

D794/3:04

-


P1512




645/12

P1513




651/3

P0262

Injector cylinder 1, short circuit to ground.

Engine only runs on 3 cylinders and has reduced power.

Check the cable harness between control unit and injector.

D794/3:13

Check the injector. 651/8

P0261

Injector cylinder 1, short circuit between cables.



D794/3:04

-

D794/3:13


P0263

Injector cylinder 1, installation-dependent error.



D794/3:04

-

D794/3:13


P0263

Injector cylinder 1, indefinable error.



D794/3:04

-

D794/3:13

Check the injector.


VDCT01.02GB

D:20

Display

651/11

1 Engine – Engine

Supplier code P1213

Description

Limitation

Action


No limitation.



Diagnostic menu

D794/3:04

-

D794/3:13


P1214


No limitation.


D794/3:04

-

D794/3:13


P1215


No limitation.


D794/3:04

-

D794/3:13


P0201

Injector cylinder 1, open circuit.

No limitation.


D794/3:04

-

D794/3:13


P0265




D794/3:06

-

D794/3:11


P0264




D794/3:06

-

D794/3:11


P0266




D794/3:06

-

D794/3:11


P0266




D794/3:06

-

D794/3:11


P1216


No limitation.


D794/3:06

-

D794/3:11


P1217


No limitation.

Check the cable harness between control unit and injector. Check the injector.

VDCT01.02GB


D794/3:06 D794/3:11

-

1 Engine – Engine

Display

652/11

Supplier code P1218

D:21

Description

Limitation

Action


No limitation.



Diagnostic menu

D794/3:06

-

D794/3:11


P0202


No limitation.


D794/3:06

-

D794/3:11


P0268




D794/3:05

-

D794/3:12


P0267




D794/3:05

-

D794/3:12


P0269




D794/3:05

-

D794/3:12


P0269




D794/3:05

-

D794/3:12


P1219


No limitation.


D794/3:05

-

D794/3:12


P121A


No limitation.


D794/3:05

-

D794/3:12


P121B


No limitation.


D794/3:05

-

D794/3:12


P0203


No limitation.


D794/3:05

-

D794/3:12

Check the injector.


VDCT01.02GB

D:22

Display

654/3

1 Engine – Engine

Supplier code P0271

Description

Limitation

Action





Diagnostic menu

D794/3:03

-

D794/3:14


P0270




D794/3:03

-

D794/3:14


P0272




D794/3:03

-

D794/3:14


P0272




D794/3:03

-

D794/3:14


P121C


No limitation.


D794/3:03

-

D794/3:14


P121D


No limitation.


D794/3:03

-

D794/3:14


P121E


No limitation.


D794/3:03

-

D794/3:14


P0204


No limitation.


D794/3:03

-

D794/3:14


P0274




D794/3:01

-

D794/3:16


P0273



Check the cable harness between control unit and injector. Check the injector.

VDCT01.02GB


D794/3:01 D794/3:16

-

1 Engine – Engine

Display

655/11

Supplier code P0275

D:23

Description

Limitation

Action





Diagnostic menu

D794/3:01

-

D794/3:16


P0275




D794/3:01

-

D794/3:16


P121F


No limitation.


D794/3:01

-

D794/3:16


P1220


No limitation.


D794/3:01

-

D794/3:16


P1221


No limitation.


D794/3:01

-

D794/3:16


P0205


No limitation.


D794/3:01

-

D794/3:16


P0277




D794/3:02

-

D794/3:15


P0276




D794/3:02

-

D794/3:15


P0278




D794/3:02

-

D794/3:15


P0278




D794/3:02

-

D794/3:15

Check the injector.


VDCT01.02GB

D:24

Display

656/11

1 Engine – Engine

Supplier code P1222

Description

Limitation

Action


No limitation.



Diagnostic menu

D794/3:02

-

D794/3:15


P1223


No limitation.


D794/3:02

-

D794/3:15


P1224


No limitation.


D794/3:02

-

D794/3:15


P0206


No limitation.


D794/3:02

-

D794/3:15


P0540

Relay, preheating (K312), signal error.

Preheating not working.

Check the cable harness between control unit and component.

D794/1:55 – K312/86

ENGINE, menu 5

D794/1:59 – K312/85

Check the component. 677/3

P0617 P1638

677/4

P0616 P1639

677/5

729/3

P163A

P0541

Relay starter motor, short circuit to voltage or activated too long.

No limitation.

Relay starter motor, short circuit to ground.

No limitation.

Relay starter motor, open circuit.

No limitation.

Relay preheating (K312), short circuit to ground.

No limitation.


D794/1:37


D794/1:37


D794/1:37


D794/1:55 – K312/86

-

D794/1:51 -

D794/1:51 -

D794/1:51 ENGINE, menu 5

D794/1:59 – K312/85


P0542

Relay preheating (K312), short circuit to voltage.

No limitation.


D794/1:55 – K312/86

ENGINE, menu 5

D794/1:59 – K312/85


P1020

Relay preheating (K312), high signal.

No limitation.

Check the cable harness between control unit and component. Check the component.

VDCT01.02GB


D794/1:55 – K312/86 D794/1:59 – K312/85

ENGINE, menu 5

1 Engine – Engine

Display

729/4

Supplier code P1021

D:25

Description

Limitation

Action

Relay preheating (K312), active too short time.

No limitation.



Diagnostic menu

D794/1:55 – K312/86

ENGINE, menu 5

D794/1:59 – K312/85


P1022

Relay preheating (K312), high signal.

No limitation.


D794/1:55 – K312/86

ENGINE, menu 5

D794/1:59 – K312/85


P1023

Relay preheating (K312), low signal.

No limitation.


D794/1:55 – K312/86

ENGINE, menu 5

D794/1:59 – K312/85


UD10E

898/12

UD10F

CAN bus, communication error.

No limitation.


D794/1:34 D794/1:35

CAN/POWER, menu 3


P1617

Voltage error at shut-off, high battery voltage.



D794/1:02

-

D794/1:02

-

D794/1:02

-

D794/1:34

CAN/POWER, menu 3


P1618

Voltage error at shut-off, low battery voltage.


Check the cable harness at the control unit. Check the component.

970/12

P1616

Voltage error at shut-off, monitoring switched off.


Check the cable harness at the control unit. Check the component.

985/2

P2519

985/12

P2519

AC compressor, incorrect CAN message.

No limitation.


D794/1:35


P2530

Ignition key lock, incorrect signal.

No limitation.


D794/1:61

-

1041/8

P2530

Switch remote start engine, fixed in activated position.

No limitation.


D794/1:61

-

1071/2

P0483

Drive circuit cooling fan, overheated.

No limitation.


D794/1:13

-


D794/1:58

VDCT01.02GB

D:26

Display

1071/3

1 Engine – Engine

Supplier code P0692


Diagnostic menu

-

Description

Limitation

Action

Drive circuit cooling fan, short circuit to voltage.

No limitation.


D794/1:13 D794/1:58

1071/3

P0694

Drive circuit cooling fan 2, short circuit to voltage.

No limitation.


-

-

1071/4

P0691

Drive circuit cooling fan, short circuit to ground.

No limitation.


D794/1:13

-

D794/1:58

1071/4

P0693

Drive circuit cooling fan 2, short circuit to ground.

No limitation.


-

-

1071/12

P0480

Drive circuit cooling fan, open circuit.

No limitation.


D794/1:13

-

D794/1:58

1072/3

P0080

Drive circuit brake valve, short circuit to voltage.

No limitation.


-

-

1072/4

P0079

Drive circuit brake valve, short circuit to ground.

No limitation.


-

-

1072/255

P1633

Drive circuit brake valve, open circuit.

No limitation.


-

-

1072/255

P1634

Drive circuit brake valve, short circuit to voltage.

No limitation.


D794/3:08

-

1074/2

P0476

Drive circuit exhaust brake, overheated.

No limitation.


D794/3:08

-

1074/3

P0478

Drive circuit exhaust brake, short circuit to voltage.

No limitation.


D794/3:08

-

1074/4

P0477

Drive circuit exhaust brake, short circuit to ground.

No limitation.


D794/3:08

-

1074/12

P0476

Drive circuit exhaust brake, open circuit.

No limitation.


D794/3:08

-

1079/3

P0643

Voltage feed 1 sensor engine, high signal.



-

-

1079/4

P0642

Voltage feed 1 sensor engine, low signal.

No limitation.


-

-

1080/3

P0653

Voltage feed 2 sensor engine, high signal.



-

-

1080/4

P0652

Voltage feed 2 sensor engine, low signal.

No limitation.


-

-

VDCT01.02GB


1 Engine – Engine

Display

1081/2

Supplier code P1638

D:27

Description

Limitation

Action

Drive circuit indicator light preheating, overheated.

No limitation.



Diagnostic menu

D794/1:38 – D797F/K1:26

ENGINE, menu 10

D794/1:38 – D797F/K1:26

ENGINE, menu 10

D794/1:38 – D797F/K1:26

ENGINE, menu 10

D794/1:38 – D797F/K1:26

ENGINE, menu 10

D794/2:09

ENGINE, menu 2


P1635

Drive circuit indicator light preheating, short circuit to voltage.

No limitation.


1081/4

P1636

Drive circuit indicator light preheating, short circuit to ground.

No limitation.


1081/12

P1637

Drive circuit indicator light preheating, open circuit.

No limitation.


1108/16

P1613

Engine speed too high.

No limitation.

Check the cable harness between control unit and the components.

D794/2:23

Check sensor camshaft rotation speed and sensor crankshaft. Check the fuel pressure. 1192/2

P0046

Valve boost pressure control, overheating.

No limitation.


D794/2:01

-

1192/3

P0048

Valve boost pressure control, short circuit to voltage.

No limitation.


D794/2:01

-

1192/3

P1000

Valve boost pressure control, signal too high.

No limitation.


D794/2:01

-

1192/4

P0047

Valve boost pressure control, short circuit to ground.

No limitation.


D794/2:01

-

1192/4

P1001

Valve boost pressure control, signal too low.

No limitation.


D794/2:01

-

1192/12

P0045

Valve boost pressure control, open circuit.

No limitation.


D794/2:01

-

1192/12

P1002

Valve boost pressure control, incorrect signal.

No limitation.


D794/2:01

-


VDCT01.02GB

D:28

Display

1 Engine – Engine

Supplier code

Description

Limitation

Action


Diagnostic menu

1213/2

P0650

Drive circuit warning lamp engine fault, overheated.

No limitation.


-

-

1213/3

P0650

Drive circuit warning lamp engine fault, short circuit to voltage.

No limitation.


-

-

1213/4

P0650

Drive circuit warning lamp engine fault, short circuit to ground.

No limitation.


-

-

1213/12

P0650

Drive circuit warning lamp engine fault, open circuit.

No limitation.


-

-

1231/12

UC038

No limitation.

UC047


D794/1:34

1235/12

CAN bus (C), electrical problem.

CAN/POWER, menu 3

D794/1:35


P0300

Misfiring on multiple cylinders.



-

-

1323/3

P0301

Misfiring cylinder 1.



-

-

1324/3

P0302




-

-

1325/3

P0303




-

-

1326/3

P0304




-

-

1327/3

P0305




-

-

1328/3

P0306




-

-

1351/2

P0645

Drive circuit AC compressor, overheated.

No limitation.


D794/2:11

-

1351/3

P0647

Drive circuit AC compressor, short circuit to voltage.

No limitation.


D794/2:11

-

1351/4

P0646

Drive circuit AC compressor, short circuit to ground.

No limitation.


D794/2:11

-

1351/12

P0645

Drive circuit AC compressor, open circuit.

No limitation.


D794/2:11

-

1485/3

P0687

Main relay 2, electrical problem.

No limitation.


-

-

VDCT01.02GB


1 Engine – Engine

Display

Supplier code

D:29

Description

Limitation

Action


Diagnostic menu

1485/4

P0686

Main relay 2, electrical problem.

No limitation.


-

-

1624/3

P2158

Sensor machine speed, speed too high.



D794/1:71

-

1624/4

P2160

Sensor machine speed, speed too low.



D794/1:71

-

1624/12

P2157

Sensor machine speed, speed message via CAN bus incorrect.



D794/1:34

CAN/POWER, menu 3

D794/1:35


1624/255

P2159

Sensor machine speed, unreasonable speed.



D794/1:71

-

1639/3

P0526

Sensor fan speed, short circuit to voltage.

No limitation.


D794/1:68

-

Sensor fan speed, short circuit to ground.

No limitation.


D794/1:68

1639/4

P0527

D794/1:69 -

D794/1:69

2634/3

P160E

Main relay, short circuit to voltage.

No limitation.


-

-

2634/4

P160F

Main relay, short circuit to ground.

No limitation.


-

-

2791/2

P0403

Drive circuit EGR valve, overheating.

No limitation.


-

-

2791/3

P0490

Drive circuit EGR valve, short circuit to voltage.

No limitation.


-

-

2791/4

P0489

Drive circuit EGR valve, short circuit to ground.

No limitation.


-

-

2791/5

P0404

Drive circuit EGR valve, open circuit.

No limitation.


-

-

520192/2

P063B

Voltage feed speed sensor, incorrect signal (ADC).

The engine is only running at idle.


-

-

-

-


P060B

Voltage feed speed sensor, signal too high (ADC).




VDCT01.02GB

D:30

Display

520192/4

1 Engine – Engine

Supplier code P061B

Description

Limitation

Action

Voltage feed speed sensor, signal too low (ADC).




Diagnostic menu

-

-

-

-

Check the sensor. 520192 /11

P062B


Voltage feed speed sensor, incorrect test impulse(ADC).


520193/3

P0103

Mass air flow sensor, air flow too high.

No limitation.


-

-

520193/4

P0102

Mass air flow sensor, air flow too low,

No limitation.


-

-

520194/2

P0649

Warning lamp speed limitation, overheated.

No limitation.


-

-

520194/3

P0649

Warning lamp speed limitation, short circuit to voltage.

No limitation.


-

-

520194/4

P0649

Warning lamp speed limitation, short circuit to ground.

No limitation.


-

-

520194/5

P0649

Warning lamp speed limitation, open circuit.

No limitation.


-

-

520195 /15

P0402

EGR control, signal too high.

No limitation.


-

-

520196 /17

P0401

EGR control, signal too low.

No limitation.


-

-

520197/3

P022C

Bypass valve cold start, short circuit to voltage.

No limitation.


-

-

520197/4

P022B

Bypass valve cold start, short circuit to ground.

No limitation.


-

-

520197 /12

P022A

Bypass valve cold start, open circuit.

No limitation.


-

-

520198/2

P0116

Sensor coolant temperature, unreasonable signal.

No limitation.


D794/2:15

ENGINE, menu 7

D794/2:15

ENGINE, menu 7


P0116

Sensor coolant temperature, unreasonable signal.

No limitation.


VDCT01.02GB


1 Engine – Engine

Display

Supplier code

D:31

Description

Limitation

Action


Diagnostic menu

520199/2

P0856

DCS, unreasonable signal.

No limitation.


-

-

520200 /20

P161F

Incorrect compression test.

No limitation.

contact Yuchai service.

-

-

520201/3

P1505

Sensor outdoor temperature (BET), signal too high.

No limitation.


-

-

520201/4

P1506

Sensor outdoor temperature (BET), signal too low.

No limitation.


-

-

520202/3

P1507

Sensor outdoor temperature (ClgZn), signal too high.

No limitation.


-

-

520202/4

P1508

Sensor outdoor temperature (ClgZn), signal too low.

No limitation.


-

-

520203/3

P1509

Sensor intake temperature, signal too high.

No limitation.


D794/2:36

-

D794/2:36

-


P150A

No limitation.

Sensor intake temperature, signal too low.


520204/2

P1635

Switch exhaust brake, unreasonable signal.

No limitation.


D794/2:29

-

520205/3

P245D

EGR valve, short circuit to voltage or overheated.

No limitation.


-

-

520205/4

P245C

EGR valve, short circuit to ground.

No limitation.


-

-

520205 /12

P245A

EGR valve, open circuit.

No limitation.


-

-

520206/2

P0470

Exhaust back pressure sensor, unreasonable signal.

No limitation.


-

-

520206/3

P0473

Sensor exhaust back pressure, signal too high.

No limitation.


-

-

520206/4

P0472

Sensor exhaust back pressure, signal too low.

No limitation.


-

-

520207/3

P1008

Relay heating coil fuel filter, short circuit to voltage.

No limitation.


D794/2:04

-

Relay heating coil fuel filter, short circuit to ground.

No limitation.


D794/2:04

520207/4

P1009


D794/2:05 -

D794/2:05

VDCT01.02GB

D:32

Display

1 Engine – Engine

Supplier code

Description

Limitation

Action


Diagnostic menu

520208/2

P0409

Sensor airflow EGR valve, unreasonable signal.

No limitation.


-

-

520208/3

P0406

Sensor airflow EGR valve, short circuit to voltage.

No limitation.


-

-

520208/4

P0405

Sensor airflow EGR valve, short circuit to ground.

No limitation.


-

-

520208 /12

P0409

Sensor airflow EGR valve, open circuit.

No limitation.


-

-

520209/2

P040B

Sensor exhaust temperature, unreasonable signal.

No limitation.


-

-

520209/3

P040D

Sensor exhaust temperature, short circuit to voltage.

No limitation.


-

-

520209/4

P040C

Sensor exhaust temperature, short circuit to ground.

No limitation.


-

-

520209 /12

P040A

Sensor exhaust temperature, open circuit.

No limitation.


-

-

520210/3 or/255

UC158

Communication error, display.

No limitation.


-

-

520211 /12

P0000

Communication error, CAN bus.

No limitation.

D794/1:34

CAN/POWER, menu 3

520212/3

UD100


520213 /12

UC103

520214 /12

UC113

520215/3

UD101

520216/3

UC156

520217/3

UD103

520218/3

UD10C

520218/4

UD10D

520218 /12

UD104

520219/3

UD110

520219 /12

UD111

520220/3

UD112

520220 /12

UD113

VDCT01.02GB



D794/1:35

1 Engine – Engine

Display

Supplier code

D:33


Diagnostic menu

Description

Limitation

Action


Engine switched off: engine cannot be started. Engine running: engine misfires.


-

-

520222 /14

P0607

520222 /14

P0607

520222 /14

P0607

520223 /20

P160C

Fuel injection, test mode.

No limitation.


-

-

520224/3

P150B

Sensor air humidity, signal too high.

No limitation.


-

-

520224/4

P150C

Sensor air humidity, signal too low.

No limitation.


-

-

520225 /11

P1302

Injection error, software error.

No limitation.


-

-

520225 /15

P1301

Injection error, uneven amount of fuel between the cylinders.

No limitation.


-

-

520225 /16

P1300

Injection error, uneven output between the cylinders.

No limitation.


-

-

520226 /12

P1225

Pressure fault on multiple injectors.

The engine is switched off.

Check the injectors.

-

-

520227/2

P154C

Multi-function lever, unreasonable position.

No limitation.


D794/1:62

-

520227/3

P154A

Multi-function lever, short circuit to voltage.

No limitation.


D794/1:62

-

520227/4

23/04

Multi-function lever, short circuit to ground.

No limitation.


D794/1:62

-

520228 /15

P1614

Sensor engine speed, unreasonable signal

No limitation.


D794/2:23

ENGINE, menu 2

-

-

-

-

D794/23:09

-


P2263

Intake pressure difference too high.

No limitation.


520230 /17

P2263

Intake pressure difference too low.

No limitation.


520231/2

P062A

Feed pump, overheated.

No limitation.


D794/23:10

Check the component.


VDCT01.02GB

D:34

Display

520231/3

1 Engine – Engine

Supplier code P0629

Description

Limitation

Action

Feed pump, short circuit to voltage.

No limitation.



Diagnostic menu

D794/23:09

-

D794/23:10


P0628

Feed pump, short circuit to ground.

No limitation.


D794/23:09

-

D794/23:10

Check the component. 520231 /12

P0627

Feed pump, open circuit.

No limitation.


D794/23:09

-

D794/23:10

Check the component. 520232/ 255

P1615

520233 /20

P1621

520234/2

P0488

520234/3

520234/4

P2142

P2141

Test mode.

No limitation.


-

-

Throttle, overheated.

No limitation.


D794/1:79

-


D794/1:79

D794/1:80

Throttle, short circuit to voltage.

No limitation.

Throttle, short circuit to ground.

The engine is running at idle.


D794/1:79

Throttle, open circuit.

No limitation.


D794/1:79

-

D794/1:80 -

D794/1:80 -

520234 /12

P0487

520235/3

P1636

Reference voltage 12 V, signal too high.

No limitation.


-

-

520235/4

P1637

Reference voltage 12 V, signal too high.

No limitation.


-

-

520236/2

P1007

Software error engine control unit (FMTC).

No limitation.


-

-

520237/3

UD114

No limitation.

UD115


D794/1:34

520238 /12


CAN/POWER, menu 3

520239/2

P161E

520239 /11

P161D

VDCT01.02GB

D794/1:80

D794/1:35

Check the cable harness between Control unit, cab (D790-1) and Control unit, engine (D794). Internal error engine control unit.

No limitation.



-

-

1 Engine – Engine

Display

Supplier code

523218 /12

UC104

523222 /12

UC157

523350/3

P1203

D:35

Description

Limitation

Action


No limitation.



Diagnostic menu

CAN/POWER, menu 3

Check the cable harness between Control unit, cab (D790-1) and Control unit, engine (D794). Injector bank 1, short circuit between cables.

The engine is only running on three cylinders.


D794/3:04


D794/3:11

-

D794/3:13 D794/3:06 D794/3:05 D794/3:12

523350/4

P1204

Injector bank 1, short circuit to ground.



D794/3:04


D794/3:11

-

D794/3:13 D794/3:06 D794/3:05 D794/3:12

523350 /11

P1205

Injector bank 1, installation-dependent error.



D794/3:04


D794/3:11

-

D794/3:13 D794/3:06 D794/3:05 D794/3:12

523350 /11

P1206

Injector bank 1, electrical problem.



D794/3:04


D794/3:11

-

D794/3:13 D794/3:06 D794/3:05 D794/3:12

523351 /11

P1207




D794/3:04


D794/3:11

-

D794/3:13 D794/3:06 D794/3:05 D794/3:12

523351 /11

P1208




D794/3:04


D794/3:11

-

D794/3:13 D794/3:06 D794/3:05 D794/3:12


VDCT01.02GB

D:36

Display

523351 /11

1 Engine – Engine

Supplier code P120A


Diagnostic menu

-

Description

Limitation

Action




D794/3:04


D794/3:11

D794/3:13 D794/3:06 D794/3:05 D794/3:12

523351 /12

P1209

Injector bank 1, open circuit.



D794/3:04


D794/3:11

-

D794/3:13 D794/3:06 D794/3:05 D794/3:12

523352/3

P120B

Injector bank 2, short circuit between cables.



D794/3:03


D794/3:16

-

D794/3:14 D794/3:01 D794/3:02 D794/3:15

523352/4

P120C

Injector bank 2, short circuit to ground.



D794/3:03


D794/3:16

-

D794/3:14 D794/3:01 D794/3:02 D794/3:15

523352 /11

P120D




D794/3:03


D794/3:16

-

D794/3:14 D794/3:01 D794/3:02 D794/3:15

523352 /11

P120E

Injector bank 2, electrical problem.



D794/3:03


D794/3:16

D794/3:14 D794/3:01 D794/3:02 D794/3:15

523353 /11

P120F




D794/3:03


D794/3:16

D794/3:14 D794/3:01 D794/3:02 D794/3:15

VDCT01.02GB


-

1 Engine – Engine

Display

523353 /11

Supplier code P1210

D:37


Diagnostic menu

-

Description

Limitation

Action




D794/3:03


D794/3:16

D794/3:14 D794/3:01 D794/3:02 D794/3:15

523353 /11

P1212




D794/3:03


D794/3:16

-

D794/3:14 D794/3:01 D794/3:02 D794/3:15

523352 /12

P1211

Injector bank 2, open circuit.



D794/3:03


D794/3:16

-

D794/3:14 D794/3:01 D794/3:02 D794/3:15




-

-

P100E

Valve fuel pressure control, leakage.



D794/2:14

-

523470/7

P1010

Valve fuel pressure control, does not open.



D794/2:14

-

523470 /11

P100F

Valve fuel pressure control, fuel pressure too high.



D794/2:14

-

523500 /12

UC001


No limitation.

D794/1:34

CAN/POWER, menu 3

523550/2

P0607


523354/2

P062B

523354/3

P062B

523354/4

P062B

523354 /12

P062B

523355/2

P062B

523355/3

P062B

523355/4

P062B

523355 /12

P062B

523420/2

P060C

523470/0

D794/1:35



VDCT01.02GB

D:38

Display

1 Engine – Engine

Supplier code

Description

Limitation

Action


Diagnostic menu

-

-

523600 /12

P0607


No limitation.


523601/3

P0699

Voltage feed 3 sensor, short circuit to voltage.



-

523601/4

P0698

Voltage feed 3 sensor, short circuit to ground.



-

523604 /12

UD1102


No limitation.

523605 /11

UD1104


523605 /12

UD1105

523606 /11

UD1106

523606 /12

UD1107

523607 /11

UD1108

523608 /11

UD110A

523608 /12

UD110B

523612/3

P1607


523612/4

P1608


523613/2

P1014

Unreasonable fuel pressure.

D794/1:34 D794/1:35

CAN/POWER, menu 3


No limitation.


-

-



D794/2:14

-

D794/2:14

-

D794/2:14

-

D794/2:14

-


P0088

Fuel pressure too high.


Check the fuel pressure. Check the fuel pump. Check the sensor.

523613/4

P0087

Fuel pressure too low.


Check the fuel pressure. Check the fuel pump. Check the fuel filters. Check the sensor.

523613/5

P1019




VDCT01.02GB


1 Engine – Engine

Display

523613/7

Supplier code P1018

D:39

Description

Limitation

Action





Diagnostic menu

D794/2:14

-

D794/2:14

-

Check the fuel pump. Check the fuel filters Check the sensor. 523613 /15

P1012




523613 /16

P1011




D794/2:14

-

523613 /17

P1013




D794/2:14

-

D794/2:14

-

Check the fuel pump. Check the fuel filters. Check the sensor. 523613 /18

P101A




523615/2

P0252

Fuel metering valve, overheated power stage.

No limitation.


-

-

523615/3

P0254

Valve fuel metering, short circuit to voltage.

No limitation.


-

-

523615/4

P0253

Valve fuel metering, short circuit to ground.

No limitation.


-

-

523615/5

P0251

Valve fuel metering, open circuit.

No limitation.


-

-

523615 /16

P025C

Fuel metering valve, status signal too low.

No limitation.


-

-

523615 /18

P025D

Fuel metering valve, status signal too high.

No limitation.


-

-

523617 /11

P060A


No limitation.


D794/1:34

CAN/POWER, menu 3

D794/1:35



VDCT01.02GB

D:40

1 Engine – Engine

Error codes engine (engine alternative Cummins QSB6.7) Table Error codes engine (engine alternative Cummins QSB6.7)

Code

J1587

84 / 2

P084 / 2

84 / 10

P084 / 10

Description

Limitation

Action


Diagnostic menu

Machine speed sensor circuit: Data erratic, intermittent or incorrect. The ECU 794 lost the machine speed signal.

Engine speed limited to Maximum Engine Speed without VSS parameter value. Cruise control, Gear-Down Protection, and Road Speed Governor will not work.


D794

ENGINE, menu 2

Manipulation of machine speed sensor circuit has been detected: Abnormal change rate. Invalid or incorrect machine speed signal. The signal indicates an erratic connection or VSS manipulation.

Engine speed limited to Maximum Engine Speed without VSS parameter value. Cruise control, Gear-Down Protection, and Road Speed Governor will not work.


D794

ENGINE, menu 2

Check the sensor.

Check the sensor.

91 / 0

P91 / 0

Accelerator pedal or lever position sensor 1: Data valid but higher than the normal working range, the most severe level. A frequency above 1500 Hz has been detected on the accelerator pedal's frequency input to ECU 794.

Heavy derating in power output of the engine. Only emergency operation power.

-

-

ENGINE, menu 1

91 / 1

P91 / 1

Frequency in the accelerator pedal or lever position sensor circuit 1: Data valid but lower than the normal working range, the most severe level. A frequency under 100 Hz has been detected on the accelerator pedal's frequency input to ECU 794.

Heavy derating in power output of the engine. Only emergency operation power.

-

-

ENGINE, menu 1

91 / 19

P91

System error for SAE J1939 multiplexing accelerator pedal or lever sensors: Network data error received. The machine's OEM control unit (VECU) detected an error on its accelerator pedal.

Engine may only idle or engine will not accelerate to full speed.

Use diagnostic menu to find incorrect segment.

-

-

91 / 2

P31 / 2

Accelerator pedal position sensor.

-

-

ENGINE, menu 1

VDCT01.02GB


1 Engine – Engine

Code

J1587

91 / 3

P091 / 3

91 / 4

P091 / 4

D:41

Description

Limitation

Action


Diagnostic menu

Accelerator pedal or lever position sensor circuit: Short.circuit high. High voltage detected in accelerator pedal or lever position circuit.

Heavy derating in power output of the engine. Only emergency operation possible.


-

ENGINE, menu 1

Accelerator pedal or lever position sensor circuit: Voltage lower than normal or shorted to low source. Low voltage detected in accelerator pedal or lever position signal circuit.

Heavy derating in power output of the engine. Only emergency operation possible.

-

ENGINE, menu 1

Check the component. Check the cable harness between control unit and component. Check the component.

94 / 1

P94 / 1

Fuel pump's delivery pressure: Data valid but below normal operational range - moderately severe level. The ECU 794 has detected the fuel pressure in the fuel rail is lower than the commanded performance.

Possibly difficult to start, low power, possibly smoke from the engine. The engine may not be possible to start.

-

D794

-

94 / 2

P094 / 2

Injector Metering Rail 1 Pressure - Data Erratic, Intermittent, or Incorrect. The ECU 794 has detected that the fuel pressure signal is not changing.

The ECU 794 will estimate fuel pressure, and power is reduced.

-

D794

-

94 / 18

P94 / 0

Fuel pump's delivery pressure: Data valid but higher than normal operational range moderately severe level. The ECU 794 has detected fuel pressure in the fuel rail that is higher than the commanded pressure.

None or possible engine noise associated with higher injection pressures (especially at idle or light load). Engine power derate.

-

D794

-

97 / 3

P097 / 3

Sensor circuit for water in fuel indicator: Voltage higher than normal or short-circuited to a high source. High voltage detected on the water in the fuel circuit.

None on performance. No water in fuel warning available.


D794

-

Sensor circuit for water in fuel indicator: Voltage lower than normal or short-circuited to a low source. Low voltage detected on the water in the fuel circuit.

None on performance. No water in fuel warning available.

D794

-

Water-in-fuel indicator Data valid but above normal operational range - least severe level. Water has been detected in the fuel filter.

Possible white smoke, loss of power, or hard starting

-

-

97 / 4

97 / 15

P097 / 4

P097 / 0

Check the sensor. Check the cable harness between control unit and component. Check the sensor.


Drain water from the fuel.

VDCT01.02GB

D:42

1 Engine – Engine

Description

Limitation

Action


Diagnostic menu

Code

J1587

100 / 1

P100 / 1

Engine oil duct pressure: Data valid but lower than normal operational range, the most severe level. The oil pressure signal indicates that the oil pressure is lower than the critical limit for the engine's protection.

Progressive power derate increasing in severity from time of alert. If the function Engine protection cut- off is activated, the engine switches off 30 seconds after the red STOP light starts flashing.

Check the oil level in the engine; fill if necessary.

-

ENGINE, menu 6

100 / 2

P100 / 2

Oil pressure switch sensor circuit Data erratic, intermittent or incorrect. An error in the engine oil pressure switch signal has been detected by ECU 794.

None on performance. No engine protection for the oil pressure.


D794

ENGINE, menu 6

Oil pressure sensor circuit: Voltage higher than normal or shorted to high source. High signal voltage detected in engine oil pressure circuit.


D794

ENGINE, menu 6

D794

ENGINE, menu 6

100 / 3

P100 / 3

Check the sensor. Check the cable harness between control unit and component. Check the sensor.

100 / 4

P100 / 4

Oil pressure sensor circuit: Voltage lower than normal or shorted to low source. Low signal voltage detected in engine oil pressure circuit.


Check the cable harness between control unit and component. Check the sensor.

100 / 18

P100 / 1

Engine oil duct pressure: Data valid but lower than normal operational range, moderately severe level. Engine oil pressure signal indicates that the engine oil pressure is lower than the limit for engine protection warning.

None on performance.

Check the oil level in the engine; fill if necessary.

-

ENGINE, menu 6

102 / 2

P102 /2

Intake manifold pressure sensor circuit: Manifold Pressure Sensor Circuit Data Erratic, Intermittent or Incorrect. The ECU 794 has detected an intake manifold pressure signal that is too high or low for current engine operating conditions.

Engine power derate.


D794

ENGINE, menu 6

Intake manifold pressure sensor circuit: Incorrect data. An error in the intake manifold pressure sensor signal has been detected by ECU 794.

Derate in power output of the engine.

D794

ENGINE, menu 6

102 / 2

VDCT01.02GB

P102 /2

Check the sensor.


Check the cable harness between control unit and component. Check the sensor.

1 Engine – Engine

Code

J1587

102 / 3

P102 / 3

102 / 4

103 / 10

P102 / 4

P103 / 10

D:43

Description

Limitation

Action


Diagnostic menu

Intake manifold pressure sensor circuit: Voltage higher than normal or shorted to high source. High signal voltage detected in the intake manifold pressure circuit.



D794

ENGINE, menu 6

Intake manifold pressure sensor circuit: Voltage lower than normal or short-circuited to low source. Low signal voltage detected in the intake manifold pressure circuit.


D794

ENGINE, menu 6

Turbocharger speed: Incorrect change rate detected. Turbocharger speed sensor detected an incorrect speed value.

Possible-low-power estimated turbocharger speed will be used.

D794

-

Check the sensor. Check the cable harness between control unit and component. Check the sensor. Check the cable harness between control unit and component. Check the sensor.

103 / 16

P103 / 0

Turbocharger number 1 speed high: Warning level. High turbocharger speed has been detected.

Engine power derate. The ECU 794 uses an estimated turbocharger speed.


D794

-

103 / 18

P103 / 1

Turbocharger number 1 speed low: Warning level. Low turbocharger speed has been detected by ECU 794.

Engine power derate. The ECU 794 uses an estimated turbocharger speed.


D794

-

105 / 0

P105 / 0

Temperate intake manifold 1: Data valid but higher than normal operational range, the most severe level. The intake manifold air temperature signal indicates that the air temperature in the intake manifold is higher than the critical limit for engine protection.


Check the coolant level in the engine; fill if necessary.

-

ENGINE, menu 7

D794

ENGINE, menu 7

Check that the charge air cooler is clean, clean if necessary. Check that the fan belts are intact. Check the sensor.

105 / 3

P105 / 3

Intake manifold air temperature sensor circuit: Voltage higher than normal or shorted to high source. High signal voltage detected in the intake manifold air temperature circuit.

Possible white smoke. Fan will stay ON if controlled by the ECU 794. No engine protection for intake manifold air temperature.


Check cable harness between control unit and component. Check the sensor.

VDCT01.02GB

D:44

1 Engine – Engine

Code

J1587

105 / 4

P105 / 4

105 / 15

P105 / 0

Description

Limitation

Action


Diagnostic menu

Intake manifold air temperature sensor circuit: Voltage lower than normal or short-circuited to low source. Low signal voltage detected in the intake manifold air temperature circuit.

Possible white smoke. Fan will stay ON if controlled by the ECU 794. No engine protection for intake manifold air temperature.

Check cable harness between control unit and component.

D794

ENGINE, menu 7

Intake manifold temperature high: Data valid but higher than normal operational range, the least severe level. The intake manifold air temperature signal indicates that the air temperature in the intake manifold is higher than the warning limit for engine protection.

Progressive power derate increasing in severity from time of alert.

Check the coolant level in the engine; fill if necessary.

D794

ENGINE, menu 7

-

-

D794

-

D794

-

-

ENGINE, menu 7

Check the sensor.

Check that the charge air cooler is clean, clean if necessary. Check that the fan belts are intact. Check the sensor.

108 / 2

108 / 3

108 / 4

110 / 0

P108 / 2

P108 / 3

P108 / 4

P110 / 0

Barometric pressure: Data erratic, intermittent or incorrect. The pressure sensor for the ambient air pressure reads an erratic value on power-up.


Barometric pressure sensor circuit: Voltage higher than normal or shorted to high source. High signal voltage detected in barometric pressure sensor circuit.


Barometric pressure sensor circuit: Voltage lower than normal or shorted to low source. Low signal voltage detected in barometric pressure sensor circuit.


Engine coolant temperature: Data valid but higher than normal operational range, the most severe level. The engine coolant temperature signal indicates that the coolant temperature is higher than the critical limit for engine protection.


Check cable harness between control unit and component. Check the sensor. Check cable harness between control unit and component. Check the sensor. Check cable harness between control unit and component. Check the sensor. Check the coolant level. Check that radiator is clean. Check if there is air in coolant system. Check the cap on the expansion tank. Check the sensor. Check the thermostat.

VDCT01.02GB


1 Engine – Engine

Code

J1587

110 / 2

P110 / 2

110 / 3

110 / 4

110 / 15

P110 / 3

P110 / 4

P110 / 0

D:45

Description

Limitation

Action


Diagnostic menu

Engine coolant temperature: Data erratic, intermittent or incorrect. The engine coolant temperature reading does not change when operating conditions change.

The ECU 794 will estimate engine coolant temperature.


D794

ENGINE, menu 7

Engine coolant temperature sensor circuit 1: Voltage higher than normal or shorted to high source. High signal voltage or open circuit detected in the engine coolant temperature circuit.

Possible white smoke. Fan will stay ON if controlled by the ECU 794. No engine protection for the engine coolant temperature.


D794

ENGINE, menu 7

Engine coolant temperature sensor circuit 1: Voltage lower than normal or shorted to low source. Low signal voltage detected in the engine coolant temperature circuit.

Possible white smoke. Fan will stay ON if controlled by the ECU 794. No engine protection for the engine coolant temperature.


D794

ENGINE, menu 7

Engine coolant temperature high: Data valid but higher than normal operational range, the least severe level. The engine coolant temperature signal indicates that the coolant temperature is higher than the warning limit for engine protection.



D794

ENGINE, menu 7

D794

ENGINE, menu 7

Check the sensor.

Check the sensor.

Check the sensor.

Check that radiator is clean. Check if there is air in coolant system. Check the cap on the expansion tank. Check the sensor. Check the thermostat.

110 / 16

P110 / 0

Engine coolant temperature: Data valid but higher than normal operational range, moderately severe level. The engine coolant temperature signal indicates that the coolant temperature is higher than the warning limit for engine protection.


Check the coolant level. Check that radiator is clean. Check if there is air in coolant system. Check the cap on the expansion tank. Check the sensor. Check the thermostat.


VDCT01.02GB

D:46

1 Engine – Engine

Code

J1587

111 / 1

P111 / 1

111 / 3

111 / 4

P111 / 3

P111 / 4

Description

Limitation

Action


Diagnostic menu

Coolant level: Data valid but lower than normal operational range, the most severe level. Low coolant level detected.

Progressive power derate increasing in severity from time of alert. If the function Motor cutoff is activated, the engine switches off in 30 seconds after the red STOP light starts flashing.

Check the coolant level; fill if necessary.

-

-

Radiator coolant level sensor circuit: Voltage higher than normal or shorted to high source. High signal voltage detected in the engine coolant level circuit.



D794

-

Radiator coolant level sensor circuit: Voltage lower than normal or shorted to low source. Low signal voltage detected in the engine coolant level circuit.


D794

-

Check the sensor.

Check the sensor. Check cable harness between control unit and component. Check the sensor.

157 / 0

P94 / 0

Injector Metering Rail Number 1 Pressure - Data Valid But Above Normal Operating Range - Most Severe Level. The ECU 794 has detected that fuel pressure in the rail fuel is higher than the commanded pressure.


-

D794

-

157 / 2

P157 / 2

Injector Metering Rail 1 Pressure - Data Erratic, Intermittent, or Incorrect. the ECU 794 has detected that the fuel pressure signal is not changing.

The ECU 794 will estimate fuel pressure, and power is reduced.

-

D794

-

157 / 3

P157 / 3

Injector measurement channel number 1, pressure sensor circuit: Voltage higher than normal or shorted to high source. High signal voltage detected in the fuel rail fuel pressure sensor circuit.

Power and or speed derate.

-

D794

-

157 / 4

P157 / 4

Injector measurement channel number 1, pressure sensor circuit: Voltage lower than normal or short-circuited to low source. Low signal voltage detected in the fuel rail fuel pressure sensor circuit.

Power and or speed derate.

-

D794

-

VDCT01.02GB


1 Engine – Engine

D:47

Description

Limitation

Action


Diagnostic menu

Code

J1587

157 / 16

P157 / 0

Injector measurement channel 1, pressure Data valid but higher than normal operational range - moderately severe level. The ECU 794 has detected that the fuel pressure is higher than the commanded pressure.


-

D794

-

157 / 18

P157 / 1

Fuel pump's delivery pressure low: Data valid but lower than normal operational range moderately severe level. The ECU 794 has detected that the fuel pressure is lower than the commanded pressure.

Possibly difficult to start, low power or smoke from the engine. The engine may not be possible to start.

-

D794

-

167 / 1

P167 / 1

Charging system voltage low: Data valid but lower than normal operational range, the most severe level. Very low battery voltage detected by battery voltage monitoring.

Warning lamp illuminated until very low battery voltage condition is corrected.

Check batteries and alternator.

D794

-

167 / 16

P167 / 0

Charging system voltage high: Data valid but higher than normal operational range, moderately severe level. High battery voltage detected by battery voltage monitoring.

Amber warning lamp illuminated until high battery voltage condition is corrected.

Check fuses. Check batteries and alternator.

D794

-

167 / 18

P167 / 1

Charging system voltage low: Data valid but lower than normal operational range, moderately severe level. Low battery voltage detected by battery voltage monitoring.

Amber lamp will light until low battery voltage condition is corrected.

Check batteries and alternator.

D794

-

168 / 16

P168 / 0

Battery 1 Voltage - Data Valid but Above Normal Operational Range Moderately Severe Level. ECU 794 supply voltage is above the maximum system voltage level.

Possible electrical damage to all electrical components.


D794

-

168 / 18

S168 / 1

Battery 1 Voltage - Data Valid but Below Normal Operational Range Moderately Severe Level. ECU 794 supply voltage is below the minimum system voltage level.

Engine may stop running or be difficult to start.


D794

-

171 / 3

P171 / 3

Outdoor temperature sensor, circuit error: Abnormally high voltage or short-circuit to higher voltage.

-

D794

-


VDCT01.02GB

D:48

1 Engine – Engine

Description

Limitation

Action


Diagnostic menu

-

D794

-

Code

J1587

171 / 4

P171 / 4

Outdoor temperature sensor, circuit error: Abnormally low voltage or short-circuit to lower voltage.

190 / 0

P190 / 0

Engine crankshaft speed/position: Data valid but higher than the normal working range: The most severe level. The engine speed signal indicates the engine speed over the engine protection limit.

Fuel injection disabled until engine speed fails below the overspeed limit.

Ease off the throttle or select higher gear.

-

-

190 / 2

P190 / 2

Engine crankshaft speed/position: Data erratic, intermittent or incorrect. Engine speed sensor on the crankshaft uneven synchronised.

The engine may misfire when steering switches from the primary to the backup speed sensor. The engine power derates while the engine is driven with the backup speed sensor.


D794

-

Engine crankshaft speed/position: Data erratic, intermittent or incorrect. The signal from the crankshaft sensor missing.

The engine runs unevenly. Can be difficult to start. The engine is driven by backup speed sensor. Engine power derated.


D794

-

190 / 2

P190 / 2

Check the sensor.

Check the sensor.

251 / 2

P251 / 2

Real-time clock power supply open circuit: Data erratic, intermittent or incorrect. The real time clock has no power.

None on performance. Data in the ECU 794 will not have accurate time and date information.

-

-

-

441 / 3

P441 / 3

Auxiliary temperature sensor input signal 1: Voltage higher than normal or shorted to high source. High signal voltage or open circuit detected in the OEM auxiliary temperature circuit.



D794

-

Auxiliary temperature sensor circuit input signal 1: Voltage lower than normal or short-circuited to low source. Low voltage detected in the OEM auxiliary temperature circuit.


D794

-

Accelerator pedal or lever idle validation circuit: Data erratic, intermittent or incorrect. Voltage detected simultaneously on the validating switches for both idling and not idling.

Engine only running at idle.

D794

-

441 / 4

558 / 2

VDCT01.02GB

P441 / 4

S230 / 2

Check the sensor. Check cable harness between control unit and component. Check the sensor.


Check cable harness between control unit and component. Check component.

1 Engine – Engine

Code

J1587

558 / 4

S230 / 4

558 / 13

S230 / 13

D:49

Description

Limitation

Action


Diagnostic menu

Accelerator pedal or lever idle validation circuit: Voltage lower than normal or short-circuited to low source. No voltage detected simultaneously on the validating switches for both idling and not idling.



D794

-

Accelerator pedal or lever idle validation circuit: Not calibrated. Voltage in the validation circuits for idling and not idling does not correspond with the accelerator pedal position.


D794

-

Check component. Check cable harness between control unit and component. Check component.

611 / 2

P089 / 2

Validation of auxiliary transfer speed switch (PTO): Data erratic, intermittent or incorrect. The position of the transfer speed protection switch 1 does not correspond with the position of the validation switch for the transfer speed protection.

Intermediate speed control switch may not operate correctly.

-

D794

-

611 / 3

S232 / 3

Circuit for sensor supply voltage 4: Voltage higher than normal or shorted to high source. High voltage detected at +5 volt sensor supply circuit to the accelerator pedal position sensor.


-

D794

-

611 / 4

S232 / 4

Circuit for sensor supply 3: Voltage lower than normal or short-circuited to low source. Low voltage detected at +5 volt sensor supply circuit to the accelerator pedal position sensor.

Possible hard starting and rough running.

-

D794

-

611 / 4

S232 / 4

Circuit for sensor supply voltage 4: Voltage lower than normal or short-circuited to low source. Low voltage detected at +5 volt sensor supply circuit to the accelerator pedal position sensor.

Engine will only die.

-

D794

-

611 / 15

S151 / 0

Turbocharger compressor outlet temperature: Data higher than normal. High outlet temperature for the turbocharger compressor calculated by ECU 794.

Fuel is limited in an attempt to decrease the calculated turbocharger compressor outlet temperature.

-

D794

-


VDCT01.02GB

D:50

1 Engine – Engine

Description

Limitation

Action


Diagnostic menu

Code

J1587

612 / 2

P190 / 2

The engine's magnetic crankshaft speed/position sensor has lost both signals: Data erratic, intermittent or incorrect. ECU 794 has detected that the signals from the primary and backup engine speed sensor are reversed.

Fuelling to the injectors is disabled, and the engine can not be started.

-

D794

-

627 / 2

S251 / 2

No power without the ignition switch turned off: Data erratic, intermittent or incorrect. The supply voltage to ECU 794 temporarily falls below 6.2 volt, or ECU 794 not allowed to shutdown correctly (battery voltage maintained for 30 seconds after the ignition has been turned off).

Possibly no noticeable performance impact, or the engine stops or is hard to start. Incorrect information, release information and maintenance monitoring data may be incorrect.


D794

-

627 / 2

S251 / 2

Power supply missing with the ignition on: Data erratic, intermittent or incorrect. The supply voltage to ECU 794 temporarily falls below 6.2 volt, or ECU 794 not allowed to shutdown correctly (battery voltage maintained for 30 seconds after the ignition has been turned off).



D794

-

627 / 2

S254 / 12

Injectors power supply: Bad Intelligent Device or Component. The ECU 794 measured injector boost voltage is low.

Possible smoke, low power, engine misfire, and/or engine will not start.


D794

-

629 / 12

S254 / 12

Engine control unit: Critical internal error. Error internally in ECU 794 related to memory hardware failures or internal ECU 794 voltage supply circuits.

Engine may not start.

Check the control unit.

D794

-

629 / 12

S254 / 12

Engine control unit, warning internal hardware error. Incorrect intelligent unit or component.

No performance effects or possible severe power derate.

Check the control unit.

D794

-

630 / 2

S253 / 2

Engine control unit data lost: Data erratic, intermittent or incorrect. Serious data loss from ECU 794.


Reprogram the software in Control unit, engine (D794).

D794

-

VDCT01.02GB


1 Engine – Engine

D:51

Description

Limitation

Action


Diagnostic menu

Code

J1587

630 / 31

S240 / 11

Error occurs in the engine control unit calibration programme memory (RAM). Serious data loss from ECU 794.


-

D794

-

633 / 31

S018 / 11

Fuelling Actuator Number 1 Circuit Error Conditions Exists. Fuel pump actuator circuit resistance too high or too low.

Possible low power.

-

D794

-

639 / 9

S231 / 9

Timeout error for SAE J1939 multiplexer-PNG: Abnormal update rate. Cummins ECU 794 did not receive a multiplexed message from an OEM-VECU by the time limit or not at all.

One or more multiplexed units not working correctly. One or more symptoms may occur.


-

CAN/POWER, menu 2

639 / 13

S231 / 13

SAE J1939 Multiplexing Configuration Error - Out of Calibration. The ECU 794 expected information from a multiplexed device but only received a portion of the necessary information.

At least one multiplexed devices will not operate properly.


-

CAN/POWER, menu 2

641 / 3

S027 / 3

VGT actuator driver circuit - voltage above normal or shorted to high source.

Possible low power. Power switched off to the turbocharger's actuator motor.

-

D794

-

641 / 4

S027 / 4

VGT actuator driver circuit - voltage below normal, or shorted to low source.

Possible low power. Power switched off to the turbocharger's actuator motor.

-

D794

-

644 / 2

S030 / 2

Input signal from external speed request (synchronisation of multiple units): Data erratic, intermittent or incorrect. The accelerator pedal input signal to the primary or secondary motor for synchronisation of multiple devices is less than 3 percent or greater than 97 percent.

Primary or secondary engines may be shut down.


-

-

Fan control circuit: Voltage higher than normal or shorted to high source. Open circuit or high voltage detected in the fan control circuit.

The fan may stay on continuously or not run at all.

D794

-

647 / 3

S033 / 3

Check component.



VDCT01.02GB

D:52

1 Engine – Engine

Code

J1587

647 / 4

S033 / 4

651 / 5

651 / 7

652 / 5

652 / 7

653 / 5

653 / 7

654 / 5

VDCT01.02GB

S001 / 5

S001 / 7

S002 / 5

S002 / 7

S003 / 5

S003 / 7

S004 / 5

Description

Limitation

Action


Diagnostic menu

Fan control circuit: Voltage lower than normal or shorted to low source. Low signal voltage detected in the fan control circuit when this is requested.

The fan may stay on continuously or not run at all.


D794

-

Circuit injector magnetic coil drive cylinder 1: Current lower than normal or open circuit. High resistance or no current detected on injector no. 1, pin DRIVE or RETURN.

Engine can misfire or possibly run rough.

D794

-

Injector magnetic coil drive cylinder 1: Mechanical system not responding correctly or incorrectly adjusted. Accidental fuel supply detected in cylinder no. 1.


D794

-



D794

-



D794

-



D794

-



D794

-



D794

-

Check component. Check cable harness between control unit and component. Check the injector. Check cable harness between control unit and component. Check the injector. Check cable harness between control unit and component. Check the injector. Check cable harness between control unit and component. Check the injector. Check cable harness between control unit and component. Check the injector. Check cable harness between control unit and component. Check the injector.


Check cable harness between control unit and component. Check the injector.

1 Engine – Engine

Code

J1587

654 / 7

S004 / 7

655 / 5

655 / 7

656 / 5

656 / 7

677 / 3

S005 / 5

S005 / 7

S006 / 5

S006 / 7

S39 / 3

D:53

Description

Limitation

Action


Diagnostic menu




D794

-



D794

-



D794

-



D794

-



D794

-

Starter relay circuit: Voltage higher than normal or shorted to high source. Open circuit or high voltage detected in the start locking circuit.

Either the engine will not start or the engine will not have starter lockout protection.

D794

ENGINE, menu 5

D794

ENGINE, menu 5

D794

-

Check the injector. Check cable harness between control unit and component. Check the injector. Check cable harness between control unit and component. Check the injector. Check cable harness between control unit and component. Check the injector. Check cable harness between control unit and component. Check the injector. Check cable harness between control unit and component. Check the relay.

677 / 4

S39 / 4

Starter relay circuit: Voltage lower than normal or shorted to low source. Low voltage detected in the start locking circuit.

The engine will not have starter lockout protection.

Check cable harness between control unit and component. Check the relay.

697 / 3

S057 / 3

Auxiliary PWM drive no. 1: Voltage higher than normal or shorted to high source. High signal voltage detected in the analogue torque circuit.

Can not control transmission.


-

VDCT01.02GB

D:54

1 Engine – Engine

Description

Limitation

Action


Diagnostic menu

Code

J1587

697 / 4

S057 / 4

Auxiliary PWM drive no. 1: Voltage lower than normal or shorted to low source. Low signal voltage detected in the analogue torque circuit.

Can not control transmission.

-

D794

-

703 / 11

S051 /11

Auxiliary Equipment Sensor Input #3 (OEM Switch) Root Cause Not Known.

Possible engine power derate.


D794

-

D794

-

D794

-

D794

-

D794

-

D794

-

D794

-

Check the component. 723 / 2

723 / 2

723 / 7

729 / 3

729 / 4

974 / 3

VDCT01.02GB

S064 / 2

S064 / 2

S064 / 7

S070 / 3

S070 / 4

P974 / 3

Engine backup crankshaft speed/position sensor no. 2: Data erratic, intermittent or incorrect Engine speed sensor on the crankshaft uneven synchronised.

Possible low power.

Engine Speed Sensor (Camshaft) Error - Data Erratic, Intermittent, or Incorrect. The ECU 794 has detected an error in the camshaft position sensor signal.

Can be difficult to start. Engine power derate.

Engine speed/position sensor camshaft and crankshaft, misaligned: Mechanical system not responding correctly or incorrectly adjusted. Mechanical misalignment between the crankshaft and camshaft speed sensors.

The engine runs at lower power. Abnormal smoke, difficult to start and erratic idling can occur.


Circuit for intake air heater no. 1: Voltage higher than normal or shorted to high source. High voltage detected at the intake air heater signal circuit.

The intake air heaters may be ON or OFF all the time.


Circuit for intake air heater no. 1: Voltage lower than normal or shorted to low source. Low voltage detected at the intake air heater signal circuit.

The intake air heaters may be ON or OFF all the time.

Circuit for remote accelerator pedal or lever position sensor 1: Voltage higher than normal or shorted to high source. High voltage detected at the remote accelerator pedal position circuit.

Remote accelerator pedal not working. Remote accelerator pedal position set to zero percent.

Check cable harness between control unit and component. Check the sensor. Check cable harness between control unit and component. Check the sensor.

Check the sensor.




1 Engine – Engine

Code

J1587

974 / 4

P974 / 4

D:55

Description

Limitation

Action


Diagnostic menu

Circuit for remote accelerator pedal or lever position sensor 1: Voltage lower than normal or short-circuited to low source. Low voltage detected in remote accelerator pedal position signal.

Remote accelerator pedal not working. Remote accelerator pedal position set to zero percent.


D794

-

Check component.

974 / 19

P29

Data error for SAE J1939 multiplexing remote accelerator pedal or lever: Network data error received. The machine's OEM control unit (VECU) detected an error on the remote accelerator pedal.

The engine does not react to the remote accelerator pedal. Perhaps the engine is only running at idle. The primary accelerator or the one in the cab can possibly be used.


-

CAN/POWER, menu 2

1043 / 3

S221 / 3

Supply voltage circuit for accelerator pedal or lever position sensor: Voltage higher than normal or shorted to high source. High voltage detected in the voltage supply circuit for the accelerator pedal or lever position sensor.



D794

-

Supply voltage circuit for accelerator pedal or lever position sensor: Voltage lower than normal or shorted to low source. Low voltage detected in the voltage supply circuit to the accelerator pedal or lever position sensor.

Engine will only die.

D794

-

Supply voltage circuit for engine speed/position sensor (crankshaft): Voltage lower than normal or shorted to low source. Low voltage detected on ECU 794 voltage supply cable to the engine speed sensor.

Possible hard starting and rough running.

D794

-

Engine brake actuator circuit no. 1: Voltage higher than normal or shorted to high source. Open circuit or high voltage detected on the signal circuit for the motor brake solenoid coil no. 1.

Engine brake on cylinders 1, 2, and 3 can not be activated or exhaust brake will not operate.

D794

-

Engine brake actuator circuit no. 1: Voltage lower than normal or shorted to low source. Low voltage detected in signal circuit for the motor brake solenoid coil no. 1.

Engine brake on cylinders 1, 2, and 3 can not be activated or exhaust brake will not operate.

D794

-

1043 / 4

1043 / 4

1072 / 3

1072 / 4

S221 / 4

S221 / 4

S028 / 3

S028 / 4

Check component.


Check cable harness between control unit and component. Check component. Check cable harness between control unit and component. Check component.



VDCT01.02GB

D:56

1 Engine – Engine

Code

J1587

1073 / 3

S029 / 3

1073 / 4

S029 / 4

Description

Limitation

Action


Diagnostic menu

Engine brake actuator circuit no. 2: Voltage higher than normal or shorted to high source. Open circuit or high voltage detected on the signal circuit for the motor brake solenoid coil no. 2.

Engine brake on cylinders 4, 5, and 6 can not be activated.


D794

-

Engine brake actuator circuit no. 2: Voltage lower than normal or shorted to low source. Low voltage detected in signal circuit for the motor brake solenoid coil no. 2.

Engine brake on cylinders 4, 5, and 6 can not be activated.

D794

-


1075 / 3

S126 / 3

Electrical lift pump for the engine fuel delivery circuit: Voltage higher than normal or shorted to high source. High signal voltage or open circuit detected in the fuel lift pump's signal circuit.

Engine can be difficult to start.

-

D794

-

1075 / 4

S126 / 4

Electrical lift pump for the engine fuel delivery circuit: Voltage lower than normal or short-circuited to low source. Low signal voltage detected in fuel lift pump circuit.

Engine can be difficult to start.

-

D794

-

1079 / 3

S212 / 3

Circuit for sensor supply voltage no. 1: Voltage higher than normal or shorted to high source. High voltage detected in the sensor supply circuit no. 1.



D794

-

Circuit for sensor supply voltage no. 1: Voltage lower than normal or shorted to low source. Low voltage detected in the sensor supply circuit no. 1.


D794

-

Circuit for sensor supply no. 2: Voltage higher than normal or shorted to high source. High voltage detected in the sensor supply circuit no. 2.


D794

-

Circuit for sensor supply voltage no. 2: Voltage lower than normal or shorted to low source. Low voltage detected in the sensor supply circuit no. 2.


D794

-

1079 / 4

1080 / 3

1080 / 4

VDCT01.02GB

S212 / 4

S232 / 3

S232 / 4

Check the sensor. Check cable harness between control unit and component. Check the sensor. Check cable harness between control unit and component. Check the sensor.


Check cable harness between control unit and component. Check the sensor.

1 Engine – Engine

D:57

Description

Limitation

Action


Diagnostic menu

Code

J1587

1137 / 2

S114 / 2

Synchronisation switch for multiple units: Data erratic, intermittent or incorrect. Synchronised ON/OFF switch for multiple units and supplementary synchronised ON/OFF switch for multiple units have different values in ECU 794.

Multiple Unit Synchronisation feature is disabled.

-

D794

-

1172 / 3

/3

Intake temperature sensor circuit for compressor turbocharger no. 1: Voltage higher than normal or shorted to high source. High signal voltage detected in the intake temperature sensor circuit for the compressor turbocharger.


-

D794

-

1172 / 4

/4

Intake temperature sensor circuit for compressor turbocharger no. 1: Voltage lower than normal or shorted to low source. Low signal voltage detected in the intake temperature sensor circuit for the compressor turbocharger.


-

D794

-

1347 / 3

S126 / 3

Circuit for the fuel high pressure solenoid valve: Voltage higher than normal or shorted to high source. Electronic fuel control actuator short-circuited high.

Engine runs badly and with derated power. Fuel rail pressure becomes higher than requested.

-

D794

-

1347 / 4

S126 / 4

Circuit for the fuel high pressure solenoid valve: Voltage lower than normal or shorted to low source. Electronic fuel control actuator short-circuited low.

The engine runs poorly when idling and has low power. Fuel pressure becomes higher than requested.

-

D794

-

1347 / 7

S126 / 7

Fuel pump pressure attachment 1: Mechanical system not responding correctly or incorrectly adjusted. Pumping imbalance between the front and rear pump pistons have been detected.

Engine will not run or possible low power.

-

D794

-

1347 / 7

S126 / 7

Fuel Pumping Element Number 1 (Front) Mechanical System Not Responding Properly or Out of Adjustment.

Engine will not run or possible low power.

-

D794

-

1378 / 31

S153 / 11

It is time to change the lubricating oil and filter. Change the engine oil and filter.

None on performance; maintenance reminder only.

-

D794

-


VDCT01.02GB

D:58

1 Engine – Engine

Description

Limitation

Action


Diagnostic menu

Code

J1587

1388 / 3

P223 / 3

Circuit for auxiliary pressure sensor, input signal 1: Voltage higher than normal or shorted to high source. High signal voltage detected in the OEM pressure circuit.


-

D794

-

1388 / 4

P223 / 4

Circuit for auxiliary pressure sensor, input signal 1: Voltage lower than normal or shorted to low source. Low signal voltage detected in the OEM pressure circuit.


-

D794

-

Undetectable error code from the engine. Error codes above 2047 cannot be shown in the display. Possible error code: 2789.

-

Contact the engine supplier for further information.

D794

-

Exhaust temperature: Data higher than normal. High exhaust temperature has been calculated by the electronic control system.

Derate in power output of the engine in attempt to decrease the calculated exhaust gas temperature value.

-

D794

-

2047 / xx

2789 / 15

VDCT01.02GB

/0



D:59

2 Transmission Error codes transmission When contacting engine suppliers, use the supplier code. •

Display indicates error code as shown in the machine, in accordance with SAE J1939 in SPN/FMI

•

The supplier code indicates the error code in accordance with the engine manufacturer's specification.

Control unit transmission can generate two states with reduced functionality to protect the transmission in the event of serious malfunctions: Limp home In this condition only gear 1-2 in each direction can be used. If the error occurs in a higher gear then downshifting to gear 1 or 2 must take place manually. Shut down In this mode the transmission is permanently in neutral as there is no oil pressure to enable gear selection. Table Error codes Dana HR32000

Display 520192 /31

520193 /31

520194 /31

520195 /31

520196 /31

Supplier code 00/31

01/31

02/31

03/31

04/31

Description

Limitation

Action

Digital input 0, active error.

No limitation or Shut down while error is active.

Check for more error codes and rectify them first.

For inactive error code, Limp home until ignition is switched off.

Check the cable harness to the control unit.




















Digital input 4, active error. The transmission control unit activates Shut down or Limp home depending on speed.



Diagnostic menu

D793/59

-

D793/58

-

D793/57

-

D793/56

-

D793/55

-

VDCT01.02GB

D:60

Display 520197 /31

520198 /31

520199 /31

520208/3


Supplier code 05/31

06/31

07/31

16/03

Description

Limitation

Action














No limitation.




Analogue input 0, short circuit to voltage.


Diagnostic menu

D793/54

-

D793/53

-

D793/52

-

D793/24

-

D793/25

Check the cable harness to the control unit. 520208/4

16/04

Analogue input 0, short circuit to ground.

No limitation.


D793/24

-

D793/25

Check the cable harness to the control unit. 520208 /16

16/16

Analogue input 0, the value is above highest normal value.

No limitation.


D793/24

-

D793/25


16/18

Analogue input 0, the value is below lowest normal value.

No limitation.


D793/24

-

D793/25


520209/3

16/31

17/03

Analogue input 0, active error.

Sensor oil temperature transmission (B766), short circuit to voltage.








VDCT01.02GB

Check the sensor.


D793/24

-

D793/25

D793/26 – B766/1 D793/27 – B766/2

TRANSM, menu 10


Display 520209/4

Supplier code 17/04

Description

Limitation

Action

Sensor oil temperature transmission (B766), short circuit to ground.

No limitation.


D:61


Diagnostic menu

D793/26 – B766/1

TRANSM, menu 10

D793/27 – B766/2


17/18

Sensor oil pressure transmission (B766), value is below lowest calibrated value.

No limitation.


D793/26 – B766/1

TRANSM, menu 10

D793/27 – B766/2


17/16

Sensor oil pressure transmission (B766), value is above highest calibrated value.

No limitation.


D793/26 – B766/1

TRANSM, menu 10

D793/27 – B766/2


17/13

Sensor oil temperature transmission (B766), calibration incorrect.

No limitation.


D793/26 – B766/1

TRANSM, menu 10

D793/27 – B766/2


17/31

Sensor oil temperature transmission (B766), active error.

No limitation or Shut down while error is active. For inactive error code, Limp home until ignition is switched off.

520210/3

18/03

Sensor oil pressure (D765), short circuit to voltage.

No limitation.


D793/26 – B766/1

TRANSM, menu 10

D793/27 – B766/2

Check the sensor. Check the cable harness between control unit and sensor.

D793/28 – B765/A

TRANSM, menu 10

D793/29 – B765/B


18/04

Sensor oil pressure (D765), short circuit to ground.

No limitation.


D793/28 – B765/A

TRANSM, menu 10

D793/29 – B765/B


18/16

Sensor oil pressure (B765), value is above highest normal value.

No limitation.


D793/28 – B765/A

TRANSM, menu 10

D793/29 – B765/B


18/18

Sensor oil pressure (B765), value is below lowest normal value.

No limitation.


D793/28 – B765/A

TRANSM, menu 10

D793/29 – B765/B


18/13

Sensor oil pressure (B765), incorrectly calibrated.

No limitation.


D793/28 – B765/A

TRANSM, menu 10

D793/29 – B765/B

Check the sensor.


VDCT01.02GB

D:62

Display 520210 /31


Supplier code 18/31

Description

Limitation

Action

Sensor oil pressure (B765), active error.



For inactive error code, Limp home until ignition is switched off. 520211/3

520211/4

19/03

19/04

520211 /16

19/16

520211 /18

19/18

520211 /13

19/13

520211 /31

19/31

Analogue input 3, short circuit to voltage.

No limitation.

Analogue input 3, short circuit to ground.

No limitation.

Analogue input 3, the value is above highest normal value.

No limitation.

Analogue input 3, the value is below lowest normal value.

No limitation.

Analogue input 3, incorrectly calibrated

No limitation.

Analogue input 3, active error.



Diagnostic menu

D793/28 – B765/A

TRANSM, menu 10

D793/29 – B765/B

Check the sensor. Check the cable harness to the control unit.

D793/13


D793/13


D793/13


D793/13 -


D793/13


D793/13


D793/09


D793/09


D793/09


D793/09

-

D793/14 -

D793/14 -

D793/14 -

D793/14 -

D793/14 -

D793/14


26/05

Speed input 0, short circuit to voltage.


-

D793/10


26/06

Speed input 0, short circuit to ground.


-

D793/10

For inactive error code, Limp home until ignition is switched off. 520218 /10

26/10

Speed input 0, value outside limit values.


-

D793/10


VDCT01.02GB

26/31

Speed input 0, active error. The transmission control unit activates Shut down or Limp home depending on speed.



D793/10

-


Display 520219/5

Supplier code 27/05

Description

Limitation

Action

Sensor turbine speed (B751), short circuit to voltage.




27/06

Sensor turbine speed (B751), short circuit to ground.


520219 /10

27/10

Sensor turbine speed (B751), value outside limit values.


520219 /31

27/31

Sensor turbine speed (B751), active error.


552022 4/3

32/03

Solenoid valve clutch forward (Y630), short circuit to voltage.


520224/4

32/04

Solenoid valve clutch forward (Y630), short circuit to ground.


520224/5

520224 /31

32/05

32/31

Solenoid valve clutch forward (Y630), open circuit or short circuit to battery.

Solenoid valve clutch forward (Y630), active error.

No limitation or Shut down while error is active. For inactive error code, Limp home until ignition is switched off. No limitation or Shut down while error is active. For inactive error code, Limp home until ignition is switched off.

520225/3

33/03

Solenoid valve clutch reverse (Y631), short circuit to voltage.


D:63

Connections and components D793/11 – B751/2

Diagnostic menu

-

D793/12 – B751/1


D793/11 – B751/2

-

D793/12 – B751/1


D793/11 – B751/2

-

D793/12 – B751/1


D793/11 – B751/2

-

D793/12 – B751/1

Check the sensor. Check the cable harness between control unit and solenoid valve.

D793/33 – Y630/1

-

D793/34 – Y630/2

Check the solenoid valve. Check the cable harness between control unit and solenoid valve.

D793/33 – Y630/1

-

D793/34 – Y630/2


D793/33 – Y630/1

-

D793/34 – Y630/2


D793/33 – Y630/1

-

D793/34 – Y630/2


D793/31 – Y631/1

-

D793/32 – Y631/2

Check the solenoid valve.


VDCT01.02GB

D:64

Display 520225/4


Supplier code 33/04

Description

Limitation

Action

Solenoid valve clutch reverse (Y631), short circuit to ground.


Check the cable harness between control unit and solenoid valve.


520225 /31

33/05

33/31

Solenoid valve clutch reverse (Y631), open circuit or short circuit to battery.

Solenoid valve clutch reverse (Y631), active error.


520226/3

34/03

Solenoid valve clutch gear 1 (Y6067-1), short circuit to voltage.


520226/4

34/04

Solenoid valve clutch gear 1 (Y6067-1), short circuit to ground.


520226/5

520226 /31

34/05

34/31

Solenoid valve clutch gear 1 (Y6067-1), open circuit or short circuit to battery.

Solenoid valve clutch gear 1 (Y6067-1), active error.


520227/3

35/03

Solenoid valve clutch gear 2 (Y6069), short circuit to voltage.


520227/5

VDCT01.02GB

35/05

Solenoid valve clutch gear 2 (Y6069), open circuit or short circuit to battery voltage.


Connections and components D793/31 – Y631/1

Diagnostic menu

-

D793/32 – Y631/2


D793/31 – Y631/1

-

D793/32 – Y631/2


D793/31 – Y631/1

-

D793/32 – Y631/2

Check the solenoid valve. Check the cable harness between control unit and solenoid valve. Check the solenoid valve. Check the cable harness between control unit and solenoid valve. Check the solenoid valve. Check the cable harness between control unit and solenoid valve. Check the solenoid valve. Check the cable harness between control unit and solenoid valve. Check the solenoid valve. Check the cable harness between control unit and solenoid valve.

D793/48 – Y60671/1

-

D793/49 – Y60672/2 D793/48 – Y60671/1

-

D793/49 – Y60672/2 D793/48 – Y60671/1

-

D793/49 – Y60672/2 D793/48 – Y60671/1

-

D793/49 – Y60672/2 D793/18 – Y6069/1

-

D793/19 – Y6069/2

Check the solenoid valve. Check the cable harness between control unit and solenoid valve. Check the solenoid valve.


D793/18 – Y6069/1 D793/19 – Y6069/2

-


Display 520227 /31

Supplier code 35/31

Description

Limitation

Action

Solenoid valve clutch gear 2 (Y6069), active error.


Check the cable harness between control unit and solenoid valve.


37/03

Digital output 05, short circuit to voltage.

D:65

Connections and components D793/18 – Y6069/1

-

D793/19 – Y6069/2

Check the solenoid valve. Check the cable harness to the control unit.

D793/17


D793/17


D793/17



D793/17





D793/35


D793/35


D793/35



D793/35




Diagnostic menu

-

D793/18


37/04

Digital output 05, short circuit to ground.


-

D793/18


37/05

Digital output 05, open circuit or short circuit to battery.


-

D793/18


520230/3

37/31

38/03

Digital output 05, active error.


-

D793/18

-

D793/50


38/04



-

D793/50


38/05



-

D793/50


38/31



-

D793/50

VDCT01.02GB

D:66

Display 520231/3


Supplier code 39/03


Diagnostic menu

-

Description

Limitation

Action




D793/01


D793/01


D793/01


D793/01



D793/01





D793/03


D793/03


D793/03


D793/03

D793/02


39/04



-

D793/02


39/05



-

D793/02


39/06



-

D793/02


520232/3

39/31

40/03



-

D793/02

-

D793/04


40/04



-

D793/04


40/05



-

D793/04


40/06



VDCT01.02GB


D793/04

-


Display 520230 /31

520240/9

520240 /19

520240 /31

520241/9

520241 /19

520241 /31

Supplier code 40/31

48/09

48/19

48/31

49/09

49/19

49/31

D:67


Diagnostic menu

D793/03

-

Description

Limitation

Action






Declutch of transmission with declutch pedal does not work.


D793/22 – D7901/K13:1

Check the cable harness between Control unit, cab (D790-1) and Control unit, transmission (D793).

D7901/K13:1 – D793/23


D793/22 – D7901/K13:1


D7901/K13:1 – D793/23



-

-

Transmission control unit does not allow change of gear range, however, operation of machine is possible.


D793/22 – D7901/K13:1

CAN/POWER, menu 3


D7901/K13:1 – D793/23


D793/22 – D7901/K13:1


D7901/K13:1 – D793/23


-

Incorrect declutch signal via the CAN bus.




Incorrect gear programme selection via the CAN bus.





D793/04

CAN/POWER, menu 3

CAN/POWER, menu 3


CAN/POWER, menu 3

-



VDCT01.02GB

D:68

Display 520242/9

520242 /19

520242 /31


Supplier code 50/09

50/19

50/31

Description

Limitation

Action


Incorrect kickdown signal via the CAN bus.

Kickdown does not work.


D793/22 – D7901/K13:1


D7901/K13:1 – D793/23


D793/22 – D7901/K13:1


D7901/K13:1 – D793/23


-

-


D793/22 – D7901/K13:1

CAN/POWER, menu 3


D7901/K13:1 – D793/23


D793/22 – D7901/K13:1


D7901/K13:1 – D793/23


-





Diagnostic menu

CAN/POWER, menu 3

CAN/POWER, menu 3


520243 /19

520243 /31

51/09

51/19

51/31

Incorrect neutral position signal via the CAN bus.



The transmission is locked in neutral position.




VDCT01.02GB


CAN/POWER, menu 3

-


Display 520244/2

520244/9

520244 /19

520244 /31

Supplier code 52/02

52/09

52/19

52/31

D:69

Description

Limitation

Action


Incorrect idle signal from accelerator pedal via CAN bus.

No limitation.


D793/22 – D7901/K13:1


D7901/K13:1 – D793/23


D793/22 – D7901/K13:1


D7901/K13:1 – D793/23


D793/22 – D7901/K13:1


D7901/K13:1 – D793/23


-

-


D793/22 – D7901/K13:1

CAN/POWER, menu 3


D7901/K13:1 – D793/23


D793/22 – D7901/K13:1


D7901/K13:1 – D793/23




No limitation.

No limitation.

No limitation.

Diagnostic menu

CAN/POWER, menu 3

CAN/POWER, menu 3

CAN/POWER, menu 3


520245/9

53/02

53/09

Incorrect full throttle signal from accelerator pedal via CAN bus.


No limitation.

No limitation.


CAN/POWER, menu 3

VDCT01.02GB

D:70

Display 520245 /19

520245 /31


Supplier code 53/19

53/31

Description

Limitation

Action



No limitation.


D793/22 – D7901/K13:1


D7901/K13:1 – D793/23


-

-


D793/22 – D7901/K13:1

CAN/POWER, menu 3


D7901/K13:1 – D793/23


D793/22 – D7901/K13:1


D7901/K13:1 – D793/23


-

-


D793/22 – D7901/K13:1

CAN/POWER, menu 3


D7901/K13:1 – D793/23


No limitation.

Diagnostic menu

CAN/POWER, menu 3


520249 /19

520249 /31

57/09

57/19

57/31

Incorrect parking brake signal via the CAN bus.






CAN/POWER, menu 3


VDCT01.02GB

58/09

Incorrect load signal via the CAN bus.

No limitation.



Display 520250 /19

520250 /31

Supplier code 58/19

58/31

D:71

Description

Limitation

Action



No limitation.


D793/22 – D7901/K13:1


D7901/K13:1 – D793/23


-

-


D793/22 – D7901/K13:1

CAN/POWER, menu 3


D7901/K13:1 – D793/23


D793/22 – D7901/K13:1


D7901/K13:1 – D793/23


-

-


D793/22 – D7901/K13:1

CAN/POWER, menu 3


D7901/K13:1 – D793/23


No limitation.

Diagnostic menu

CAN/POWER, menu 3


520251 /19

520251 /31

520252/9

59/09

59/19

59/31

60/09

Incorrect signal for disengagement 4WD/2WD via the CAN bus.

No limitation.


No limitation.


No limitation.

Incorrect high/low gear signal via the CAN bus.

No limitation.

CAN/POWER, menu 3



VDCT01.02GB

D:72

Display 520252 /19

250252 /31


Supplier code 60/19

60/31

Description

Limitation

Action



No limitation.


D793/22 – D7901/K13:1


D7901/K13:1 – D793/23


-

-


D793/22 – D7901/K13:1

CAN/POWER, menu 3


D7901/K13:1 – D793/23


D793/22 – D7901/K13:1


D7901/K13:1 – D793/23


-

-

-

-


D793/22 – D7901/K13:1

CAN/POWER, menu 3


D7901/K13:1 – D793/23

No limitation.


Diagnostic menu

CAN/POWER, menu 3


520253 /19

520253 /31

61/09

61/19

61/31

Incorrect extra neutral position signal via the CAN bus.



No limitation.

No limitation.

No limitation.

CAN/POWER, menu 3


62/01

Low oil pressure transmission.

Risk of slipping clutches.

Check the transmission oil level. Check the sensor.

520254/9

VDCT01.02GB

62/09

Incorrect oil pressure signal via the CAN bus.

No limitation.



Display 520254 /19

520254 /31

Supplier code 62/19

62/31

D:73

Description

Limitation

Action


Incorrect oil pressure signal via the CAN bus.

No limitation.


D793/22 – D7901/K13:1


D7901/K13:1 – D793/23


-

-


D793/22 – D7901/K13:1

CAN/POWER, menu 3


D7901/K13:1 – D793/23


D793/22 – D7901/K13:1


D7901/K13:1 – D793/23


-

-


D793/22 – D7901/K13:1

CAN/POWER, menu 3


D7901/K13:1 – D793/23

No limitation.

Oil pressure signal, active error.

Diagnostic menu

CAN/POWER, menu 3


520255 /19

520255 /31

63/09

63/19

63/31

Incorrect brake signal via the CAN bus.


Brake signal, active error.

No limitation.

No limitation.

No limitation.

CAN/POWER, menu 3


64/09

Incorrect signal for operator-in-seat via the CAN bus.

No limitation.


VDCT01.02GB

D:74

Display 520256 /19

520256 /31


Supplier code 64/19

64/31

Description

Limitation

Action


Incorrect signal for operator-in-seat via the CAN bus.

No limitation.


D793/22 – D7901/K13:1


D7901/K13:1 – D793/23


-

-


D793/22 – D7901/K13:1

CAN/POWER, menu 3


D7901/K13:1 – D793/23


D793/22 – D7901/K13:1


D7901/K13:1 – D793/23


-

-


D793/22 – D7901/K13:1

CAN/POWER, menu 3


D7901/K13:1 – D793/23

No limitation.

Signal operator-inseat, active error.

Diagnostic menu

CAN/POWER, menu 3


520257 /19

520257 /31

65/09

65/19

65/31

Incorrect signal for seat direction via the CAN bus.

Incorrect signal for seat direction via the CAN bus.

Signal for seat direction, active error.

No limitation.

No limitation.

No limitation.

CAN/POWER, menu 3


VDCT01.02GB

66/09

Incorrect signal for prevent shifting via the CAN bus.

No limitation.



Display 520258 /19

520258 /31

Supplier code 66/19

66/31

D:75

Description

Limitation

Action


Incorrect signal for prevent shifting via the CAN bus.

No limitation.


D793/22 – D7901/K13:1


D7901/K13:1 – D793/23


-

-

-

-


D793/22 – D7901/K13:1

CAN/POWER, menu 3


D7901/K13:1 – D793/23


D793/22 – D7901/K13:1


D7901/K13:1 – D793/23


-

-


D793/22 – D7901/K13:1

CAN/POWER, menu 3


D7901/K13:1 – D793/23

Signal prevent shifting, active error.

No limitation.

Diagnostic menu

CAN/POWER, menu 3


520260/9

520260 /19

520260 /31

68/00

68/09

68/19

68/31

High transmission oil temperature.

Incorrect transmission oil temperature via the CAN bus.

Incorrect transmission oil temperature via the CAN bus.

Transmission oil temperature, active error.

Control unit indicates the error to make operator aware of the warning's level.

No limitation.

No limitation.

No limitation.

Check the transmission oil cooler, clean if necessary. Check the thermostat in the transmission oil cooler.

CAN/POWER, menu 3


69/09

Incorrect signal for lock-up function via the CAN bus.

No limitation.


VDCT01.02GB

D:76

Display 520261 /19

520261 /31


Supplier code 69/19

68/31

Description

Limitation

Action


Incorrect signal for lock-up function via the CAN bus.

No limitation.


D793/22 – D7901/K13:1


D7901/K13:1 – D793/23


-

-


D793/22 – D7901/K13:1

CAN/POWER, menu 3


D7901/K13:1 – D793/23


D793/22 – D7901/K13:1


D7901/K13:1 – D793/23


-

-


D793/22 – D7901/K13:1

CAN/POWER, menu 3


D7901/K13:1 – D793/23

Signal lock-up function active error.

No limitation.

Diagnostic menu

CAN/POWER, menu 3


520262 /19

520262 /31

70/09

70/19

70/31

Incorrect signal for exhaust brake via the CAN bus.

Incorrect signal for exhaust brake via the CAN bus.

Exhaust brake signal, active error.

No limitation.

No limitation.

No limitation.

CAN/POWER, menu 3


VDCT01.02GB

71/09

Incorrect signal for retarder via the CAN bus.

No limitation.



Display 520263 /19

520263 /31

Supplier code 71/19

71/31

D:77

Description

Limitation

Action


Incorrect signal for retarder via the CAN bus.

No limitation.


D793/22 – D7901/K13:1


D7901/K13:1 – D793/23


-

-


D793/22 – D7901/K13:1

CAN/POWER, menu 3


D7901/K13:1 – D793/23


D793/22 – D7901/K13:1


D7901/K13:1 – D793/23


-

-

Signal retarder, active error.

No limitation.

Diagnostic menu

CAN/POWER, menu 3


520264 /19

520264 /31

72/09

72/19

72/31

No limitation.

Incorrect signal for raised idle via the CAN bus.

No limitation.

Incorrect signal for raised idle via the CAN bus.

No limitation.

Signal raised idle, active error.

CAN/POWER, menu 3


84/02

Incorrect gear position limitation.

No limitation.


-

-

520276/9

84/09

Incorrect gear position limitation via the CAN bus.

No limitation.


D793/22 – D7901/K13:1

CAN/POWER, menu 3


D7901/K13:1 – D793/23


VDCT01.02GB

D:78

Display 520276 /19

520276 /31


Supplier code 84/19

84/31

Description

Limitation

Action


Incorrect gear position limitation via the CAN bus.

No limitation.


D793/22 – D7901/K13:1


D7901/K13:1 – D793/23


-

-


D793/22 – D7901/K13:1

CAN/POWER, menu 3


D7901/K13:1 – D793/23


D793/22 – D7901/K13:1


D7901/K13:1 – D793/23


-

-


D793/22 – D7901/K13:1

CAN/POWER, menu 3


D7901/K13:1 – D793/23

Signal gear position limitation, active error.

No limitation.

Diagnostic menu

CAN/POWER, menu 3


520277 /19

520277 /31

85/09

85/19

85/31

Incorrect signal for customer function 1 via the CAN bus.


Signal customer function 1, active error.

No limitation.

No limitation.

No limitation.

CAN/POWER, menu 3


VDCT01.02GB

86/09


No limitation.



Display 520278 /19

520278 /31

Supplier code 86/19

86/31

D:79

Description

Limitation

Action



No limitation.


D793/22 – D7901/K13:1


D7901/K13:1 – D793/23


-

-


D793/22 – D7901/K13:1

CAN/POWER, menu 3


D7901/K13:1 – D793/23


D793/22 – D7901/K13:1


D7901/K13:1 – D793/23


-

-


D793/22 – D7901/K13:1

CAN/POWER, menu 3


D7901/K13:1 – D793/23


No limitation.

Diagnostic menu

CAN/POWER, menu 3


520279 /19

520279 /31

87/09

87/19

87/31




No limitation.

No limitation.

No limitation.

CAN/POWER, menu 3


88/09


No limitation.


VDCT01.02GB

D:80

Display 520280 /19

520280 /31


Supplier code 88/19

88/31

Description

Limitation

Action



No limitation.


D793/22 – D7901/K13:1


D7901/K13:1 – D793/23


-

-


D793/22 – D7901/K13:1

CAN/POWER, menu 3


D7901/K13:1 – D793/23


D793/22 – D7901/K13:1


D7901/K13:1 – D793/23


-

-


D793/22 – D7901/K13:1

CAN/POWER, menu 3


D7901/K13:1 – D793/23


No limitation.

Diagnostic menu

CAN/POWER, menu 3


520281 /19

520281 /31

89/09

89/19

89/31




No limitation.

No limitation.

No limitation.

CAN/POWER, menu 3


VDCT01.02GB

90/09


No limitation.



Display 520282 /19

520282 /31

Supplier code 90/19

90/31

D:81

Description

Limitation

Action



No limitation.


D793/22 – D7901/K13:1


D7901/K13:1 – D793/23


-

-


D793/22 – D7901/K13:1

CAN/POWER, menu 3


D7901/K13:1 – D793/23


D793/22 – D7901/K13:1


D7901/K13:1 – D793/23


-

-


D793/22 – D7901/K13:1

CAN/POWER, menu 3


D7901/K13:1 – D793/23


No limitation.

Diagnostic menu

CAN/POWER, menu 3


520283 /19

520283 /31

91/09

91/19

91/31




No limitation.

No limitation.

No limitation.

CAN/POWER, menu 3


92/09


No limitation.


VDCT01.02GB

D:82

Display 520284 /19

520284 /31


Supplier code 92/19

92/31

Description

Limitation

Action



No limitation.


D793/22 – D7901/K13:1


D7901/K13:1 – D793/23


-

-


D793/22 – D7901/K13:1

CAN/POWER, menu 3


D7901/K13:1 – D793/23


D793/22 – D7901/K13:1


D7901/K13:1 – D793/23


-

-


D793/22 – D7901/K13:1

CAN/POWER, menu 3


D7901/K13:1 – D793/23

No limitation.


Diagnostic menu

CAN/POWER, menu 3


520285 /19

520285 /31

93/09

93/19

93/31

No limitation.


No limitation.


No limitation.


CAN/POWER, menu 3


VDCT01.02GB

94/09


No limitation.



Display 520286 /19

520286 /31

Supplier code 94/19

94/31

D:83

Description

Limitation

Action



No limitation.


D793/22 – D7901/K13:1


D7901/K13:1 – D793/23


-

-


-

-



D793/22 – D7901/K13:1

CAN/POWER, menu 3



D7901/K13:1 – D793/23



D793/22 – D7901/K13:1



D7901/K13:1 – D793/23



-

-



No limitation.


-

-

No limitation.


Diagnostic menu

CAN/POWER, menu 3


95/02

Incorrect signal from gear selector.


520287/9

520287 /19

520287 /31

520288 /02

95/09

95/19

95/31

96/02

Incorrect signal for gear selection via the CAN bus.

Incorrect signal for gear selection via the CAN bus.

Signal gear selection, active error.

Incorrect signal from accelerator pedal.

CAN/POWER, menu 3



VDCT01.02GB

D:84

Display 520288 /09

520288 /19

520288 /31


Supplier code 96/09

96/19

96/31

Description

Limitation

Action


Incorrect accelerator pedal signal via the CAN bus.

No limitation.


D793/22 – D7901/K13:1


D7901/K13:1 – D793/23


D793/22 – D7901/K13:1


D7901/K13:1 – D793/23


-

-

-

-


D793/22 – D7901/K13:1

CAN/POWER, menu 3


D7901/K13:1 – D793/23


D793/22 – D7901/K13:1


D7901/K13:1 – D793/23


-

Incorrect accelerator pedal signal via the CAN bus.

No limitation.

No limitation.

Signal accelerator pedal, active error.

Diagnostic menu

CAN/POWER, menu 3

CAN/POWER, menu 3


97/02

No limitation.

Incorrect signal from brake pedal.

Check for more error codes and rectify them first. Check the cable harness to the control unit.

520289/9

520289 /19

520289 /31

97/09

97/19

97/31



Signal brake pedal, active error.

No limitation.

No limitation.

No limitation.


VDCT01.02GB


CAN/POWER, menu 3

-


Display 520290/0

Supplier code 98/00

Description

Limitation

Action

Transmission oil temperature too high sump.

Transmission locked in neutral position (Shut down).

Check the transmission oil cooler, clean if necessary.

D:85


Diagnostic menu

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

Check the thermostat in the transmission oil cooler. 520290/2

520290 /16

98/02

98/16

Incorrect signal from sensor for transmission oil temperature sump.


High transmission oil temperature sump.

No limitation.

Check for more error codes and rectify them first. Check the cable harness to the control unit. Check the transmission oil cooler, clean if necessary. Check the thermostat in the transmission oil cooler.

520290 /31

98/31

Signal transmission oil temperature sump, active error.

No limitation.


520291/0

99/00

Transmission oil temperature too high, radiator.


Check the transmission oil cooler, clean if necessary. Check the thermostat in the transmission oil cooler.

520291/2

520291 /16

99/02

99/16

Incorrect signal from sensor for transmission oil temperature radiator.


High transmission oil temperature radiator.

No limitation.

Check for more error codes and rectify them first. Check the cable harness to the control unit. Check the transmission oil cooler, clean if necessary. Check the thermostat in the transmission oil cooler.

520291 /31

99/31

Signal transmission oil temperature cooler, active error.

No limitation.


520293/1

101/01

Oil pressure too low, transmission.

Risk of slipping clutches

Check the transmission oil level Check the sensor.


VDCT01.02GB

D:86

Display 520293/2


Supplier code 101/02

Description

Limitation

Action

Incorrect signal oil pressure transmission.

Transmission in locked neutral position (Shut down).



Diagnostic menu

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-


101/31

No limitation.

Signal oil pressure transmission, active error.


520294/0

102/00

No limitation.

Clutch pressure, clutch forward, too high.

Check the transmission oil level Check the sensor. Check the hydraulics in the transmission.

520294/2

102/02

Incorrect signal clutch pressure, clutch forward.

No limitation.


520294 /16

102/16

High clutch pressure, clutch forward.

No limitation.


520294 /31

102/31

Signal clutch pressure, clutch forward, active error.

No limitation.


520295/0

103/00

No limitation.

Clutch pressure, clutch reverse, too high.


520294/2

103/02

Incorrect signal clutch pressure, clutch reverse.

No limitation.


520295 /16

103/16

High clutch pressure, clutch reverse.

No limitation.


VDCT01.02GB



Display 520295 /31


Description

Limitation

Action

Signal clutch pressure, clutch reverse, active error.

No limitation.


D:87


Diagnostic menu

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-


104/00

No limitation.

Clutch pressure, clutch forward high gear, too high.


520296/2

104/02

Incorrect signal clutch pressure, clutch forward, high gear.

No limitation.


520296 /16

104/16

High clutch pressure, clutch forward high gear.

No limitation.


520296 /31

104/31

Signal clutch pressure, clutch forward high gear, active error.

No limitation.


520297/0

105/00

No limitation.

Clutch pressure, clutch gear 1, too high.


520297/2

105/02

Incorrect signal clutch pressure, clutch gear 1.

No limitation.


520297 /16

105/16

High clutch pressure, clutch gear 1.

No limitation.


520297 /31

105/31

Signal clutch pressure, clutch gear 1, active error.

No limitation.



VDCT01.02GB

D:88

Display 520298/0



Description

Limitation

Action


No limitation.

Check the transmission oil level


Diagnostic menu

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

Check the sensor. Check the hydraulics in the transmission.

520298/2

106/02


No limitation.


520298 /16

106/16


No limitation.


520298 /31

106/31


No limitation.


520299/0

107/00

No limitation.



520299/2

107/02


No limitation.


520299 /16

107/16


No limitation.


520299 /31

107/31


No limitation.


520300/0

108/00


No limitation.


VDCT01.02GB



Display 520300/2


Description

Limitation

Action


No limitation.


D:89


Diagnostic menu

-

-

-

-

-

-

-

-

CAN/POWER, menu 3


108/16


No limitation.


520300 /31

108/31


No limitation.


520314/0

520314/9

520314 /19

520314 /31

520315/2

122/02

122/09

122/19

122/31

123/02

Incorrect signal engine speed.

Incorrect signal for engine speed via the CAN bus.

Incorrect signal for engine speed via the CAN bus.

Signal engine speed, active error.

Incorrect signal from Sensor, turbine speed.







D793/22 – D7901/K13:1



D7901/K13:1 – D793/23



D793/22 – D7901/K13:1



D7901/K13:1 – D793/23



-

-




Check the cable harness between the sensor and control unit.

D793/11 – B751/2

-


CAN/POWER, menu 3

D793/12 – B751/1

Check the sensor.


VDCT01.02GB

D:90

Display 520315 /31



Description

Limitation

Action

Signal turbine speed, active error.

No limitation.


520316/2

520316 /31

124/02

124/31

Incorrect signal rotation speed drum.

Signal rotation speed drum, active error.





No limitation.


Connections and components D793/11 – B751/2

Diagnostic menu

-

D793/12 – B751/1

-

-

-

-

-

-

-

-

D793/45

CAN/POWER, menu 15

D793/45

CAN/POWER, menu 15

D793/45

CAN/POWER, menu 15


520317 /31

125/02

125/31

Incorrect signal rotation speed output shaft.

Signal rotation speed output shaft, active error.





No limitation.


520336/0

520336/1

520336 /16

VDCT01.02GB

144/00

144/01

144/16

Control unit, transmission (D793), battery voltage too high.



Control unit, transmission (D793), battery voltage too low.



Control unit, transmission (D793), battery voltage high.

No limitation.

If equipment for assisted start is connected, disconnect it.

Check alternator, battery and cable harness between battery and alternator. Check the voltage feed. If equipment for assisted start is connected, disconnect it.



Display 520336 /18


Description

Limitation

Action

Control unit, transmission (D793), battery voltage low.

No limitation.


D:91


Diagnostic menu

D793/45

CAN/POWER, menu 15

D793/20

CAN/POWER, menu 15

Check alternator, battery and cable harness between battery and alternator. 520337/0

520337/1

520337 /16

520337 /18

145/00

145/01

145/16

145/18

Control unit, transmission (D793), ignition voltage too high.



Control unit, transmission (D793), ignition voltage too low.



Control unit, transmission (D793), ignition voltage high.

No limitation.

Control unit, transmission (D793), ignition voltage low.

No limitation.

D793/60

If equipment for assisted start is connected, disconnect it. D793/20 D793/60

CAN/POWER, menu 15

Check alternator, battery and cable harness between battery and alternator. Check the voltage feed.

D793/20 D793/60

If equipment for assisted start is connected, disconnect it. Check the cable harness to the control unit.

D793/20 D793/60

CAN/POWER, menu 15

CAN/POWER, menu 15

Check alternator, battery and cable harness between battery and alternator. 520346 /12

154/12

Control unit, transmission (D793), memory error.


Switch off the ignition and the battery voltage, and check if the error remains.

-

-

520346 /31

154/31




-

-

520347 /31

155/31




-

-

520348 /31

156/31




-

-

520353 /31

161/31

Incorrect configuration.

No limitation.

Reprogram the control unit.

-

-

520354 /31

162/31


No limitation.


-

-


VDCT01.02GB

D:92

Display


Supplier code

Description

Limitation

Action


Diagnostic menu

520355 /31

163/31


No limitation.


-

-

520356 /31

164/31


No limitation.


-

-

520368 /31

176/31

Output parking brake, active error.

No limitation.


-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-


179/31

No limitation.

Output disengagement 4WD/2WD, active error.


520372 /31

180/31

Output high/low gear, active error.

No limitation.


520373 /31

181/31

Output speed limitation, active error.

No limitation.


520374 /31

182/31

Output signal start interlock neutral position, active error.

No limitation.


520375 /31

183/31

Output signal warning lamp transmission error, active error.

No limitation.


520376 /31

184/31

Output signal lock-up, active error.

No limitation.


520377 /31

185/31

Output gear position, active error.

No limitation.


VDCT01.02GB



Display 520385/9

520386/9

520387/9

520389/9

520390/9


194/09

195/09

197/09

198/09

D:93

Description

Limitation

Action


Control unit, cab (D790-1), communication error.

No limitation.


D793/22 – D7901/K13:1


D7901/K13:1 – D793/23


D793/22 – D7901/K13:1


D7901/K13:1 – D793/23


D793/22 – D7901/K13:1


D7901/K13:1 – D793/23


D793/22 – D7901/K13:1


D7901/K13:1 – D793/23


D793/22 – D7901/K13:1


D7901/K13:1 – D793/23





No limitation.

No limitation.

No limitation.

No limitation.

Diagnostic menu

CAN/POWER, menu 3

CAN/POWER, menu 3

CAN/POWER, menu 3

CAN/POWER, menu 3

CAN/POWER, menu 3

520432 /XX

240/XX


No limitation.

Reprogram Control unit, transmission (D793).

-

-

520433 /XX

241/XX


No limitation.


-

-

520434 /XX

242/XX


No limitation.


-

-


VDCT01.02GB

D:94

Display


Supplier code

Description

Limitation

Action


Diagnostic menu

520435 /XX

243/XX


No limitation.


-

-

520436 /XX

244/XX


No limitation.


-

-

520437 /XX

245/XX


No limitation.


-

-

520438 /XX

246/XX


No limitation.


-

-

520439 /XX

247/XX


No limitation.


-

-

520440 /XX

248/XX


No limitation.


-

-

520441 /XX

249/XX


No limitation.


-

-

520442 /XX

250/XX


No limitation.


-

-

520443 /XX

251/XX


No limitation.


-

-

520444 /XX

253/XX


No limitation.


-

-

VDCT01.02GB



D:95

8 Control system Error codes machine Error codes marked with * do not apply to the machine, but can be shown with an error in the cable harness to the control unit.

Code


Diagnostic menu

Group

D797-1

CAN/POWER, menu 1-3

11.6.2 Redundant CAN bus


D797-2

CAN/POWER, menu 1-3


-


D791-1

CAN/POWER, menu 1-3


Communication error with Control unit KID (D795).

-


D795

CAN/POWER, menu 1-3


11

Error in cable, CAN network, segment 1.

-


Varies depending on machine configuration.

CAN/POWER, menu 1-3


12


-



CAN/POWER, menu 1-3


13


-



CAN/POWER, menu 1-3


14


-



CAN/POWER, menu 2 and 3


15


-



CAN/POWER, menu 1-3


19 *

Accelerator pedal 2 VBFS not calibrated.

Accelerator pedal for reversing does not work. Engine speed limited to idle.


D790-1/K6:12 – R690-2

CALIBRATION: DRIVETRAIN, menu 5 and 6

1. Engine

20

Accelerator pedal not calibrated.

Accelerator pedal does not work. Engine speed limited to idle.


D790-1/K6:11 – R690-1

CALIBRATION: DRIVETRAIN, menu 1 and 2

1. Engine

Description

Limitation

Action

1

Communication error with frame control unit (D797-1)

-


2*

Communication error with frame control unit (D797-2).

-

3

Communication error with Control unit, attachment (D791-1).

8


VDCT01.02GB

D:96

Code 21

22


Description

Limitation

Action


Communication error with Control unit, transmission (D793).

Gear selection not working.


D790-1/K13:1 – D793/M2


D790-1/K13:2 – D793/L2

Communication error with Control unit, engine (D794).

Engine does not respond to commands from the cab.


Volvo: D7901/K13:1, K13:2 – D794/2, 1


Diagnostic menu

Group

CAN/POWER, menu 4

11.6.3 CAN bus drive-train

CAN/POWER, menu 4

11.6.3 CAN bus drive-train

Cummins: D790-1/K13:1, K13:2 – D794/46, 37

23

The set-up file cannot be read in Control unit, cab (D790-1).

No controls in the cab are working.

Contact Cargotec.

D790-1

-

11.5.3.1 Control unit, cab

24

Power supply to cab fan below 18 V.

Cab fan not working.

Check fuse F58-5/3

D790-1/K2:8 – 58-5/3:2

-

9.4.3 Cabin fan

25

Interference during software download. Buffer for error codes from Control unit, engine (D794), active error code when downloading.

Error code stored in Control unit, engine (D794).

Switch the ignition off and on.

D794

ENGINE, menu 8

11.5.3.10 Engine control unit

Incorrect power supply to Control unit, cab (D790-1). Voltage below 18 V or above 32 V.

Controls in cab not working.

Check fuse F58-5/1.

D790-1/K1:2, K1:3, K1:4 – F58-5/1:1, 1:2

CAN/POWER, menu 7

11.5.1.3 Ignition voltage (15)

D790-1/K4:5, K 5:11, K5:13, K7:2, K 9:7

CAN/POWER, menu 7

11.5.3.1 Control unit, cab

D790-1/K11:13 – K3009-1/87

CAN/POWER, menu 5

11.5.1.4 Emergency stop switch voltage (15E)

D791-1/K8:5 – S107/7

HYD, menu 5

4.5 Parking brake

26 27 28 29

Repeat software download.

30 31

Check cabling between the control unit and the component with diagnostic menu. Check the control unit.

32

33

34

Incorrect 5 V reference voltage to analogue cab controls. Voltage below 4.9 V or above 5.1 V.

Analogue controls in cab not working (miniwheel/steering lever and controls for air conditioning).

Check the wiring between the control unit and component with the diagnostic menu.

No feedback signal for emergency stop switch voltage from Relay, emergency stop switch voltage (K3009-1).

Control breaker cannot be disengaged. All hydraulic functions are blocked.

Check fuse F58-3/8.

Incorrect signal from Switch, parking brake (S107), indicates released and applied at same time or nothing at all.


VDCT01.02GB

Check component.


Check cabling between the control unit and the component with diagnostic menu. Check the switch.


D791-1/K8:13 – S107/1


Code 35 36 37 38 39

Description

Limitation

Action

Interference during software download. Buffer for error codes from Control unit, transmission (D793), active error code when downloading.

Error code stored in Control unit, transmission (D793).

Switch the ignition off and on.

Transistor has been triggered due to short circuit or open circuit in circuit for rear wiper motor (M650-2).

Wiper rear not working.


Transistor has been triggered due to short circuit or open circuit in circuit for rotating beacon (H428).

Revolving beacon not working.

Transistor has been triggered due to short circuit or open circuit in circuit for left reversing light (E405L).

Left cab reversing light not working.

Check bulb.

Transistor has been triggered due to short circuit or open circuit in circuit for right reversing light (E405R).

Right cab reversing light not working.

Check bulb.

Transistor has been triggered due to short circuit or open circuit in circuit for front wiper motor (M650-1).

Wiper front not working.

Transistor has been triggered due to short circuit or open circuit in circuit for fan motor (M657).

Cab fan not working.

Transistor has been triggered due to short circuit or open circuit in circuit for recirculation actuating motor (M612).

Recirculation damper to ventilation not working.

Transistor has been triggered due to short circuit or open circuit in circuit for water valve (Y673).

Heat in cab cannot be adjusted.


D:97

Diagnostic menu

Group

D793

TRANSM, menu 13

11.5.3.9 Transmission control unit

D790-1/K2:4 – M650-2/53

CAB, menu 3

9.5.7 Wiper motor rear

D790-1/K2:5 – H428

LIGHTS, menu 6

9.6.8 Revolving beacon

D790-1/K2:6 – E405L

LIGHTS, menu 8

9.6.5 Back-up lights

D790-1/K2:7 – E405R

LIGHTS, menu 8

9.6.5 Back-up lights

D790-1/K2:1 – M650-1/53

CAB, menu 2

9.5.5 Wiper motor front

D790-1/K2:2 – M657/2

CLIMATE, menu 6

9.4.3 Cabin fan

D790-1/K2:3 – M612/3

CLIMATE, menu 6

9.4.2 Fresh air filter and recirculation damper

D790-1/K4:1 – Y673/5

CLIMATE, menu 7

9.4.5 Water valve

Repeat software download.

40 41

42

43

44

45

46

47

48

Check the motor. Check cabling between the control unit and the component with diagnostic menu. Check the component.


Check cabling between the control unit and the component with diagnostic menu. Check cabling between the control unit and the component with diagnostic menu. Check the component. Check cabling between the control unit and the component with diagnostic menu. Check the motor. Check cabling between the control unit and the component with diagnostic menu. Check the motor.

Check cabling between the control unit and the component with diagnostic menu. Check the motor.


VDCT01.02GB

D:98

Code 49

50

51

52 *

53

54

55

56

57


Description

Limitation

Action

Transistor has been triggered due to short circuit or open circuit in circuit for water valve (Y673).

Heat in cab cannot be adjusted.


Transistor has been triggered due to short circuit or open circuit in circuit for actuating motor (Y672).

Air distribution in cab cannot be adjusted.

Transistor has been triggered due to short circuit or open circuit in circuit for actuating motor (Y672).

Air distribution in cab cannot be adjusted.

Transistor has been triggered due to short circuit or open circuit in circuit for bypass of external top lift attachment.

Bypass of external top lift attachment not working.

Check component.

Transistor has been triggered due to short circuit or open circuit in circuit for roof and rear washer motor (M651-2).

Windscreen washer rear and roof not working.


Transistor has been triggered due to short circuit or open circuit in circuit for flashing hazard light switch (S109).

Flashing hazard lights not working.

Transistor has been triggered due to short circuit or open circuit in circuit for background lighting in switches and instruments.

Reduced or no background lighting in instruments and controls.

Transistor has been triggered due to short circuit or open circuit in circuit for relay for 20' working lights.

Work lights 20' not working.

Transistor has been triggered due to short circuit or open circuit in circuit for indicator light for levelling lock in joystick (S815).

Indicator light for levelling lock in joystick not working.

VDCT01.02GB


Diagnostic menu

Group

D790-1/K4:2 – Y673/6

CLIMATE, menu 7

9.4.5 Water valve

D790-1/K4:3 – Y672/5

CLIMATE, menu 8

9.4.14 Air distributor

D790-1/K4:4 – Y672/6

CLIMATE, menu 8

9.4.14 Air distributor

D790-1/K5:3 –

-

-

D790-1/K5:4 – M651-2

CAB, menu 1

9.5.4 Washer motor and reservoir

D790-1/K5:5 – S109/

LIGHTS, menu 7

9.6.7 Flashing hazard lights

D7901/K6:1, K 8:15, K 9:2, all inputs of type A Digital in

LIGHTS, menu 14

9.1 Controls and instruments

D790-1/ K7:8 – R3017-2/86

LIGHTS, menu 12

9.6.10 Working lights, cab

D790-1/ K7:9 – S815/7

-

7.1.1 Control levers/Joystick

Check the motor. Check cabling between the control unit and the component with diagnostic menu. Check the motor. Check cabling between the control unit and the component with diagnostic menu. Check the motor.

Check the wiring.

Check the motor.

Check cabling between the control unit and the component with diagnostic menu. Check the switch. Check bulbs for background lighting, replace if necessary. Check the cable harness for background lighting.

Check cabling between the control unit and the component with diagnostic menu. Check the component. Check cabling between the control unit and the component with diagnostic menu. Check the component.



Code 58 *

59 *

60

61

63

64

65

66

Description

Limitation

Action

Transistor has been triggered due to short circuit or open circuit in circuit for relay for twistlock on external top lift attachment (K3005).

Twistlock on external top lift attachment does not work.


Transistor has been triggered due to short circuit or open circuit in circuit for relay for spreading on external top lift attachment (K3006).

Spreading on external top lift attachment does not work.

Transistor has been triggered due to short circuit or open circuit in circuit for relay for heating element in driver's seat (K383).

Seat heating does not work.

Transistor has been triggered due to short circuit or open circuit in circuit for relay for 40' working lights (K3017-1).

Work lights 40' not working.

Transistor has been triggered due to short circuit or open circuit in circuit for relay for ignition voltage (K315-1).

No ignition voltage to the machine's Control units.

The transistor has been triggered due to short circuit or open circuit in circuit for Relay, emergency stop switch voltage (K3009-1).

No emergency stop switch voltage to the machine's Control units.


The transistor has been triggered due to short circuit or open circuit in circuit for Relay, emergency stop switch voltage (K3009-2).

No emergency stop switch voltage to the machine's Control units.


Transistor has been triggered due to short circuit or open circuit in circuit for windscreen washer motor (M651-1, M651-2).

Windshield washer not working.



D:99

Diagnostic menu

Group

D790-1/ K7:10 – K3005/86

EXTATTACH, menu 6

7.9.2 Twistlocks

D790-1/ K7:11 – K3006/86

EXTATTACH, menu 6

7.10.5.1 Spreading

D790-1/ K10:7 – K383/86

CAB, menu 8

9.3.3 Heating coil

D790-1/ K10:8 – K3017-1/86

LIGHTS, menu 12

9.6.10 Working lights, cab

D790-1/K10:10 – K315-1/86

CAN/POWER, menu 5


D790-1/K10:11 – K3009-1/86

CAN/POWER, menu 6

11.5.1.4 Emergency stop switch voltage

D790-1/K10:12 – K3009-2/86

CAN/POWER, menu 6


D790-1/K10:13 – M651-1, M651-2

CAB, menu 1

9.5.4 Washer motor and reservoir


Check cabling between the control unit and the component with diagnostic menu. Check the component.


Check cabling between the control unit and the component with diagnostic menu. Check the component. Check cabling between the control unit and the component with diagnostic menu. Check the component.





VDCT01.02GB

D:100

Code 67

68 *

69

71

75

80


Description

Limitation

Action

Transistor has been triggered due to short circuit or open circuit in circuit for roof wiper motor (M650-3).

Wiper roof not working.


Transistor has been triggered due to short circuit or open circuit in circuit for circulation pump, pause heater (M667).

Pause heater not working.

Transistor has been triggered due to short circuit or open circuit in circuit for relay for drivetrain ignition voltage (K315-2).

No voltage feed to engine and transmission.

Transistor has been triggered due to short circuit or open circuit in circuit for cab interior lighting (E434-1).

Interior lighting in cab not working.

Check bulb.

Relay ignition voltage (K315-1) has jammed in position on.

The cab control unit (D790-1) still has a power supply and is thereby active.


Air conditioning not working.

Check the drive belt for the compressor for air conditioning.

No signal from Pressure switch, air conditioning (S246), despite the AC compressor being activated.


Diagnostic menu

Group

D790-1/K10:14 – M650-3

CAB, menu 4

9.5.6 Wiper motor roof

D790-1/K10:15 – M667

-

9.4 Heating, ventilation and air conditioning

D790-1/K10:16 – K315-2/86

-


D790-1/K11:6 – E434-1

LIGHTS, menu 9

9.6.11 Interior lighting cab

-

CAN/POWER, menu 5

11.5.1.3 Ignition voltage

D797-1/K1:40 – S246

CLIMATE, menu 3

9.4.10 Pressure switch

D790-1/K4:7 – Y672/9

CLIMATE, menu 4

9.4.6 Fresh air and recirculation damper

D790-1/K6:11 – B690-1/2

ENGINE, menu 1

1 Engine

D790-1/K6:12 – B690-2/2

VBFS, menu 4

1 Engine

Check the motor. Check cabling between the control unit and the component with diagnostic menu. Check the motor.




Check that compressor for air conditioning is activated. Check cabling between the control unit and the component with diagnostic menu.

81

85

86 *

Incorrect signal from Damper motor (Y672). Signal voltage below 0.2 V or above 4.8 V.

Air distribution cannot be adjusted.

Incorrect signal from accelerator pedal (B690-1). Signal voltage below 0.2 V or above 4.8 V.

Accelerator pedal for driving forward does not work. Engine speed limited to idle.


Incorrect signal from extra accelerator pedal (B690-2). Signal voltage below 0.2 V or above 4.8 V.

Accelerator pedal for reversing does not work. Engine speed limited to idle.

Check the wiring between the control unit and component with the diagnostic menu.

VDCT01.02GB

Check cabling between the control unit and the component with diagnostic menu. Check the motor.


Check component.



Code 87

88

89

90 *

91 *

92 *

93 *

94

95 *

Description

Limitation

Action

Error signal from Control lever lifting/lowering (R8071). Signal voltage below 0.2 V or above 4.8 V.

Lift and lower not working.


Error signal from Control lever tilt (R8072). Signal voltage below 0.2 V or above 4.8 V.

Tilt not working.

Error signal from Control lever side shift (R8073). Signal voltage below 0.2 V or above 4.8 V.

Side shift not working.

Error signal from Control lever spreading (R8074). Signal voltage below 0.2 V or above 4.8 V.

Spreading not working.

Error signal from Control lever extra function (R8075-1). Signal voltage below 0.2 V or above 4.8 V.

Extra load handling function not working.

Incorrect signal from Steering lever (R825-1) or Mini-wheel (R825-1). Signal voltage below 0.2 V or above 4.8 V.

Joystick control or mini-wheel not working.

Incorrect signal from Mini-wheel (R825-2). Signal voltage below 0.2 V or above 4.8 V.

Joystick control or mini-wheel not working.

Incorrect signal from Water valve, cab heating (Y673). Signal voltage below 0.2 V or above 4.8 V.

Cab heat cannot be adjusted.

Error signal from Control lever extra function (R8075-2). Signal voltage below 0.2 V or above 4.8 V.

Extra load handling function not working.


D:101

Diagnostic menu

Group

D790-1/K7:3 – R8071/3

ELSERV, menu 1 (P1)

7.1.1 Control lever

D790-1/K7:4 – R8072/3

ELSERV, menu 1 (P2)

7.1.1 Control lever

D790-1/K7:5 – R8073/3

ELSERV, menu 1 (P3)

7.1.1 Control lever

D790-1/K7:6 – R8074/3

ELSERV, menu 2 (P4)

7.1.1 Control lever

D790-1/K7:7 –R8075-1/3

ELSERV, menu 2 (P5)

7.1.1 Control lever

D790-1/K9:8 – R825-1/H1

EL-STEERING, menu 1

5.1.2 Miniwheel

D790-1/K9:9 – R825-2/H2

EL-STEERING, menu 1

5.1.2 Mini steering wheel

D790-1/K10:4 – Y673/9

CLIMATE, menu 4

9.4.5 Water valve

D790-1/K9:9 – R8075-2/3

ELSERV, menu 2 (P7)

7.1.1 Control lever

Check the lever. Check cabling between the control unit and the component with diagnostic menu. Check the lever. Check cabling between the control unit and the component with diagnostic menu. Check the lever. Check cabling between the control unit and the component with diagnostic menu. Check the lever. Check the wiring between the control unit and component with the diagnostic menu. Check component. Check cabling between the control unit and the component with diagnostic menu.

5.1.3 Joystick

Check the switch.

Check cabling between the control unit and the component with diagnostic menu. Check the switch. Check cabling between the control unit and the component with diagnostic menu. Check the motor. Check cabling between the control unit and the component with diagnostic menu. Check the lever.


VDCT01.02GB

D:102

Code 96

97

98

99

101

102

103

104


Description

Limitation

Action

Incorrect signal from Sensor, cab temperature (B775-1). Sensor indicates temperature below -43 °C or above 105 °C.



Incorrect signal from Sensor, outer temperature (B774). Temperature signal above 105 °C.


Incorrect signal from Sensor, outlet fan temperature (B775-2). Sensor indicates temperature below -43 °C or above 105 °C.


Incorrect signal from Sensor, refrigerant temperature (B775-3). Sensor indicates temperature below -43 °C or above 105 °C.


Redundant voltage feed left to frame control unit (D797-1) does not reach destination.

-

Redundant voltage feed right to frame control unit (D797-1) does not reach destination.

-

Incorrect power supply to Control unit, frame (D797-1). Voltage below 18 V or above 32 V.

No electric power feed to components.

Incorrect emergency stop switch voltage to frame control unit (D797-1).

Functions normally supplied emergency stop switch voltage have no feed. All hydraulic functions are blocked.

VDCT01.02GB


Diagnostic menu

D790-1/K4:8 – B775-1/2

CLIMATE, menu 1

9.4.17 Sensor cab temperature

D790-1/K4:9 – B774/2

CLIMATE, menu 2

9.4.18 Sensor, ambient temperature

D790-1/K4:10 – B775-2/2

CLIMATE, menu 2

9.4.16 Sensor, temperature outlet fan

D790-1/K4:11 – B775-3/2

CLIMATE, menu 2

9.4.12 Sensor temperature refrigerant

D797-1/K2:7

CAN/POWER, menu 10

11.5.1.2 Redundant voltage feed of control units

D797-1/K2:8

CAN/POWER, menu 10


D797-1/K2:1, K2:9, K2:10 – F58-2/1:1, 1:2

CAN/POWER, menu 10


D797-1/K2:11 – F58-2/1:1

CAN/POWER, menu 10


Group

Check the sensor.

Check cabling between the control unit and the component with diagnostic menu. Check the sensor. Check cabling between the control unit and the component with diagnostic menu. Check the sensor.

Check cabling between the control unit and the component with diagnostic menu. Check the sensor.

Check cabling between the control unit and the component with diagnostic menu. Check the control unit. Check cabling between the control unit and the component with diagnostic menu. Check the control unit. Check fuse F58-2/1, replace if necessary. Check cabling between the control unit and the component with diagnostic menu. Check fuse F58-2:1 and replace if necessary. Check the wiring between the control unit and component with the diagnostic menu. Check component.



Code 105

106

107

108

109

111

112

113

114

Description

Limitation

Action

Incorrect 5 V reference voltage to pressure sensor. Voltage below 4.9 V or above 5.1 V.

Incorrect function, lift and tilt sensor.


Transistor has been triggered due to short circuit or open circuit in circuit for hydraulic oil cooling fan (M668).

Cooling fan hydraulic oil not working.

Transistor has been triggered due to short circuit or open circuit in circuit for mast work lights (E404R-1, E404L-1).

Mast work lights not working.

Transistor has been triggered due to short circuit or open circuit in circuit for high beam (E402R-1, E402L-1).

High beam not working.

Transistor has been triggered due to short circuit or open circuit in circuit for low beam (E400L, E400R).

Low beams not working.

Transistor has been triggered due to short circuit or open circuit in circuit for running lights (H416-1, H416-2, H417-1, H417-2).

Running lights not working.

Transistor has been triggered due to short circuit or open circuit in circuit for brake oil cooling fan (M674).

Cooling fan brake oil not working.

Transistor has been triggered due to short circuit or open circuit in circuit for solenoid valve, lift mast (Y6005) and solenoid valve, lower mast (Y6004).

Lift and lower not working.

Transistor has been triggered due to short circuit or open circuit in circuit for solenoid valve, tilt in (Y6011) and solenoid valve, tilt out (Y6010)

Tilt not working.

D:103


Diagnostic menu

Group

D797-1/K1:8 – B768-1/1, B768-2/1

CAN/POWER, menu 11

8.2.1 Overload protection

D797-1/K1:14 – M668/1

HYD, menu 1

10.6.3 Cooling fan

D797-1/K1:1 – E404L-1, E404R-1

LIGHTS, menu 10

9.6.9 Working lights mast

D797-1/K1:15 – E402L-1, E402R-1

LIGHTS, menu 3

9.6.1 Headlights

D797-1/K1:28 – E400L, E400R

LIGHTS, menu 3

9.6.1 Headlights

D797-1/K1:2 – H416-1, H416-2, H417-1, H417-2

LIGHTS, menu 2

9.6.2 Running lights

D797-1/K1:3 – M674/1

HYD, menu 2

4.8.9 Cooling fan

D797-1/K1:4 – Y6004/1, Y6005/1

ELSERV, menu 3 and 4

7.2.5 Control valve, lift and tilt

D797-1/K1:5 – Y6010/1, Y6011/1

ELSERV, menu 5 and 6


Check the sensor. Check cabling between the control unit and the component with diagnostic menu. Check the motor. Check bulb. Check the bulb holder. Check cabling between the control unit and the component with diagnostic menu. Check bulb. Check the bulb holder. Check cabling between the control unit and the component with diagnostic menu. Check bulb. Check the bulb holder. Check cabling between the control unit and the component with diagnostic menu. Check bulb. Check the bulb holder. Check cabling between the control unit and the component with diagnostic menu. Check cabling between the control unit and the component with diagnostic menu. Check the motor. Check cabling between the control unit and the component with diagnostic menu. Check the solenoid valves.

Check cabling between the control unit and the component with diagnostic menu. Check the solenoid valve.


VDCT01.02GB

D:104

Code 115

116

117

118

119

120

121

122 123


Description

Limitation

Action

Transistor has been triggered due to short circuit or open circuit in circuit for left direction indicator (H422, H426).

Left direction indicator not working.

Check bulb.

Transistor has been triggered due to short circuit or open circuit in circuit for right direction indicator (H423, H427).

Right direction indicator not working.

Transistor has been triggered due to short circuit or open circuit in circuit for start relay (K315) for starter motor.

Starter motor not working.

Transistor has been triggered due to short circuit or open circuit in circuit for tail light (H412L, H412R).

Tail lights not working.

Transistor has been triggered due to short circuit or open circuit in circuit for left brake light (H411L).

Brake light left not working.

Transistor has been triggered due to short circuit or open circuit in circuit for right brake light (H411R).

Brake light right not working.

The transistor has been triggered due to short circuit or open circuit in circuit for Back-up warning device (H965).

Back-up alarm not working.

Transistor has been triggered due to short circuit or open circuit in circuit for electromagnetic clutch of AC compressor (M645).


Check the bulb holder.

Diagnostic menu

Group

D797-1/K1:30 – H422/1, H426/1

LIGHTS, menu 4

9.6.6 Direction indicators

D797-1/K1:31 – H423/1, H427/1

LIGHTS, menu 4

9.6.6 Direction indicators

D797-1/K1:32 – K315/85

ENGINE, menu 5

1.11 Start and stop

D797-1/K1:33 – H412L/1, H412R/1

LIGHTS, menu 2

9.6.3 Tail lights

D797-1/K1:7 – H411L/1

LIGHTS, menu 8

9.6.4 Brake light

D797-1/K1:9 – H411R/1

LIGHTS, menu 8

9.6.4 Brake light

D797-1/K1:10 – H965/1

LIGHTS, menu 8

9.7.5 Back-up alarm

D797-1/K1:25 – M645/1

CLIMATE, menu 6

9.4.7 Compressor

Check cabling between the control unit and the component with diagnostic menu. Check bulb. Check the bulb holder. Check cabling between the control unit and the component with diagnostic menu. Check cabling between the control unit and the component with diagnostic menu. Check the component. Check bulb. Check the bulb holder. Check cabling between the control unit and the component with diagnostic menu. Check bulb. Check the bulb holder. Check cabling between the control unit and the component with diagnostic menu. Check bulb. Check the bulb holder. Check cabling between the control unit and the component with diagnostic menu. Check cabling between the control unit and the component with diagnostic menu. Check the component. Check cabling between the control unit and the component with diagnostic menu. Check the component.

NOTE! Error code 122 and 123 apply to the same user.

VDCT01.02GB



D797-1/K1:29 – M645/1


Code 124

125 *

126 *

132

133 *

D:105


Diagnostic menu

D797-1/K1:39 – Y6062/1

HYD, menu 6

7.4.9 Lift, tilt and attachment control valve

D797-1/K1:11 – Y6051/1

ELSERV, menu 15

7.2.6 Valve block lift cylinder

D797-1/K1:12 – Y6052/1

ELSERV, menu 15

7.2.6 Valve block lift cylinder

-

-

-

-

Check the sensor.

D797-1/K1:21 – B768-1/3

HYD, menu 3

7.2.8 Sensor hydraulic pressure lift cylinder

Description

Limitation

Action

Transistor has been triggered due to short circuit or open circuit in circuit for solenoid valve, hydraulic pump disengagement (Y6062).

Pressurising of attachment control valve does not work. No attachment functions working.


Transistor has been triggered due to short circuit or open circuit in circuit for solenoid valve regeneration, lift, right (Y6051).

Regeneration not working.


Transistor has been triggered due to short circuit or open circuit in circuit for solenoid valve regeneration, lift, left (Y6052).

Regeneration not working.

Vehicle Data file missing.

Some functions in machine not working.

Faulty signal from hydraulic pressure sensor for lift cylinder (B768-1).

Scales, regeneration and slack chain logic, not working.

Group


Check component.

Check cabling between the control unit and the component with diagnostic menu. Check component.


OLS, menu 1

Overload system not working. Error code 150 activated. 134 *

135 *

137

Faulty signal from hydraulic pressure sensor for tilt cylinder (B768-2).

Overload system not working. Error code 150 activated.

No feedback signal from brake oil cooling fan (M674).

-

Error signal from Solenoid valve lift mast (Y6005). Return current does not correspond with control current.

Lift mast not working.

Check the sensor. Check cabling between the control unit and the component with diagnostic menu.

Check that cooling fan is working.

D797-1/K1:22 – B768-2/3

HYD, menu 3 OLS, menu 1

7.7.8 Hydraulic pressure sensor, tilt cylinder

D797-1/K2:6 – M674/2

HYD, menu 2

4.8.9 Cooling fan

D797-1/K1:16 – Y6005/2

ELSERV, menu 3


Check cabling between the control unit and the component with diagnostic menu. Check cabling between the control unit and the component with diagnostic menu. Check the solenoid valve.


VDCT01.02GB

D:106

Code 138

139

140

141

142

143 *

144 *

145 *


Description

Limitation

Action

Error signal from Solenoid valve lower mast (Y6004). Return current does not correspond with control current.

Lower mast not working.


Incorrect signal from Solenoid valve, tilt in (Y6011). Return current does not correspond with control current.

Tilt in not working.

Incorrect signal from Solenoid valve, tilt out (Y6010). Return current does not correspond with control current.

Tilt out not working.

Transistor has been triggered due to short circuit or open circuit in circuit for parking brake solenoid valve (Y642).


Transistor has been triggered due to short circuit or open circuit in circuit for solenoid valve, hydraulic pump disengagement (Y6012/6062).

Pressurising of attachment control valve does not work. No attachment functions working.


Transistor has been triggered due to short circuit or open circuit in circuit for solenoid valve, lock twistlocks/spreading out (Y6039/6018).

Spreading and twistlocks on top lift attachment not working.


Transistor has been triggered due to short circuit or open circuit in circuit for solenoid valve, open twistlocks/spreading in (Y6040/6019).

Spreading and twistlocks on top lift attachment not working.


High brake oil temperature.

Reduced braking capacity. If the temperature continues to rise, speed is limited to 5 km/h.


VDCT01.02GB


Diagnostic menu

D797-1/K1:17 – Y6004/2

ELSERV, menu 4


D797-1/K1:18 – Y6011/2

ELSERV, menu 5


D797-1/K1:19 – Y6010/2

ELSERV, menu 6


D797-1/K1:34 – Y642/1

HYD, menu 5

4.5.3 Solenoid valve parking brake

D797-1/K1:35 – Y6012/6062/1

HYD, menu 6

7.4.9 Lift, tilt and attachment control valve

D797-1/K1:36 – Y6039/6018/1

EXTATTACH, menu 5

7.10.5 Separate top lift attachment

D797-1/K1:37 – Y6040/6019/1

EXTATTACH, menu 5

7.10.5 Separate top lift attachment

D797-1/K2:6 – B772/1

HYD, menu 2

4.8.10 Sensor brake oil temperature

Group

Check the solenoid valve. Check cabling between the control unit and the component with diagnostic menu. Check the solenoid valve. Check cabling between the control unit and the component with diagnostic menu. Check the solenoid valve. Check cabling between the control unit and the component with diagnostic menu. Check the solenoid valve.




Check that the radiator is not clogged. Check the brake oil level. Check the sensor.



Code 146 *

147

148

149

150 *

Description

Limitation

Action

Incorrect signal from Sensor, brake oil temperature (Y772). Signal voltage below 0.2 V or above 4.8 V.

Speed limited to 5 km/h.

Check the sensor.

High temperature hydraulic oil.

Reduced braking capacity. If the temperature continues to rise, speed is limited to 5 km/h.

194

251

252



Diagnostic menu

D797-1/K2:6 – B772/1

HYD, menu 2

4.8.10 Sensor brake oil temperature

D797-1/K2:13 – B776/1

HYD, menu 1

10.6.4 Sensor hydraulic oil temperature

D797-1/K2:13 – B776/1

HYD, menu 1

10.6.4 Sensor hydraulic oil temperature

D797-1/K2:15 –B757/1

CAB, menu 7

1.2.2 Sensor fuel level

Check that the radiator is not clogged.

Group

Check the sensor.

Incorrect signal from Sensor, hydraulic oil temperature (B776).

Incorrect temperature display.

Incorrect signal from fuel level sensor (B757). Resistance above 180Ω.

Incorrect display of fuel volume (empty or full).

Defective overload protection.

Overload system not working. All lift functions run at reduced speed.

Check if there are error codes for sensors in the overload system.

-

OLS, menu 1–7

8.2.1 Overload protection

Transistor has been triggered due to short circuit or open circuit in circuit for right front brake light (H410R).

Right front brake light not working.

Check bulb.

D797-1/K1:36 – H410R/1

VBFS, menu 8

9.6.4 Brake light

Transistor has been triggered due to short circuit or open circuit in circuit for left front brake light (H410L).

Left front brake light not working.

D797-1/K1:37 – H410L/1

VBFS, menu 8

9.6.4 Brake light

Redundant voltage feed left to attachment control unit (D791-1) does not reach destination.

-

D791-1/K2:7

CAN/POWER, menu 15

11.5.1.2 Redundant voltage feed of Control units

Redundant voltage feed right to frame control unit (D791-1) does not reach destination.

-

D791-1/K2:8

CAN/POWER, menu 15

11.5.1.2 Redundant voltage feed of Control units

This error code cannot be removed with Reset. 193


D:107

Check the sensor. Check cabling between the control unit and the component with diagnostic menu. Check the sensor. Check cabling between the control unit and the component with diagnostic menu.

Check the bulb holder. Check cabling between the control unit and the component with diagnostic menu. Check bulb. Check the bulb holder. Check cabling between the control unit and the component with diagnostic menu. Check cabling between the control unit and the component with diagnostic menu. Check the control unit. Check cabling between the control unit and the component with diagnostic menu. Check the control unit.


VDCT01.02GB

D:108

Code 253

254

255

256

257

258

259

260 *


Description

Limitation

Action

Incorrect power supply to Control unit, attachment (D791-1). Voltage below 18 V or above 32 V.

Functions normally supplied emergency stop switch voltage have no feed. No attachment functions working.

Check fuse F58-3/1, replace if necessary.

Incorrect emergency stop switch voltage to Control unit, attachment (D791-1).

Functions normally supplied emergency stop switch voltage have no feed. No attachment functions working.

Incorrect 5 V reference voltage to pressure sensor. Voltage below 4.9 V or above 5.1 V.

-

Transistor has been triggered due to short circuit or open circuit in circuit for central unit for central lubrication (M693-2).

Central lubrication attachment not working.

Transistor has been triggered due to short circuit or open circuit in circuit for attachment work lights, left (E404L-3).

Work light attachment left not working.

Transistor has been triggered due to short circuit or open circuit in circuit for attachment work lights, right (E404R-3).

Work light attachment right not working.

Transistor has been triggered due to short circuit or open circuit in circuit for warning signal, automatic spreading (H9003).

Warning signal for automatic spreading not working.

Transistor has been triggered due to short circuit or open circuit in circuit for control valve for levelling clockwise (Y637-1, Y637-2).

Levelling of attachment not working.

VDCT01.02GB


Check fuse F58-3/1, replace if necessary.


Diagnostic menu

D791-1/K2:1, K2:9, K2:10 – F58-3/1:1

CAN/POWER, menu 15


D791-1/K2:11 – F58-3/1:1

CAN/POWER, menu 15


D791-1/K1:8

CAN/POWER, menu 16

11.5.1 Power supply

D791-1/K1:14 – M693-2/1

OPT, menu 2

9.14.1 Pump unit

D791-1/K1:1 – E404L, E404UL, E404LL-3/1

LIGHTS, menu 13

9.6.12 Work light attachment

D791-1/K1:15 – E404R, E404UR, E404LR-3/1

LIGHTS, menu 13

9.6.12 Work light attachment

D791-1/K1:28 – H9003/1

ATTACH, menu 21

7.5.7 Buzzer, automatic spread 20"-40"

D791-1/K1:42 – Y637-1/1, Y637-2/1

ATTACH, menu 15

-



Group

Check the sensor. Check cabling between the control unit and the component with diagnostic menu. Check the component.

Check bulb. Check the bulb holder. Check cabling between the control unit and the component with diagnostic menu. Check bulb. Check the bulb holder. Check cabling between the control unit and the component with diagnostic menu. Check the buzzer. Check cabling between the control unit and the component with diagnostic menu.




Code 261

262

263

264

265 *

266 *

267

268

269

Description

Limitation

Action

Transistor has been triggered due to short circuit or open circuit in circuit for solenoid valve, spreading left in (Y6019L).

Spreading left in of attachment not working.


Transistor has been triggered due to short circuit or open circuit in circuit for solenoid valve, spreading left out (Y6018L).

Spreading left out of attachment not functioning.

Transistor has been triggered due to short circuit or open circuit in circuit for solenoid valve, spreading right in (Y6019R).

Spreading right in of attachment not working.

Transistor has been triggered due to short circuit or open circuit in circuit for solenoid valve, spreading right out (Y6018R).

Spreading right out of attachment not functioning.

Transistor has been triggered due to short circuit or open circuit in circuit for levelling, left (Y6036).

Levelling left of attachment not working.

Transistor has been triggered due to short circuit or open circuit in circuit for solenoid valve, levelling right (Y6035).

Levelling right of attachment not working.

Transistor has been triggered due to short circuit or open circuit in circuit for solenoid valve, side shift left (Y6020).

Side shift left of attachment not working.

Transistor has been triggered due to short circuit or open circuit in circuit for solenoid valve, side shift right (Y6021).

Side shift right of attachment not working.

Transistor has been triggered due to short circuit or open circuit in circuit for solenoid valve for locked twistlocks (Y6040).

Twistlock not working.

D:109


Diagnostic menu

D791-1/K1:16 – Y6019L/2

ATTACH, menu 18

7.5.2 Control valve attachment

D791-1/K1:16 – Y6018L/2

ATTACH, menu 17


D791-1/K1:17 – Y6019R/2

ATTACH, menu 20


D791-1/K1:17 – Y6018R/2

ATTACH, menu 19


D791-1/K1:19 – Y6036/2

ATTACH, menu 13

-

D791-1/K1:19 – Y6036/2

ATTACH, menu 14

-

D791-1/K1:18 – Y6020/2

ATTACH, menu 11


D791-1/K1:18 – Y6021/2

ATTACH, menu 12


D791-1/K1:7 – Y6040/1

ATTACH, menu 9

7.9.1.2 Control valve attachment

Group

Check the solenoid valve. Check cabling between the control unit and the component with diagnostic menu. Check the solenoid valve. Check cabling between the control unit and the component with diagnostic menu. Check the solenoid valve. Check cabling between the control unit and the component with diagnostic menu. Check the solenoid valve. Check cabling between the control unit and the component with diagnostic menu. Check the solenoid valve. Check cabling between the control unit and the component with diagnostic menu. Check the solenoid valve. Check cabling between the control unit and the component with diagnostic menu. Check the solenoid valve. Check cabling between the control unit and the component with diagnostic menu. Check the solenoid valve. Check cabling between the control unit and the component with diagnostic menu. Check the solenoid valve.


VDCT01.02GB

D:110

Code 270

271

272

273

274

287

288


Description

Limitation

Action

Transistor has been triggered due to short circuit or open circuit in circuit for solenoid valve for open twistlocks(Y6039).



The transistor has been triggered due to short circuit or open circuit in circuit for Voltage feed, position sensor attachment.

Twistlocks and spreading not working.

The transistor has been triggered due to short circuit or open circuit in the circuit for Indicator light, open twistlocks (H562).

Indicator light, open twistlock/lock tongue not working.

The transistor has been triggered due to short circuit or open circuit in the circuit for Indicator light, locked twistlocks (H563).

Indicator light, locked twistlock/lock tongues not working.

The transistor has been triggered due to short circuit or open circuit in circuit for Indicator light, alignment (H564).

Indicator light, attachment alignment not working.

Error signal from the Solenoid valve spreading left in (Y6019L) and Solenoid valve spreading left out(Y6018L). Return current does not correspond with control current.

Spreading left not working.

Error signal from the Solenoid valve spreading right in (Y6019R) and Solenoid valve spreading right out (Y6018R). Return current does not correspond with control current.

Spreading right not working.

VDCT01.02GB


Diagnostic menu

D791-1/K1:9 – Y6039/1

ATTACH, menu 9


D791-1/K1:10 – B769L/A, B769R/A, B777L/A, B777R/A, B7203L/A, B7203R/A, B7204L/A, B7204R/A, B7205LL/A, B7205RL/A

CAN/POWER, menu 16


D791-1/K1:25 – H562/1

ATTACH, menu 10

7.9.1 Twistlocks

D791-1/K1:29 – H563/1

ATTACH, menu 10

7.9.1 Twistlocks

D791-1/K1:39 – H564/1

ATTACH, menu 10

7.9.1 Twistlocks

D791-1/K1:16 – Y6019L/2, Y6019R/2

ATTACH, menu 17 and 18


D791-1/K1:17 – Y6019R/2, Y6018R/2



Group

Check the solenoid valve. Check cabling between the control unit and the component with diagnostic menu. Check the sensor.

Check bulb. Check the bulb holder. Check cabling between the control unit and the component with diagnostic menu. Check bulb. Check the bulb holder. Check cabling between the control unit and the component with diagnostic menu. Check bulb. Check the bulb holder. Check cabling between the control unit and the component with diagnostic menu. Check cabling between the control unit and the component with diagnostic menu. Check the solenoid valve.




Code 289

290 *

291 *

292

298

299

300

Description

Limitation

Action

Error signal from Solenoid valve for side shift left (Y6020) and Solenoid valve for side shift right (Y6021). Return current does not correspond with control current.

Side shift of attachment not working.


Error signal from Solenoid valve levelling right (Y6036) and Solenoid valve levelling left (Y6035). Return current does not correspond with control current.

Levelling of attachment not working.

Transistor has been triggered due to short circuit or open circuit in circuit for indicator light, upper alignment (H564UL).

Indicator light for upper alignment not working.

Transistor has been triggered due to short circuit or open circuit in circuit for solenoid valve, spreading in (Y6019).

Spreading in of attachment not working.

Sensor twistlock left side indicates both locked and open twistlock at the same time.

-

Sensor twistlock right side indicates both locked and open twistlock at the same time.

-

Sensor, alignment, indicates unreasonable distance.


D:111


Diagnostic menu

Group

D791-1/K1:18 – Y6020/2, Y6021/2



D791-1/K1:19 – Y6035/2, Y6036/2


-

D791-1/K1:34 – H564UL/1

ATTACH, menu 23

-

D791-1/K1:35 – Y6019/1

ATTACH, menu 14


D791-1/K2:13

ATTACH, menu 8

7.9.1.7 Sensor twistlocks

D791-1/K2:15

ATTACH, menu 8

7.9.1.7 Sensor twistlocks

-

ATTACH, menu 7

7.9.1.6 Sensor alignment



Check bulb. Check the bulb holder. Check cabling between the control unit and the component with diagnostic menu. Check cabling between the control unit and the component with diagnostic menu. Check the solenoid valve. Check that Sensors, twistlock, are clean and correctly adjusted. Check cabling between the control unit and the component with diagnostic menu. Check that Sensors, twistlock, are clean and correctly adjusted. Check cabling between the control unit and the component with diagnostic menu. Check that Sensors, alignment, are clean and correctly adjusted. Check that the contact pin runs smoothly. Check cabling between the control unit and the component with diagnostic menu.


VDCT01.02GB

D:112

Code



Diagnostic menu

Description

Limitation

Action

451

Redundant voltage feed left to Control unit KID (D795) does not reach destination.

-


D795/K1:7

CAN/POWER, menu 9


452

Redundant voltage feed right to Control unit KID (D795) does not reach destination.

-


D795/K1:8

CAN/POWER, menu 9


460

No messages received on CAN buffer 1.

Incorrect values in operating menus.

Use diagnostic menu to check the CAN bus.

D795/K1:10, K1:11, K1:12, K1:13

CAN/POWER, menu 1, 2, 17


461

No messages received on CAN buffer 2.

Error codes from other Control units cannot be shown.

Use diagnostic menu to check the CAN bus.

D795/K1:5, K1:6

CAN/POWER, menu 1, 2, 17


500

Time for service.

-

Check that servicing has been performed. If servicing has been performed following the Cargotec service schedule, reset the service indicator; see section 8 Control system, group 8.2.4 Service indicator.

-

-

C Preventive maintenance

VDCT01.02GB


Group

E:1

E Schematics

Contents E Schematics Schematics......................................................................................................... E:3 Common hydraulics ........................................................................................ E:3 Hydraulic diagrams, compilation ................................................................ E:3 Hydraulic diagrams..................................................................................... E:4 Common electrics ........................................................................................... E:6 Circuit diagram, description ....................................................................... E:6 Component designations ........................................................................... E:8 Circuit diagrams, compilation ..................................................................... E:8


VDCT01.02GB

E:2

VDCT01.02GB


E Schematics – Schematics

E:3

E Schematics Common hydraulics Hydraulic diagrams, compilation Designation

Drawing number

Hydraulic diagrams, page E:4

A54948.0100


VDCT01.02GB

VDCT01.02GB


3

36

2

4

35

34

015048 [A58447-0200 ver . 03]

1

3

1

5

6

7

32

8

a

33

12

b

13

10

9

11

14

13

15

31

a

30

b

29

20

c

28

d

e

27 26

16

f

d

e

g

17

h

25

a

24

24

19

c

22

21

25 23

b

22 23

18

E:4 E Schematics – Common hydraulics

Hydraulic diagrams

E Schematics – Common hydraulics

1.

Wheel brakes

17. Spreading cylinder right spreader beam

2.

Drive axle block

18. Main valve

3.

Brake cylinder

4.

Parking brake caliper

5.

Make-contact (closing switch) declutch (S220)

6.

Make-contact (closing switch) brake light (S216)

7.

Brake valve

8.

Valve block brake system a b

9.

Accumulator drain valve Solenoid valve parking brake (Y642)

a

Solenoid valve hydraulic pressure attachment (Y6012/6062)

b

Relief valve, attachment

c

Servo valve, lift (Y6005)

d

Servo valve, lower (Y6004)

e

Servo valve, tilt in (Y6011)

f

Servo valve, tilt out (Y6010)

19. Lift, tilt and attachment control valve 20. Valve block accumulator charging and priority valve

Switch (NC) low brake pressure (S204)

21. Accumulator lift cylinder

10. Switch (NO), parking brake (S200)

22. Load control valve

11. Accumulator brake system

23. Lift cylinder

12. Side shift cylinder

24. Overcentre valve

13. Lock cylinder, twistlock

25. Tilt cylinder

14. Overcentre valve

26. Hydraulic oil tank

15. Control valve, attachment

27. Breather filter

a

Servo valve, side shift left (Y6020)

b

Servo valve, side shift right (Y6021)

c

Servo valve, open twistlock (Y6039)

d

Servo valve, lock twistlock (Y6040)

e

Servo valve spreading out left (Y6018L)

f

Servo valve spreading in left (Y6019L)

g

Servo valve spreading out right (Y6018R)

h

Servo valve spreading in right (Y6019R)

16. Spreading cylinder left spreader beam

E:5

28. Hydraulic oil pump, load handling 29. Hydraulic oil pump, brake and steering 30. Hydraulic oil filter, load handling 31. Hydraulic oil filter, cooling circuit 32. Steering valve 33. Steering cylinder 34. Oil cooler 35. Thermal bypass valve 36. Fine filter


VDCT01.02GB

E:6

E Schematics – Common electrics

Common electrics Circuit diagram, description A circuit diagram is divided into circuit names (drawing numbers) and consists of a set of numbered pages. The circuits and their contents are governed by the following set of rules: •

20015.0001 circuit drawings-post designations K-standard.

•

K-standard 1: norms, rules

•

K-standard 2: cables, general physical

•

K-standard 5: Designation and marking system, item designations circuit drawings

The following is an explanation of symbols and texts in a circuit diagram: Connectors

-X M 6 7 4 m

Connectors

-X M 6 7 4 f

2

Connectors in the wiring start with an X followed by a number and end with f = female or m = male. If a connector is connected to a component then the component number is inherited into the connector's number, e.g. XB72002Rm which is the connector for Sensor, alignment front right (B7202R). -X 3 7 -2 0 1

013017

2

Under the connector's number the pin is specified with numbers or letters depending on the connector. •

X000-X199: In the cab.

•

X200-X299: On the frame.

•

X300-X399: On the boom.

•

X400-: On the attachment.

•

X37-: All grounding points start with X37, e.g. X37-201, which is a grounding point on the frame. X37-A, X37-B, X37-C and X37-D are grounding points in electronic box, cab. Zero references are in the control units.

Components

Components

+ C H A S S IS -S 2 2 0 -2

P 1

2 D E C L U C H IN G 3 ,0 M P a

VDCT01.02GB

1 013018

1

Components are described with component number (S220-2) and a short descriptive text. Components (sensors, switches, etc.) are shown in standby mode i.e. de-energised mode or not mechanical standby mode. •

S indicates the type of component, see Component designations, page E:8.

•

220 is component number and indicates the function the component has.

•

-2 indicates that it is the second component of this type for the specific diagram.



Cable marking

E:7

A 01012

0525

W 212D

Cable marking

A 01011

0524

W 212C

All cables are either white (ground signal) or grey (other wiring) and labelled with numbers. Cable numbering is interpreted as follows:

0523

W 212B

A 01016

0527

W 212E

013019

A 01010

W 212A

References

5

1

013020

/9 .1 0 _ 1 .A 2

1

00816

0525: the number on a cable can usually be traced to a pin in a connector, in this example, connector X052 pin 5.

•

W212: cables that start with W and serial number cannot be traced directly to a connector.

•

A01012: cables that start with A are in the electronic box in the cab.

•

W212D: cables that end with a capital letter are jointed in the wiring from a main cable with the same number. Each joint will have its own letter.

References

0

/4 .0 _ 1 .B 1

•

00816

An arrow symbol means that the circuit continues on another page in the circuit diagram at the specified coordinates. Sometimes there are also references for components that can then be part of a component whose other parts are on a different diagram. In some cases there is also a help text where the cable connects. Example: /11.5_1.D3 means page 11.5_1 coordinate D3.

Connection to control unit

Connection to control unit K 1 :2 1

A n a lo g In 0 -5 V /0 .0 _ 4 .D 5

+BO O M -D 7 9 1 -1

M E A S U R E P O IN T S C A L E

013021

-X 4 1 1 21

Connections to control units are described as a table with two fields; the upper one shows the type of connection, the lower one has a reference to the compilation of the control unit's connections. Together with this there are descriptive texts that specify control unit and signal. For more information about the different connection types on the control units, see section 11 Common electrics, group 11.5.5 Wiring.

Fuses Fuse boxes always start with F5. Example: F58-3 means fuse box 3 with 8 fuses. For most fuse boxes there is also a table and an explanation of the circuits that the various fuses protect.


VDCT01.02GB

E:8


Component designations The components in circuit diagrams have a prefix and number, the prefix describes the type of component, the number which component. Component list with component number, prefix and designation is provided as an appendix after the circuit diagrams.

Prefix

Description

B

Converter from non-electric to electric signals or vice versa. Example: inductive sensor.

D

Binary element, delay unit, memory. Example: control unit.

E

White light. Example: work lighting.

F

Protective device. Example: fuse.

G

Alternator, power supply device. Example: battery.

H

Signal device. Example: horn, brake lights.

K

Relay, contactor. Example: power relay ignition key lock.

M

Motor. Example: electric motor.

P

Measuring instrument, testing equipment. Example: hour meter.

R

Resistor. Example: potentiometer.

S

Electric switch for control circuit, selector. Example: switch.

X

Outlet/socket, connecting device. Example: connection terminal.

Y

Electrically controlled mechanical device. Example: solenoid valve, hydraulic valve.

Circuit diagrams, compilation Circuit diagrams are attached as an appendix in the following order. Circuit diagram basic machine, drawing number A49226.0100. The circuit contains pages for several machine models, those applying to DCT 80-90 are listed here.

VDCT01.02GB

Sheet

Designation

0.0-1

Cross-reference list

0.0-2


0.0-3


0.0-4


0.1-1

Truth table opt.

1.0-1

Circuit, drivetrain, engine

1.0-2E1

Circuit, Cummins QSB6.7 engine

1.0-2E2

Circuit, Cummins QSB6.7 engine

2.0-1

Circuit, drivetrain gearbox

4.0-1

Circuit, brake system

4.8-1

Circuit, brake oil cooling

7.0-1

Circuit, electric servo levers

7.0-2

Circuit, electric servo joystick

7.0-4

Circuit, accessory attachment

7.0-5

Circuit, accessory attachment

7.2-1

Circuit, lift/lower electric servo

7.2-6

Circuit, mast valves

7.7-1

Circuit, tilt electric servo



Sheet

Designation

7.7-2

Circuit, tilt indication

7.9-1

Circuit, twistlock

8.2-1

Circuit, bypassing

9.0-1

Circuit, std. opt.

9.1-1

Circuit, optional equipment

9.1-2

Circuit, hour counter

9.3-1

Circuit, seat heating

9.3-2

Circuit, air suspension seat

9.4-1

Circuit, climate system

9.4-2

Circuit, climate system

9.4-3

Circuit, condenser chassis

9.5-1

Circuit, wipers

9.6-1

Circuit, work lights 20'-40'

9.6-2

Circuit, work lights, carriage

9.6-3

Circuit, work lights, mast

9.6-4

Circuit lighting

9.6-5

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

9.9-2

Circuit, camera

9.10-1

Circuit, cab tilt/sliding cab

9.14–1

Circuit, central lubrication

10.4-1

Circuit, hydr. pump disengagement

10.6-1

Circuit, hydraulic oil cooling

11.5-1

Circuit, current

11.5-2

Circuit, current

11.5-3

Circuit, current

11.5-4

Circuit, current


E:9

VDCT01.02GB

E:10


Sheet

Designation

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

11.5-10

Circuit, option, ground

11.5-11

Circuit, option, ground

11.6-1

Circuit CAN bus ground

Circuit diagram Yuchai YC6A240-30 and Dana HR32000, drawing number A59539.0100.

Sheet

Designation

1.0_1A1

Circuit Yuchai YC6A240-30

1.0_1A2

Circuit Yuchai YC6A240-30

2.0_1A1

Circuit Dana HR32335

2.0_1A2

Circuit Dana HR32335

Circuit diagram for side lift attachment, drawing number A50400.0100.

VDCT01.02GB

Sheet

Designation

0.0_1


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


7.9_5B


9.6_1

Circuit, work lights, carriage/attachment

9.14_1

Circuit, central lubrication

11.5_1

Circuit, current

11.5_2

Circuit, current

11.6_1

Circuit, CAN bus


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E Schema – Komponentförteckning / E Schematics – List of Components

NUMBER A 32 A 685 A 779 A 782 A 783 A 784 A 785 A 786 A 799 A 806 A 810 A 827 A 900 A 905 A 907 A 908 A 909 A 911 A 912 A 940 A 950 A 955 A 960

SVENSKA Kretskort elcentral Reglerenhet termostat AC Reglersystem återladdning (EC) Logik interface 2 drivmotorer Logik interface gaspådrag Logik interface bromsregl Logik interface styrsystem Servoförstärkare styrsystem Logik allm (option) Aggregat klimatanläggning Kondensor AC, fläkt Växellåda Radio/bandspelare Kommunikationsradio Monitor Kamera Skrivare Dataterminal Alkolås Logik batterivakt Logik transistortändning Logik övervarvningsskydd (LPG) Logik rev-spärr/aut-vxl

A B B B B B B B B B B B B B

961 649 690 697 751 752 753 754 755 756 757 758 759 760

Motor/kupevärmare Termostat klimatannläggning Fartreglage (EC) Elbroms Givare varvtal turbin Givare varvtal inre växellåda Varvtalsgivare motor Givare lufttryck Givare hydraulfilter indikering Temperatur kylvätska motor Bränslenivågivare Varvtalsgivare v-låda Nivåindikator kylvätska Givare rev-spärr/aut-vxl trans

B

761 Givare rev-spärr/aut-vxl motor

B B B B B B B B B B B

762 763 764 765 766 767 768 769 770 771 772

Givare temp,spolkrets bromsar Givare nivå hydraulolja Givare servotryck växellåda Givare oljetryck v-låda Givare oljetemp. v-låda Givare oljetryck motor Givare oljetryck hydraulik Givare ändläge Givare rattutslag Givare vinkel Givare temp bromsolja

1

ENGLISH Printed circuit board, Junction box Control unit, termostat AC Control system, recharging (EC) Logic (interface) two main motors (EC) Logic (interface) throttle Logic (interface) brake control Logic (interface) control system Servo amplifier steering system Logic, general (option) Aggregate, air conditioner Condensor AC, fan Gearbox Radio/tape recorder Communication radio Monitor Camera Printer Dataterminal Interlock device Logic switch , battery watch Logic transistor ignition Logic overspeed protection (LPG) Logic unit, reversing interlock/automatic gear changing Engine- and cab heater Thermostat, air condition Speed control (EC) Electric brake Transmitter, speed turbin Transmitter, speed internal gear chain Transmitter, engine revolution Transmitter, air pressure Transmitter, hydraulics filter indication Transmitter, engine coolant temperature Transmitter, fuel level Transmitter, gear box revolution Transmitter, coolant level Transmitter, reversing interlock / automatic gear change system (on gearbox output shaft) Transmitter, reversing interlock / automatic gear changing system (engine speed) Transmitter, brake flushing circuit Transmitter, hydraulic fluid level Transmitter, gear box servo pressure Transmitter, oil pressure gear box Transmitter, oil temperature gear box Transmitter, oil pressure engine Transmitter, hydraulic pressure Transmitter, end position Transmitter, steering wheel angle Transmitter, angle Transmitter, temperature brake fluid

Verkstadmanual / Workshop Manual – DCT 80–-90

VDCT01.02SE/GB


2

NUMBER B 773 B 774 B 775 B 776 B 777 B 778 B 789 B 902 B 7224 B 7225 B 7226 B 7227 B 7228 B 7229 B 7230 B 7231 B 7232 B 7233 B 7234 B 7235 B 7236 C 821 D 740 D 742 D 743 D 744 D 780 D 781 D 790 D 791 D 792 D 793 D 794 D 796 D 797 D 798 D 2000

SVENSKA Givare närvaro Givare utomhustemp Givare temp klimatanläggning Givare temp hydraulolja Givare läge Givare drivbrytning Givare allmän Högtalare Givare, mätläge våg Givare, rotationsstopp Givare, tryck lyftcylinder Givare, tryck klämma Givare lyfthöjd analog Givare tiltvinkel analog Givare ultraljud last position Givare, Over Height, Ben uppe Givare,IR Last position Givare lambda sond Givare vatten i bränsle Givare temp avgaser Givare tryck avgaser KONDENSATOR FleetManager kontrollenhet FleetManager kortläsare FleetManager accelerations givare Galvaniskt isolerad CAN brygga Reglersystem drivmotor Reglersystem pumpmotor Elektronisk kontrollenhet ECU, hytt Elektronisk kontrollenhet aggregat Elektronisk kontrollenhet styrning Elektronisk kontrollenhet växellåda Elektronisk kontrollenhet motor Elektronisk kontrollenhet, lasthantering Elektronisk kontrollenhet, ram Elektronisk kontrollenhet, stolvändning Elektronisk kontrollenhet, proportionalventil

ENGLISH Transmitter, presence Transmitter, ambient temperature Transmitter, temperature air condition Transmitter, hydraulic temperature Transmitter, position Transmitter, drive break Transmitter, common Loud speaker Sensor, measurepoint scale Sensor, rotation stop Sensor, pressure lift cylinder Sensor, pressure clamp Sensor lift height analogue Sensor tilt angle analogue Sensor, ultrasonic load position Sensor, Over Height, Leg upper position Givare,IR Load position Sensor lambda sond Transmitter water in fuel Sensor exhaust temperature Sensor exhaust pressure CAPACITOR FleetManager control unit FleetManager card device FleetManager acceleration sensor Galvanic insulated CAN bridge Control system traction motor Control system pump motor Electronic Control Unit ECU, cab Electronic Control Unit, attachment Electronic Control Unit, steering system Electronic Control Unit, gearbox Electronic Control Unit, engine Electronic Control Unit, Loadhandling Electronic Control Unit, frame Electronic Control Unit, seat rotation Electronic control unit, propotional valve

D E E E E E E E E E E E E

9001 400 400 401 401 402 403 404 405 406 406 408 408

Åkerströms fjärrkontroll G-lampa vä fram G-lampa hö fram G-lampa vä bak G-lampa hö bak G-lampa fjärrljus G-lampa lastljus G-lampa arbetsljus G-lampa backljus G-lampa cont belysning vänster G-lampa cont belysning höger G-lampa park ljus vä fram G-lampa park ljus hö fram

Åkerströms Remote Control Light bulb, roading light left hand front Light bulb, roading light right hand rear Light bulb, roading light left hand front Light bulb, roading light right hand rear Light bulb, distance light Light bulb, mast light Light bulb, working light Light bulb, rear light Container light left-hand Container light right-hand Light bulb, parking light, left-hand forward Light bulb, parking light, right-hand forward

E E

429 G-lampa cigarettändare belysning 431 G-lampa instrument belysning

Light bulb, cigarett lighter illumination Light bulb, instrument illumination


VDCT01.02SE/GB


NUMBER E 432 E 433 E 434 E 435 E 436 E 437 E 438 E 439 E 440 E 456 E 456 E 458 E 458

SVENSKA G-lampa handsfack belysning G-lampa instegs belysning G-lampa innerbelysning G-lampa låsbelysning G-lampa identifikationsljus G-lampa identifikationsljus/takskylt G-lampa motorrumsbelysning Nummerskyltsbelysning G-lampa värmereglage belysning G-lampa backljus blackout IR vänster G-lampa backljus blackout IR höger G-lampa fram blackout vänster G-lampa fram blackout höger

E

459 G-lampa fram blackout IR vänster

E

459 G-lampa fram blackout IR höger

E

460 G-lampa arb.belysning hytt blackout IR vä

E

460 G-lampa arb.belysning hytt blackout IR hö

E

461 G-lampa arb.bel. bom 20' blackout IR vä

E

461 G-lampa arb.bel. bom 20' blackout IR hö

E

462 G-lampa arb.bel. bom 40' blackout IR vä

E

462 G-lampa arb.bel. bom 40' blackout IR hö

E E E E E E E E E E E

464 464 669 802 803 804 805 808 835 888 962

G-lampa cont belysning IR vänster G-lampa cont belysning IR höger Värmare kupe/ motor diesel Eluppvärmd backspegel Eluppvärmd stol Cigarettändare Elvärme hytt Eluppvärmd lufttorkare Tändstift Lufttork, kompressor Logik slitageind kol elmotor

E E F F F F F F F G G G

4370 8092 51 52 56 58 59 62 64 30 658 659

Sökljus Eluppvärmd ruta Säkringshållare 1-polig Säkringshållare 2-polig Säkringshållare 6-polig Säkringshållare 8-polig Säkringshållare 12-polig Batterihandske 2-polig Batterihandske 4-polig Batteri Generator (extra) Generator utan laddregulator

3

ENGLISH Light bulb, glove pocket light Light bulb, step-in lighting Light bulb, interior lighting Light bulb, reading lighting Light bulb, identification light Light bulb, identification light/roof sign Light bulb, engine compartment light Light license plate Light bulb, heating control light Light bulb, rear light blackout IR left-hand Light bulb, rear light blackout IR right-hand Light bulb, roading light blackout left-hand Light bulb, roading light blackout right-hand Light bulb, roading light blackout IR lefthand Light bulb, roading light blackout IR righthand Light bulb, working light cab blackout IR left Light bulb, working light cab blackout IR right Light bulb, working light boom20' b.out IR left Light bulb, working light boom20' b.out IR right Light bulb, working light boom40' b.out IR left Light bulb, working light boom40' b.out IR right Light bulb,Container light IR left-hand Light bulb,Container light IR right-hand Heater compartment/engine diesel Electrical heated observation mirror Electrical heated seat Cigarett lighter Electrical heating cab Electrical heater air dryer Ignition plug Air Dryer, Compressor Logic indication of wear, brush electrical motor Search light Electrical heated window Fuse holder, 1-pole Fuse holder, 2-pole Fuse holder, 6-pole Fuse holder, 8-pole Fuse holder, 12-pole Battery connector, 2-pole Battery connector, 4-pole Battery Alternator extra Alternator without loading regulator


VDCT01.02SE/GB


NUMBER G 660 G 662 H 410 H 410 H 411 H 411 H 412 H 412 H 413

SVENSKA Generator med laddregulator Laddregulator G-lampa broms ljus vä fram G-lampa broms ljus hö fram G-lampa broms ljus vä bak G-lampa broms ljus hö bak G-lampa bak ljus vä bak G-lampa bak ljus hö bak G-lampa bak ljus vä fram (VBFS)

4

ENGLISH Alternator with loading regulator Loading regulator Light bulb, brake light, left-hand forward Light bulb, brake light, right-hand forward Light bulb, brake light, left-hand rear Light bulb, brake light, right-hand rear Light bulb, rear light, left-hand rear Light bulb, rear light right-hand rear Light bulb, rear light, left-hand forward (VBFS) Light bulb, rear light,right-hand forward (VBFS) Light bulb, side position light, left-hand forward Light bulb, side position light, left-hand rear

H

413 G-lampa bak ljus hö fram (VBFS)

H

416 G-lampa sidomarkering vä fram

H

416 G-lampa sidomarkering vä bak

H

417 G-lampa sidomarkering hö fram

H

417 G-lampa sidomarkering hö bak

H H H

420 G-lampa positionsljus vänster 421 G-lampa positionsljus höger 422 G-lampa körvisare vä fram

H

423 G-lampa körvisare hö fram

H

426 G-lampa körvisare vä bak

H

427 G-lampa körvisare hö bak

H H H H H H

428 445 446 451 452 453

H

453 G-lampa bromsljus/körvisare höger

H H H H

454 454 457 457

G-lampa bromsljus blackout vänster G-lampa bromsljus blackout höger G-lampa positionsljus blackout vänster G-lampa positionsljus blackout höger

Light bulb, brake light/dir. indicator righthand Light bulb, brake light blackout left-hand Light bulb, brake light blackout right-hand Light bulb, position light blackout left-hand Light bulb, position light blackout right-hand

H

463 G-lampa bak ljus vänster bak, blackout

Light bulb, rear light left-hand rear, blackout

H

463 G-lampa bak ljus höger bak, blackout

H H H H H H

465 466 467 468 500 501

Light bulb, rear light right-hand rear, blackout Light-bulb, red extender exended Light bulb, orange vertical hold on Light bulb, green clamp pressure OK Light bulb,Red Overload Indicating lamp, direction indicator Indicating lamp, direction indicator extra

G-lampa roterande varningsljus G-lampa körvisare vä (extra) G-lampa körvisare hö (extra) G-lampa dimbakljus vänster G-lampa dimbakljus höger G-lampa bromsljus/körvisare vänster

G-lampa röd saxagregat ute G-lampa orange vertikalhålning på G-lampa grön klämtryck OK G-Lampa Röd Maxlast Kont lampa körvisare Kont lampa körvisare (extra)

Light bulb, side position light, right -hand forward Light bulb, side position light, right-hand rear Light bulb, position light, left-hand Light bulb, position light, right-hand Light bulb, direction indicator left-hand forward Light bulb, direction indicator right-hand forwrd Light bulb, direction indicator left-hand rear Light bulb, direction indicator right-hand rear Light bulb, flashing beacon lamp Light bulb, extra direction indicator left Light bulb, extra direction indicator right Light bulb, fog light rear left Light bulb, fog light rear right Light bulb, brake light/dir. indicator left-hand


VDCT01.02SE/GB


NUMBER H 503 H 504 H 505 H 506 H 507 H 508 H 509 H 510 H 512 H 514 H 519 H 524 H 525 H 528 H 530 H 531 H 532 H 533 H 547 H 549 H 550 H 551 H 552 H 554

SVENSKA Varn lampa oljetryck motor Kont lampa helljus Varn lampa laddning Varn lampa laddning (extra) Varn lampa färdbroms Varn lampa parkerings broms Varn lampa nivå kylvatten Kont lampa diff spärr Varn lampa temp momentförst Kont lampa överväxel Kont lampa halvljus Kont lampa luftfilter Kont lampa UNIKAT Kont lampa förvärmning Kont lampa framhjuls styrning Kont lampa 4-hjuls styrning Kont lampa crab styrning Kont lampa hyd.pump Varn lampa centralvarning Varn lampa oljetryck v-låda Varn lampa hyttlåsning Varn lampa temp v-låda Varn lampa bromstryck Varn lampa temp spolkrets bromsar

5

H

555 Varn lampa temp kylvatten mot

ENGLISH Warning lamp, oil pressure engine Indicating lamp, main beam Warning lamp, loading Warning lamp, loading extra Warning lamp, brake Warning lamp, parking brake Warning lamp, coolant level Indicating lamp, diff. interlock Warning lamp, temperature converter Indicating lamp, overdrive clutch Indicating lamp, dipped lights Indicating lamp, air filter Indicating lamp, UNIKAT Indicating lamp, preheating Indicating lamp, forward wheel steering Indicating lamp, 4-wheel steering Indicating lamp, crab steering Indicating lamp, emergency hyd. pump Warning lamp, central warning Warning lamp, oil pressure gear box Warning lamp, cab lock Warning lamp, temperature gear box Warning lamp, brake pressure Warning lamp, temp. cooling system brakes Warning lamp, temperature coolant engine

H H H H H H H H H H

556 560 561 562 563 564 565 569 569 570

Varn lampa låsning vändskiva Varn lampa temp drivmotor el Varn lampa temp pumpmotor el Varn lampa öppen twistlock Varn lampa låst twistlock Varn lampa anliggning Varn lampa temp motor el Kont lampa elvärme Kont lampa elvärme Varn lampa överkoppling säkerhetssystem

Warning lamp, interlocking of turntable Warning lamp, temperature, drive motor Warning lamp, temperature, pump motor Warning lamp, unlocked twist lock Warning lamp, locked twist lock Warning lamp, alignement Warning lamp ,temperature motor Indicating lamp, electric heater Indicating lamp, electric heater Warning lamp, by-pass safety system

H H H H H

571 572 573 574 575

Kont lampa bränslenivå Varningslampa lyfthöjd Kontroll lampa motor information Kontroll lampa stödben nere Kontroll lampa stödben ur arb.läge

H H H H H H H H H H

576 577 578 579 580 581 582 583 584 599

Kontroll lampa anliggning främre ben Kontroll lampa anliggning bakre ben Kontroll lampa klämläge främre ben Kontroll lampa klämläge bakre ben Kontroll lampa främre ben uppe Kontroll lampa främre ben nere Varningslampa överlast Kontroll lampa anliggning ett ben Kontroll lampa anliggning alla ben Kont lampa option

Indicating lamp, fuel level Warning lamp lifting height Indicator lamp engine information Indicator lamp support jacks down Indicator lamp support jacks out of working pos Indicator lamp, alignment front legs Indicator lamp, alignment rear legs Indicator lamp, clamp position front legs Indicator lamp, clamp position rear legs Indicator lamp, front legs upper position Indicator lamp, front legs lower position Warning lamp overload Indicator lamp, alignment one leg Indicator lamp, alignment all legs Indicating lamp, option


VDCT01.02SE/GB


NUMBER H 850 H 853 H 965 H 5000 H 5001 H 9003 K 300 K 301 K 302 K 303 K 304 K 305 K 306 K 307 K 308 K 309 K 310 K 311 K 312 K 313 K 314 K 315 K 316 K 317 K 318 K 319 K 320 K 321 K 322 K 323 K 324 K 325 K 326 K 327 K 328 K 329 K 330 K 331 K 332 K 333 K 334 K 335

SVENSKA Signalhorn Summer Backvarnare Kont lampa tryck lyfttång Varn lampa, Over Height ben uppe Varningssignal aut. rörelse Relä hel/halvljus Relä dimljus Relä fjärrljus Relä lastljus Relä arbetsljus Relä backljus Relä helljus Relä halvljus Relä bromsljus Relä parkeringsbroms Relä körvisare vä Relä körvisare hö Relä startelement Relä vändbar förarstol Relä parkeringsbroms Relä tändningslås Relä torkare Relä strålkastartorkare Relä AT-regulator Relä varningsblinkers Relä elektrisk stopp Relä intervalltorkare Relä kylvätskenivå Relä blinkers Relä rangespärr Relä blinkande bromsljus (back) Relä blinkande bromsljus (runt) Relä växel neutral Relä växelskifte Relä växel hög/låg Relä startspärr Relä drivning fram Relä drivning bak Tidrelä förvärmning Relä frikoppling/drivbrytning Relä växelventil 1:a (diesel, gas)

K

336 Relä växelventil 2:a (diesel, gas)

K K K K K K K K K

337 338 339 340 341 342 343 344 345

Relä drivriktning motor Relä kylfläkt drivmotor Relä kylfläkt elskåp Tidrelä fördröjt tillslag Tidrelä fördröjt frånslag Relä drivning 2/4 hjul Relä dimbakljus Relä momentförstärkare Relä låsning vändskiva

6

ENGLISH Horn Buzzer Reversing alarm Indicating lamp, pressure lift tong Warn. Lamp, Over Height leg upper pos Warning alarm aut. movement Relay, main/dipped beam Relay, fog light Relay, distance light Relay, mast light Relay, working light Relay, reversing light Relay, main beam Relay, dipped beam Relay, brake light Relay, parking light Relay, direction indicator left Relay, direction indicator right Relay,element preheater Relay, rotating driver´s seat (VBFS) Relay, parking brake Relay, ignition key Relay, wiper Relay, roading lights wiper Relay, AT-regulator Relay, hazard blinkers Relay, electical stop Relay, intermittent wiper Relay, coolant level Relay, blinkers Relay, range interlock Relay, flashing brake lights (reversing) Relay, flashing hazard brake lights Relay, gear neutral Relay, gear shift Relay, high/low gear Relay, start interlock Relay, forward driving Relay, reversing driving Time relay, automatically preheating Relay, free wheel/drive disconnection Relay, gear change valve 1-gear (diesel,LPG) Relay, gear change valve 2-gear (diesel,LPG) Relay, motor drive direction Relay, cooling fan drive motor Relay, cooling fan electrical box Time relay, start delay Time relay, stop delay Relay, switching 2/4 WD Relay, fog light rear Relay, torque amplifier Relay, interlocking of turntable


VDCT01.02SE/GB


NUMBER SVENSKA K 346 Relä frikoppling stollåsning K 347 Relä stolvändning/ljussignal

7

K K K K K K K K K K K K K K K K K K K K K K K K K

348 349 350 351 352 353 354 355 356 357 358 359 360 361 362 363 364 365 366 367 368 369 370 371 372

Relä fläktmotor värmare Relä fartreglage Relä pumpkontaktor/pumpkontroll Relä hyttlyft upp Relä hyttlyft ner Relä säkerhetsslinga Relä styrsystem Relä sensorstyrning Skiftrelä längskörning/tvärskörning Relä roterande varningsljus Relä komressor luft Relä Hydrauloljekylare Relä startsolenoid Relä kompressor AC Relä vattenventil AC Relä kondensor AC Relä stolsbrytare Relä fönsterhiss upp Relä fönsterhiss ner Relä styrning Relä lågt bromstryck Relä centralsmörjning Relä centralsmörjning, aggregat Relä lyfthöjd Relä blinkande varn.ljus, höjdbegränsn.

ENGLISH Relay, releasing of seat interlocking Relay, multifunction, seat rotation/light signal Relay, fan heating Relay, speed control Relay, pump contactor/pump control Relay, cab hoist up Relay, cab hoist down Relay, safety loop Relay, signal control system Relay, sensor control Shift relay, length/sideways driving Relay, hazard beacon Relay, compressor air Relay hydraulic oil cooler Relay, starting solenoid Relay, compressor air conditione Relay, water valve air conditioner Relay, condenser air conditione Relay seat switch Relay, electrical screen elevator up Relay, electrical screen elevator down Relay, steerin Relay, low brake pressure Relay, central lubrication Relay, central lubrication, attatchment Relay, liftheight Relay, flashing beacon, lifting height limiter

K K K K K

373 375 376 377 378

K K K K K K K K K K K K K K K K K K K

379 380 381 382 383 384 385 386 387 388 389 399 3001 3002 3003 3004 3005 3006 3007

Relä bakljus Huvudkontaktor reglersystem Kontaktor fram reglersystem Kontaktor bak reglersystem Kontaktor by-pass reglersystem/Fältförsvagning Kontaktor pumpmotor Kontaktor Kontaktor återladdning Relä, förbikoppling säkerhetssystem Relä, Stolsvärme Relä vattenseparator Relä bränslepump insprutning Relä, hög motortemperatur. Relä alternativ gaspedal Relä, Extra färdriktningsväljare Relä, Pausvärme Relä option Relä rotation Relä tilt Relä sidoföring Relä längdinställning Relä twist lock Relä spridning Relä lyft/sänk

Relay light Main contactor, operating control Contactor, forward operating control Contactor, reversing operating control Contactor, ¿by-pass¿ operating control/ Field weakening Contactor, pump motor Contactor Contactor, recharging Relay, by-pass safety system Relay, heated seat Relay, waterseparator Relay, fuel injection pump Relay, high motor temperature Relay alternative throttle pedal Relay, Extra direction selector Relay, Paus heat Relay, option Relay, rotation Relay, tilt Relay, side shifting Relay, length adjustment Relay, twist lock Relay, spreading Relay, lifting/lowering


VDCT01.02SE/GB


NUMBER K 3008 K 3009 K 3010 K 3011 K 3012 K 3013 K 3014 K 3015

SVENSKA Relä hydraulfunktion extra Relä manöverbrytare hydr Relä bromsljus vxl std/blackout Relä backljus vxl std/blackout Relä arb.bel hytt vxl std/blackout Relä arb.bel. bom 20' vxl std/blackout Relä arb.bel. bom 40' vxl std/blackout Relä vxl bromsljus/blinkers vä

K

3015 Relä vxl bromsljus/blinkers hö

K K K K

3016 3017 3018 3305

Relä signalhorn Relä containerbelysning Relä containerbelysning IR Relä VBFS, backljus

K K K K

3306 3307 3308 3310

Relä VBFS, helljus Relä VBFS, halvljus Relä VBFS, bromsljus Relä VBFS, körvisare vä

K

3311 Relä VBFS, körvisare hö

K K

3330 Relä, säkerhetsbälte 3331 Relä VBFS, drivning fram

K

3332 Relä VBFS, drivning bak

K

3349 Relä VBFS, fartreglage

K K K K K K K K K K K K L M M M M M M M M M M M

3404 3405 3412 3768 3769 3770 3771 3772 3773 3774 3776 93774 830 608 609 612 650 650 650 650 651 652 653 654

Relä VBFS, mastljus Relä,backalarm Relä bak ljus Relä oljetryck hydraulik Relä, blockering av hyttilt Relä anliggning Relä Krok Relä laddsignal (D+) Relä 12V för minne radio Relä kylfläkt olja Relä värmare ruta Relä hållkrets Tändspole Pumpaggregat hyttlyft Ställmotor gaspådrag Ställmotor recirkulation Torkarmotor fram Torkarmotor fram Torkarmotor fram Torkarmotor fram Vindrutespolarmotor Strålkastarmotor Strålkastarspolarmotor Startmotor

8

ENGLISH Relay, extra hydraulic function Relay, operating switch Relay, brake light shift std/blackout Relay, reversing light shift std/blackout Relay, working light cab, shift std/blackout Relay,working light boom20' shift std/b.out Relay,working light boom40' shift std/b.out Relay, shift brake light/direction indicator left Relay, shift brake light/direction indicator right relay, horn Relay, Container light Relay, Container light IR Relay, rotating driver´s seat, reversing light Relay, rotating driver´s seat, main beam Relay, rotating driver´s seat, dipped beam Relay, rotating driver´s seat, brake light Relay, rotating driver´s seat, direction indicator left Relay, rotating driver´s seat, direction indicator right Relay, seat belt Relay, rotating driver´s seat, forward driving Relay, rotating driver´s seat, reversing driving Relay, rotating driver´s seat, speed control Relay, rotating driver´s seat, mast light Relay,reversealarm Relay, rotating driver´s seat, rear light Relay, hydraulic pressure Relay, blocking of cab tilt Relay, alignment Relay, Hook Relay, charge signal (D+) Relay 12V for radio memory Relay, cooling fan oil Relay heated window Relay, Holdcircuit Ignition coil Pump unit, cab hoist Regulating motor, throttle Regulating motor, re-circulation

Washer motor Light motor Light washer motor Starter motor


VDCT01.02SE/GB


NUMBER M 655 M 656 M 657 M 661 M 663 M 664 M 666 M 667 M 668 M 670 M 671 M 672 M 674 M 675 M 677 M 693 M 694 M 695 M 696 M 698 M 9000 P 700 P 701 P 702 P 703 P 704 P 705 P 706 P 707 P 708 P 709 P 710 P 711 P 712 P 714 P 715 P 795 Q 144 R 807 R 820 R 825 R 828 R 8071 R 8072 R 8073 R 8074 R 8075 R 8076 R 8077 R 8078 R 8079 R 8080 R 8081 R 8082

SVENSKA Kylfläkt drivmotor (EC) Kylfläkt elskåp (EC) Fläktmotor värme Fönsterhissmotor Doseringspump klimatanläggning Cirk pump klimatanläggning Fläktmotor cirkulation Cirkulationspump värmesystem Kylfläkt hydraulolja Kompressor Doseringspump diesel Spjäll motor, ECC Kylfläkt bromsolja Motor, Stolsvändning Motor Låsning stolsvridning Pump centralsmörjning Styrmotor Drivmotor (EC) Pumpaggregate nödstyrning Pumpmotor (EC) Motor höj/sänkbar stolspelare Hastighetsmätare Mätare oljetemp v-låda Klocka Varvtalsmätare Tryckluftsmätare Mätare oljetryck v-låda Termometer temp kylvätska motor Bränslemätare Timräknare Kapacitetsmätare batteri Tidur motor/kupevärmare Räknare, impuls Mätare oljetryck motor Mätare, temp. Hydraulolja Extra instrument allm Display Batterifrånskiljare Potentiometer Motstånd Reglage spakstyrning Shuntmotstånd Potentiometer lyft/sänk Potentiometer tilt Potentiometer sidoföring Potentiometer spridning Potentiometer extra Potentiometer mast in/ut Potentiometer höger framhjul Potentiometer vänster framhjul Potentiometer höger bakhjul Potentiometer vänster bakhjul Potentiometer tiltvinkel Potentiometer fläkthastighet, ECC

9

ENGLISH Cooling fan, main motor (EC) Cooling fan, electrical box (EC) Heating fan Screenelevator motor Dosage pump, air condition Circulating pump, air condition Circulation fan Circulation pump heating system Cooling fan, hydraulic oil Compressor Dosage pump diesel Draught valve motor, ECC Cooling fan, brake fluid Motor, Seat rotation Motor Locking revolving seat Pump, central lubrication Steering motor Drive motor (EC) Pump, emergency steering Pump motor (EC) Motor rise/lower seat column Speedometer Gear box oil temperature gauge Clock Engine rev meter Air pressure gauge Gear box oil pressure gauge Temperature gauge, engine coolant Fuel gauge Hour meter Capacity gauge, battery Timer, engine- and cab heater Counter, impulse Motor oil pressure gauge Hydraulic fluidtemperature, guage Extra instrument, general Display Battery disconnecting switch Potentiometer Resistor Controls, (steering with control levers). Shunt-resitor Potentiometer lift/lower Potentiometer tilt Potentiometer side shifting Potentiometer spreading Potentiometer extra Potentiometer reach in/out Potentiometer right front wheel Potentiometer left front wheel Potentiometer right rear wheel Potentiometer left rear wheel Potentiometer tilt angle Potentiometer fan speed, ECC


VDCT01.02SE/GB


NUMBER R 8083 R 8084 R 8085 R 8086 R 8087 R 8088 R 8089 S 100 S 101 S 102 S 103 S 104 S 105 S 106 S 107 S 108 S 109 S 110 S 111 S 112 S 113 S 114 S 115 S 116 S 117 S 118 S 119 S 120 S 121 S 122 S 123 S 124 S 125 S 126 S 127 S 128 S 129 S 130 S 131 S 132 S 135 S 136 S 137 S 138 S 139 S 141 S 142 S 143 S 145 S 147 S 149 S 150 S 152 S 156

SVENSKA Potentiometer temperatur, ECC Potentiometer spjäll, ECC Potentiometer rotation Potentiometer sax Potentiometer klämma Potentiometer skevning Potentiometer kroklåsning Strömställare ljus Strömställare omk hel/halvljus Strömställare dimljus Strömställare fjärrljus Strömställare lastljus Strömställare arbetsljus Strömställare containerljus Strömställare park broms Strömställare centr smörjning Strömställare varningsljus Strömställare rot varningsljus Strömställare fönsterhiss Strömställare kylanläggning (AC) Strömställare styrning alt Strömställare läsbelysning Strömställare instr belysning Strömställare innerbelysning Strömställare värme Strömställare fläktm värme Strömställare vindrutetorkare Strömställare spolare Strömställare blackout Strömställare nöd hydraulpump Strömställare backspegel Strömställare kallstart Strömställare avgasbroms Strömställare diff spärr/broms Strömställare värmesystem diesel Strömställare kraftuttag sida Strömställare kraftuttag bak Strömställare hög/lågväxel Strömställare färdväljare fram Strömställare färdväljare bak Strömställare växelväljare Strömställare framhjuls styrning Strömställare 4-hjuls styrning Strömställare crab styrning Strömställare defroster Strömställare Stegbelysning Strömställare fot Strömställare sitsvärme Strömställare AT-regulator Strömställare körvisare Strömställare signalhorn Strömställare startlås/ellas Strömställare intervalltorkare Strömställare kupevärmare

10

ENGLISH Potentiometer temperature, ECC Potentiometer draught valve, ECC Potentiometer rotation Potentiometer extender Potentiometer clamp Potentiometer levelling Potentiometer flaps Switch, light Switch, main/dipped beam Switch, fog light Switch, distance light Switch, mast lights Switch, working lights Switch, container light Switch, parking brake Switch, central lubricator Switch, hazard lights Switch, rotating hazard beacon Switch, window regulator Switch, air conditioner (AC) Switch, alternative steering Switch, reading light Switch, instrument illumination Switch, interior lighting Switch, heating Switch, heater fan Switch, wiper Switch, washer Switch, blackout Switch, emergency hydraulic pump Switch, observation mirror Switch, cold start Switch, exhaust brake Switch, diff. Block Switch, heating system diesel Switch, power take off side Switch, power take off rear Switch, high/low gear Switch, gear selector forward Switch, gear selector rear Switch, gear shift Switch, forward wheel steering Switch, 4-wheel steering Switch, crab steering Switch, defroster Switch, Steplight Switch, foot Switch, seat heater Switch, AT-regulator Switch, direction indicators Switch, horn Switch, main key switch Switch, intermittent wiper Switch, cab heating


VDCT01.02SE/GB


NUMBER S 157 S 158 S 159 S 160 S 161

SVENSKA Strömställare stoltilt Strömställare dimbakljus Strömställare extra fram/back väljare Strömställare komb fram/back Strömställare komb signal, ljus hel/halv spol,torkare m intervall körvisare

S

162 Strömställare komb signal ljus hel/halv, spol, torkare m 2 int, fram/bacK

S S S S S S S S S S S S S S S S S S S S S S S S S S

163 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 190 191 192 195 196 197 198 199 200

S S

201 Brytkontakt lampa färdbroms 202 Brytkontakt lampa oljetryck motor

S

204 Brytkontakt tryck ackumulator

S S S S

205 206 207 208

S S S S S S S

214 215 216 217 218 219 220

Strömställare start på 2-an Strömställare stolvärme Strömställare låsning vändskiva Strömställare luftfjädring Strömställare låsn stol Strömställare stolsvändning Strömställare förångare (LPG) Strömställare v-skiva upp/ner Strömställare v-skiva fr/back Strömställare v-skiva skevning Strömställare,utskjut Strömställare hyttlyft upp Strömställare hyttlyft ner Strömställare hyttskjutning Strömställare nollställning Strömställare Aut/man växling Strömställare fyrhjulsdrift Strömställare klimatanläggning Strömställare recirkulation Strömställare vattenavskiljare Strömställare joy-stick X Strömställare joy-stick X+Y Strömställare längs/tvärskörning Strömställare flytläge skevning Strömställare option Brytkontakt lampa park broms

Brytkontakt innerbelysning Brytkontakt handskfack belysning Slutkontakt diff spärr Slutkontakt lampa temperatur spolkrets bromsar Slutkontakt överväxel Slutkontakt temp motor Slutkontakt bromsljus Slutkontakt backljus Slutkontakt AT-regulator Slutkontakt lampa luftfilter Brytkontakt drivning

11

ENGLISH Switch, seat tilt Switch, rear fog light Switch, extra direction selector Switch, combi-forward/reverse Switch, combi-horn, light main/dipped beam, washer, wiper (intermittent), direction indicator Switch, combi horn, light main/dipped beam, washer, wiper w 2int., forward/revers Switch, start 2nd gear Switch, seat heater Switch, interlocking of turntable Switch, pneumatic springing Switch, interlocking of seat Switch, reversible seat Switch, evaporator (LPG) Switch, fifth wheel up/down Switch, fifth wheel forward/reverse Switch, fifth wheel, levelling Switch, projecting Switch, cab hoist up Switch, cab hoist down Switch, cab movement Switch, reset Switch Aut/man gearshifting Switch, 4-WD Switch, air conditioner Switch, re-circulation Switch, joy-stick X Switch, joy-stick X+Y Switch, length/sideways driwing Switch, equalizing fifth wheel Switch, option Contact, breaking,warning lamp,parking brake Contact, breaking, warning lamp, brake Contact, breaking, warning lamp, oil pressure engine Contact, breaking, pressure accumulatortank Contact, breaking, interior lighting Contact, breaking, glove Contact, making, diff. interlock Contact, making, warning lamp temperature brake Contact, making, over drive Contact, making, temperature engine Contact, making, brake lights Contact, making, reversing light Contact, making, AT-control Contact, making, indicating light air filter Contact, breaking, drive cut off


VDCT01.02SE/GB


NUMBER SVENSKA S 221 Slutkontakt temp växellåda S 222 Slutkontakt lampa temp moment förstärkare S 223 Släpkontakt signal S 224 Slutkontakt insprutningspump S 225 Brytkontakt säkerhetsbälte S 228 Slutkontakt hyttlåsning S 229 Slutkontakt stolslåsning S 230 Brytkontakt stol S 231 Slutkontakt fotkontroll stolvändning S 232 Brytkontakt lampa luftanslutning släp

12

S S S S S S

233 235 236 239 240 241

S

242 Slutkontakt lampa oljetryck v-låda

S

243 Brytkontakt tryck kylmedia AC

S S

244 Slutkontakt hydraulik aktiverad 245 Slutkontakt hydraultryck styrning

ENGLISH Contact, making, temperature gear box Contact, making, warning lamp temperature torque amplifier. Contact, brush, horn Contact, making, injection pump Contact, breaking, seat belt Contact, making, cab locking Contact, making, seat locking Contact, breaking, seat Contact, making, seat rotation, foot switch Contact, breaking, warning lamp air connection Contact, warning, interlocking of turntable Contact, making, side shifting of seat Contact, water level Contact, breaking, thermic Contact, making, thermic Contact, breaking, warning lamp air supply to trailer Contact, making, warning lamp, oil pressure gear box Contact, breaking, coolant pressure (air condition) Contact, making, hydraulics Contact, making, hydraulic pressure control

S S S S S S S S S S S S S S S S S

246 250 251 260 261 262 263 264 265 266 267 268 269 270 271 299 720

Contact, pressure refrigerant Operating Switch Contact, making, VBFS Contact, making, hoist step 1 Contact, making, hoist step 2 Contact, making, tilting Contact, making, fork positioning Contact, making, sideshift Contact, making, lifting mast in-out Contact, breaking cab door Contact, making, brake pressure Contact, making, Compressor Contact, making extender in Contact, making, overload protection Contact, making, filter gearbox Contact, making/braking option Transmitter, revolving driver´s seat (VBFS)

S S S S S S S S

800 815 840 1001 1002 1003 1004 1005

S

Slutkontakt lampa låsning vändskiva Slutkontakt sidoskjutning stol Slutkontakt vattennivå Brytkontakt termisk Slutkontakt termisk Brytkontakt lampa luftmatning släp

Slutkontakt tryck kylmedia Manöverbrytare Slutkontakt vändbar förarstol Slutkontakt lyft steg 1 Slutkontakt lyft steg 2 Slutkontakt tilt Slutkontakt gaffelspridning Slutkontakt sidoföring Slutkontakt stativ in/ut Brytkontakt hyttdörr Slutkontakt bromstryck Slutkontakt kompressor Slutkontakt sax inne Slutkontakt överlastskydd Slutkontakt, filter växellåda Slut/brytkontakt option Givare vändbar förarstol

Startelement Manöverspak Strömfördelare Strömställare, TW Strömställare, lossa TW Strömställare, låsa TW Strömställare, stopp vid 30'-35' Strömställare, förbikoppling av säkerhetssystem 1006 Strömställare, fällning främre ben

Start element Control lever Distributor Switch, TW Switch, unlocking of TW Switch, locking of TW Switch, stop at 30 -35¿ Switch, overriding of the safety system Switch, front legs down


VDCT01.02SE/GB


NUMBER S 1007 S 1008 S 1009 S 1010 S 1011 S 1012 S 1013 S 1014 S 1015 S 1017 S 1018 S 1019 S 1020 S S S S S S

1021 1022 1023 1024 1025 1026

S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S

1027 1028 1029 1030 1031 1032 1033 1034 1035 1036 1037 1038 1039 1040 1041 1042 1043 1044 1045 1046 1047 1048 1049 1440 7200 7201 7202 7202 7203 7203 7204 7204 7205

SVENSKA Strömställare, fällning bakre ben Strömställare, klämma/lossa ben Strömställare, Motor information Srömställare, tilt av hytt Strömställare IR ljus Strömställare utskjut 20¿-40¿ Strömställare stödben Strömställare förbikoppling rotationstopp Strömställare förbikoppling höjdbeg/tp-beg Strömställare diagnostik öka/minska Strömställare diagnostik on/off Strömställare rastvärme Strömställare automatisk släpp/kläm funktion Strömställare sax Strömställare vertikalhållning Strömställare låsning övre arm Strömställare Korta Armen av/på Strömställare pappersfunktioner av/på Strömställare omkoppling pappers/klämmagregat Strömställare lyfthöjdsförval Strömställare lyfthöjdsförval öka Strömställare lyfthöjdsförval minska Strömställare läraringång givare ultraljud Strömställare, Over Height Upp/Ned Brytare backljus Flytta korta armen Strömställare förbikoppling startspärr Strömställare Val av klämtryck Strömställare Korta Armen av/på Strömställare låsning skevning Strömställare Övre armpar/Sidoföring Strömställare Inching Switch stopp motor Strömställare motorrumsbelysning Strömställare höjdjustering stol Strömställare längdjustering stol Strömställare Tankväljare Strömställare Avstängning backalarm Strömställare eluppvärmd ruta Henrik testar en brytare! Strömställare fjärrstyrning Strömställare styrning spegel Huvudströmbrytare Givare, axeltryck höger Givare, axeltryck vänster Givare, anliggning vänster fram Givare, anliggning höger fram Givare, anliggning vänster bak Givare, anliggning höger bak Givare, öppen vänster twistlock Givare, öppen höger twistlock Givare, låst vänster twistlock

13

ENGLISH Switch, rear legs down Switch, clamping/-releasing legs Switch, Engine information Switch, tilt of cab Switch IR light Switch, Extension 20¿-40¿ Switch, Support jacks Switch, over ride rotation stop Switch, over ride height limit/tp-limit Switch, diagnostics increase/decrease Switch, diagnostics on/off Switch, paus heat Switch automatic release/clamp funktion Switch extender Switch, vertical position Switch, lock upper arm Switch, Short Arm on/off Switch, paper funktions on/off Switch, switch papper/bale clamp Switch, lift height selection Switch, lift height selection increase Switch, lift height selection decrease Switch, teaching ultrasonic sensor Switch, Over Height Up/Down Switch reverse light. Move short arm Switch Override Start interlock Switch, Clamp pressure selection Switch , Short Arm on/off Switch, lock levelling Switch Upper arms/Sideshift Switch, Inching Switch, Stop engine Switch, light engine compartment Switch, Seat height level Switch, Seat for/aft adjustment Switch, Tankselector Switch, Rev. Alarm on/off Switch electrical heated shield Switch remote control Switch mirror control Sensor, axle pressure right Sensor, axle pressure left Sensor, alignment left front Sensor, alignment right front Sensor, alignment left rear Sensor, alignment right rear Sensor, unlocked twistlock left Sensor, unlocked twistlock right Sensor, locked twistlock left


VDCT01.02SE/GB


NUMBER S 7205 S 7206 S 7207 S 7208 S 7209 S 7210 S 7211 S 7212 S 7213 S 7214 S 7215 S 7216 S 7217 S 7218 S 7219 S 7220 S 7221 S 7222 S 7223 U 741 U 823 U 824 U 901 U 910 U 941 V 665 V 8090 W 903 W 906 W 8093 X 37 X 39 X 72 X 77 X 78 Y 600 Y 601 Y 602 Y 603 Y 604 Y 605 Y 606 Y 607 Y 610 Y 611 Y 613 Y 614 Y 615 Y 616 Y 617 Y 618 Y 620 Y 621 Y 622

SVENSKA Givare, låst höger twistlock Givare, gaffel aggregat Givare, 2WD/4WD Givare, hytt i körläge Givare, oljefilter indikering Givare, hytt i transportläge Givare, lyfthöjd Givare, körläge Givare, Anliggning främre ben Givare, Anliggning bakre ben Givare, kläm främre ben Givare, kläm bakre ben Givare, främnre knä Givare, bakre knä Givare, främre ben Givare, bakre ben Givare, styraxel Givare, stödben uppe Givare, stödben nere FleetManager batterifilter Signalomvandlare höger Signalomvandlare vänster Spänningsomvandlare Spänningsomvandlare 80V/24V Laddningsutjämnare Diod Laser, pappersaggretgat Antenn radio Antenn kommunikationsradio Genomföring, kablage Terminal stomanslutning Terminal minusanslutning Stickuttag 2-polig Stickuttag 7-polig Stickuttag extra 7-polig M-ventil avgasbroms M-ventil diff spärr M-ventil broms M-ventil värme M-ventil kraftuttag sida M-ventil kraftuttag bak M-ventil 2/4 hjulsdrift M-ventil hög/låg växel M-ventil hydraulsystem allm M-ventil flödesbegränsning M-ventil momentförstärkare M-ventil rangespärr M-ventil hjulvridning M-ventil kallstart M-ventil AT-regulator by-pass M-ventil vatten klimatanläggning M-ventil vändskiva upp M-ventil vändskiva ner M-ventil vändskiva fram

14

ENGLISH Sensor, locked twistlock right Sensor, fork attachment Sensor, 2WD/4WD Sensor, Cab in drive position Sensor, Oil filter indication Sensor, Cab in transportation position Sensor, lifting height Sensor, driving position Sensor, Alignment front legs Sensor, Alignment rear legs Sensor, Clamp front legs Sensor, Clamp rear legs Sensor, front knee Sensor, rear knee Sensor, front legs Sensor, rear legs Sensor, steering axle Sensor, brace up Sensor, brace down FleetManager battery filter Signal amplifier, right Signal amplifier, left Voltage converter Voltage converter 80 V / 24 V Even charger Diode Lase, Pulp an Paper Aerial, radio Aerial, communication radio Lead-through, harness Earthing terminal on chassis Terminal, negative terminal Outlet, 2-pole Outlet, 7-pole Outlet, extra, 7-pole Solenoid valve, exhaust brake Solenoid valve, diff. interlock Solenoid valve, brake Solenoid valve, heater Solenoid valve, power take off, side Solenoid valve, power take off, rear Solenoid valve, 2/4WD Solenoid valve, high/low gear Solenoid valve, hydraulics, general Solenoid valve, flow restriction Solenoid valve, torque amplifier Solenoid valve, ranging interlock Solenoid valve, wheel turning Solenoid valve, cold start aid Solenoid valve, AT-regulator ¿by-pass¿ Solenoid valve, water air conditioner Solenoid valve, fifth wheel up Solenoid valve, fifth wheel down Solenoid valve, fifth wheel forward


VDCT01.02SE/GB


NUMBER Y 623 Y 624 Y 625 Y 626 Y 627 Y 628 Y 630 Y 631 Y 632 Y 633 Y 634 Y 635 Y 636 Y 637 Y 638 Y 639 Y 640 Y 641 Y 642 Y 643 Y 644 Y 645 Y 646 Y 647 Y 648 Y 673 Y 676 Y 699 Y 826 Y 6001 Y 6002 Y 6003

SVENSKA M-ventil vändskiva bak M-ventil skevning hö M-ventil skevning vä M-ventil AT-regulator M-ventil vakuum M-ventil bränsleblandning M-ventil v-låda fram M-ventil v-låda back M-ventil v-låda spole 1 M-ventil v-låda spole 2 M-ventil v-låda spole 3 M-ventil klämtryck M-ventil styrning M-ventil flytläge skevning M-ventil stopp insprut pump M-ventil låsning orbitrol ls M-ventil gasol M-ventil förångare (LPG) M-ventil park broms M-ventil låsning stol (VBFS) M-ventil låsning vändskiva Magnetkoppling komp AC M-ventil stolsvändning M-ventil stolstilt M-ventil luftfjädring Vatten ventil motor, ECC M-ventil Broms stolsvändning M-ventil option Ventil spakstyrning M-ventil blockering höger M-ventil blockering vänster M-ventil inkoppling av hydraulik till topplyft

Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y

6004 6005 6006 6007 6008 6009 6010 6011 6012 6013 6014 6015 6016 6017 6018 6019 6020 6021 6022

M-ventil sänk M-ventil lyft M-ventil bom ut M-ventil bom in M-ventil vridning medsols M-ventil vridning motsols M-ventil tilt ut M-ventil tilt in M-ventil tilt M-ventil fällning främre ben M-ventil fällning bakre ben M-ventil klämma/lossa ben M-ventil Hyttskjutning fram M-ventil Hyttskjutning bak M-ventil spridning ut M-ventil spridning in M-ventil sidoföring vänster M-ventil sidoföring höger M-ventil extra hydraulfunktion ut

Y

6023 M-ventil extra hydraulfunktion in

15

ENGLISH Solenoid valve, fifth wheel rear Solenoid valve, levelling right hand Solenoid valve, levelling left hand Solenoid valve, AT-regulator Solenoid valve vacuum Solenoid valve fuelmixture Solenoid valve, gear box, forward gear Solenoid valve, gear box, rear gear Solenoid valve, gear box, 1 gear Solenoid valve, gear box, 2 gear Solenoid valve, gear box, 3 gear Solenoid valve, clamping pressure Solenoid valve, steering Solenoid valve, equalizing fifth wheel Solenoid valve, stop injection pump Solenoid valve, locking LS orbitrol Solenoid valve, LPG Solenoid valve, evaporator (LPG) Solenoid valve, parking brake Solenoid valve, seat locking (VBFS) Solenoid valve, fifth wheel locking Magnetic clutch, compressor AC Solenoid valve, seat rotation Solenoid valve, seat tilt Solenoid valve, pneumatic springing Water valve motor, ECC Solenoid valve Brake seat turning Solenoid valve, option Valve, (steering with control levers). Solenoid valve, blocking right Solenoid valve, blocking left Solenoid valve, activation of toplift hydraulics Solenoid valve, lower Solenoid valve, lift Solenoid valve, boom out Solenoid valve, boom in Solenoid valve, rotation clockwise Solenoid valve, rotation counter-clockwise Solenoid valve, tilt out Solenoid valve, tilt in Solenoid valve, tilt Solenoid valve, lowering front legs Solenoid valve, lowering rear legs Solenoid valve, clamping/releasing legs Solenoid valve, cab movement forward Solenoid valve, cab movement reverse Solenoid valve, spreading out Solenoid valve, spreading in Solenoid valve, side shift left Solenoid valve, side shift right Solenoid valve, extra hydraulic function out Solenoid valve, extra hydraulic function in


VDCT01.02SE/GB


NUMBER Y 6024 Y 6025 Y 6026

SVENSKA M-ventil stativ ut M-ventil stativ in M-ventil höger framhjul styrning vänster

Y

6027 M-ventil höger framhjul styrning höger

Y

6028 M-ventil vänster framhjul styrning vänster

Y

6029 M-ventil vänster framhjul styrning höger

Y

6030 M-ventil höger bakhjul styrning vänster

Y

6031 M-ventil höger bakhjul styrning höger

Y

6032 M-ventil vänster bakhjul styrning vänster

Y

6033 M-ventil vänster bakhjul styrning höger

Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y

6034 6035 6036 6037 6038 6039 6040 6041 6042 6043 6044 6045 6046 6047 6048 6049 6050 6051 6052 6053 6054 6055 6056 6057 6058 6059 6060 6061 6062 6063 6064 6065 6066 6067

Y

6068 M-ventil sax/rotation

M-ventil skevning M-ventil skevning höger M-ventil skevning vänster M-ventil kylfläkt M-ventil frikoppling koppling M-ventil öppna twistlock M-ventil låsa twistlock M-ventil nöd, twistlock M-ventil mellan bom Magnetventil, fällning torn (RTCH) M-ventil blockering twistlock M-ventil blockering lyft M-ventil utskjut M-ventil, hyttilt upp M-ventil, hyttilt ner M-ventil, kylkrets broms M-ventil blockering utskjut M-ventil, regenerering höger M-ventil, regenerering vänster M-ventil, körläge M-ventil, klämma ihop M-ventil, klämma isär M-ventil, främre knä ut M-ventil, främre knä in M-ventil, bakre knä ut M-ventil, bakre knä in M-ventil, främre ben upp M-ventil, bakre ben upp M-ventil, urkoppling hydraulpump M-ventil, stödben upp M-ventil, stödben ner M-ventil, frikoppling vridbroms M-ventil, v-låda, drivning M-ventil, v-låda, oljetryck till 1:a/3:e växeln

16

ENGLISH Solenoid valve, mast out Solenoid valve, mast in Solenoid valve, right front wheel, steering left Solenoid valve, right front wheel, steering right Solenoid valve, left front wheel, steering left Solenoid valve, left front wheel, steering right Solenoid valve, right rear wheel, steering left Solenoid valve, right rear wheel, steering right Solenoid valve, left rear wheel, steering left Solenoid valve, left rear wheel, steering right Solenoid valve, levelling Solenoid valve, levelling right Solenoid valve, levelling left Solenoid valve, Cooling fan Solenoid valve, lockup clutch Solenoid valve, unlocked twist lock Solenoid valve, locked twist lock Solenoid valve, emergency, twistlock Solenoid valve, middle boom Solenoid valve, boom lowering (RTCH) Solenoid valve, blocking twistlock Solenoid valve, blocking lift Solenoid valve, projecting Solenoid valve, cab tilt up Solenoid valve, cab tilt down Solenoid valve, cooling cicuit brake Solenoid valve, blocking projecting Solenoid valve, regeneration right Solenoid valve, regeneration left Solenoid valve, driving position Solenoid valve, clambing in Solenoid valve, clambing out Solenoid valve, front knee out Solenoid valve, front knee in Solenoid valve, rear knee out Solenoid valve, rear knee in Solenoid valve, front legs up Solenoid valve, rear legs up Solenoid valve interruption hydraulic pump Solenoid valve, brace up Solenoid valve, brace down Solenoid valve, lockup rotation brake Solenoid valve, gearbox, drive Solenoid valve, gearbox,oilpressure to 1st/3rd gear Solenoid valve externder/rotation


VDCT01.02SE/GB


NUMBER SVENSKA Y 6069 M-ventil, v-låda, oljetryck till 2:a/4:e växeln Y Y Y Y Y

6070 6071 6072 6073 6074

Y

6075

Y Y Y Y Y Y Y Z

6076 6077 6078 6079 6080 6081 6082 822

M-ventil Over Height upp M-ventil Over Height ner M-ventil klämtryck Propertional ventil, Opti speed M-ventil, v-låda, växelväljare för 2:a/4:e växeln M-ventil, v-låda, växelväljare för 1:a/3:e växeln M-ventil blockering sänk M-ventil Inching M-ventil,Avstängning Övre klämarm M-Ventil, Sidoföring/Övre armar M-ventil, aktivering hyttkörning M-ventil, ackumulatorladdning M-ventil tryckbegränsning Signalfilter

17

ENGLISH Solenoid valve, gearbox,oilpressure to 2nd/4th gear Solenoid valve, Over Height up Solenoid valve, Over Height down Solenoid valve clamp pressure Proportional valve, Opti speed Solenoid valve, gearbox, gearswitch for 2nd/4th gear Solenoid valve, gearbox, gearswitch for 1st/3rd gear Solenoid valve, blocking lower Solenoid valve, Inching Solenoid valve, upper arm off Solenoid valve, Sideshift/Upper arms Solenoid valve, activate sliding cab Solenoid valve, accumulator charge Solenoid valve, pressure restriction Signal filter


VDCT01.02SE/GB



18

VDCT01.02SE/GB

F:1

F Technical data

Contents F Technical data Technical data.................................................................................................... F:3 Data .................................................................................................................F:3 Volumes ...........................................................................................................F:4 Specification for lifting capacity and dimensions..............................................F:6 Oils and lubricants, recommendation...............................................................F:8 Tightening torques, recommendations...........................................................F:10 Tightening torque, connections for air conditioning .......................................F:11 Tightening torque, ORFS connections ...........................................................F:12 Unit explanations ...........................................................................................F:13 Conversion SI-units........................................................................................F:14 Conversion table length .................................................................................F:15 Conversion table area....................................................................................F:15 Conversion table volume ...............................................................................F:15 Conversion table weight.................................................................................F:15 Conversion table pressure .............................................................................F:16


VDCT01.02GB

F:2

VDCT01.02GB


F Technical data – Technical data

F:3

F Technical data Data The machine's weights and dimensions vary depending on how the machine is equipped. Detailed information regarding this is given in the product specification and data sheet for the machine in question.

1. Engine

Yuchai YC6A240-30

Power acc. to ISO 3046 (net power)

164 kW at 2200 rpm

164 kW at 2200 rpm

Torque ISO 3046

800 Nm at 1500 rpm

949 Nm at 1500 rpm

Max. rotation speed

2200 rpm

2200 rpm

Number of cylinders

6 cylinders

6 cylinders

2640 W

2240 W

Alternator, output System voltage, voltage-capacity

Cummins QSB6.7

24 V (2x12 V / 135 Ah)

2. Transmission

Dana HR32000 3 – 3

No. of gears, forward - reverse

3. Power transmission Drive axle, type

Kessler D81 Kessler D91

4. Brakes Service brake system – actuated wheel

Wet Disc Brake - drive wheel

Parking brake system – actuated wheel

Spring brake - drive wheel

5. Steering Hydraulic servo

Steering system

6. Wheels 12.00x24

Dimensions, front and rear

14.00x24 Tyre pressure, also see pressure plate Tyre type, front and rear

1.0 MPa Inflated. Spare and replacement tyres must be from a manufacturer approved by Cargotec.

Spirit Delta

9. Cab Equivalent sound pressure level in cab according to EN12053 with measurement uncertainty σR=2.5 dB. Measurement value with standard engine. Whole-body vibrations according to EN13059 with measurement uncertainty k=0.3 x measured value.

Yuchai YC6A240-30

Cummins QSB6.7

LpAZ 67 dB(A)

LpAZ 65 dB(A)

0.4 - 0.7 m/s2


VDCT01.02GB

F:4


9.6 Frame, body, cab and accessories, lighting system Lamp

Output (W)

Socket

Check lamps

1.2

W2x4.6d

Interior lighting

10

S8.5

Tail lights

5

BA15s

Brake light

21

BA15s

Direction indicators

21

BA15s

Position lamps

5

W2.1x9.5d

75/70

P43t-38 (H4)

Back-up lights

70

PK22s (H3)

Work lights

70

PK22s (H3)

35

D1S Xenon tubes. Cartridge and ballast replaced complete.

70

PK22s (H3)

Headlights (high and low beams)

Work lights, Xenon Revolving beacon

Volumes Any deviation from this table must be approved in writing by Cargotec.

1.2 Engine, fuel system

Yuchai YC6A240-30

Cummins QSB6.7

Fuel tank, volume

380 l

Fuel quality

Diesel according to: EN590, ASTM D 975 No 1-D, ASTM D 975 No 2-D.

1.7 Engine, cooling system Coolant volume Coolant, filling point

32 l

29 l

Volvo Penta Coolant VCS, ready-mixed.

ES Compleat, Premix

See Oils and lubricants, recommendation, page F:8.

CAUTION Different types of coolant may not be mixed. Risk of engine damage and damage to the cooling system if different types of coolant are mixed. When changing and topping up coolant, the same type of coolant must be used as was used before. 1.8 Engine, lubrication system Oil type, quality Oil volume, incl. filter

See Oils and lubricants, recommendation, page F:8. 24 l

2.6 Transmission, lubrication system Oil type

HR32000 See Oils and lubricants, recommendation, page F:8. 32 l

Oil volume

VDCT01.02GB

20 l



F:5

3.3 Power transmission, drive axle

Kessler D81

Oil grade


Kessler D91

Oil volume, differential

42 l

54 l

Oil volume, hub reduction

2x4 l

2x4 l

7 Load handling Oil grade


9 Frame, body, cab and accessories R134a

Refrigerant, air conditioning Refrigerant volume Lubricant, air conditioning

See air conditioning plate ZEXEL PAG oil ZXL100 5 l

Washer fluid, volume

10 Common hydraulics Oil grade


Hydraulic oil tank, volume

320 l

Hydraulic oil system, volume

450 l


VDCT01.02GB

F:6


Specification for lifting capacity and dimensions

β

α A2 100

100

H4 H5

B S H3

R2

R1

H6 H8

H10

014020

100 100 L3 L

L2

A1

DCT80 E5

DCT90 E6

E7

E8

E5

E6

E7

E8

Lifting capacity Classed [kg x 103] Centre of gravity distance (L4 [mm])

8

9

1220

1220

Number of containers, 8'6” container

5

6

7

8

5

6

7

8

Number of containers, 9'6” container

5

5

6

7

5

5

6

7

Dimensions 6900

6900

Truck width (B [mm])

4050

4100

Height, base machine Spirit Delta (H6 [mm])

3940

4000

Seat height (H8 [mm])

2800

2860

Spacing drive axle - attachment front section (L2 [mm])

1185

1185

Wheelbase (L3 [mm])

4550

4550

3270 – 2250

3270 – 2200

Slewing radius, outer (R1 [mm])

6750

7000

Slewing radius, inner (R2 [mm])

1150

1500

Truck length (L [mm])

Track (front - rear) (S [mm])

VDCT01.02GB



F:7

DCT80 E5

DCT90 E6

E7

E8

E5

E6

250

300

Minimum aisle width for 90° stacking, 20' container (A1 [mm])

10600

10850

Minimum aisle width for 90° stacking, 40' container (A2 [mm])

14200

14350

Ground clearance, min. [mm]

E7

E8

Standard Duplex mast Lifting height (H4 [mm]) Mast height, min. (H3 [mm]) Mast height, max. (H5 [mm])

15220

16220

18720

21220

15280

16280

18780

21280

8540

9040

10290

11540

8600

9100

10350

11600

15040

16040

18540

21040

15100

16100

18600

21100

3 – 3

3 – 3

2220

2280

-

-

600

600

Mast tilting, forward - backward (α - ß [mm])

Attachment Height under twistlock (H10 [mm]) Height under lifting hooks (H10 [mm]) Side shift ± (V1 [mm])

Weight Service weight [kg x 103]

35.5

36.1

37.6

39.1

36.4

37.0

38.5

40.0

Axle pressure front, (without load) [kg x 103]

22.7

23.3

24.8

26.3

22.9

23.5

25.0

26.5

Axle pressure front, (with classified load) [kg x 103]

34.9

35.5

37.0

38.5

36.7

37.3

38.8

40.3

Axle weight rear, (without load) [kg]

12800

13500

Axle weight rear, (with classed load) [kg]

8600

8700


VDCT01.02GB

F:8


Oils and lubricants, recommendation The service intervals specified by Cargotec in the maintenance manual only apply if oils are selected in accordance with the table below. The table indicates recommended viscosity for different oil types, and grades, depending on the outdoor temperature. Any deviation from this table must be approved in writing by Cargotec, and may mean changed service intervals. Oil type, quality

ºC

-20

-10

0

+10

+20

+30

+40

ºF

-4

+14

+32

+50

+68

+86

+104

1.8 Engine, lubrication system Yuchai YC6A240-30

SAE 15W-40 (motor oil)

API CH-4 or ACEA E5

SAE 15W-30 (motor oil) SAE 10W-30 (motor oil) SAE 5W-30 (motor oil)


Cummins QSB6.7 API CH-4 or ACEA E5


2.6 Transmission, lubrication system GM Allison C-4

SAE 50

John Deere J20 C, D

SAE 40

Caterpillar TO-4

SAE 30

MIL-PRF-2104G

SAE 20 SAE 10W

NOTE

SAE 0W-20

Engine oil or GL-5 oil must not be used. 3.3 Power transmission, drive axle

SAE 80W-140

API GL-5

SAE 75W-90

10 Common hydraulics ISO VG 68

DIN 51524 Part 3 HVLP

ISO VG 46 HV ISO VG 32

NOTE Oil filters shall always be changed in connection with oil change. Change interval for engine oil requires that the sulphur content in the fuel does not exceed 0.5%. *) The oil in the brake system must meet one of the quality requirements as well as be a UTTO oil (Universal Tractor Transmission Oil). ACEA = Association des Constructeurs Européenne d'Automobiles API = American Petroleum Institute

VDCT01.02GB



F:9

Lubricating grease Use a universal grease type EP according to NLGI Grade 2 (EP2) for all lubrication points except hoisting equipment and slide plates. For hoisting equipment use a universal grease type EP according to NLGI Grade 2 (EP2) with 3-5% molybdenum sulphide content. For slide plates use a lubricant approved by Cargotec. Order from Cargotec Spare Parts Department. 0.65 kg cartridge for grease gun, part no. 923110.0360 and 5 kg can part no. 923595.0003.

NOTE Select lubrication class according to the prevailing climate.

Contact grease Contact grease 923836.0552.

Sealant silicone Sealant silicone 923107.0308.

Silicone adhesive Silicone adhesive 923854.0100.

Coolant Use ready-mixed recommended coolant. Choose the mixture of coolant that is adapted for the right temperature.

NOTE It is important that the coolant is mixed correctly all year round to ensure adequate corrosion protection. The corrosion-protective properties decline with time which is why the coolant has to be changed in accordance with specified intervals.



VDCT01.02GB

F:10


Tightening torques, recommendations The tightening torques in the following table are recommendations when tightening bolts and nuts. When torque-tightening using a machine, for example, bolt runner, the tightening torque should be reduced by approx. 5%. For soft surfaces (lower hardness than 200 HB), use washer under both bolt head and nut. As an alternative, flange bolt or flange nut can be used. Tighten to the prescribed torque without stopping. Recommended tightening torque may vary depending on surface treatment. Certain combinations of nut and bolt require lubrication in accordance with the table below.

Condition

Nut

Screw

Lubrication

1

untreated

untreated

oil

2

bright galvanised

untreated or bright galvanised

dry or oil

3

hot-galvanised

untreated

dry or oil

8.8

Quality

10.9

12.9

1

2

3

1

1

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

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

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

Condition Fine M-thread

M-thread

UNC-thread

VDCT01.02GB



8.8

Quality

F:11

10.9

12.9

3/4

370 Nm

390 Nm

418 Nm

524 Nm

619 Nm

7/8

594 Nm

528 Nm

671 Nm

839 Nm

990 Nm

1

889 Nm

791 Nm

1005 Nm

1260 Nm

1480 Nm

1 1/8

1260 Nm

1120 Nm

1424 Nm

1780 Nm

2100 Nm

1 1/4

1760 Nm

1565 Nm

1990 Nm

2490 Nm

2940 Nm

1 3/8

2320 Nm

2065 Nm

2620 Nm

3280 Nm

3870 Nm

1 1/2

3060 Nm

2720 Nm

3455 Nm

4320 Nm

5100 Nm

Tightening torque, connections for air conditioning O-ring couplings cooling hoses Hose diameter

Thread

Tightening torque

mm

inch

inch

Nm

6

1/4"

7/16"

7-13 Nm

10

3/8"

5/8"

14-20 Nm

10

3/8"

11/16"

14-20 Nm

12

1/2"

3/4"

14-26 Nm

16

5/8"

7/8"

27-41 Nm

19

3/4"

1 1/16"

34-46 Nm

3/8"

7-13 Nm

Pressure switch

7/16" The above values should be considered guidelines and may vary depending on installation.


VDCT01.02GB

F:12


Tightening torque, ORFS connections Pipe and hose fitting

VDCT01.02GB

Pipe diameter

Tightening torque

mm

Nm

inch 6

1/4

8

5/16

10

3/8

12

1/2

14

-

15

-

16

5/8

18

3/4

20

-

22

7/8

25

1"

28

-

30

-

32

1"1/4

35

-

38

1"1/2

23-25 33-38 51-57

80-90

120-130

150-170

180-200

200-240

Wrench size

Tightening torque

mm

Nm

inch 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



F:13

Material fitting UNF-UN

Metric-ISO

BSSP

Thread (inch)

Tightening torque (Nm)

Thread (mm)


Thread (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

Unit explanations Unit

Abbreviation

Newton metre

Nm

Kgf/m

kpm

Kilo pascal

kPa

Mega pascal

MPa

Kilowatt

kW

Kilojoule

kJ

British thermal unit

Btu

Calorie

ca

Inch

in

Feet

ft

Yard

yd

Mile

mile

Centimetre

cm

Metre

m

Kilometre

km


VDCT01.02GB

F:14


Conversion SI-units Recalculation factor

Non-SI

Recalculation factor

SI

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

kPa

x 4.0

= in.H2O

x 0.249

= kPa

kPa

x 0.30

= in.Hg

x 3.38

= kPa

kPa

x 0.145

= psi

x 6.89

= kPa

SI-unit Torque

Pressure (Pa = N/m2)

bar

x 14.5

= psi

x 0.069

= bar

kp/cm

2

x 14.22

= psi

x 0.070

= kp/cm2

N/mm

2

x 145.04

= psi

x 0.069

= bar

x 145

= psi

x 0.00689

= MPa

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

kJ

x 0.948

= Btu

x 1.055

= kJ

J

x 0.239

= calorie

x 4.19

= J

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

MPa Power (W = J/s)

Energy (J = Nm)

Speed and acceleration

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)

VDCT01.02GB

x 0.264

= US gal/min x 3.785


= litre/min


F:15

Conversion table length Unit

cm

m

km

in

ft

yd

mile

cm

1

0.01

0.00001

0.3937

0.03281

0.01094

0.000006

m

100

1

0.001

39.37

3.2808

1.0936

0.00062

km

100000

1000

1

39370.7

3280.8

1093.6

0.62137

in

2.54

0.0254

0.000025

1

0.08333

0.02777

0.000015

ft

30.48

0.3048

0.000304

12

1

0.3333

0.000189

yd

91.44

0.9144

0.000914

36

3

1

0.000568

mile

160930

1609.3

1.6093

63360

5280

1760

1

1 mm = 0.1 cm – 1 mm = 0.001 m

Conversion table area Unit

cm2

m2

km2

a

ft2

yd2

in2

cm2

1

0.0001

-

0.000001

0.001076

0.000012

0.155000

m2

10000

1

0.000001

0.01

10.764

1.1958

1550.000

km2

-

1000000

1

10000

1076400

1195800

-

a

0.01

100

0.0001

1

1076.4

119.58

-

ft2

-

0.092903

-

0.000929

1

0.1111

144.000

yd2

-

0.83613

-

0.008361

9

1

1296.00

in2

6.4516

0.000645

-

-

0.006943

0.000771

1

1 ha = 100 a – 1 mile2 = 259 ha = 2.59 km2

Conversion table volume Unit

cm3 = cc

m3

l

in3

ft3

yd3

cm3 = ml

1

0.000001

0.001

0.061024

0.000035

0.000001

m3

1000000

1

1000

61024

35.315

1.30796

dm3 (l)

1000

0.001

1

61.024

0.035315

0.001308

in3

16.387

0.000016

0.01638

1

0.000578

0.000021

ft3

28316.8

0.028317

28.317

1728

1

0.03704

yd3

764529.8

0.76453

764.53

46656

27

1

1 gal (US) = 3785.41 cm3 = 231 in3 = 0.83267 gal (UK)

Conversion table weight Unit

g

kg

t

oz

lb

g

1

0.001

0.000001

0.03527

0.0022

kg

1000

1

0.001

35.273

2.20459

t

1000000

1000

1

35273

2204.59

oz

28.3495

0.02835

0.000028

1

0.0625

lb

453.592

0.45359

0.000454

16

1

1 tonne (metric) = 1.1023 ton (US) = 0.9842 ton (UK)


VDCT01.02GB

F:16


Conversion table pressure Unit

kp/cm2

bar

Pa = N/m2

kPa

lbf/in2

lbf/ft2

kp/cm2

1

0.98067

98066.5

98.0665

14.2233

2048.16

bar

1.01972

1

100000

100

14.5037

2088.6

Pa = N/m2

0.00001

0.001

1

0.001

0.00015

0.02086

kPa

0.01020

0.01

1000

1

0.14504

20.886

lbf/in2

0.07032

0.0689

6894.76

6.89476

1

144

lbf/ft2

0.00047

0.00047

47.88028

0.04788

0.00694

1

kg/cm2 = 735.56 Dry (mmHg) = 0.96784 atm

VDCT01.02GB


G:1

G Terminology and index

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


VDCT01.02GB

G:2

VDCT01.02GB


G Terminology and index – Terminology and index

G:3

G Terminology and index Terminology Explanations Term

Description

Accumulator

Reservoir that stores (accumulates) pressure for, i.e. hydraulic functions.

Attachment

Part of the machine that grips the load when lifting.

Anti-corrosion agent

Prevents oxidation, in simple terms, rustproofing.

Working hydraulics

All load handling functions, that is, lift and lower, tilt, side shift, spreading (extension) and levelling.

Wheelbase

Distance between drive axle and steering axle.

Bar

Unit to express pressure.


Cuts off power supply from battery.

Daily inspection

Actions that should be performed daily to ensure the machine's functionality.

Decitonne

Tenth of a tonne, measure of machine's lift capacity.

Display

"Window" showing digital information, i.e. on steering wheel panel in the cab.

Operating time

Number of hours machine has been in operation, shown on hour meter in cab.

Drive axle

Driving axle that receives the torque from the drive-train.

Drive-train

Parts in machine involved in power transmission; engine, torque converter, transmission, propeller shaft, and drive axle with differential and hub reduction.

ECC

Electric Climate Control. Air conditioning system with thermostat-controlled cooling, dehumidification and heating.

EHC

Electric Heat Control. Heating system with thermostat-controlled heating.

Electrolyte level

Fluid level in battery cells.

Expansion tank

Tank for coolant.

Fixed displacement

Non-adjustable volume (capacity) in a pump.

Hanging load

Lifted load.

FMI

Fault Message Identifier.

Main fuse

Located by battery. Breaks the current to all systems in the whole machine.

Hydraulic oil

Oil for hydraulic system. See specifications in operator's manual.

Hydraulic oil pump

Pump in hydraulic system.

Hydraulic system

System that uses oil pressure to transfer power to different functions.

Indicator

Manual "sensor", for example, shows that a filter is clogged and needs to be changed.

Refrigerant

Fluid/gas in air conditioning. Must only be handled by authorised trained personnel.

Low-emission engine

Engine with low emissions of hazardous substances. Manufactured in accordance with regulations.

LC

Load centre.

Lift capacity

Indicates machine's maximum lift capacity.

Lifting point

Attaching point for lift device when lifting an object.

Trolley

Lifts the load, located on the mast.

Solenoid valve

An electro-magnetically controlled valve. See also proportional valve.

Control valve

Valves that can be used to control something, for example, to release pressure and thus lower a boom or a fork.

Machine model

Machine type. Specified, for example: DCT 80-90. See also type designation.


VDCT01.02GB

G:4

G Terminology and index – Terminology

Term

Description

Environmental waste

Used oils, filters, etc., must be handled according to governing national laws and regulations.

Torque converter

Hydraulic, variable clutch.

Hub reduction

Type of final drive (often next to drive wheel) that reduces rpm and increases torque from the drive-train.

Pilot oil pressure

A low control pressure to, for example, a valve.

Planetary gear

Type of transmission with the gears in constant mesh.

Product alternative

One of several alternatives is selected for a machine, e.g. engine alternative.

Proportional valve

An electro-magnetically controlled valve. If a voltage is applied, the valve is activated in proportion to the voltage amplitude. In simple terms, infinitely variable valve, as opposed to on/off valve. For example, found on transmission's valve housing.

Frame member

Structural members in the frame.

Recirculation

Circulate over and over again.

Serial number

Unique machine designation. On the machine plate.

Service position

How machine should be safely positioned before service may be started.

Servo

A small movement by the user results in a large angle, i.e. servo steering.

Servo pressure

A low control pressure to control a higher pressure, for example, to a valve.

Side lift

Attachment. See attachment

Side shift

Parallel sideways movement of attachment.

Levelling

Attachment is tilted, for example if load stands on uneven ground.

Spirit Delta

Enclosed type of cab.

SPN

Suspect Parameter Number.

Spreading (positioning)

Widening of attachment.

Mast

Carrier of trolley, attachment and load.

Dust reservoir

The air filter collects the coarsest particles in a dust reservoir, which is emptied automatically during operation.

Steering axle

Wheel axle with steering.

Buzzer

Acoustic alarm to catch the operator's attention.

Option

Extra equipment for machine.

Tilting

Load is leaned forward or backward.

Transmission oil

Oil for transmission and torque converter. See specifications in operator's manual.

Securing machine for transport

Actions before transporting machine.

Twistlocks

Two lock pins, one in each corner of the attachment, pushed down in corresponding holes in container and twisted to lock the container when lifting.

Type designation

Indicates machine type and capacity. See also machine model.

Maintenance

Periodic maintenance actions so that machine functions safely and for a long service life.

Wet brakes

Brake discs in oil bath.

Valve slide

Moveable part in valve. Determines oil's path.

VDCT01.02GB


G Terminology and index – Index

Index A About the documentation . About the Workshop Manual Accelerator . . . . . . . Accumulator . . . . . . . Accumulator charging valve Accumulator drain valve . . Accumulator lift . . . . . . Air cleaning system . . . . Air distributor . . . . . . . Air intake and exhaust outlet Air suspension . . . . . . Alternator . . . . . . . . Arm rest . . . . . . . . . ATTACH . . . . . . . . . ATTACH, menu 1 . . . . . ATTACH, menu 10 . . . . ATTACH, menu 11 . . . . ATTACH, menu 12 . . . . ATTACH, menu 13 . . . . ATTACH, menu 14 . . . . ATTACH, menu 15 . . . . ATTACH, menu 16 . . . . ATTACH, menu 17 . . . . ATTACH, menu 18 . . . . ATTACH, menu 19 . . . . ATTACH, menu 2 . . . . . ATTACH, menu 20 . . . . ATTACH, menu 21 . . . . ATTACH, menu 3 . . . . . ATTACH, menu 4 . . . . . ATTACH, menu 5 . . . . . ATTACH, menu 6 . . . . . ATTACH, menu 7 . . . . . ATTACH, menu 8 . . . . . ATTACH, menu 9 . . . . . ATTACHMENT . . . . . .

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. . A:12 . . . A:3 . . . 1:20 4:10, 10:5 . . . 4:7 . . . 10:3 . . . 7:30 . . . 1:23 . . . 9:50 . . . 1:23 . . . 9:17 . . . 11:6 . . . 9:18 . . . 8:76 . . . 8:76 . . . 8:81 . . . 8:82 . . . 8:83 . . . 8:84 . . . 8:84 . . . 8:84 . . . 8:84 . . . 8:85 . . . 8:86 . . . 8:87 . . . 8:76 . . . 8:88 . . . 8:89 . . . 8:77 . . . 8:77 . . . 8:78 . . . 8:78 . . . 8:79 . . . 8:79 . . . 8:80 . . 8:104

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B Back rest cushion . . . . . . . . . . . . . Back-up alarm . . . . . . . . . . . . . . Back-up lights . . . . . . . . . . . . . . Batteries. . . . . . . . . . . . . . . . . Battery disconnector . . . . . . . . . . . Body structure . . . . . . . . . . . . . . Brake cylinder . . . . . . . . . . . . . . Brake lights . . . . . . . . . . . . . . . Brake oil filter . . . . . . . . . . . . . . Brake pedal . . . . . . . . . . . . . . . Brake valve . . . . . . . . . . . . . . . Brakes . . . . . . . . . . . . . . . . . Break contact (opening switch) brake pressure Break contact (opening switch) parking brake Breather filter hydraulic oil tank . . . . . . . Bumper . . . . . . . . . . . . . . . . . Buzzer, automatic spread 20'-40' . . . . . . Bypass . . . . . . . . . . . . . . . . . Bypass valve, cooler . . . . . . . . . . .

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9:15 9:71 9:64 11:4 11:3 9:85 4:26 9:63 4:6 4:3 4:14 4:3 4:19 4:36 10:24 . 9:16 . 7:56 . 8:7 10:23

C CAB . . . . . . . . . . . . . . . . . . . . . . . 8:37 Cab frame . . . . . . . . . . . . . . . . . . . . . 9:80 Cab interior . . . . . . . . . . . . . . . . . . . . 9:81

G:5

Cab structure and suspension . . . . . . . . . . . . 9:80 Cab substructure . . . . . . . . . . . . . . . . . . 9:80 CAB, menu 1. . . . . . . . . . . . . . . . . . . . 8:37 CAB, menu 2. . . . . . . . . . . . . . . . . . . . 8:38 CAB, menu 3. . . . . . . . . . . . . . . . . . . . 8:39 CAB, menu 4. . . . . . . . . . . . . . . . . . . . 8:40 CAB, menu 5. . . . . . . . . . . . . . . . . . . . 8:41 CAB, menu 6. . . . . . . . . . . . . . . . . . . . 8:42 CAB, menu 7. . . . . . . . . . . . . . . . . . . . 8:43 CAB, menu 8. . . . . . . . . . . . . . . . . . . . 8:44 Cabin fan . . . . . . . . . . . . . . . . . . . . . 9:32 Cable harness . . . . . . . . . . . . . . . . . . 11:25 Calibrate DRIVE-TRAIN . . . . . . . . . . . . . . 8:114 Calibration . . . . . . . . . . . . . . . . . . . . 8:112 CAN bus . . . . . . . . . . . . . . . . . . . . 11:34 CAN bus drive-train . . . . . . . . . . . . . . . . 11:38 CAN/POWER . . . . . . . . . . . . . . . . . . . 8:11 CAN/POWER, menu 1 . . . . . . . . . . . . . . . 8:11 CAN/POWER, menu 10 . . . . . . . . . . . . . . . 8:20 CAN/POWER, menu 11 . . . . . . . . . . . . . . . 8:21 CAN/POWER, menu 12 . . . . . . . . . . . . . . . 8:21 CAN/POWER, menu 13 . . . . . . . . . . . . . . . 8:22 CAN/POWER, menu 14 . . . . . . . . . . . . . . . 8:22 CAN/POWER, menu 15 . . . . . . . . . . . . . . . 8:22 CAN/POWER, menu 16 . . . . . . . . . . . . . . . 8:23 CAN/POWER, menu 17 . . . . . . . . . . . . . . . 8:24 CAN/POWER, menu 2 . . . . . . . . . . . . . . . 8:12 CAN/POWER, menu 3 . . . . . . . . . . . . . . . 8:13 CAN/POWER, menu 4 . . . . . . . . . . . . . . . 8:13 CAN/POWER, menu 5 . . . . . . . . . . . . . . . 8:14 CAN/POWER, menu 6 . . . . . . . . . . . . . . . 8:15 CAN/POWER, menu 7 . . . . . . . . . . . . . . . 8:17 CAN/POWER, menu 8 . . . . . . . . . . . . . . . 8:18 CAN/POWER, menu 9 . . . . . . . . . . . . . . . 8:20 Central lubrication . . . . . . . . . . . . . . . . . 9:87 Chassis . . . . . . . . . . . . . . . . . . . . . . 9:84 CLIMATE . . . . . . . . . . . . . . . . . . . . . 8:45 CLIMATE, menu 1 . . . . . . . . . . . . . . . . . 8:45 CLIMATE, menu 2 . . . . . . . . . . . . . . . . . 8:45 CLIMATE, menu 3 . . . . . . . . . . . . . . . . . 8:46 CLIMATE, menu 4 . . . . . . . . . . . . . . . . . 8:47 CLIMATE, menu 5 . . . . . . . . . . . . . . . . . 8:47 CLIMATE, menu 6 . . . . . . . . . . . . . . . . . 8:48 CLIMATE, menu 7 . . . . . . . . . . . . . . . . . 8:49 CLIMATE, menu 8 . . . . . . . . . . . . . . . . . 8:50 Common electrics . . . . . . . . . . . . . . . 11:3, E:6 Common hydraulics . . . . . . . . . . . . . . 10:3, E:3 Communication. . . . . . . . . . . . . . . . . . 11:34 Communication between PC and machine . . . . . . 11:39 Complete machine . . . . . . . . . . . . . . . . . 0:3 Compressor . . . . . . . . . . . . . . . . . . . . 9:39 Compressor air-suspension seat . . . . . . . . . . . 9:17 Condenser . . . . . . . . . . . . . . . . . . . . . 9:43 Container counter. . . . . . . . . . . . . . . . . . 7:75 Control breaker . . . . . . . . . . . . . . . . 9:10, 11:3 Control levers . . . . . . . . . . . . . . . . . . . 7:4 Control system . . . . . . . . . . . . . . . . 8:3, D:95 Control system, engine . . . . . . . . . . . . . . . 1:30 Control system, transmission . . . . . . . . . . . . . 2:18 Control unit KID . . . . . . . . . . . . . . . . . 11:24 Control unit KIT. . . . . . . . . . . . . . . . . . 11:23 Control unit, attachment . . . . . . . . . . . . . . 11:19 Control unit, cab . . . . . . . . . . . . . . . . . 11:17 Control units . . . . . . . . . . . . . . . . . . . 11:16 Control valve, attachment . . . . . . . . . 7:33, 7:48, 7:67 Control valve, lift and tilt . . . . . . . . . . . . 7:14, 7:60 Controls and instruments . . . . 1:20, 2:9, 4:3, 7:4, 8:4, 9:3 Coolant . . . . . . . . . . . . . . . . . . . . . . 1:26 Cooler hydraulic oil . . . . . . . . . . . . . . . . 10:20 Cooling fan . . . . . . . . . . . . . . . . 1:26, 10:21 Cooling system . . . . . . . . . . . . . . . . 1:25, 2:17


VDCT01.02GB

G:6


Counterweights. . . . . . . . . . . . . . . . . . . 9:86

D Defroster nozzles . . . Diagnostics . . . . . Direction indicators . . Disc pack . . . . . . Distribution block . . . Distribution of electricity Doors . . . . . . . . Drive axle . . . . . . Drive axle block . . . DRIVE-TRAIN . . . .

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9:51 8:9 9:64 4:26 9:90 11:7 9:80 3:4 4:18 8:108

EL-STEERING . . . . . . . . . . Electric protection. . . . . . . . . ELECTRIC SERVO . . . . . . . . Electronic box . . . . . . . . . . Electronic box frame . . . . . . . Electronic box, cab . . . . . . . . ELSERV. . . . . . . . . . . . . ELSERV, menu 1 . . . . . . . . . ELSERV, menu 10 . . . . . . . . ELSERV, menu 11 . . . . . . . . ELSERV, menu 12 . . . . . . . . ELSERV, menu 13 . . . . . . . . ELSERV, menu 14 . . . . . . . . ELSERV, menu 15 . . . . . . . . ELSERV, menu 2 . . . . . . . . . ELSERV, menu 3 . . . . . . . . . ELSERV, menu 4 . . . . . . . . . ELSERV, menu 5 . . . . . . . . . ELSERV, menu 6 . . . . . . . . . ELSERV, menu 7 . . . . . . . . . ELSERV, menu 8 . . . . . . . . . ELSERV, menu 9 . . . . . . . . . Emergency stop switch voltage (15E) Engine . . . . . . . . . . . . . ENGINE . . . . . . . . . . . . . Engine control unit . . . . . . . . ENGINE, menu 1 . . . . . . . . . ENGINE, menu 10 . . . . . . . . ENGINE, menu 2 . . . . . . . . . ENGINE, menu 3 . . . . . . . . . ENGINE, menu 4 . . . . . . . . . ENGINE, menu 5 . . . . . . . . . ENGINE, menu 6 . . . . . . . . . ENGINE, menu 7 . . . . . . . . . ENGINE, menu 8 . . . . . . . . . ENGINE, menu 9 . . . . . . . . . Entertainment and communication . Environment . . . . . . . . . . . Error code menu . . . . . . . . . Error codes . . . . . . . . . . . Exhaust system . . . . . . . . . Expansion valve . . . . . . . . . EXT-ATTACH . . . . . . . . . . EXTRA . . . . . . . . . . . . .

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. . . 8:90 . . . 11:3 . . . 8:98 . . 11:14 . . 11:15 . . 11:14 . . . 8:69 . . . 8:69 . . . 8:74 . . . 8:74 . . . 8:74 . . . 8:75 . . . 8:75 . . . 8:75 . . . 8:69 . . . 8:70 . . . 8:71 . . . 8:72 . . . 8:73 . . . 8:73 . . . 8:74 . . . 8:74 . . 11:11 . 1:3, D:9 . . . 8:55 1:30, 11:21 . . . 8:55 . . . 8:60 . . . 8:55 . . . 8:56 . . . 8:57 . . . 8:57 . . . 8:58 . . . 8:59 . . . 8:59 . . . 8:60 . . . 9:72 . . B:20 . . . 8:4 . . . D:3 . . . 1:23 . . . 9:46 . . . 8:90 . . . 8:89

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. . A:13 . . 10:27 . . . 9:10 9:64, 9:70 . . . 2:10 . . . 9:82 . . . 9:85

E

F Feedback . . . . . . Fine filter hydraulic oil . Fire extinguisher . . . Flashing hazard lights . Flex plates . . . . . . Floor covering . . . . Footsteps and hand rail VDCT01.02GB

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Foreword . . . . . . . . . . . . Frame control unit . . . . . . . . Frame, body, cab and accessories . FREELIFT . . . . . . . . . . . . Fresh air filter . . . . . . . . . . Fresh air filter or recirculation damper Fuel system . . . . . . . . . . . Fuel tank . . . . . . . . . . . . Fuses . . . . . . . . . . . . . .

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A:3 11:18 . 9:3 . 8:90 . 9:28 . 9:29 . 1:21 . 1:21 . 11:3

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G Gear pump with fixed displacement . Gear selector and multi-function lever General safety information . . . . . Glass/windows/mirrors . . . . . .

H Headlights . . . . . . . . . . . . . . . . . . . . . 9:63 Heat exchanger heat . . . . . . . . . . . . . . . . 9:35 Heat exchanger, cooling . . . . . . . . . . . . . . . 9:49 Heating coil . . . . . . . . . . . . . . . . . . . . 9:16 Heating, ventilation and air conditioning . . . . . . . . 9:21 Hood engine compartment . . . . . . . . . . . . . . 9:85 Horn . . . . . . . . . . . . . . . . . . . . . . . 9:70 Hoses, pipes and valves . . . . . . . . . . . . . . 10:13 HYD . . . . . . . . . . . . . . . . . . . . . . . 8:51 HYD, menu 1 . . . . . . . . . . . . . . . . . . . 8:51 HYD, menu 2 . . . . . . . . . . . . . . . . . . . 8:51 HYD, menu 3 . . . . . . . . . . . . . . . . . . . 8:52 HYD, menu 4 . . . . . . . . . . . . . . . . . . . 8:52 HYD, menu 5 . . . . . . . . . . . . . . . . . . . 8:53 HYD, menu 6 . . . . . . . . . . . . . . . . . . . 8:54 HYD, menu 7 . . . . . . . . . . . . . . . . . . . 8:54 HYD, menu 8 . . . . . . . . . . . . . . . . . . . 8:54 Hydraulic cylinders . . . . . . . . . . . . . . . . 10:29 Hydraulic oil . . . . . . . . . . . . . . . . . . . 10:26 Hydraulic oil filter . . 4:30, 7:30, 7:40, 7:57, 7:62, 7:74, 10:24 Hydraulic oil pump . . . . . . . . . . . . 4:6, 4:30, 5:3, 7:10, 7:32, 7:47, 7:59, 7:66 Hydraulic oil tank . . . . . . . . . . . . . . . . . . 10:5

I I/O . . . . . . . . . . . . Ignition . . . . . . . . . . Ignition voltage (15) . . . . . Initiation . . . . . . . . . . Instrument and control panels Insulation . . . . . . . . . Intercooler . . . . . . . . . Interior fittings, plastic . . . . Interior fittings, textile . . . . Interior lighting . . . . . . .

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8:94 1:20 11:9 8:95 9:81 9:82 1:24 9:82 9:82 9:66

Levelling. . . . . . . . . . . . . Lift and lower. . . . . . . . . . . Lift cylinder . . . . . . . . . . . Lift, tilt and attachment control valve. Lighting system. . . . . . . . . . LIGHTS . . . . . . . . . . . . . LIGHTS, menu 1 . . . . . . . . . LIGHTS, menu 10 . . . . . . . . LIGHTS, menu 11. . . . . . . . . LIGHTS, menu 12 . . . . . . . . LIGHTS, menu 13 . . . . . . . . LIGHTS, menu 14 . . . . . . . .

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. . . . . 7:63 . . . . . 7:8 . . . . . 7:15 7:40, 7:56, 7:74 . . . . . 9:59 . . . . . 8:25 . . . . . 8:25 . . . . . 8:32 . . . . . 8:33 . . . . . 8:33 . . . . . 8:34 . . . . . 8:36

L



LIGHTS, menu 15 . LIGHTS, menu 2 . . LIGHTS, menu 3 . . LIGHTS, menu 4 . . LIGHTS, menu 5 . . LIGHTS, menu 6 . . LIGHTS, menu 7 . . LIGHTS, menu 8 . . LIGHTS, menu 9 . . Lines . . . . . . . Link arm . . . . . . Load carrier . . . . Load handling . . . Load retention valve Lock cylinder . . . . Lock mechanism . . Lubrication system .

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8:36 8:25 8:26 8:27 8:28 8:29 8:29 8:30 8:31 9:90 5:11 7:64 7:3 7:61 7:68 7:69 2:13

M Main beam, side lift attachment . . . . . . Main valve . . . . . . . . . . . . . . . Make-contact (closing switch) brake lights . Make-contact (closing switch) water in fuel . Mast . . . . . . . . . . . . . . . . . Mast position sensor . . . . . . . . . . Mechanical seat adjustment . . . . . . . Moisture filter . . . . . . . . . . . . . Monitoring . . . . . . . . . . . . . . . MOVE-CAB . . . . . . . . . . . . . .

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. . 7:51 . 10:14 . . 4:21 . . 1:22 7:16, 7:62 . . . 7:25 . . . 9:18 . . . 9:45 . . . 8:7 . . . 8:90

N NO (normally open) switch, disengagement . . . . . . 2:18 Nut, washer and clamp . . . . . . . . . . . . . . . 6:17

O Oil cooler . . . OLS . . . . . OPT . . . . . Other . . . . . Other functions .

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2:15, 2:17 . . 8:89 . . 8:90 . 10:29 . . 7:75

P Paint/coatings . . . . . . . . . . . . . . . . . . . Parking brake caliper . . . . . . . . . . . . . . . . Parking brake disc . . . . . . . . . . . . . . . . . Parking brake pads . . . . . . . . . . . . . . . . . Parking brake system . . . . . . . . . . . . . . . . Parking brake unit . . . . . . . . . . . . . . . . . Passenger seat. . . . . . . . . . . . . . . . . . . Pipes and hoses . . 4:26, 4:36, 5:12, 7:30, 7:39, 7:56, 7:62, 7:74, 10:4–10:5, 10:12–10:13, 10:27 Position sensor, spreading . . . . . . . . . . . . . . Power assisted system . . . . . . . . . . . . . . . Power transmission . . . . . . . . . . . . . . . . . Power-assisted brake system . . . . . . . . . . . . Pressure limiting valve . . . . . . . . . . . . . . . Pressure reducer . . . . . . . . . . . . . . . . . . Pressure switch . . . . . . . . . . . . . . . . . . Preventive maintenance . . . . . . . . . . . . . . . Priority valve . . . . . . . . . . . . . . . . . . . . Propeller shaft . . . . . . . . . . . . . . . . . . . Pump unit . . . . . . . . . . . . . . . . . . . . . Pumps . . . . . . . . . . . . . . . . . . . . . .

9:91 4:34 4:35 4:34 4:29 4:32 9:18 7:56 5:3 3:3 4:5 10:4 7:11 9:45 C:1 5:4 3:3 9:89 10:6

G:7

R Radiator and expansion tank . . . . . Reading instructions . . . . . . . . Reading-lamp . . . . . . . . . . . Rear view mirror . . . . . . . . . . Rear window . . . . . . . . . . . . Redundant CAN bus . . . . . . . . Redundant voltage feed of control units Relief valve, attachment . . . . . . . Revolving beacon. . . . . . . . . . Rim . . . . . . . . . . . . . . . . RMI . . . . . . . . . . . . . . . . Roof window . . . . . . . . . . . . Running lights . . . . . . . . . . .

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. . . . . . . 1:25 . . . . . . . A:4 . . . . . . . 9:83 . . . . . . . 9:79 . . . . . . . 9:79 . . . . . . 11:36 . . . . . . . 11:7 7:39, 7:56, 7:74, 10:3 . . . . . 9:64, 9:71 . . . . . . . . 6:16 . . . . . . . . 8:94 . . . . . . . . 9:79 . . . . . . . . 9:63

S Safety . . . . . . . . . . . . . Safety and emergency equipment. Safety instructions . . . . . . . Safety valves. . . . . . . . . . Schematics . . . . . . . . . . Seat . . . . . . . . . . . . . Seat belt. . . . . . . . . . . . Seat buzzer . . . . . . . . . . Seat cushion . . . . . . . . . . Sensor cab temperature . . . . . Sensor fuel level . . . . . . . . Sensor hydraulic oil temperature . Sensor twistlocks . . . . . . . . Sensor, alignment . . . . . . . Sensor, ambient temperature . . . Sensor, engine temperature . . . Sensor, operator-in-seat . . . . . Sensor, temperature outlet fan . . Sensor, temperature refrigerant . . Service indicator . . . . . . . . Setup . . . . . . . . . . . . . Side shift . . . . . . . . . . . Side shift cylinder . . . . . . . . Side window . . . . . . . . . . Signalling system . . . . . . . . SLIDING-CAB . . . . . . . . . Solenoid valve parking brake . . . Speed limitation . . . . . . . . Spreader beam . . . . . . . . . Spreading (positioning) . . . . . Spreading cylinder . . . . . . . Start battery . . . . . . . . . . Start/stop . . . . . . . . . . . Starter motor . . . . . . . . . . Steering . . . . . . . . . . . . STEERING . . . . . . . . . . Steering axle cradle . . . . . . . Steering cylinder . . . . . . . . Steering valve . . . . . . . . . Stopping device . . . . . . . . Suspension . . . . . . . . . . Switch, automatic spreading . . . Switch, direction indicators . . . . Switch, lock twistlock . . . . . . Switch, spreading 20\q-40\q . . . Switch, stop at 30\q . . . . . . .

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. . B:3 . . 9:10 . . B:4 . . 10:3 . . E:3 . . 9:11 . . 9:10 . . 9:10 . . 9:14 . . 9:53 . . 1:22 . 10:21 . . 7:72 . . 7:71 . . 9:54 . . 9:38 . . 9:19 . . 9:52 . . 9:48 . . 8:8 . . 8:95 . . 7:31 . . 7:37 . . 9:76 . . 9:68 . 8:112 . . 4:31 . . 8:7 . . 7:49 . . 7:41 . . 7:49 . . 11:4 . . 1:31 . . 1:31 . . 5:3 . 8:108 5:11, 6:4 . . 5:9 . . 5:7 . . 1:31 . . 6:3 . . 7:7 . . 9:9 . . 7:5 . . 7:6 . . 7:6

T Tail lights . . . . . . . . . . . . . . . . . . . . . 9:63 Tanks and accumulators . . . . . . . . . . . . . . . 10:5 Technical data . . . . . . . . . . . . . . . . . . . F:3


VDCT01.02GB

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. 10:18 . . 9:83 . . G:3 . . G:3 . . 7:58 . . 7:61 . . 2:10 . . 8:62 . . 8:62 . . 8:67 . . 8:67 . . 8:67 . . 8:67 . . 8:68 . . 8:63 . . 8:63 . . 8:64 . . 8:65 . . 8:66 . . 8:66 . . 8:66 . . 8:66 2:3, D:59 . . . 2:18 2:18, 11:20 7:26, 7:37 . . . 7:68 7:64, 7:69 . . . 6:15 . . . 6:13

V

Temperature control, cleaning and hydraulic oil Terminal console . . . . . . . . . . . . . Terminology . . . . . . . . . . . . . . . Terminology and index . . . . . . . . . . Tilt . . . . . . . . . . . . . . . . . . . Tilt cylinder . . . . . . . . . . . . . . . Torque converter/Clutch system . . . . . . TRANSM . . . . . . . . . . . . . . . . TRANSM, menu 1 . . . . . . . . . . . . TRANSM, menu 10 . . . . . . . . . . . . TRANSM, menu 11 . . . . . . . . . . . . TRANSM, menu 12 . . . . . . . . . . . . TRANSM, menu 13 . . . . . . . . . . . . TRANSM, menu 14 . . . . . . . . . . . . TRANSM, menu 2 . . . . . . . . . . . . TRANSM, menu 3 . . . . . . . . . . . . TRANSM, menu 4 . . . . . . . . . . . . TRANSM, menu 5 . . . . . . . . . . . . TRANSM, menu 6 . . . . . . . . . . . . TRANSM, menu 7 . . . . . . . . . . . . TRANSM, menu 8 . . . . . . . . . . . . TRANSM, menu 9 . . . . . . . . . . . . Transmission. . . . . . . . . . . . . . . Transmission cable harness . . . . . . . . Transmission control unit . . . . . . . . . Trolley. . . . . . . . . . . . . . . . . . Twistlock overcentre valve . . . . . . . . . Twistlocks . . . . . . . . . . . . . . . . Tyres . . . . . . . . . . . . . . . . . . Tyres and rims . . . . . . . . . . . . . .

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VDCT01.02GB


Valve block brake system VBFS . . . . . . . . . Voltage converter . . . . Voltage feed . . . . . .

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. 4:27, 4:36 . . . . 8:89 . . . 11:13 . . . . 11:7

Warning parking brake . . Washer motor and reservoir Water valve . . . . . . . Wheel brakes . . . . . . Wheel hub . . . . . . . . Wheel spindle . . . . . . Windscreen . . . . . . . Wings . . . . . . . . . . Wiper front . . . . . . . . Wiper motor front . . . . . Wiper motor rear . . . . . Wiper motor roof . . . . . Wiper rear . . . . . . . . Wiper roof . . . . . . . . Wiper/washer system . . . Work lights, front wing . . . Working lights, attachment . Working lights, cab . . . . Working lights, mast. . . . Writing desk . . . . . . .

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. . 9:71 . . 9:55 . . 9:38 . . 4:24 5:12, 6:8 5:12, 6:6 . . 9:74 . . 9:85 . . 9:55 . . 9:56 . . 9:58 . . 9:57 . . 9:55 . . 9:55 . . 9:55 . . 9:67 . . 9:67 . . 9:66 . . 9:64 . . 9:83



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Cargotec improves the efficiency of cargo flows by offering solutions for the loading and unloading of goods on land and at sea – wherever cargo is on the move. Cargotec’s main daughter brands for cargo handling Hiab, Kalmar and MacGregor are global market leaders in their fields. Cargotec’s global network offers extensive services that ensure the continuous, reliable and sustainable performance of equipment.

Cargotec Sweden AB Torggatan 3 SE-340 10, Lidhult, Sweden tel. +46 372 260 00 fax +46 372 263 90 www.cargotec.com

DCT80 Workshop Manual[1]

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