DRF Manual de Taller - Workshop

Reachstackers 40-45 tonnes
Publ. no VDRF03.02GB
Workshop Manual in original
WORKSHOP MANUAL
DRF 400-450
A Foreword
B Safety
C Preventive maintenance
0 Complete machine
Workshop
manual
1 Engine
2 Transmission
3 Driveline/axle
4 Brakes
5 Steering
6 Suspension
7 Load handling
8 Control system
9 Frame, body, cab and accessories
10 Common hydraulics
11 Common electrics
12 Common pneumatics
D Error codes
E Schematics
F Technical data
G Terminologi och Index
A Foreword
A Foreword
Table of Contents A Foreword

mm mm mm mm mm mm
Foreword......................................................................................................... 3
About the Workshop Manual ...................................................................... 3
General .............................................................................................................
Conditions .........................................................................................................
Storage ..............................................................................................................
About the machine version ................................................................................
Copyright ...........................................................................................................
3
3
3
3
3
Reading instructions ................................................................................... 4

Warning information ..........................................................................................
Important information ........................................................................................
Read the Operators Manual .............................................................................
Read the Maintenance Manual .........................................................................
Workshop manual contents ...............................................................................
Function group structure ...................................................................................
References between different information types ...............................................
Product alternatives and optional equipment ....................................................
Machine card .....................................................................................................
Function descriptions ........................................................................................
4
4
4
4
5
6
7
8
8
9
About the documentation ......................................................................... 12

Documentation sections .................................................................................. 12
Ordering of documentation .............................................................................. 12
Feedback .................................................................................................. 13
Form for copying ............................................................................................. 13
Workshop manual DRF 400-450
VDRF03.02GB
VDRF03.02GB
A Foreword
A Foreword Foreword
mm mm mm mm mm mm
Foreword
About the Workshop Manual
page
General
Thank you for choosing Cargotec as your machine supplier. We hope
that we will meet your expectations.
page
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 governing national standards and regulations for lifting devices.
Cargotec will not accept any responsibility for modifications performed
without permission from Cargotec, or in the event of the use of lifting
devices, tools or work methods other than those described in this
manual.
page
Storage
NOTE
The workshop manual should be accessible to service personnel.
page
About the machine version

The information in this publication corresponds to the machines design and appearance at the time of delivery from Cargotec. Due to customisations, there may be variations and/or deviations.
Cargotec reserves the right to modify specifications and equipment
without prior notice. All information and data in this manual are valid at
the time of publication.
D ANGER
External equipment must only be used if it is
approved by Cargotec.
Danger to life and property!
Only use equipment approved by Cargotec.
page
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.
Duplication by any means such as copying, printing, etc., is prohibited.
VDRF03.02GB
A Foreword Reading instructions
Reading instructions
Warning information
page
Warnings inform on potential dangers which can, if the warnings are

not heeded, result in personal injury or product damage.
D ANGER
Situation that may result in serious personal injury,
possible death, if the instruction is not followed.
WARN IN G
Situation that may result in serious personal injury if
the instruction is not followed.
C AUTION
Situation that may result in damage to the product if
the instruction is not followed.
Important information
page
Important information marked with NOTE facilitates the work process,

operation/handling or increases understanding of the information.
NOTE
Information that is important without being safety related.
Read the Operators Manual
page
000262
The symbol to the left is used in certain cases on the machine and refers to important information in the operators manual.
Read the Maintenance Manual

001128
page
The symbol to the left is sometimes found on the machine. It refers to

important information in the Maintenance Manual.
VDRF03.02GB
Workshop manual contents
page
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. If 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. 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.
Safety
Keep in mind for your safety.
Preventive maintenance
Reference to maintenance manual: Preventive maintenance.
Complete machine
Engine
Transmission
Driveline/axle
Brakes
Steering
Suspension
Load handling
Control system
Frame, body, cab and

accessories
10
Common hydraulics
11
Common electrics
12
Common pneumatics
Error codes
Error code information and instructions for reading error code information.
Schematics
Wiring diagrams, hydraulic diagrams and list of electrical components.
Technical data
Technical data, conversion tables, information for conversion of units.
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 function are described under each subfunction.
Consequently, common components are described in several places, 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).
VDRF03.02GB
page
Function group structure

The information in the manual is divided into a structure of functions at
different levels based on machine structure and usage. The categories
are known as function groups.
The highest level (called main group) indicates area, such as group 7
Load handling. The second level (called two-position) indicates function, such as 7.2 Lifting/lowering. The third and fourth levels are used
to break down functions into smaller parts (components).
The main group and two-position group level structure for the function
groups is used for all Cargotec machines, e.g. 4.3 Power-assisted
brake system. Machine-specific function group adaptations are done
at the third and fourth group level, e.g. 4.3.9 Wheel brake and 4.3.9.1
Disc assembly. Function groups (headings) are only included in the
documentation of a machine if the machine has that function or component. Thus, there may be gaps in function group numbering, e.g. the
three-position heading level 4.8.7 Oil cooler is included for some machines but not for others.
The function groups are intended as a search term to be able to find
various types of information between different sections and manuals.
The information of a function group is divided into smaller segments
based on type of content, such as description or replacement.
The Maintenance Manual and Workshop Manual contain different information. The Maintenance Manual only contains information required for preventive maintenance and minor troubleshooting. The
Workshop Manual contains more in-depth information and repair
instructions.
References between sections in the same manual are indicated using
section and group number, e.g., "see section 4 Brakes , group 4.3.9
Wheel brake ". Reference within a section are indicated with page
number, e.g., "see Sensor fuel level, description page 24 ".
There are no references between the Maintenance Manual and Workshop Manual. If more information on a function group is required,
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 7.
VDRF03.02GB
References between different information types
page
The maintenance manual and workshop manual are mainly divided

into function groups, see Workshop manual contents page 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 function groups to
find different types of information regarding the function or component
in question. As a complement to this, there are references according
to the below.
Function descriptions
Hydraulic diagrams
(Technical description)
(Section E)
Component descriptions
Error codes
(Technical description, usually in Workshop manual)
(Section D)
Diagnostics
Wiring diagrams
(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.
VDRF03.02GB
Product alternatives and optional equipment
page
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 8.
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 are 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 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. The optional equipment description covers how the equipment affects standard function and what
components are added.
page
Machine card
NOTE
If the machine has been modified after delivery, information on
the machine card may be incomplete or incorrect.
The machine card indicates of which drawings the machine consists,
in many cases these can be associated options and product alternatives. For more information about handling of product alternatives and
optional equipment, see Product alternatives and optional equipment
page 8. The machine card is delivered with the parts catalogue.
The machine card is divided into the same function groups as the
spare parts catalogue, maintenance manual and workshop manual.
For reasons of practicality, the machine card only uses the first and
second level of the function group register. The function groups are
written in groups of four characters, e.g. group 0107 refers to group 1.7
Cooling system in the manual.
For more information on how the machine card is used to order spare
parts, see the foreword of the spare parts catalogue.
If the information on the card machine does not help, contact
Cargotec.
VDRF03.02GB
NOTE
All documents that accompany the machine are non-registered
documents. No notification is made regarding changes.
page
Function descriptions are schematic overviews that describe how a

function works as well as which components and signals work
together.
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.
Function descriptions use symbols to illustrate components such as
valves, sensors, etc.
10
3
9
4
5
7
000520
VDRF03.02GB
10
Example of function description

1.
Hydraulic force (solid double line)
2.
Flag pressure check connection (Check point), indicates that

there is pressure check connection for checking pressure signal
3.
Flag diagnostic test, indicates that the signal can be checked with
diagnostic test, see section 8 Control system, group 8.4
Diagnostics
4.
Illustration of function, (apply brake)
5.
Reference to description of component
6.
Signal description, reference value for signal out from component
7.
Description of component's function
8.
Position number, reference to position in illustration
9.
Position number in illustration, reference to row in table
10. Electric power (solid single line)
VDRF03.02GB
11
Symbol explanation function descriptions
The following symbols are used in function descriptions, the symbols

are based on standard symbols used in wiring and hydraulic diagrams.
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
10. Disc brake

11. Filter
11
12
12. Radiator
13. Bulb
D790-1
13
14. Control system, two control units with CAN-bus
14
D797-F
15. Restriction
16. Adjustable restriction
15
16
17
18
19
21
17. Inductive position sensor

18. Electrically controlled servo valve
19. Thermal bypass valve
20 C
22
20. Temperature-controlled switch

21. Temperature sensor
Pa
22. Pressure sensor
23 Pa
24
23. Pressure-controlled switch

24. Hydraulic cylinder
25
25. Double-acting hydraulic cylinder

26. Spring brake cylinder
26
27. Valve block
27
28. Shuttle valve
28
29
000523
29. Non-return valve
VDRF03.02GB
12
A Foreword About the documentation
About the documentation

page
Documentation sections
The documentation to the machine comprises the following sections:
Operators manual
The operators manual is supplied with the machine in the cab.
Documentation kit
Maintenance manual and spare parts catalogue with machine card are
supplied with the machine as a separate documentation kit.
Supplementary documentation
Supplementary documentation can be ordered for the machine.
page
Workshop manual.
Supplier documentation for engine, transmission and drive axle.
Ordering of documentation
Documentation is ordered from your Cargotec dealer.
Always specify the publication number when ordering.
See the machine card for publication number.
VDRF03.02GB
A Foreword Feedback
13
Feedback
Form for copying
page
Cargotecs ambition is that you who work with maintenance of a Kalmar machine shall have access to correct information.
Your feedback is important to be able to improve the information.
Copy this form, write down your views and send it to us. Thank you for
your participation!
To:
Cargotec Sweden AB
Technical Documentation
Torggatan 3
SE-340 10 Lidhult
SWEDEN
Fax: +46 372 263 93
From:
Company / Sender: ..........................................................................................................................................
Telephone:
..........................................................................................................................................................
E-mail:
.................................................................................................................................................................
Date: .................................... - .................. - ..................

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

Suggestions,
views,
remarks,
etc.
...........................................................................................................................................................................
...........................................................................................................................................................................
...........................................................................................................................................................................
...........................................................................................................................................................................
...........................................................................................................................................................................
...........................................................................................................................................................................
VDRF03.02GB
14
VDRF03.02GB
A Foreword Feedback
B Safety
B Safety
Table of Contents B Safety

mm mm mm mm mm mm
Safety .............................................................................................................. 3
General safety information ......................................................................... 3
Safety concerns everyone! ................................................................................ 3
A near accident is a warning! ............................................................................ 3
Safety instructions ...................................................................................... 4

General ............................................................................................................. 4
Service position ................................................................................................. 4
Hydraulic and brake systems, depressurising ................................................... 5
Oils .................................................................................................................... 6
Fuel system ....................................................................................................... 7
Clothing, etc. ..................................................................................................... 8
Several mechanics on the same machine ......................................................... 9
Working under machine .................................................................................... 9
Lifting heavy components ............................................................................... 10
Vibrations ........................................................................................................ 10
Noise ............................................................................................................... 11
Solvents .......................................................................................................... 11
Fire and explosion risks ................................................................................... 12
Fluid or gas under pressure ............................................................................ 13
Coolant ............................................................................................................ 14
Refrigerant ...................................................................................................... 14
Air pollution ..................................................................................................... 15
Tensioned springs ........................................................................................... 16
Electric motors ................................................................................................. 16
Rotating components and tools ....................................................................... 17
Tyres and rims ................................................................................................. 18
Lifting equipment ............................................................................................. 18
Spare parts ...................................................................................................... 19
Non-ionised radiation ...................................................................................... 20
Environment ............................................................................................. 21
General ........................................................................................................... 21
VDRF03.02GB
VDRF03.02GB
B Safety
B Safety Safety
mm mm mm mm mm mm
Safety
General safety information
page
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 risk of damage to machine or machine property!
Remember to:
follow the instructions in this manual
be trained for the work in question
follow local laws, safety rules and regulations
use the correct equipment and tools for the job
wear the correct clothes
use common sense and work carefully. Do not take any risks!
Cargotec has in this publication documented and warned for situations

and risks that may occur in connection with using as well as service or
repairs of the machine during normal circumstances.
That is why it is important that all who work with the machine, or repair
or service the machine, read and follow the information in the Workshop Manual and Operators Manual.
page
A near accident is a warning!

A near-accident is an unexpected event where neither persons, machine or property are injured or damaged. However, a near-accident
indicates that there is an injury risk and actions must be taken to avoid
the risk of injuries.
VDRF03.02GB
B Safety Safety instructions
Safety instructions
General
page
Read, consider and follow the safety instructions below before starting
to work in the machine:
Service position page 4
Hydraulic and brake systems, depressurising page 5
Oils page 6
Fuel system page 7
Clothing, etc. page 8
Several mechanics on the same machine page 9
Working under machine page 9
Lifting heavy components page 10
Vibrations page 10
Noise page 11
Solvents page 11
Fire and explosion risks page 12
Fluid or gas under pressure page 13
Coolant page 14
Refrigerant page 14
Air pollution page 15
Tensioned springs page 16
Electric motors page 16
Rotating components and tools page 17
Tyres and rims page 18
Lifting equipment page 18
Spare parts page 19
Non-ionised radiation page 20
Service position
page
General
Service position is used for service, maintenance and other situations
when the machine needs to be secured.
Service position means:
Machine parked, that is, parking brake applied.
Boom fully retracted and lowered to horizontal position.
Engine off.
Main electric power off (with battery disconnector).
003603
Machine with a fully retracted and lowered boom
VDRF03.02GB
Hydraulic and brake systems, depressurising
page
1 Machine in service position.

2 Depressurise the hydraulic system.
Turn the start key to position I and activate extension out, a
strong hissing sound is heard if there is pressure in the hydraulic
system. Activate lift, extension and side shift several times.
3 Turn the start key to position 0 and turn off the main electric
power.
4 Depressurise the attachment.

Open the relief valve for top lift.
C AUTION
Hydraulic oil may be directed the wrong way.
Risk of damage to the fine filter for hydraulic oil.
002269
Check that the relief valve top lift is closed before the
engine is started after the completion of work.
The illustration above shows closed valve.
VDRF03.02GB
5 Depressurise the brake system by opening the drain valve on the

accumulator charging valve.
NOTE
Keep the drain valve open as long as work is in progress.
NOTE
After work is finished, close drain valve and tighten the lock
ring.
page
Oils
The following safety instructions shall be followed for work when handling oils.
WARN IN G
Warm and pressurised oil.
Always depressurise hydraulic and brake systems
completely before starting to work in the systems.
Hydraulic and brake systems are pressurised and the
oil may cause personal injuries.
Avoid skin contact with the oil, use protective gloves.
Warm oil can cause burn injuries, rashes and
irritation! The oil may also be corrosive to mucous
membranes in, e.g., the eyes, skin and throat.
I M P OR TA NT
Always clean the area around components and
connections before they are loosened. Dirt in oil
systems causes increased wear, resulting in
subsequent material damages.
Always take action to avoid spills. In places where
drain containers cannot be used, use a pump or hose
for safe handling.
Always check that plugs seal tight before collection
containers are moved.
Handle all oil as environmentally hazardous waste.
Oils freely released cause damage to the environment
and may also cause fires. Waste oils/fluids shall
always be handled by an authorised company.
VDRF03.02GB
page
Fuel system
The following safety instructions shall be followed for work when handling fuel.
D ANGER
Pay attention to the risk of fire when working on the
fuel system.
Work on the fuel system shall be avoided when the
engine is warm since fuel can spill on hot surfaces
and may ignite.
Ensure that naked flames, sparks or glowing objects
have been removed before work begins on or near the
fuel system.
Do not smoke in the vicinity of the machine when
working on the fuel system.
WARN IN G
Use protective gloves and protective goggles. If a
component is to be disconnected, hold a rag over the
connection as protection and to collect fuel. The
engines fuel system operates at very high pressure.
The pressure is so high that the jet can injure the skin,
resulting in severe injuries. Risk of personal injuries.
Avoid skin contact with fuel, use protective gloves.
Fuel is corrosive to mucous membranes in, e.g., eyes,
skin and throat.
C AUTION
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 damages.
VDRF03.02GB
I M P OR TA NT
Always take action to avoid spills. In places where
drain containers cannot be used, use a pump or hose
for safe handling.
Always check that plugs and connections seal tight
before moving collection containers.
Handle the fuel as environmentally hazardous waste.
Fuel freely released causes damage to the environment and may also cause fires. Fuel shall always be
handled by an authorised company.
page
Clothing, etc.
Clothes should be in good condition. Remove loosely hanging clothing
(tie, scarf, etc.). Do not wear clothes with wide sleeves, wide trouser
legs, etc.
Remove jewellery as it may conduct electricity and get caught in moving parts.
Long hair should be adequately gathered since it can easily get caught
in moving parts. Be careful when working with welding or an open
flame since hair easily catches on fire.
VDRF03.02GB
Several mechanics on the same machine
page
WARN IN G
If several mechanics are working on the same vehicle,
take extra care so that unintentional movements do
not injury another person. Communicate so that everyone knows where all are and what they are doing.
Risks
Work with wheels or axle suspension, mountings, etc. may result in
components on the other side moving and causing damage/injury.
Movements performed from the operators station, e.g., movement of
lifting equipment, may cause severe personal injuries.
Safety precautions
Make sure that the machine's lifting equipment is completely lowered or secured in another way.
Move battery disconnector to position zero, remove the key.
Be aware of the risks when several persons work around the

vehicle.
Make your co-workers aware of what youre working with.
Do not work with drive wheels on the machine's both sides at the
same time.
Working under machine
page
Working under cab

On machines with liftable cab, the cab must be secured in the raised
position with the locks designed for this purpose.
Working under the frame

A raised vehicle may not, for any reason, be supported or lifted in parts
that belong to the wheel suspension or steering. Always support under
the frame or wheel axle.
Risks
001977
Locks on lift mast for securing the liftable cab in the

raised position.
Mechanical or hydraulic tools and lifting devices can fall over or accidentally be lowered due to malfunctions or incorrect use.
Safety precautions
Use axle stands and supports that stand securely.
Lifting tools should be inspected and type approved for use.
VDRF03.02GB
10
page
Lifting heavy components
WARN IN G
Careless handling of heavy components can lead to
serious personal injury and material damage.
Use type approved lifting tools or other devices to
move heavy components. Make sure that the device is
stable and intact.
Risks
Unsuitable lift slings, straps, etc. may break or slip.
The centre of gravity (balance point) of the component can change
during the course of the work, and the component may then make unexpected movements which may cause severe personal injuries and
material damage.
A component lifted with lifting equipment can start to turn if the equilibrium is upset.
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, especially
when there are such adapted for certain work. See workshop manual
for methods.
If lifting must be performed without lifting device:
page
Lift near the body.
Keep your back vertical. Raise and lower with legs and arms, do
not bend your back. Do not rotate your body while lifting. Ask for
assistance in advance.
Wear gloves. They're good protection against minor crushing injuries and cuts to fingers.
Always use protective shoes.
Vibrations
In case of long-term use of vibrating tools, for example, impact nut runners or grinders, injuries may be sustained as vibrations can be transmitted from tools to hands. Especially when fingers are cold.
Safety precautions
Use heavy gloves to protect against cold and somewhat against
vibrations.
Switch between work duties to give the body time to rest.
Vary work position and grip so that the body is not stressed in only one
position by the vibrations.
VDRF03.02GB
page
11
Noise
Noise louder than 85 dB (A) that lasts for longer than 8 hours is considered harmful to hearing. (Limit values may vary between different
countries.) High tones (high frequencies) are more damaging than low
tones at the same sound level. Impact noise can also be hazardous,
e.g. hammer blows.
Risks
At noise levels higher than the limits hearing damage can occur. In
more severe cases, hearing damage can become permanent.
Safety precautions
Use hearing protection. Make sure that it is tested and protects against
the noise level in question.
Limit noise with noise-absorbing dividers, for example, noise-absorbing materials in roof and on walls.
page
Solvents
Fluids that (as opposed to water) dissolve grease, paint, lacquer, wax,
oil, adhesive, rubber, etc. are called organic solvents. Examples:
White (petroleum) spirits, gasoline, thinner, alcohols, diesel, xylene,
trichloroethylene, toluene. Many solvents are flammable and constitute a fire hazard.
Risks
Products containing solvents produce vapours that can cause dizziness, headaches and nausea. They may also irritate mucous membranes in the throat and respiratory tracts.
If the solvent ends up directly on the skin it may dry out and crack. Risk
of skin allergies increases. Solvents may also cause injury if they penetrate through the skin and are absorbed by the blood.
If the body is continuously exposed to solvents, the nervous system
may be damaged. Symptoms include sleep disorders, depressions,
nervousness, poor memory or general tiredness and fatigue. Continuous inhalation of gasoline and diesel fumes is suspected to cause
cancer.
Safety precautions
Avoid inhaling solvent fumes by providing good ventilation, or wearing
a fresh-air mask or respiratory device with a suitable filter for the toxic
gases.
Never leave a solvent container without tight-sealing lid.
Use solvents with a low content of aromatic substances. It reduces the
risk of injury.
Avoid skin contact.
Use protective gloves.
Make sure that work clothes are solvent-resistant.
VDRF03.02GB
12
page
Fire and explosion risks

Examples of flammable and explosive substances are oils, gasoline,
diesel fuel oil, organic solvents (lacquer, plastics, cleaning agents),
rustproofing agents, welding gas, gas for heating (acetylene), high
concentration of dust particles consisting of combustible materials.
Rubber tyres are flammable and cause explosive fires.
Risks
Examples of cause of ignition is welding, cutting, smoking, sparks
when working with grinders, contact between hot machine parts and
flammable materials, heat development in rag drenched with oil or
paint (linseed oil) and oxygen. Oxygen cylinders, lines and valves shall
be kept free from oil and grease.
Fumes from, e.g., gasoline are heavier than air and may "run" down
into a sloping plane, or down in a grease pit, where welding flames,
grinding sparks or cigarette embers may cause an explosion. Evaporated gasoline explodes very forcefully.
Special cases
Diesel fuel oil with added gasoline has a lower ignition point. Risk of
explosion already at room temperature. The explosion risk for warmed
diesel fuel oil is higher than for gasoline.
When changing oil in the engine, hydraulic system and transmission,
keep in mind that the oil may be hot and can cause burn injuries.
Welding on or near machine. If diesel and or other oils have leaked out
and been absorbed by rags, absorbent agents, paper or other porous
material, hot welding sparks can cause ignition and explosive fires.
When a battery is charged, the battery fluid is divided into oxygen and
hydrogen gas. This mixture is very explosive. The risk of explosion is
especially high when using a booster battery or quick-charger, as this
increases the risk of sparks.
Todays machines contain a lot of electronic equipment. When welding, the control units must be disconnected and the electric power
must be turned 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 may not be done near
plastic or rubber materials without first protecting them from the heat.
Paints, plastics, and rubber develop a number of substances that may
be hazardous to health when heated. Be careful with machines that
have been exposed to intense heat or fire.
VDRF03.02GB
13
Safety precautions
Store hazardous substance in approved and sealed container.
Make sure that there is no ignition source near flammable or explosive
substances.
Make sure that ventilation is adequate or there is an air extraction unit
when handling flammable substances.
page
Fluid or gas under pressure

High-pressure lines can be damaged during work, and fluid or gas can
stream out.
There may be high pressure in a line even if the pump has stopped.
Therefore, gas or fluid can leak out when the connection to the hose
is loosened.
A gas cylinder subjected to careless handling can explode, for example, if it falls onto a hard surface. Gas can stream out through damaged valves.
Risks
Risk of damage/injuries in connection with work on:
Hydraulic systems (e.g., working hydraulics and brake system).
Fuel system.
Tyre repairs.
Air conditioning.
Safety precautions
Use safety glasses and protective gloves.
Never work on a pressurised system.
Never adjust a pressure limiting valve to a higher pressure than

recommended by the manufacturer.
A hydraulic hose that swells, for example, at a connection, is

about to rupture. Replace it as soon as possible! Check connections thoroughly.
Use fluid when checking for leaks.
Never blow clothes clean with compressed air.
Discarded pressure accumulator shall 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 directly to detect a leak. A fine high-pressure stream from a hydraulic hose can easily penetrate a hand
and causes very severe injuries.
VDRF03.02GB
14
page
Coolant
The coolant in the machines cooling system consists of water, anticorrosion compound and (when needed) anti-freeze fluid, for example,
ethylene glycol.
Coolant must not be drained into the sewer system or directly onto the
ground.
Risks
The cooling system operates at high pressure when the engine is
warm. Hot coolant can jet out and cause scalding in case of a leak or
when the expansion tank cap (filler cap) is opened.
Ingesting ethylene glycol and anti-corrosion compound is dangerous
and hazardous to health.
Safety precautions
page
Use protective gloves and safety glasses if there is a risk of

splashing or spraying.
Open the filler cap first, to release the excess pressure. Open
carefully. Hot steam and coolant can stream out.
If possible, avoid working on the cooling system when the coolant

is hot.
Refrigerant
Refrigerant is used in the machines air conditioning system.
Work on the air conditioning system must be performed by accredited/
authorised and trained personnel according to national legislation and
local regulations.
Risks
The air conditioning operates at high pressure. Escaping refrigerant
can cause frostbite.
Refrigerant that is heated (e.g., when repairing leaking climate/AC
system), generates gases that are very dangerous to inhale.
Safety precautions
VDRF03.02GB
Use special instructions and equipment for refrigerant according

to the manual when working on the air conditioning system. Special certification and authorisation is often required of the person
who may do the work. (Note national legislation and local
regulations!)
Use protective gloves and safety glasses if theres a risk of leaks.
Make sure that heat-producing sources or objects are not close by

(cigarette glow, welding flame).
page
15
Air pollution
Air pollution is the impurities in the air around us and which are regarded as hazardous to health. Certain pollution is more prominent in certain environments.
The following health-hazardous air pollution is especially prominent in
workshops:
Carbon monoxide (fumes) is present in exhaust fumes. Odourless and therefore especially dangerous.
Nitrogen oxides (nitrous gases) are present in exhaust fumes.
Welding smoke especially hazardous to health when welding on

oily surfaces, galvanised or lacquered materials.
Oil mist for example, when applying anti-corrosion agent.
Grinding dust and gases generated when grinding and heating

plastics, lacquer, anti-corrosion agents, lubricants, paint, etc.
Isocyanates are present in certain paints, fillers, adhesives and

foam plastics used on machines.
Risks
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 may be
present in aerosols) when cutting, grinding or welding. Can irritate mucous membranes producing symptoms similar to asthma and impairing lung function. Even brief exposure to high concentrations can give
problems with persistent high sensitivity.
Safety precautions
Make sure of adequate ventilation with fresh air when welding,

battery charging and other work when hazardous gases are
generated.
Use suitable protective gloves and breathing protection when

there is a risk of oil mist. Make sure that the protection is oil-proof.
Apply oil-resistant protective lotion to unprotected skin.
Make sure that an eye-wash station is in the immediate vicinity

when working with corrosive substances.
Avoid unnecessary operation of the machine inside the workshop.

Connect an air extractor to the exhaust pipe so that the exhaust
fumes are removed from the workshop.
VDRF03.02GB
16
page
Tensioned springs
Examples of tensioned springs:
1.
Torque springs in pedals for example
2.
Return spring (cup springs) in parking brake cylinder.
3.
Lock rings
4.
Gas springs
Risks
If a tensioned spring releases, it is shot out by the spring force and can
also take adjoining parts with it.
Small springs can cause eye injuries.
Parking brake springs are tensioned with high force and can cause
very severe accidents if they are accidentally released in an uncontrolled manner.
Gas springs and gas-charged shock absorbers are tensioned with
high force and can cause very severe accidents if they are accidentally
released in an uncontrolled manner.
Safety precautions
page
Use safety glasses.
Lock rings should be of a suitable type and in good condition.
Follow the instructions in this and other manual when performing

maintenance and changing parts and components.
Always use recommended tools.
Electric motors
Safety precautions
Always turn off the battery disconnector when working on electric
motors.
Always block the machines wheels and make sure that the parking
brake is activated and that the gear selector is in neutral position before starting any work on the machine.
VDRF03.02GB
page
17
Rotating components and tools

Examples of rotating components and tools:
Cooling fan
Drive belts
Propeller shafts
Drills
Grinders
Risks
Rotating components, for example, fans or shafts, can cause severe
injuries if touched.
Drills, lathes, grinders or other machines with rotating parts can cause
severe accidents if clothes or hair get caught and are wound up in the
machine.
Safety precautions
Do not use gloves when working with a drill.
Remove loose, hanging clothing, scarf or tie.
Never use clothing with wide sleeves or trouser legs.
Make sure that clothing is intact and in good condition.
Long hair should be gathered up in a hair-net or similar.
Remove large or loose hanging jewellery from hands, arms and

neck.
VDRF03.02GB
18
page
Tyres and rims
D ANGER
Tires shall be regarded as pressure reservoirs. If handled incorrectly, they constitute a fatal danger
Parts can be thrown with explosive force and may
cause severe injuries.
Never repair damaged tyres, rims or lock rings. Tyre
changes shall be performed by authorised personnel.
Risks
Dismantling wheels: Tyres, rims or lock rings can be thrown.
Inflating of wheels: Tires, rims or lock rings may be ejected.
Safety precautions
page
Always deflate the tyre before starting to work on the wheel.
Check that tyres, rims and lock rings arent damaged. Never repair damaged rims or lock rings.
Wheels shall be inflated on the machine or in a protective device,

designed and dimensioned so that it can handle or dissipate a
shock wave from a tyre explosion as well as catch the ejected
parts.
Use protective screen and safety glasses.
Lifting equipment
When working on the machine in general, and with the machines lifting equipment in particular, the greatest caution must be exercised
with respect to securing the boom and attachment.
For this reason, always be in the habit of having the boom fully lowered
and fully retracted during work on the machine.
Risks
Risk of crushing if the machines lifting equipment is not lowered or
secured.
Risk of crushing is extra high when depressurising the hydraulic system, see Hydraulic and brake systems, depressurising page 5.
Safety precautions
VDRF03.02GB
Do not start work until the boom is lowered and fully retracted if
possible.
page
19
Spare parts
WARN IN G
The following parts must, for safety reasons, only be
replaced with original spare parts:
Brake valve
Drive axle
Valve for mini-wheel/lever steering
Steering valve (Orbitrol)
Steering valve incl. priority valve
Steering axle
Steering cylinder
Rims
Lift boom
Boom nose extension
Lift cylinder
Valve block lift
Extension cylinder
Valve block extension
Rotation motor unit
Tilt cylinder
Twistlocks, lifting shoe
Safety switch (for hydraulic function)
Emergency switch
Frame
Accumulator
Main valve load handling
Accumulator charging valve
All control units
VDRF03.02GB
20
page
Non-ionised radiation
WARN IN G
Extra equipment such as communication radio, RMI,
phone, etc. can emit non-ionised radiation.
Danger of disruption to active or inactive medical
products.
Use communication radio, RMI, phone, etc. when
there are no people with active or inactive medical
products in the vicinity.
NOTE
When there are no people with active or inactive products in the
vicinity the phone and communication radio in the cab may be
used.
Equipment should not be used during operation or load handling
as your concentration as operator is reduced.
Cargotec accepts no responsibility for equipment not installed by
Cargotec or with Cargotec approved installation.
VDRF03.02GB
B Safety Environment
21
Environment
page
General
Ever-increasing industrialisation of our world is having a significant impact on our global environment. Nature, animals and man are subjected daily to risks in connection with various forms of chemical handling.
There are still no environmentally safe chemicals, such as oils and
coolants, available on the market. Therefore, all who handle, perform
service on or repair machines must use the tools, assisting devices
and methods necessary to protect the environment in an environmentally sound manner.
By following the simple rules below, you will contribute to protecting
our environment.
Recycling
Well-thought out recycling of the machine is the cornerstone of ending
its life cycle and being able to re-use materials in new products. According to calculations by Cargotec, the machine can be recycled to
more than 90% by weight.
Environmentally hazardous waste

Components such as batteries, plastics, and other materials that may
be considered as environmentally hazardous waste must be handled
in an environmentally correct manner.
Discarded batteries contain substances hazardous to personal health
and the environment. Therefore, handle batteries in an 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 must always be taken care of by an authorised
disposal company.
Pay close attention to oil leaks and other fluid leaks! Take immediate
action to seal the leaks.
Air conditioning unit

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

The machine shall be equipped for work within a contaminated area
(environmental contamination or health-hazardous area) before work
is started. Also, special local regulations apply to such handling and to
service work on such a machine.
VDRF03.02GB
22
B Safety Environment
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, then refrigerant of the
type R134a is used, in an amount between 1-3 kg.
VDRF03.02GB
C Preventive maintenance C Preventive maintenance
mm mm mm mm mm mm
page
The information is found in the
Maintenance Manual
The information is found in the Maintenance Manual.
For information on how to order the Maintenance Manual, see the
section A Foreword.
Workshop manual DRF 400450
VDRF03.02GB
VDRF03.02GB
C Preventive maintenance C Preventive maintenance
0 Complete machine
0 Complete machine
Table of Contents 0 Complete machine

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

Complete machine, description .............................................................................
Troubleshooting, general work instructions ............................................................
Troubleshooting without an error code, example ...................................................
Troubleshooting with error code, example .............................................................
Troubleshooting cable harness ..............................................................................
Troubleshooting hydraulic hoses ............................................................................
3
4
5
5
7
8
VDRF03.02GB
VDRF03.02GB
0 Complete machine
0 Complete machine Complete machine
mm mm mm mm mm mm
page
Complete machine
Complete machine, description
The Kalmar DRF 400450 is a "Reachstacker" for container handling.
The machine a lifting capacity of 4045 tonnes depending on version.
The drive source is a six-cylinder, four-stroke diesel engine with direct
injection.
The transmission is hydromechanical, with constant mesh gears. It
has four speeds forwards and four speeds in reverse. Engine power is
transmitted by a torque converter.
The driveline/axle comprises a propeller shaft and a rigid drive axle
with hub reduction. Drive is via the front wheels.
The service brake is of wet disc type, built together with drive wheel
hubs. The parking brake is a disc brake and acts on the drive axle input shaft.
Steering is via the rear wheels and a double acting hydraulic cylinder.
The steering axle is pendulum-suspended in the frame.
The wheels are mounted on the hubs with clamps. Twin wheels are
mounted on the drive axle, while the steering axle has single wheels.
Load handling comprises components and functions for managing
loads. Loads are lifted with and attachment that is fitted on a liftable
telescopic boom. Load handling is divided into lifting/lowering, extension, side shift, spreading, rotation, tilt, levelling and load carrier functions.
Lifting/lowering is the function used to raise and lower the boom.
Extension is the function to extend the boom in and out.
Side shift is used to move the lift attachment laterally in relation to

the machine.
Spreading is used to adjust the width between the attachments

lifting points.
Rotation is rotating the load in relation to the machine.
Tilt is angling the load in the longitudinal direction of the truck.
Levelling is angling the load in the lateral direction of the truck.
The load carriers are designed to hold a fixed load.
The control system is functions for warning the operator of dangerous

situations and machine faults. The control system has diagnostic resources that simplify troubleshooting.
The frame supports the machine. Mounted in the frame are the engine,
transmission, drive axle and steering. The side of the frame houses
tanks for fuel, hydraulic oil and oil for the brake system. The cab is centrally located and can be tilted longitudinally. As an option the cab is
available in a side-mounted version that can be raised and lowered.
VDRF03.02GB
page
Troubleshooting, general work

instructions
When troubleshooting, it is important that the work is structured and
logical. The point of the troubleshooting described in the maintenance
manual is to exclude components as error source so that the real error
source can be pin-pointed. A suggested structured work method is described below.
When troubleshooting, it is important to understand how the machine
functions. Certain malfunctions can be pin-pointed directly using function descriptions. Sections 012 contain descriptions of the various
functions of the machine.
Troubleshooting procedure
1 Check that there is battery voltage available.
Battery disconnector, must be in position 1.
Battery voltage, should be 2230 V.
Fuses, check that they are intact.
2 Check that all oil and fluid levels are normal.
Fuel
Engine oil
Transmission oil
Brake system fluid
Hydraulic oil
Coolant
Washer fluid
3 Check if there are error codes.

4 If there are error codes, use the error code lists as a guide. See
Troubleshooting with error code, example page 5.
In the error code lists there are recommended actions for every
error code. Error code lists are found in section D Error codes.
5 If there is no error code or the problem persists, use the function
description for the function in question in section 012.
The function description contains information on which components are involved in the function and how these components
work together. In some cases, there is information on what conditions are required in order for it to be possible to activate the
function. Measurement points are marked with flags (C for measuring outlet, D for diagnostic menu).
VDRF03.02GB
page
Troubleshooting without an error

code, example
1 Choose suitable section 012 to find the function and sub-function 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 in question to find where in the function chain that signal or
reaction is incorrect.
4 The fault is probably between the two units where the signal is
failing. Start by checking the component that should send the
signal.
5 If the component that is to send the signal seems to be correct,
check transmission of the signal (electric wiring or hydraulic
hoses).
For electric cabling, see Troubleshooting cable harness page 7.
For hydraulic hoses,
see Troubleshooting hydraulic hoses page 8.
6 If the leads or hoses between the components seem in order,
then check the component that receives the signal.
page
Troubleshooting with error code,

example
Error codes are strong 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. Its important to not draw conclusions too fast based on an error code.
1 Read out error codes from the display, e.g., error code 34.
2 Use the error code lists and search information about the error
code, see "Example of error code information in error code list"
below.
Error code lists are found in section D Error codes.
For detailed instruction on reading out error code, see section D
Error codes.
3 Follow the instructions in the field Action.
4 Use diagnostic menus and circuit diagrams to determine if the 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 012 there is function description, the function's included components and their position as well as, in certain cases,
work instructions for how components are checked, cleaned or
adjusted.
VDRF03.02GB
6 If possible, eliminate component fault by testing the component

individually.
Electric components can sometimes be checked with resistance
measurements using a multimeter.
Hydraulic components are often checked by measuring pressure
(then described in the function group and indicated in the
section C Preventive maintenance). Sometimes valves can be
activated mechanically to determine if the malfunction is electric
or hydraulic.
7 If the components measurement values are correct, continue by
troubleshooting electric cables and hydraulic hoses.
For electric cabling, see Troubleshooting cable harness page 7.
For hydraulic hoses, see Troubleshooting hydraulic hoses page
8.
8 If the cable is not defective, then connect the lead to the control
unit.
NOTE
The main electric power shall be turned off with the battery
disconnector!
9 Disconnect the cable from the component in question.
10 Turn on the main electric power with the battery disconnector.
11 Turn the ignition key to the operating position.
12 Check that voltage reaches the component.
Table 1. Example of error code information in error code list
Code
Description
Limitation
Action
34
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.
VDRF03.02GB
Connections
and
components
D791-1/K8:5 S107, K8:13 S107
Check component.
Diagnostic menu
Function
group
HYD,
menu 5
4.1.2 Parking
brake control
page
Troubleshooting cable harness

NOTE
Perform troubleshooting for all cables in the same way to avoid
damage to control units, components or measuring equipment.
1 Study the circuit diagram in question, check where the suspected
cable is connected and if, and if so where, it is spliced.
2 Turn off the main electric power with the battery disconnector.
3 Unplug the connector at the control unit or component in
question.
C AUTION
Wipe and re-grease the connectors.
Risk of corrosion on contact surfaces.
Clean all connectors loosened during troubleshooting using electronic cleaner 923836.0826 and regrease them with connector grease 923836.0552.
4 Check if there is open circuit.
NOTE
Some components cannot be checked without power supply
to the component. In such an event, proceed to point 5.
a.
Measure resistance between connections for the component

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

a.
Unplug the connector at both the control unit and the component in question.
b.
Measure the resistance of one lead at a time. Measure between the lead and a frame-connected part of the machine.
c.
The multimeter should show endless resistance.
VDRF03.02GB
page
Troubleshooting hydraulic hoses
WARN IN G
Oil under high pressure!
Personal injury!
Always depressurise hydraulic and brake systems
before starting to work on the systems.
1 Depressurise the hydraulic and brake systems; see section B
Safety.
2 Study the relevant hydraulic diagram, check between whichever
components the suspect hose is connected and correspondingly
where it is spliced.
3 Locate the hose on the machine.
Start at one component and follow the hose to the next
component.
4 Inspect the entire hose and splicing points with respect to chafing
damage, pinching damage and leaks.
Change damaged hoses. When removing a hydraulic hose,
change of O-ring is always recommended on the hoses that have
these (ORFS).
VDRF03.02GB
1 Engine
1 Engine
Table of Contents1 Engine

mm mm mm mm mm mm
1
Engine ............................................................................................................. 3
1.1
Controls and instruments ......................................................................... 23
1.1.1
Ignition switch ...................................................................................... 23
1.1.2
Accelerator pedal ................................................................................. 24
1.2
Fuel system .............................................................................................. 25
1.2.1
Fuel tank .............................................................................................. 25
1.2.2
Sensor, fuel level ................................................................................. 25
1.6
Air intake and exhaust outlet .................................................................... 26
1.6.1
Air cleaning system .............................................................................. 26
1.6.3
Exhaust system ................................................................................... 26
1.6.4
Intercooler ............................................................................................ 27
1.7
Cooling system ......................................................................................... 28
1.7.4
Radiator and expansion tank ............................................................... 29
1.7.5
Cooling fan ........................................................................................... 30
1.7.7
Coolant ................................................................................................ 32
1.7.10
Engine heater ...................................................................................... 35
1.9
Engine control system .............................................................................. 36
1.9.1
Control unit, engine .............................................................................. 36
1.11
Start/stop .................................................................................................. 37
1.11.1
Starter motor ........................................................................................ 37
1.11.2
Stopping device ................................................................................... 37
VDRF03.02GB
VDRF03.02GB
1 Engine
1 Engine
mm mm mm mm mm mm
page
1 Engine
Engine, general
Engine alternative
The machine can be equipped with one of the following engine
alternatives:
Volvo TWD1240VE stage II as per Directive 97/68/EC
Volvo TAD1250VE (stage III as per Directive 97/68/EC)
Cummins QSM11 (stage III as per Directive 97/68/EC )
If there are differences between engine alternatives, this is written in

brackets after headings or under figures to clarify that which is shown.
Volvo engines have many similarities. Descriptions and instructions
that are the same for both engine alternatives are denominated "(engine alternative Volvo)". If a description or set of instructions only applies to one engine alternative then the whole engine designation is
written out, for instance "(engine alternative Volvo TAD1250VE).
Component supplier documentation

The Workshop manual only describes components and work descriptions that concern installation in the machine. For descriptions and instructions for the engines components and systems, refer to supplier
documentation.
References to component supplier documentation are only provided in
exceptional cases. If information about a component is not found, the
component supplier documentation should be used.
VDRF03.02GB
1 Engine
Engine alternative Volvo, function

description
page
Condition
Reference value
Reference
Engine heater
Disconnected (when cable is in start lock-out is

activated)
Engine heater, description page 35
C
.
0
I
rpm
kph
II
D5
III
<
1, 5
D10
D1
10
2, 11
D790-1
D790-2
D793
20, 22
bar
6, 15
D794
3, 7, 12
D7
D795
18, 21
D797-R
14, 23
17
D16
D14
D19
D3
H2O
SENSORS
16
13
008223
19
9
Pos
Explanation
Signal description
Reference
The ignition key lock sends a voltage signal to the cab control unit (D790-1) when
the start key is turned to position 1 or the
preheating position.
U = 24 V
Ignition switch, description page 23
Cab control unit (D790-1) sends ignition on

via the CAN bus. If the key is turned to the
preheating position, then preheating is
also sent on the CAN bus.
Checked by control system, error shown with

error code.
Section 11 Common electrics, group

11.5.3.1 Cab control unit
If preheating is activated with the start key

then Control unit, engine (D794) supplies
power to the preheating element.
U = 24 V
D3: Diagnostic menu, see section 8 Control

system , group 8.4.6.5 ENGINE, menu 5
The preheating coil warms the engine

intake air.

VDRF03.02GB

system , group 8.4.1.4 CAN/POWER,
menu 4 and 8.4.6.4 ENGINE, menu 4
1 Engine
Pos
Explanation
Signal description
Reference
The ignition key lock sends a voltage signal to the Control unit KIT (D790-2) when
the start key is turned to the start position.
U = 24 V
Control unit KIT (D790-2) transmits a start

signal on the CAN bus.
Checked by control
system, error shown
with error code.

11.5.3.11 Control unit KIT
The engine control unit (D794) supplies

power to the starter motor.
U = 24 V
Starter motor, description (engine alternative Volvo) page 37


8
The starter motor cranks the engine.
Starter motor, description (engine alternative Volvo) page 37

The engines sensors send signals to the

engine control unit (D794), which regulates
the injectors so that the engine starts.

error code.

11.5.3.10 Engine control unit
10
The accelerator pedal sends the cab control unit (D790-1) a voltage signal proportional to the downward press of the pedal.
U = 0.54.5 V
Section 9 Frame, body, cab and accessories, group 9.1 Controls and instruments
11
The cab control unit (D790-1) transmits a

message with the rpm request on the CAN
bus

error code.

12
The engine control unit (D794) increases

engine speed.

13
The NO switch for coolant level sends a

voltage signal to Control unit, engine
(D794) if the coolant level in the expansion
tank is low.
U = 24 V
Cooling system, description page 28
14
The engine control unit (D794) transmits

engine data and warning messages on the
CAN bus.

error code.

The KID control unit (D795) shows engine

data via display figures.

11.5.3.12 KID control unit
15
Lower voltage than 0.5

V and higher voltage
than 4.5 V used to detect malfunction in cable
harnesses and controls.
D10: Diagnostic menu, see section 8 Control system , group 8.4.6.1 ENGINE,
menu 1
D14: Diagnostic menu, see section 8 Control system , group 8.4.6.6 ENGINE,
menu 6 and 8.4.6.7 ENGINE, menu 7
VDRF03.02GB
1 Engine
Pos
Explanation
Signal description
Reference
16
The fuel level sensor (B757) sends a voltage signal to Control unit, frame rear
(D797-R) proportional to the fuel level in
the tank.
U = 0.54.5 V
Sensor, fuel level, description page 25

D16: Diagnostic menu, see section 8

Control system , group 8.4.3.7 CAB,
menu 7
17
Control unit, frame rear (D797-R) transmits

fuel level on the CAN bus.

error code.

11.5.3.3 Control unit, frame rear
18
The KID control unit (D795) displays the

fuel level in the operating menu for engine.

19
The output shaft sensor (B758) sends the

transmission control unit (D793) pulses
with frequency proportional to output shaft
rpm.

Control system , group 8.4.7.6 TRANSM,
menu 6
20
The transmission control unit (D793)

transmits speed on the CAN bus.

error code.

11.5.3.9 Control unit, transmission
21
The KID control unit (D795) shows the machines speed.

22
If output shaft rpm is so high that it reaches

the limit for the machines speed limitation,
the cab control unit (D790-1) transmits a
reduce engine rpm request on the CAN
bus.

error code.

23
Control unit engine (D794) restricts engine

rpm.

VDRF03.02GB
1 Engine
Engine alternative Cummins QSM11,

function description
(model year-2008)
page
Condition
Reference value
Reference
Engine heater

activated)
C
.
bar
rpm
kph
II
III
1, 3
D1
D8
2, 9
D790-1
18, 20
D793
D3
D790-2
4, 13
D794
D795
16, 19
D797-R
12, 21
5, 10, 15
D14
D12
D5
D17
17
H2O
11
SENSORS
14
008224
<
Pos
Explanation
Signal description
Reference
The ignition switch sends a voltage signal to the cab control unit (D790-1) when
the ignition key is turned to position 1.
U = 24 V
The cab control unit (D790-1) transmits

Ignition on as a start message on the
CAN bus.
Checked by control
system, error shown
with error code.

The ignition switch sends a voltage signal to Control unit KIT (D790-2) when the
start key is turned to the start position.
U = 24 V
The KIT control unit (D790-2) transmits a

start signal on the CAN bus.
Checked by control
system, error shown
with error code.

system , group 8.4.1.4 CAN/POWER, menu 4
and 8.4.6.4 ENGINE, menu 4


VDRF03.02GB
1 Engine
Pos
Explanation
Signal description
Reference
Control unit, frame rear (D797-R)

supplies power to the starter motor.
U = 24 V
Starter motor, description (engine alternative

Cummins) page 37

Cummins) page 37

engine control unit (D794), which
regulates the injectors so that the engine
starts.

The accelerator pedal sends the cab

control unit (D790-1) a voltage signal
proportional to the downward press of
the pedal.
U = 0.54.5 V
Section 9 Frame, body, cab and accessories,

group 9.1 Controls and instruments

message with the rpm request on the
CAN bus
Checked by control
system, error shown
with error code.

10
The engine control unit (D794) controls

engine speed.

11
The NO switch for coolant level sends a

voltage signal to Control unit, engine
(D794) if the coolant level in the expansion tank is low.
U = 24 V
12

engine data and warning messages on
the CAN bus.

error code.

13
The KID control unit (D795) shows engine data via display figures.

14
The fuel level sensor (B757) sends a

voltage signal to Control unit, frame rear
the tank.
U = 0.54.5 V


system , group 8.4.3.7 CAB, menu 7
15

transmits fuel level on the CAN bus.
Checked by control
system, error shown
with error code.

16

fuel level in the operating menu for
engine.

VDRF03.02GB



system , group 8.4.6.6 ENGINE, menu 6 and
8.4.6.7 ENGINE, menu 7
1 Engine
Pos
Explanation
Signal description
Reference
17
The output shaft sensor (B758) sends

the transmission control unit (D793)
pulses with frequency proportional to
output shaft rpm.

system , group 8.4.7.6 TRANSM, menu 6
18

transmits speed information on the CAN
bus.
Checked by control
system, error shown
with error code.

19
The KID control unit (D795) shows the

machines speed.

20
If the speed is at the machines speed

limitation limit, the cab control unit
(D790-1) transmits an engine speed
reduction request on the CAN bus.
Checked by control
system, error shown
with error code.

21
Control unit engine (D794) restricts

engine rpm.

VDRF03.02GB
10
1 Engine

(model year 2009-)
page
Condition
Reference value
Reference
Engine heater

activated)
bar
rpm
kph
II
III
1, 3
D1
2, 9
D3
D790-1
19, 21
D790-2
D793
4, 14
D794
D795
D797-R
13, 22
12
17, 20
5, 10, 16
D15
D13
D5
D18
18
H2O
11
SENSORS
15
013025a
D8
Pos
Explanation
Signal description
Reference
The ignition switch sends a voltage signal to the cab control unit (D790-1) when
the ignition key is turned to position 1.
U = 24 V

Ignition on as a start message on the
CAN bus.

error code.

The ignition switch sends a voltage signal to Control unit KIT (D790-2) when the
start key is turned to the start position.
U = 24 V

start signal on the CAN bus.

error code.
VDRF03.02GB

system , group 8.4.1.4 CAN/POWER, menu 4
and 8.4.6.4 ENGINE, menu 4


1 Engine
11
Pos
Explanation
Signal description
Reference
Control unit, frame rear (D797-R) supplies power to the starter motor.
U = 24 V

Cummins) page 37

Cummins) page 37

engine control unit (D794), which regulates the injectors so that the engine
starts.

The accelerator pedal sends the cab

proportional to the downward press of
the pedal.
U = 0.54.5 V


message with the rpm request on the
CAN bus
Checked by control
system, error shown
with error code.

10
The engine control unit (D794) controls

engine speed.

11
The NO switch for coolant level grounds

the control terminal of the coolant level
relay (K322) if the coolant level is low in
the expansion tank.
Low coolant level: U

K322:85 = 0 V
12
Coolant level relay (K322) breaks the circuit to Control unit, engine (D794) if the
coolant level is low in the expansion
tank.
13

engine data and warning messages on
the CAN bus.

error code.

14
The KID control unit (D795) shows engine data via display figures.

15
The fuel level sensor (B757) sends a

voltage signal to Control unit, frame rear
the tank.
U = 0.54.5 V





system , group 8.4.6.6 ENGINE, menu 6 and
8.4.6.7 ENGINE, menu 7
VDRF03.02GB
12
1 Engine
Pos
Explanation
Signal description
Reference
16

transmits fuel level on the CAN bus.
Checked by control
system, error shown
with error code.

17

fuel level in the operating menu for
engine.

18
The output shaft sensor (B758) sends

pulses with frequency proportional to
output shaft rpm.

19

bus.
Checked by control
system, error shown
with error code.

20

machines speed.

21
If the speed is at the machines speed

limitation limit, the cab control unit
(D790-1) transmits an engine speed
Checked by control
system, error shown
with error code.

22
Control unit engine (D794) restricts

engine rpm.

VDRF03.02GB
1 Engine
13
Engine alternative Volvo

TWD1240VE, component location
page
20
19
8
18
9
10
17
11
15
14
13
001641
16
12
Engine alternative, Volvo TWD1240VE, right side (in machines

direction of travel)
1. Air nipple, cooling system
11. Sensor, engine speed
2. Charge air pressure and charge air temperature sensor
12. Fuel pre-filter
3. Engine control unit (D794)

4. Intercooler
13. Draining of condensation from fuel filter and water-in-fuel

sensor
5. Coolant temperature sensor
14. NO switch, fuel pressure
6. Dipstick
15. Fuel filter
7. Engine oil filling point
16. Extra coolant pump
8. Fuel connection (intake)
17. Oil pressure and oil temperature sensor
9. Fuel connection (return)
18. Compressor, air conditioning
10. Starter motor
19. Alternator
20. Sensor camshaft rpm
VDRF03.02GB
14
1 Engine
17
16
15
14
13
12
11
Engine alternative, Volvo TWD1240VE, left side (in machines

direction of travel)
1. Connection cab heat
9. Transmission oil cooler
2. Air cleaner connection
10. Thermostat, transmission oil cooler
3. Turbocharger
11. Radiator connection intake
4. Exhaust system connection
12. Coolant pump
5. Radiator connection outlet
13. Coolant filter
6. Expansion tank connection
14. Engine oil drain plug
7. Thermostat
15. Coolant shut-off cock
8. Water cooler
16. Oil filter (full flow)

17. Oil filter (bypass)
VDRF03.02GB
003160
10
1 Engine
15
Engine alternative Volvo

TAD1250VE, component location
page
6
7
8
9
20
18
17
15
13
11
10
006446
21
19
16
14
12
Volvo TAD1250VE engine right side (in machines direction of travel)

1.
Intercooler
12.
Water separator
2.
Water cooler
13.
Sensor, water-in-fuel
3.
Transmission oil cooler
14.
Fuel filter
4.
Preheating element
15.
Engine control unit (D794)
5.
Charge air pressure and charge air temperature sensor 16.
Oil level sensor
6.
Engine oil filling point
17.
Crankcase pressure sensor
7.
Coolant temperature sensor
18.
Engine oil drain plug
8.
Starter motor
19.
Oil pressure and temperature sensor
9.
Sensor, engine speed
20.
Dipstick
10.
NO switch, fuel pressure
21.
Alternator
11.
Fuel pre-filter
VDRF03.02GB
16
1 Engine
4
5
10
006400
Volvo TAD1250VE engine, left side (in machines direction of travel)

1.
Connection cab heat
6.
Coolant pump
2.
Expansion tank
7.
Coolant filter (behind console)
3.
Sensor, coolant level
8.
Oil filter (full flow)
4.
Thermostat
9.
Oil filter (bypass)
5.
Turbocharger
10.
Oil pressure sensor, piston cooling
VDRF03.02GB
1 Engine
17

component location
page
11
10
001643
12
Engine alternative, Cummins, right side (in machines direction of

travel)
1. Location for air conditioning compressor
7. Draining of condensation from fuel filter and water-in-fuel sensor
2. Fuel connection (outlet)
8. Fuel filter
3. Engine control unit (D794)
9. Sensor fuel pressure
4. Engine oil drain plug
10. Fuel pump
5. Starter motor
11. Oil pressure and oil temperature sensor
6. Fuel connection (intake)
12. Crankshaft position sensor
VDRF03.02GB
18
1 Engine
10
11
12
13
14
15
16
25
17
23
22
21
20
19
003163
18
24
Engine alternative, Cummins, left side (in machines direction of travel)

1. Engine oil filling point
13. Radiator connection (outlet)
2. Dipstick
14. Intake, intercooler
3. Connection cab heat
15. Intercooler
4. Air cleaner connection
16. Water cooler
5. Turbocharger
17. Thermostat
6. Intercooler connection (outlet)
7. Intercooler connection (intake)
19. Radiator connection (intake)
8. Intake temperature sensor
20. Coolant pump
9. Exhaust system connection
10. Boost pressure sensor
22. Thermostat housing
23. Oil filter
12. Alternator (coolant temperature sensor behind alternator)
24. Coolant filter

VDRF03.02GB
1 Engine
page
19
Engine and transmission,

separation (engine alternative
Volvo)
Separation
1 Machine in service position, see section B Safety.
2 Disconnect the requisite hoses and cables before separating
engine and transmission.
NOTE
Drain and collect liquids before detaching hoses.
3 Attach hoisting equipment to the engine.
4 Use a jack to secure the transmission.
5 Remove the plugs in front of the flywheel.

Use the outer hole to turn the engine round.
6 Remove the flex plates attaching bolt. Turn the engine until flex
plates attaching bolts are visible in the inner hole. The flex plate
has eight attachment points to be loosened.
7 Take up the slack in the hoisting equipment.
NOTE
Do not lift the engine or transmission.
VDRF03.02GB
20
1 Engine
8 Remove the bolts between the engine and the transmission.

9 Loosen the engine or transmission attachment brackets and separate the engine and transmission.
Assembly
10 Check that the holes for the flex plates mounting in the flywheel
are just in front of the flex plates retaining nuts.
The flex plate has eight attachment points to be connected with
the flywheel on the engine.
11 Fit the engine or transmission brackets.
Tighten to a torque of 168 Nm.
12 Connect the engine to the transmission.
13 Fit the bolts between the engine and transmission. Tighten to a

torque of 40 Nm.
14 Fit the flex plates 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.
15 Fit the plugs in front of the flywheel.
16 Remove the hoisting equipment from the engine.
17 Remove the jack from underneath the transmission.
18 Connect the requisite hoses and cables for the engine and transmission. Check and fill fluids as needed.
19 Bleed air from the engines fuel system before start.
VDRF03.02GB
1 Engine
page
21

separation (engine alternative
Cummins QSM11)
Separation
2 Attach hoisting equipment to the engine.
3 Disconnect the requisite hoses and cables before separating engine and transmission.
NOTE
Drain and collect liquids before detaching hoses.
4 Use a jack to secure the transmission.
5 Remove the cover washer.
VDRF03.02GB
22
1 Engine
6 Rotate the engine for each bolt in the flex plate that has to be
removed.
7 Remove the screws of the flex plate through the hole under the
cover washer.
8 Take up the slack in the hoisting equipment.
NOTE
Do not lift the engine.
9 Remove the bolts between engine and transmission.
10 Loosen the engine and transmission brackets.
11 Withdraw the engine rearwards to separate it from the
transmission.
Assembly
12 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 attachment points to be connected with
the flywheel on the engine.
13 Fit the bolts to the engine and transmission brackets. Tighten to
a torque of 168 Nm.
14 Connect the engine to the transmission.
15 Fit the bolts between engine and transmission. Tighten to a
torque of 52 Nm.
16 Fit the flex plates 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.
17 Fit the plug in front of the flywheel.
18 Remove the hoisting equipment from the engine.
19 Remove the jack from underneath the transmission.
20 Connect the requisite hoses and cables for the engine and transmission. Check and fill fluids as needed.
VDRF03.02GB
1 Engine 1.1 Controls and instruments
1.1
23
Controls and instruments
1.1.1
Ignition switch
Ignition switch, description
page
P No function.
0
Stop position. Everything switched off; key can be removed.
Operating position.
Voltage to all electrical functions. Engine and transmission control units are now ready for start.
The signal can be checked from the diagnostic menu, see section
8 Control system , group 8.4.1.4 CAN/POWER, menu 4.
II
Preheating position.
In the preheating position the engines intake air is heated by the
electric heater to a suitable temperature. The preheating lamp illuminates during preheating.
8 Control system , group 8.4.6.4 ENGINE, menu 4.
III Start position.
Engagement of starter motor for engine start.
NOTE
II
III
000317
The machine is equipped with an electric restart interlock,

which prevents engagement of the starter motor when the
engine is rotating.
Conditions for starter motor engagement are that
transmission is in neutral position and the engine is not
already running.
8 Control system , group 8.4.6.4 ENGINE, menu 4.
VDRF03.02GB
24
1 Engine 1.1.2 Accelerator pedal
1.1.2
page
Accelerator pedal
Accelerator pedal, replacement

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

See section 8 Control system, group 8.5.2.3 Calibrate DRIVE-TRAIN.
VDRF03.02GB
1 Engine 1.2 Fuel system
1.2
25
Fuel system
Fuel system, description
page
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 sucks fuel from the tank
through the fuel filter and forces it to the unit injections. The unit injectors spray in the fuel and atomises the fuel to the engines combustion
chamber.
1.2.1
Fuel tank
Fuel tank, description
page
The fuel tank is located on the left-hand side of the machine behind the
brake fluid reservoir.
1.2.2
Sensor, fuel level
Sensor, fuel level, description
page
002289
The signal can be checked from the diagnostic menu, see section 8
Control system , group 8.4.3.7 CAB, menu 7.
1. Fuel filler orifice

2. Fuel tank
3. Sensor, fuel level (behind air filter)
VDRF03.02GB
26
1 Engine 1.6 Air intake and exhaust outlet
1.6
1.6.1
Air intake and exhaust outlet

Air cleaning system
Air cleaning system, description
page
Combustion in the engine requires air. Free unobstructed flow for

fresh air and exhausts is essential for effective engine operation.
001357
Air cleaning system, overview

1. Intake hose
2. Filter indicator
3. Air cleaner
4. Intake
5. Dust reservoir
1.6.3
Exhaust system
Exhaust system, description
page
3
4
The exhaust system is installed in the chassis. A heat shield is installed between the engine and the exhaust system to protect wiring,
etc. A flex-pipe between the turbo and silencer absorbs the engines
movements. On the outside of the machine, there is a heat shield fitted
over the exhaust system.
001356
WARN IN G
Exhaust system overview
1. Turbocharger
2. Flex pipe
3. Exhaust pipe
4. Tail pipe
5. Silencer
VDRF03.02GB
Hot exhaust system!

Risk of burn injuries!
Never touch the turbo or muffler when the machine is
running or just after it has been turned off!
1 Engine 1.6.4 Intercooler
1.6.4
27
Intercooler
Intercooler, description
page
Engine alternative Volvo TAD1250VE and Cummins

QSM11
The charge air is cooled by an air-air intercooler in the upper part of
the cooling unit.
Engine alternative Volvo TWD1240VE

The charge air is cooled by a water-air intercooler on the engine, see
engine supplier documentation.
Also refer to Cooling system, description page 28.
5
4
003215
Cooling unit, engine alternative Volvo TAD1250VE

and Cummins QSM11
1. Intercooler
2. Engine cooler
4. Transmission oil thermostat
5. Condenser mounting (to AC)
VDRF03.02GB
28
1 Engine 1.7 Cooling system
1.7
page
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
Coolant filter
How the engine cooling system works:

1.
The coolant pump pumps coolant through the cylinder head, engine block and oil cooler. On the engine alternative Volvo
TWD1240VE a separate coolant pump pumps coolant through the
intercooler.
2.
The thermostat directs the heated coolant back to the coolant

pump or through the radiator.
3.
When the coolant is colder than the thermostat opening temperature it is pumped back to the engine.
When the coolant is warmer than the thermostat opening temperature it is pumped through the radiator and then back to the coolant pump.
4.
VDRF03.02GB
The expansion tank allows the coolant to expand without escaping from the engine.
1 Engine 1.7.4 Radiator and expansion tank
1.7.4
29
Radiator and expansion tank
Radiator and expansion tank, description
page
Radiator for the engine is located in the cooling unit which is fitted behind the engine.
The purpose of the cooler assembly is to cool:
Engine coolant
Transmission oil (cooled in the lower part of the cooling unit), see
also section 2 Transmission, group 2.6.3 Oil cooler.
The charge air (engine alternative Volvo TAD1250VE and Cummins QSM11) is cooled in the upper cooling unit), see also Intercooler, description page 27.
Engine alternative Volvo TWD1240VE has water-air intercooler
mounted directly on the engine.
Also refer to Cooling system, description page 28.

For more information, see supplier documentation, engine.
5
4
1
Cooling unit, engine alternative Volvo TAD1250VE

and Cummins QSM11
1. Intercooler
2. Engine cooler
4
3
003214
003215
Cooling unit, engine alternative Volvo TWD1240VE

1. Engine cooler
VDRF03.02GB
30
1 Engine 1.7.5 Cooling fan
1.7.5
page
Cooling fan
Fan belt, replacement (engine alternative Volvo)

1 Position the cab in the front position.
3 Remove the cover plates over the engine and radiator.
4 Release the tension on the fan belt and release the fan belt from
belt pulley on the belt tensioner.
5 Remove the fan belt.
6 Fit the new fan belt as illustrated.
The figure shows engine without cooling fan.
VDRF03.02GB
1 Engine 1.7.5 Cooling fan
page
31
Drive belt, extra water pump, replacement (engine

alternative Volvo TWD1240VE)
4 Release the tension on the fan belt.
5 Remove the drive belt.
6 Fit the new drive belt as illustrated.
The figure shows engine without cooling fan.
VDRF03.02GB
32
1 Engine 1.7.7 Coolant
Fan belt, replacement (engine alternative Cummins)
page

4 Loosen the belt tensioner.
5 Remove the fan belt.
6 Fit a new fan belt.
7 Tension the fan belt with the belt tensioner.
1.7.7
Coolant
Coolant, changing (engine alternative Volvo)
page
NOTE
Read the safety instructions for coolant before starting work, see
section B Safety.
2 Remove the cap on the expansion tank.
3 Place a receptacle under the radiator and engine. (The cooling
system holds about 40 l.)
004851
A. Location, expansion tank

B. Filling point
C. Level marking
VDRF03.02GB
33
4 Drain the cooling system.

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

6 Once all the coolant has drained out, close drain cocks.
7 Fill the new premixed coolant of the correct type in the expansion
tank. For volume and quality, see section F Technical data.
C AUTION
Different types of coolant cannot be mixed.
Risk of engine damage and damage to the
cooling system if different coolant types are mixed.
When changing and refilling the coolant the coolant
must be of the same type as was previously used.
8 Open the bleed nipple to release the air and speed up the filling.
Close the bleed nipple when clean coolant without air bubbles is
flowing out.
9 Turn on the main electric power and start the engine.
10 Turn on max. heat in the cab.
11 Run the engine to operating temperature so the thermostat
opens and coolant is pumped around the whole system.
12 Check the level in the expansion tank, fill if required.
13 Check the coolant level again after 10 operating hours.
VDRF03.02GB
34
Coolant, changing (engine alternative Cummins

QSM11)
page
NOTE
Read the safety instructions for coolant before starting work, see
section B Safety
2 Remove the cap on the expansion tank.
3 Place a receptacle under the radiator and engine. (The cooling
system holds about 40 l.)
004851
A. Location, expansion tank

B. Filling point
C. Level marking
4 Drain the cooling system.
Open the drain cock on the bottom of the radiator. Collect the
coolant in the receptacle.
VDRF03.02GB
1 Engine 1.7.10 Engine heater
35
5 Open the drain cock on the engine.

6 Once all the coolant has drained out, close drain cocks.
7 Fill the new premixed coolant of the correct type in the expansion
tank. For volume and quality, see section F Technical data.
C AUTION
Risk of engine damage and damage to the
cooling system if different coolant types are mixed.

9 Turn on max. heat in the cab.
2. Coolant filter
3. Oil filter
10 Run the engine to operating temperature so the thermostat

opens and coolant is pumped around the whole system.
11 Check the level in the expansion tank, fill if required.
12 Check the coolant level again after 10 operating hours.
1.7.10
page
Engine heater
Engine heater, description
See supplier documentation, engine.

A start-inhibitor function is available as an option coupled with the engine heater. The function is activated when the heater is running.
VDRF03.02GB
36
1 Engine 1.9 Engine control system
1.9
1.9.1
page
Engine control system

Control unit, engine
Engine control unit, general

See section 11 Common electrics, group 11.5.3.10 Engine control
unit and supplier documentation, engine.
VDRF03.02GB
1 Engine 1.11 Start/stop
1.11
1.11.1
page
37
Start/stop
Starter motor
Starter motor, description (engine alternative Volvo)

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 the engine
control unit (D794).
page

Cummins)
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,
frame rear (D797-R).
Control system , group 8.4.6.5 ENGINE, menu 5.
1.11.2
page
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 switch.
NOTE
The battery disconnect switch must not be used for emergency
stop!
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 and idling.
VDRF03.02GB
38
VDRF03.02GB
1 Engine 1.11.2 Stopping device
2 Transmission
2 Transmission
Table of Contents 2 Transmission

mm mm mm mm mm mm
2
Transmission.................................................................................................. 3
2.1
Controls and instruments ......................................................................... 21
2.1.1
Gear selector and multi-function lever ................................................. 21
2.2
Torque converter/Clutch system .............................................................. 22
2.2.1
Flex plates ........................................................................................... 22
2.6
Lubrication system ................................................................................... 26
2.6.3
Oil cooler .............................................................................................. 29
2.7
Cooling system ......................................................................................... 31
2.7.3
Oil cooler .............................................................................................. 31
2.8
Transmission control system .................................................................... 32
2.8.1
Control unit transmission ..................................................................... 32
2.8.2
Normally closed (NC) switch, disengagement ..................................... 32
2.8.3
Transmission cable harness ................................................................ 32
VDRF03.02GB
VDRF03.02GB
2 Transmission
2 Transmission 2 Transmission
mm mm mm mm mm mm
page
2 Transmission
Transmission, general
The workshop manual only describes components and work descriptions that concern installation in the machine. For descriptions of and
instructions for the transmissions components and systems, refer to
the supplier documentation.
References to component supplier documentation are only provided in
exceptional cases. If information about a component is not found, the
component supplier documentation should be used.
VDRF03.02GB
Transmission, function description

(transmission alternative Dana)
page
F
R
22
1
D1
5
D5
D22
6, 23
10, 16, 18, 20, 26

D12
D790-1
D790-2
D793
D794
D13
D795
D797-F
21
19
25
D24
D14
D15
D9
Pa
D8 8
Pa
24
15
12 13 14
17
11
002212
2, 7
Pos
Explanation
Signal description
Reference
The gear selector sends a voltage signal to the KIT control unit (D790-2).
Forward, Conn. F:
U = 24 V

Reverse, Conn. R:
U = 24 V

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

error code.
Section 11 Common electrics, group 11.5.3.11

KIT control unit
The transmissions oil pump pumps oil

when the engine is running.
The transmissions oil filter cleans the

oil from impurities.
The accelerator pedal transmits a signal to the cab control unit (D790-1).
U = 0.5-4.5 V
Section 1 Engine, group 1.1.2

Accelerator pedal
VDRF03.02GB
Pos
Explanation
Signal description
Reference
The cab control unit (D790-1) transmits the desired throttle application on
the CAN bus.

error code.

Cab control unit
The KIT control unit (D790-2) transmits the selected shifting program on
the CAN bus.

error code.

KIT control unit
The oil pressure sensor sends the

transmission control unit (D793) a
voltage signal proportional to oil pressure.
Checked by Control unit

transmission, error
shown with error code.

The engine speed and oil temperature

sensor (B758/766) sends the transmission control unit (D793) a pulse
signal with frequency proportional to
engine speed and a voltage signal
proportional to the transmission oil
temperature.

transmission, error
D9: Diagnostic menu, See Section 8 Control

system , group 8.4.7.6 TRANSM, menu 6 and
8.4.7.10 TRANSM, menu 10
10

supplies voltage to valve block transmission control to obtain desired function.

transmission, error

Transmission control unit
11
Solenoid valves for travel direction

and gear position in valve block transmission control activate gears in the
transmission and the engines power
is transmitted to the transmissions
output shaft.

transmission, error
12
The turbine speed sensor (B751)

sends the transmission control unit
(D793) a pulse signal with frequency
proportional to turbine speed.

transmission, error

system , group 8.4.7.6 TRANS, menu 6
13
The drum sensor (B752) sends the

pulse signal with frequency proportional to drum speed.

transmission, error

14
The output shaft speed sensor (B758)

proportional to output shaft speed.

transmission, error

15
The torque converter temperature

switch (S221) sends the transmission
control unit (D793) a voltage signal if
oil temperature in the torque converter
becomes too high.

transmission, error

VDRF03.02GB
Pos
Explanation
Signal description
Reference
16

controls gear shifting according to selected shifting program.

transmission, error

17
The oil cooler cools the transmission

oil. A thermostat senses the oils temperature and directs the oil back to the
transmission if the oil is cold.
Oil cooler, description page 31
18

transmits temperature and speed data
on the CAN bus.

error code.

19
The KID control unit (D795) shows

transmission information in operating
menus.

error code.

KID control unit
20
If the signal from the output shaft

speed sensor (B758) indicates that
machine speed exceeds the speed
limitation, the transmission control
unit (D793) transmits a engine speed

21
The engine control unit (D794) reduces engine speed.

Engine control unit
22
If the clutch pedal (S220-1) is depressed, it sends a voltage signal to

the cab control unit (D790-1).
U = 24 V

23
The cab control unit (D790-1) transmits disengage drive on CAN bus.

error code.

Cab control unit
24
Normally closed (NC) switch, disengagement (S220-2) sends the Control

unit, frame front (D797-F) a voltage
signal if brake pressure is high
enough to allow drive disengagement.
Brake pressure above

0.2 MPa:
Normally closed (NC) switch, disengagement,

description page 32
Conn 1, U = 24 V


Conn 2, U = 24 V
Brake pressure below
0.2 MPa:
Conn 1, U = 24 V
Conn 2, U = 0 V
25
Control unit, frame front (D797-F)

transmits disengagement approved
on the CAN bus.

error code.

Control unit, frame front
26

supplies voltage to valve block transmission control so that drive is disengaged.

transmission, error

VDRF03.02GB
Transmission, function description

(transmission alternative Dana full
flow)
page
F
R
30
D30
6, 31
12, 24, 26, 28, 34

D13
D8
8
Pa
1
D1
D5
D1
D790-1
D790-2
D793
D794
2, 7
29
D795
D797-F
D10
10 20 21 22
27
33
D32
Pa
Pa
23
32
D11
19
11
18
17
16
25
15
010494
14
13
Pos
Explanation
Signal description
Reference
The gear selector sends a voltage signal to the KIT control unit (D790-2).
Forward, Conn. F: U = 24 V
Reverse, Conn. R: U = 24 V

2

11.5.3.11 KIT control unit
The KIT control unit (D790-2) transmits

the selected direction of travel (forward
or reverse) on the CAN bus.
Checked by control system,

error shown with error code.
The transmissions oil pump pumps oil

when the engine is running.
The transmissions oil filter cleans the

oil from impurities.
The accelerator pedal transmits a signal to the cab control unit (D790-1).
U = 0.5-4.5 V
Section 1 Engine, group 1.1.2 Accelerator

pedal


VDRF03.02GB
Pos
Explanation
Signal description
Reference

the desired throttle application on the
CAN bus.


The KIT control unit (D790-2) transmits

the selected shifting program on the
CAN bus.


11.5.3.11 KIT control unit
Pressure sensor gear 1/3 (B6067)

(D793) a voltage signal proportional to
oil pressure.

transmission, error shown
with error code.

system , group 8.4.7.10 TRANSM,
menu 10

oil pressure.

with error code.

system , group 8.4.7.10 TRANSM,
menu 10
10
Sensor, engine speed (B7530) sends a

pulse signal with frequency proportional to the engine speed to Control unit,
transmission (D793).

with error code.
D10: Diagnostic menu, see section 8 Control system , group 8.4.7.6 TRANSM,
menu 6
11
The oil temperature sensor (B7660)

transmission oil temperature.

with error code.
menu 10
12

supplies voltage to the solenoid and
servo valves to obtain the desired function.

with error code.

11.5.3.9 Transmission control unit
13
Solenoid valve drive forward (Y6066F)

or Solenoid valve drive reverse
(Y6066R) and Servo valve gear forward/reverse (Y6300) are activated to
select the direction of travel.

with error code.
D13: Diagnostic menu, See Section 8 Control system , group 8.4.7.7 TRANSM, menu
7 , 8.4.7.8 TRANSM, menu 8 and 8.4.7.9
TRANSM, menu 9

with error code.
D10: Diagnostic menu, see section 8 Control system , group 8.4.7.6 TRANS, menu 6
14
15
16
17
18
19
Solenoid valve gear selection 1/3

(Y6075) and Servo valve gear 1/3
(Y6067) or Solenoid valve gear selection 2/4 (Y6074) and Servo valve gear
2/4 (Y6069) are activated to select gear
position.
The engines power is transferred to
the transmissions output shaft.
20
The turbine speed sensor (B7510)

proportional to turbine speed.
VDRF03.02GB
Pos
Explanation
Signal description
Reference
21
The drum sensor (B7520) sends the

pulse signal with frequency proportional to drum speed.

with error code.
menu 6
22
The output shaft speed sensor (B7580)

proportional to output shaft speed.

with error code.
menu 6
23
The torque converter temperature

switch (S2210) sends the transmission
control unit (D793) a voltage signal if oil
temperature in the torque converter becomes too high.

with error code.
menu 10
24

controls gear shifting according to selected shifting program.

with error code.

25
The oil cooler cools the transmission

oil. A thermostat senses the oils temperature and directs the oil back to the
transmission if the oil is cold.
26

transmits temperature and speed data
on the CAN bus.


27

transmission information in operating
menus.


28
If the signal from the output shaft speed

sensor (B7580) indicates that machine
speed exceeds the speed limitation,
transmits a engine speed reduction request on the CAN bus.
menu 6
29
The engine control unit (D794) reduces

engine speed.

30
If the clutch pedal (S220-1) is depressed, it sends a voltage signal to the

cab control unit (D790-1).
U = 24 V

disengage drive on CAN bus.

31
menu 1

VDRF03.02GB
10
Pos
Explanation
Signal description
Reference
32
Normally closed (NC) switch, disengagement (S220-2) sends the Control

unit, frame front (D797-F) a voltage signal if brake pressure is high enough to
allow drive disengagement.

0.2 MPa:
Normally closed (NC) switch, disengagement, description page 32
Conn 1, U = 24 V
menu 1
Conn 2, U = 24 V
0.2 MPa:
Conn 1, U = 24 V
Conn 2, U = 0 V
33

transmits disengagement approved on
the CAN bus.


11.5.3.2 Control unit, frame front
34

supplies voltage to valve block transmission control so that drive is disengaged.

with error code.

VDRF03.02GB
11
Transmission shifting, function

description (transmission
alternative Dana)
page
Fwd
2/4
11
13
Rev
1/3
15
RSP
38
8
10
12
16
14
5
37
39
17
36
18
19
20
23
24
Rev
35
VFS 1/3
VFS 2/4
1/3
25
26
2/4
33
Fwd
4:th
2:nd
27
28
Rev
29
3:rd
1:st
30
31
32
Pos
Explanation
Signal description
Reference
1.
Bottom strainer oil sump, separates particles

from the oil before the pumps.
2.
The transmissions oil pump 1 feeds the transmission with control pressure for control of the
transmission.
100.5 l/min at 1973 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 governor releases pressure to the

torque converter if the pressure becomes too
high.
Opening pressure: 2200

kPa
6.
The pressure reducer reduces the feed pressure

to servo pressure.
1200 kPa
7.
Solenoid valve neutral position (RSP) (Y6066)

controls Valve spool neutral position.
Diagnostic menu, see section 8

Control system , group 8.4.7.7
TRANSM, menu 7
008210
34
22
21
Fwd
VDRF03.02GB
12
Pos
Explanation
Signal description
Reference
8.
Valve spool neutral position opens or closes to

allow control pressure to the transmission.
9.
Solenoid valve drive forward (Y630) controls

Pressure booster drive forward.
0-600 kPa

TRANSM, menu 8 and 8.4.7.9
TRANSM, menu 9
10.
Pressure booster forward increases the pressure

and pressurises Drive clutch forward.
0-2000 kPa
11.
Solenoid valve gear 2/4 (Y6069) controls Pressure booster gear 2/4.
0-600 kPa

TRANSM, menu 9
12.
Pressure booster gear 2/4 increases the pressure and feeds Valve slide gear selection 2/4 as
well as Valve slide gear 2/4 control.
0-2000 kPa
13.
Solenoid valve drive reverse controls Pressure

booster drive reverse.
0-600 kPa

TRANSM, menu 9
14.
Pressure booster reverse increases the pressure

and pressurises Drive clutch reverse.
0-2000 kPa
15.
Solenoid valve 1/3 (Y6067) controls Pressure

booster gear 1/3.
0-600 kPa

TRANSM, menu 9
16.
Pressure booster gear 1/3 increases the pressure and feeds Valve slide gear selection 1/3 as
well as Valve slide gear 1/3 control.
0-2000 kPa
17.
Contact drive sends signal to the control unit to

verify that drive clutches for travel direction and
gear selection are activated when solenoid valve
neutral position (RSP) (Y6066) is activated.
18.
The drive control valve compares pressure signals from drive clutches for direction of travel and
gear selection and sends the pressure signal on
to the drive contact.
19.
The valve spool for reverse drive control opens

when the reverse drive clutch is pressurised and
leads a pressure signal to the drive control valve.
0-2000 kPa
20.
The valve spool for forward drive control opens

when the forward drive clutch is pressurised and
0-2000 kPa
21.
Solenoid valve VFS 2/4 (Y6074) controls servo

pressure to Valve slide gear selection 2/4.
1200 kPa

TRANSM, menu 7
VDRF03.02GB
13
Pos
Explanation
Signal description
Reference
22.
Solenoid valve VFS 1/3 (Y6075) controls servo

pressure to Valve spool gear selection 1/3.
1200 kPa

TRANSM, menu 7
23.
The valve slide for gear 1/3 control opens when

valve slide gear selection 1/3 is pressurised and
0-2000 kPa
24.
The valve slide for gear 2/4 control opens when

valve slide gear selection 2/4 is pressurised and
0-2000 kPa
25.
Valve slide gear selection 2/4 pressurises drive

clutch gear 2 or drive clutch gear 4.
0-2000 kPa
26.
Valve spool gear selection 1/3 pressurises Drive

clutch gear 1 or Drive clutch gear 3.
0-2000 kPa
27.
Drive clutch forward locks the transmission in forward drive when the clutch is pressurised.
28.
Drive clutch gear 2 locks the transmission in gear

position 2 when the clutch is pressurised.
29.

30.
Drive clutch reverse locks the transmission in reverse drive when the clutch is pressurised..
31.

32.

33.
The transmission oil pump pumps oil through the

cooler and supplies the torque converter with oil
pressure to run the machine.
85.1 l/min at 1973 rpm
34.
35.
The bypass valve in the filter bracket leads the oil

past the filter if the resistance through the filter
becomes too high.
36.
The oil is distributed to different lubrication points

in the transmission.
37.
The transmission oil cooler cools the oil.
38.
The torque converter transmits the engines

power to the transmission.
39.
The safety valve leads the oil back to the sump if

the pressure in the torque converter becomes
too high.
Opening pressure: 900 kPa
VDRF03.02GB
14
Transmission shifting, function

description (transmission
alternative Dana full flow)
page
30
28
5
6
27
11
29
26
25
Pa
18
12
19
13
8
3
22
Pa
24
17
16
31
23
Fwd
Rev
10
1st
14
2nd
3rd
20
15
21
013040
4th
Pos
Explanation
Signal description
Reference
Bottom strainer oil sump, separates particles

from the oil before the pumps.
The transmissions oil pump 1 feeds the transmission with control pressure for control of the
transmission.
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
The pressure governor releases pressure to

the torque converter if the pressure becomes
too high.
Servo valve front/rear (Y6300) controls pressure to Valve travel direction, proportional to
the desired traction.

TRANSM, menu 7
Solenoid valve drive forward (Y6066F) or Solenoid valve drive reverse (Y6066R) controls
Valve travel direction for drive forward or reverse.

TRANSM, menu 9
Depending on the solenoid valve activated,

Valve travel direction controls pressure to
drive clutch forward or drive clutch reverse.
VDRF03.02GB
15
Pos
Explanation
Signal description
Reference
The accumulator evens out the pressure.
Drive clutch reverse locks the transmission in

reverse drive when the clutch is pressurised..
Drive reverse: 2200-2600 kPa
10
Drive clutch forward locks the transmission in

forward drive when the clutch is pressurised.
Drive forward: 2200-2600 kPa
11
Servo Valve 1/3 (Y6067) controls pressure to

Solenoid valve gear selection gear 1/3
(Y6075) proportional to the desired engagement force.

TRANSM, menu 9
12

(Y6075) pressurises Drive clutch gear 1 or
Drive clutch gear 3.

TRANSM, menu 7
13
14
Drive clutch gear 1 locks the transmission in

gear position 1 when the clutch is pressurised.
Gear selected: 2200-2600 kPa
15

16
Pressure sensor gear 1/3 (B6067) sends the

transmission control unit (D793) a voltage signal proportional to engagement pressure.

TRANSM, menu 10
17
Servo Valve 2/4 (Y6069) controls pressure to

(Y6075) proportional to the desired engagement force.

TRANSM, menu 9
18

(Y6074) pressurises Drive clutch gear 1 or
Drive clutch gear 3.

TRANSM, menu 7
19
20

21

22
Pressure sensor gear 2/4 (B6069) sends the

transmission control unit (D793) a voltage signal proportional to engagement pressure.

TRANSM, menu 10
23
The transmission oil pump pumps oil through

the cooler and supplies the torque converter
with oil pressure to run the machine.
24
25
The bypass valve in the filter bracket leads the

oil past the filter if the resistance through the
filter becomes too high.
VDRF03.02GB
16
Pos
Explanation
Signal description
Reference
26
The oil is distributed to different lubrication

points in the transmission.
27
The transmission oil cooler cools the oil.
28
The torque converter transmits the engines

power to the transmission.
29
The safety valve leads the oil back to the

sump if the pressure in the torque converter
becomes too high.
30
The torque converter temperature switch

(S2210) sends the transmission control unit
(D793) a voltage signal if oil temperature in
the torque converter becomes too high.

TRANSM, menu 10
31
The oil temperature sensor (B7660) sends the

transmission control unit (D793) a voltage signal proportional to oil temperature.

TRANSM, menu 10
VDRF03.02GB
17
Transmission, component location

page
2
1
5
9
10
8
11
14
13
006768
12
15
1.
Power take-off
9.
Engine rpm and oil temperature sensor (B758/766)

(from radiator to sump)
2.
Transmission oil dipstick and filler orifice
10.
Temperature switch, torque converter (S221)
3.
Thermostat
11.
Turbine speed sensor (B751)
4.
12.
Sensor, drum rpm (B752)
5.
Oil pump transmission
13.
Oil filter transmission
6.
Gearbox
14.
Sensor rpm output shaft (B758)
7.
Valve block transmission control
15.
Output shaft
8.
Torque converter
VDRF03.02GB
18
11
6
10
9
006752
1.
Accelerator pedal (B690)
7.
Transmission control unit (D793)
2.
Control unit KIT (D790-2)
8.
Diagnostic socket, transmission
3.
Control unit KID (D795)
9.
Declutch pedal (S220-1)
4.
Multi-function lever (S162)
10.
NO switch, declutch (S220-2)
5.
Control unit cab (D790-1)
11.
Control unit frame front (D797-F)
6.
Control unit frame rear (D797-R)
VDRF03.02GB
19
Transmission, component location

(transmission alternative Dana full
flow)
page
18
19
20
21
25
24
17
9
23
16 15 14 13 12 11
10
8
013433
22
1.
Power take-off
14.
Servo valve gear 2/4 (Y6069)
2.
Dipstick
15.
Solenoid valve gear selection 2/4 (Y6074)
3.
Filling of transmission oil
16.
Solenoid valve drive reverse (Y6066R)
4.
Thermostat
17.
Torque converter
5.
18.
Sensor engine speed (B7530)
6.
Oil pump transmission
19.
Temperature switch, torque converter (S2210)
7.
Gearbox
20.
Turbine speed sensor (B7510)
8.
Solenoid valve drive forward (Y6066F)
21.
Sensor, drum rpm (B7520)
9.
Servo valve gear forward/reverse (Y6300)
22.
10.
Servo valve gear 1/3 (Y6067)
23.
Sensor rpm output shaft (B7580)
11.
Solenoid valve gear selection 1/3 (Y6075)
24.
Sensor oil temperature (B7660) (from radiator to sump)
12.
25.
Output shaft
13.
VDRF03.02GB
20
11
6
10
9
006752
1.
Accelerator pedal (B690)
7.
2.
8.
Diagnostic socket, transmission
3.
9.
Declutch pedal (S220-1)
4.
10.
NO switch, declutch (S220-2)
5.
11.
6.
page

separation
Engine alternative Volvo: see section 1 Engine , group 1 Engine and
transmission separation (Engine alternative Volvo).
Engine alternative Cummins: see section 1 Engine , group 1 Engine
and transmission separation (Engine alternative Cummins).
VDRF03.02GB
2 Transmission 2.1 Controls and instruments
2.1
2.1.1
21

Gear selector and multi-function
lever
Gear and multi-function lever, description
page
Travel direction is selected with the gear and multi-function lever.
Selection of travel direction:
F Forward
N Neutral
R Reverse
002209
The switch is supplied voltage by and sends signals to the KIT control
unit (D790-2).
Control system , group 8.4.7.2 TRANSM, menu 2.
VDRF03.02GB
22
2 Transmission 2.2 Torque converter/Clutch system
2.2
2.2.1
page
Torque converter/Clutch
system
Flex plates
Flex plates, replacement (engine alternative Volvo)

2 Remove the cover plate for the flywheel.
3 Remove the bolts for the flex plate.
VDRF03.02GB
2 Transmission 2.2.1 Flex plates
23
4 Turn the engine for each bolt to be removed from 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.
VDRF03.02GB
24
8 Remove the bolts holding the flex plate to the transmission.

9 Replace the flex plate.
10 Fit in the reverse order. Fit the attaching bolts with 40 Nm.
11 Before the machine is put into operation, the transmission must
be calibrated; see Transmission, calibration page 32.
Flex plate attachment.

page
Flex plates, replacement (engine alternative

Cummins QSM11)
2 Remove the cover plate.
3 Remove the bolts for the flex plate.
4 Turn the engine for each bolt to be removed from the flex plate.
5 Attach the transmission to an overhead crane.
6 Remove the bolts holding together the transmission and engine.
VDRF03.02GB
25
7 Carefully separate the transmission and engine.
8 Remove the bolts holding the flex plate to the transmission.

9 Replace the flex plate.
10 Fit in the reverse order. Fit the attaching bolts with 40 Nm.
11 Before the machine is put into operation, the transmission must
be calibrated; see Transmission, calibration page 32.
Flex plate attachment.
VDRF03.02GB
26
2 Transmission 2.6 Lubrication system
2.6
page
Lubrication system
Lubrication system, description

The transmission lubricating system has the following function:
Lubricate gear wheel 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 transmissions oil sump through a strainer, and it then pumps it through two
oil filters to a control valve.
The control valve supplies oil at the correct pressure to the transmissions valve housing to activate the clutch plates for FORWARD or
REVERSE and gear 1, 2, 3 or 4. 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.
page
Oil and oil filter, changing
NOTE
Read the safety instructions for oil before working, see section B
Safety.
NOTE
The transmission must not be over filled!
1 Operate and warm up the transmission oil.
3 Remove the drain plug for transmission oil and let the oil drain
into the receptacle.
Draining transmission oil
VDRF03.02GB
27
4 Change oil filter.

Moisten the O-ring of the new oil filters with transmission oil.
Tighten until it makes contact and then another two-thirds of a
turn.
5 When the transmission oil has drained, fit the drain plug.
Make sure that the washer for the oil plug is included.
6 Fill with new transmission oil through the filler orifice (position B).
For volume and grade, see section F Technical data.

7 Start the engine and allow it to idle for at least two minutes.
8 Check that the transmission oil drain plug is airtight.
9 Check the transmission oil level with the engine running at idle
and top up to the marking for low level.
013334
A. Location of filler orifice and level control

B. Filling
C. Dipstick
10 Warm up the transmission so that the display shows an oil temperature between 60-65 C. Use the oil temperature operating
menu to check transmission oil temperature.
a
b
000356
11 Check the oil level. Fill to the MAX mark.
Operating menu, oil temperature

a. Transmission oil temperature
b. Hydraulic oil temperature
VDRF03.02GB
28
Oil level, check
page
NOTE
Safety.
The transmissions oil filler pipe and dipstick (position B) are located
under the service hatch in front of the cab.
1 Check the oil level with the engine at idle, transmission in neutral
position and at operating temperature (approx. 60-65 C in the
display). The dipstick has two markings, MAX and MIN. The oil
level should be at MAX.
Wipe off the dipstick before checking.
NOTE
The oil dipstick is long. Wear gloves.
013334
2 Fill transmission oil (position B) if required (for volume and grade,

see section F Technical data).
A. Location of filler orifice and level control

B. Filling
C. Dipstick
VDRF03.02GB
Fill wait a moment check the dipstick.
NOTE
Work carefully when filling transmission oil to prevent other
fluids or particles from contaminating the oil, which means
risk of transmission damage.
2 Transmission 2.6.3 Oil cooler
2.6.3
29
Oil cooler
Oil cooler, description
page
The transmission oil is cooled in the lower section of the cooling 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
working temperature. This means that the oil reaches normal working
temperature more quickly.
For more detailed information, see supplier documentation, transmission.
5
4
Cooling unit, engine alternative Cummins QSM11 and

Volvo TAD1250VE
1. Intercooler
2. Radiator, engine
4
3
003214
003215
Cooling unit, engine alternative Volvo TWD1240VE

1. Radiator, engine
VDRF03.02GB
30
2 Transmission 2.6.3 Oil cooler
Thermostat transmission oil cooler, changing
page
NOTE
Safety.
2 Drain the oil from the transmission, see Oil and oil filter, changing
page 26.
3 Loosen the cover plug and remove the thermostat.
4 Check the O-ring and the spring in the bottom, change as needed.
007447
5 Install the new thermostat, and the cover plug.
I M P OR TA NT
It is very important that the thermostat is used with
the temperature bulb facing out as shown.
6 Fill with transmission oil; see Oil and oil filter, changing page 26.
7 Start the engine and check for leaks.
8 Check the transmission oil level; see Oil level, check page 28.
VDRF03.02GB
2 Transmission 2.7 Cooling system
2.7
2.7.3
page
31
Cooling system
Oil cooler

See Oil cooler, description page 29.
VDRF03.02GB
32
2 Transmission 2.8 Transmission control system
2.8
Transmission control system
Transmission, calibration
page
See section 8 Control system, group 8.5.2.3 Calibrate DRIVE-TRAIN.
2.8.1
Control unit transmission
Transmission control unit, general
page
See section 11 Common electrics , group 11.5.3.9 Transmission control unit and Supplier documentation.
2.8.2
Normally closed (NC) switch,

disengagement
Normally closed (NC) switch, disengagement,

description
page
10
1
1
2
3
3
5
The NC switch for disengagement detects if the wheel brakes are

pressurised. The NC switch is located on the distribution block for the
brake system, above the drive axles differential.
The sensor can be checked from the diagnostic menu, see section 8
Control system , group 8.4.7.1 TRANSM, menu 1.
4
5
6
000439
1. Brake cooling connection, return from wheel brake

2. Brake cooling connection, return to cooler and tank
3. Brake cooling connection, to wheel brake
4. Brake cooling connection from accumulator charging valve
5. Brake cylinder connection, to wheel brake
6. Brake pressure connection, from brake valve
7. NO switch, declutch (S220)
8. NO switch, brake lights (S216)
9. Measuring outlet, brake pressure
10. Measuring outlet, brake cooling back pressure
2.8.3
page
Transmission cable harness
Transmission cable harness, description

See section E Schematics.
VDRF03.02GB
3 Driveline/axle
3 Driveline/axle
Table of Contents 3 Driveline/Axle

mm mm mm mm mm mm
3
3.2
3.3
Driveline/axle .................................................................................................. 3
Propeller shaft ............................................................................................ 3
Drive axle ................................................................................................... 4
VDRF03.02GB
VDRF03.02GB
3 Driveline/axle
3 Driveline/axle
mm mm mm mm mm mm
3 Driveline/axle
3.2
page
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.
page
Propeller shaft, replacement

2 Clean the contact surfaces (cross-toothed) on the drive axle and
transmission.
3 Fit the propeller shaft in position with the coupling upward.

4 Fit the propeller shaft attaching bolts.
Tightening torque 156 Nm. Retighten the attaching bolts after
50 hours of operation.
VDRF03.02GB
3 Driveline/axle 3.3 Drive axle
3.3
page
Drive axle
Drive axle, general

The workshop manual only describes components and work descriptions related to installation in the machine. Please refer to the component supplier documentation for descriptions and instructions of drive
axle components and systems.
References to supplier documentation are only used in exceptional
cases. If information about a component is missing, use the supplier
documentation.
page
Drive axle, replacement
D ANGER
Drive axle and machine are very heavy.
Risk of pinch injury!
Do go under a machine which has been lifted by a jack
etc under any circumstances. For machine weights,
please refer to section F Technical data
1 Park the machine with blocks behind the steering wheels.

2 Depressurise the brake and hydraulic systems, see section
B Safety.
power.
4 Install wedges between the steering axle and frame.
VDRF03.02GB
5 Disconnect hydraulic hoses (position 1) and cabling (position 2)

from the distribution block.
NOTE
Plug all unions at once to protect the hydraulic system from
contamination.
004501
2
1. Hydraulic hoses
2. Cables
6 Remove the casing (position 3) on the parking brake.
004505
3. Casing parking brake

7 Loosen the lock nut (position 4) and screw in the screw
(position 5), this compresses the brake spring. Screw until the
brake pads release from the brake disc. Reinstall the casing on
the parking brake (position 3).
8 Disconnect the hydraulic hose (position 6) from the parking

brake.
NOTE
contamination.
004506
4. Lock nut
5. Release screw
6. Hydraulic hose, parking brake
VDRF03.02GB
9 Disconnect the propeller shaft from the drive axle. Secure the
propeller shaft, otherwise there is a risk that it will be pulled apart.
Securing propeller shaft.

10 Lift the machine so that the wheels are off the ground.
11 Remove the drive wheels from the drive axle.
12 Block up the drive axle under the hubs.
C AUTION
The drive axle may start to roll.
Crushing injury!
Make sure that the drive axle does not roll away when
not under control.
Lifting the machine
13 Remove the bolts that secure the drive axle in the frame.
14 Lift away the drive axle.
C AUTION
Crushing injury!
not under control.
15 Transfer parts from the old drive axle to the new one.
Attaching bolts, drive axle
NOTE
contamination.
16 Clean the contact surfaces on the drive axle and frame. Also
clean the bolts contact surface on the underside of the drive axle.
VDRF03.02GB
17 Remove the nuts for attaching the drive axle, blow clean and reinstall the nuts.
18 Transfer the guide pins from the old axle to the new axle.
19 Lift the drive axle into place under the frame.
C AUTION
Crushing injury!
not under control.
20 Lower the frame toward the drive axle. Check that the guide pins
fit in the frame.
21 Fit the new bolts that secure the drive axle in the frame. Tighten
the bolts to a torque of 2820 Nm.
22 Install the drive wheels on the new axle.
23 Rustproof the bolts with suitable paint.
24 Connect hydraulic hoses (position 1) and cabling (position 2) to

the distribution block on the drive axle.
25 Connect the hydraulic hose to the parking brake, adjust the parking brake.
26 Connect the drive shaft to the drive axle, tighten the bolts to a
torque of 156 Nm. (Retighten the attaching bolts after 50 hr operating time).
27 Check the oil level in the drive axle.
28 Start the machine and bleed the brakes; see section 4 Brakes,
group 4.3.9 Wheel brake.
004501
29 Check for leaks.
VDRF03.02GB
VDRF03.02GB
4 Brakes
4 Brakes
Table of Contents 4 Brakes

mm mm mm mm mm mm
4
Brakes ............................................................................................................. 3
4.1
Controls and instruments ........................................................................... 3
4.1.1
Brake pedal ............................................................................................ 3
4.3
Power-assisted brake system .................................................................... 5
4.3.1
Brake fluid pump .................................................................................... 7
4.3.2
Brake fluid filter .................................................................................... 12
4.3.3
Accumulator charging valve ................................................................. 13
4.3.4
Accumulator ......................................................................................... 16
4.3.5
Brake valve .......................................................................................... 20
4.3.6
Drive axle block ................................................................................... 24
4.3.7
NC switch, brake fluid pressure ........................................................... 25
4.3.8
NO (normally open) switch, brake lights .............................................. 26
4.3.9
Wheel brake ......................................................................................... 28
4.3.10
Pipes and hoses .................................................................................. 30
4.5
Parking brake system ............................................................................... 31
4.5.1
Brake fluid pump .................................................................................. 32
4.5.2
4.5.3
M-valve parking brake ......................................................................... 33
4.5.4
Parking brake unit ................................................................................ 34
4.5.5
Parking brake NC switch ..................................................................... 37
4.5.6
Pipes and hoses .................................................................................. 37
4.8
Temperature control, cleaning and brake oil ............................................ 38
4.8.1
Brake fluid tank .................................................................................... 39
4.8.2
Tank heater .......................................................................................... 40
4.8.3
Brake fluid pump .................................................................................. 40
4.8.4
Accumulator charging valve ................................................................. 40
4.8.5
Drive axle block ................................................................................... 40
4.8.6
Wheel brake ......................................................................................... 40
4.8.7
Oil cooler .............................................................................................. 41
4.8.8
Cooling fan ........................................................................................... 42
4.8.9
Thermal bypass valve .......................................................................... 42
4.8.10
Sensor brake oil temperature .............................................................. 43
4.8.11
Breather filter ....................................................................................... 44
4.8.12
4.8.13
Pipes and hoses .................................................................................. 46
4.8.14
Brake system fluid ............................................................................... 46
VDRF03.02GB
VDRF03.02GB
4 Brakes
4 Brakes
4 Brakes
mm mm mm mm mm mm
4.1
4.1.1

Brake pedal
Brake pedal, checking and adjusting
page
1 Clean the floor round the brake pedal and check that nothing is
obstructing the movement of the brake pedal.
2 Check that the brake pedal springs back adequately and that the
clearance between brake pedal and brake valve is 11.5 mm. If
needed, adjust the brake pedals stop bolt to correct clearance.
3 Check that the pedal moves easily.
Stop screw for adjusting clearance between brake

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

shows a loose brake pedal.)
page
Brake pedal, replacement
NOTE
Read the safety instructions for oil before working, see section
B Safety.
1 Turn off the engine and the main electrical power.
B Safety.
3 Detach the brake valve from the brake pedal.
Secure the brake valve on the cabs underside and remove the
brake valve attaching bolt.
VDRF03.02GB
4 Brakes 4.1.1 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 bracket.

Secure the steering valve on the cabs underside. Remove the
steering valves attaching bolts. Pull down the valve slightly so
that the steering axle releases from the steering valve.
6 Detach the steering wheel shaft from the brake pedal.
Undo the bolts and pull the steering wheel shaft up slightly so that
the brake pedal can be removed.
7 Detach the clutch-release pedal from the brake pedal.
8 Remove the brake pedal.
Remove the brake pedals attaching bolt and lift away the brake
pedal.
Mounting of steering wheel shaft and steering valve in
pedal bracket.
9 Transfer the pedal rubber to the new pedal.

10 Fit the new brake pedal.
Fit the pedal and fit the pedals 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 the drain valve on the accumulator charging valve.
NOTE
Check that the accumulator drain valve is fully closed and
tighten the lock ring.
15 Grease and adjust the brake pedal, see Brake pedal, checking
and adjusting page 3.
VDRF03.02GB
4 Brakes 4.3 Power-assisted brake system
4.3
Power-assisted brake system
Power assisted brake system, function

description
page
13
D790-2
B
P
D10
10
D797-R
D797-F
9, 12
11
C5
Pa
D8
D11
C3
Pa
7
ACC
C1
3
P
1
006401
B
Pos
Explanation
Signal description
Reference
The brake fluid pump pumps fluid from

the brake fluid tank.
P = 20.5 1.0 MPa
Brake fluid tank, description page 39
The brake oil filter cleans the oil.
Brake fluid filter, description page 45
The accumulator charging valve directs

oil to charging of accumulators or
through the brake system's cooling
circuit.
Accumulator charging valve, description

page 13
The accumulators store oil pressure.
See the pressure plate, Accumulator pressure brake

system, on the left-hand
frame member.
Accumulator, description page 16
The brake valve directs pressure from

the accumulators to the brake cylinders
proportional to pressing of the pedal.
Brake valve, description page 20
Brake fluid pump, description page 7
VDRF03.02GB
4 Brakes 4.3 Power-assisted brake system
Pos
Explanation
Signal description
Reference
The brake cylinders compress the discs

in the brake unit.
See the pressure plate,

Brake pressure, on lefthand frame member.
Wheel brake, description page 28
The wheel brakes brake the machine.
The brake light NO switch (S216) closes

the circuit when the brake cylinders are
pressurised.

0.2 MPa:
Switch normally open (NO), brake lights,

description page 26
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
0.2 MPa:
Conn 1, U = 24 V
Conn 2, U = 0 V
9
Control unit, frame front (D797-F) transmits the brake light request on the CAN
bus.


10
The brake lights are activated by Control

unit, frame rear (D797-R).
U = 24 V
Section 9 Frame, body, cab and accessories, group 9.6.4 Brake lights
Control system , group 8.4.2.11 LIGHTS,
menu 11
11
NC switch, brake oil pressure (S204)

opens the circuit if the pressure in the
accumulators is low.

11.5 MPa:
NC switch, brake oil pressure, description

page 25
Conn 1, U = 24 V
D11: Diagnostic menu, see section

8 Control system , group 8.4.5.4 HYD,
menu 4
Conn 2, U = 24 V
11.5 MPa:
Conn 1, U = 24 V
Conn 2, U = 0 V
12
Control unit, frame front (D797-F) transmits a warning about low brake pressure
on the CAN bus.


13
Control unit KIT (D790-2) activates

Warning light brake pressure.


Hydraulic diagram, basic machine
VDRF03.02GB
4 Brakes 4.3.1 Brake fluid pump
4.3.1
Brake fluid pump
Brake fluid pump, description
page
The brake system has a gear pump with fixed displacement. The
brake oil pump is fitted at the front of the left-hand main pump. The
pump generates hydraulic power, which is stored in the accumulators
for brake force to the power-assisted brake and parking brake. It also
generates the oil flow used for cleaning and cooling. The switchover
between power generation and flow is regulated by the accumulator
charging valve, see Accumulator charging valve, description page 13.
The brake oil pump is driven by the main pumps shaft from gearbox
power take-off. The brake oil pumps speed is directly dependent on
engine speed. The pump flow rate increases with engine speed and
varies with the speed of the input shaft.
2
1. Brake fluid pump
2. Pump cooling and filtering, working hydraulics
page
000006
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 pumps power output.
Brake fluid pump, check
NOTE
Safety.
Checking pump pressure

1 Operate and warm up the machine so that the oil in the brake system reaches operating temperature, at least 50 C.
2 Machine in service position, see section B Safety
B Safety.
4 Connect a pressure gauge (025 MPa) to the pump pressure
measuring outlet on the accumulator charging valve.
5 Start the engine and run it at idling speed.
Measuring outlet, pump pressure
VDRF03.02GB
6 Close the drain valve on the accumulator charging valve and

check the pump pressure during charging.
During charging the pressure should increase to 20.5 1.0 MPa
before the accumulator charging valve switches to cooling. When
the accumulator charging valve switches to cooling, the pressure
drops.
7 Check the pressure during cooling.
During cooling the pressure should be max. 1.01.5 MPa at max.
engine rpm.
8 Stop the engine
Close the accumulator charging valve

B Safety.
10 Remove the pressure gauge and fit the protective cap on the
measuring outlet.
Checking accumulator charging

B Safety.
13 Connect a pressure gauge (025 MPa) to the measuring outlet
for accumulator pressure on the accumulator charging valve.
16 Check that the pressure increases slowly to 20.5 1.0 MPa.
17 Brake repeatedly and check at which pressure the accumulator
charging valve switches to charging.
The valve must switch to cooling at 15.5 0.5 MPa.
Measuring outlet, accumulator pressure

B Safety.
measuring outlet.
NOTE
VDRF03.02GB
page
Brake oil pump, replacement (hydraulic oil pump

alternative Rexroth)
NOTE
B Safety.
B Safety.
3 Mark up and detach the hydraulic hoses from the pump.
NOTE
Plug all connections immediately to protect the brake
system from impurities.
4 Remove the attaching bolts, pull the pump out backwards and lift
it away.
5 Transfer the connection adapters and the contact to the new
pump.
6 Remove the spacer ring from the brake pump or hydraulic oil
pump.
Clean the O-rings contact surfaces on the spacer ring.
7 Check the O-rings and replace as required. Install the O-rings on
the spacer ring. Brush sealing silicone on the sealing face against
the brake pump, see section F Technical data.
NOTE
Only use silicone on the side facing the brake pump.
VDRF03.02GB
10
8 Fit the spacer ring on the main pump.
9 Brush sealing silicone on the brake pumps sealing face against

the spacer ring; see section F Technical data.
10 Fit the brake pump on the main pump.
Fir the pump and check that the gear engages in the shaft and
that the spacer ring is directly against the brake pump.
Fit the pumps attaching bolts.
11 Connect the hydraulic hoses to the brake pump.
NOTE
Check that the O-rings are intact and are fitted correctly.
NOTE
VDRF03.02GB
11
14 Check that the hose connections and seal between the hydraulic
oil pump and brake pump are fully sealed.
Check the feed pressure from the brake pump, see Brake fluid
pump, check page 7.
15 Check the oil level in the brake system, fill as necessary.
NOTE
If the pump is replaced due to malfunction, change the oil
and filter in the brake system as well.
page
Brake oil pump, replacement (hydraulic oil pump

alternative Sauer-Danfoss)
NOTE
B Safety.
1 Machine in service position, section B Safety.
B Safety.
NOTE
Plug all connections immediately to protect the brake system from impurities.
it away.
pump.
VDRF03.02GB
12
4 Brakes 4.3.2 Brake fluid filter
6 Brush sealing silicone on the brake pumps sealing face; see

section F Technical data.
Position the pump and check that the pumps splines engage in
the shaft in the main pump.
NOTE
NOTE
11 Check that the hose connections and seal between the hydraulic
oil pump and brake pump are fully sealed.
Check the feed pressure from the brake pump, see Brake fluid
pump, check page 7.
NOTE
and filter in the brake system as well.
4.3.2
page
Brake fluid filter
Brake fluid filter, general

See Brake fluid filter, description page 45.
VDRF03.02GB
4 Brakes 4.3.3 Accumulator charging valve
4.3.3
page
13
12
11
10
000431
1. Safety valve
2. Connection from pump (P)
3. Wheel brake connection (T)
4. Measuring outlet, pump pressure (P)
5. Measuring outlet, accumulator pressure (M)
6. Solenoid valve parking brake (Y642)
7. NC switch, parking brake (GHB) (S200)
8. Connection, accumulators (ACC)
9. NC switch, brake fluid pressure (LB) (S204)
10. Connection, parking brake caliper (HB)
11. Drain valve
12. Main valve, charging
13. Pressure limiting valve
The accumulator charging valve distributes oil from the hydraulic oil
pump between pressure storage and cooling of the wheel brakes. The
accumulator charging valve is fitted on the beam in front of the gearbox in the engine compartment.
The accumulator charging valve stores pressure by guiding the oil to
the accumulators. The wheel brakes are cooled by oil being guided to
the drive axle cooling circuit and then on to the brake system cooler.
The accumulator charging valve prioritises charging of the accumulators above cooling. A restriction of the charging means that a small
quantity of oil also flows to cooling during accumulator charging. At
idling speed the flow from the pump is so small that all oil flows to pressure storage.
The drain valve (position 11) is used to relieve the pressure in the accumulators to the tank. The valve opens a connection between the accumulators and the wheel brakes cooling circuit. The oil is drained
through the wheel brake to the tank.
page
13
There is a measuring outlet for measuring the accumulator pressure

(position 5) and pump pressure (position 4) on the accumulator charging valve. The pressures are individual to each machine and each are
specified on the pressure plate on the left-hand frame member, see
section 10 Common hydraulics. The accumulator charging valve also
houses the parking brake solenoid valve (position 6), brake fluid pressure NC switch (position 9) and parking brake NC switch (position 7).
Solenoid valve parking brake, description page 33
NC switch, brake oil pressure, description page 25
Parking brake NC switch, description page 37
Accumulator charging, checking and adjustment
NOTE
B Safety.
2 Check accumulator charging; see Brake fluid pump, check page
7.
VDRF03.02GB
14
3 If necessary, adjust the accumulator charging pressure on the

pressure limiting slide.
Undo the lock nut and adjust the pressure by turning the adjusting
screw.
Clockwise: reduce pressure.
Counter-clockwise: increase pressure.
4 Open the drain valve on the accumulator charging valve so that
the accumulators are drained and the valve switches to charging.
Close the valves and check the max. pressure again.
5 Repeat steps 3 and 4 until the pressure is correct.
Adjusting screw accumulator charging pressure
NOTE
page
Accumulator charging valve, replacement
NOTE
B Safety.
B Safety.
3 Mark up hydraulic hoses and electric cables.
4 Detach the wiring from the accumulator charging valve.
5 Detach and plug all hydraulic hoses from the accumulator
charging valve.
Remove the parking brake valve (C) for easier access.
NOTE
VDRF03.02GB
15
6 Remove the accumulator charging valve.

7 Transfer the connection adapters and sensors to the new accumulator charging valve.
8 Fit the new valve.
9 Connect the hoses to the accumulator charging valve in accordance with the marking.
NOTE
10 Fit the parking brake valve and NC switch parking brake.
11 Connect the wiring to the accumulator charging valve.
NOTE
Check that the hydraulic connections are sealed tightly.
14 Check the charging and changing function, see Accumulator
charging, checking and adjustment page 13.
VDRF03.02GB
16
4 Brakes 4.3.4 Accumulator
4.3.4
Accumulator
Accumulator, description
page
The accumulators store pressure so that there is a pressure reserve

in the event of engine or brake system malfunction. The brake system
has four accumulators connected in parallel. These are fitted at the
front in the engine compartment, above the drive axle.
The accumulators are of the diaphragm type. Each accumulator is divided into two spaces 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.
000001
The accumulator has test outlets for checking the gas pressure on the
opposite side to the pressure connection.
page
Accumulator, checking
NOTE
B Safety.
B Safety.
3 The accumulators can be tested with separate test equipment or
in the machine. Primarily, separate test equipment should be
used since it is faster and more accurate.
Test equipment can be ordered from Cargotec.
VDRF03.02GB
Check with test equipment: continue with step 4.
Check in machine: continue with step 6.
17
Checking with test equipment

4 Remove the accumulators and test them with the intended test
equipment.
The accumulators gas pressure should match with the pressure
plate.
5 Continue with step 17.
MPa
MPa
MPa
MPa
MPa
MPa
MPa
MPa
MPa
920643.0024
001031
MPa
Pressure plate, gas pressure brake accumulators
Checking in machine
6 Detach three of the accumulators from the distribution block. Plug
the distribution block connections with plugs that can withstand
high pressure. Plug the connections on the accumulators to protect against contamination.
for accumulator pressure on the accumulator charging valve.
charge the accumulator until the accumulator charging valve
changes to cooling.
10 Check that the plugs seal properly.
11 Stop the engine
12 Lower the pressure by means of braking carefully several times
while checking the pressure on the pressure gauge.
When the pressure reaches approx. 10 MPa the pressure must
decrease immediately to 0 MPa.
If the pressure drops immediately when the engine is shut off,
then the accumulator does not have any pre-charge pressure.
This indicates internal leakage and the accumulator must be
changed.
If the pressure can be reduced slowly to a pressure below
10 MPa then the precharge pressure is too low and the
accumulator must be replaced or given to authorised personnel
for maintenance.
VDRF03.02GB
18

B Safety.
14 Mark up and disconnect the tested accumulator. Plug the
connections. Connect one of the other accumulators to the
distribution block.
15 Repeat steps 8 - 14 until all accumulators have been checked.
B Safety.
Installing and final checking

17 Connect all accumulators to the distribution blocks. If needed,
replace or fill defective accumulators.
NOTE
Check that the seals are intact and are fitted correctly.
NOTE
20 Check that the accumulators connections are sealed tightly.
21 When the accumulators are fully charged, shut off the engine and
turn the start key to position I.
22 Check that at least 8 brake applications (pedal depressions) can
be performed before the pressure drops to 10 MPa.
At 11.5 MPa the warning lamp for low brake pressure must come
on.
page
Accumulator, replacement
NOTE
B Safety.
B Safety.
VDRF03.02GB
19
4 Detach the accumulators clamp and remove the bolt.

5 Detach the accumulator from the distribution block.
NOTE
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.
NOTE
Check that the seal is intact and is fitted correctly.
8 Secure the accumulators clamp and tighten the bolt.
VDRF03.02GB
20
4 Brakes 4.3.5 Brake valve
NOTE
11 Check that the accumulator's connection is sealed tightly.
12 Check precharging and function, see Accumulator, checking
page 16 steps 18-19.
4.3.5
Brake valve
Brake valve, description
page
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.
1
2
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).
000013
1. Inlet from accumulator [P]

2. Return connection [T]
3. Outlet to brake cylinders [B]
page
Brake valve, checking
NOTE
B Safety.
1 Operate and warm up the machine so that the brake fluid reaches
operating temperature, at least 50 C.
B Safety.
VDRF03.02GB
21
4 Connect a pressure gauge (0-25 MPa) to the measuring outlet for

brake pressure on the distribution block on the front axle.
6 Start the machine and run it at idling speed until the accumulators
are charged and the accumulator charging valve changes to
cooling.
7 Press down the pedal completely and read off the pressure.
Compare to the pressure plate on the left frame member.
8 Stop the engine
9 Depress the pedal fully and keep it pressed down, check the
pressure.
The brake pressure must correspond with the value specified on
the pressure plate and must not decrease from this value for
15 seconds.
MPa
10 Release the pedal, the brake pressure must decrease to 0 MPa

immediately. Otherwise the brake valve is not sealed and can
cause the brakes to remain applied and then overheat during
operation.
MPa
MPa
MPa
MPa
MPa
Replace the brake valve if it is not sealed.
MPa

B Safety.
MPa
MPa
008214
MPa
measuring outlet.
NOTE
VDRF03.02GB
22
page
Brake valve, replacement
NOTE
B Safety.
1 Slide the cab forward slightly so that the brake valve is accessible
under the cab.
B Safety.
4 Mark up and detach the hydraulic hoses from the brake valve.
NOTE
Plug the connections immediately to protect the brake system from impurities.
5 Secure the brake valve under the cab.
6 Remove the brake valve attaching bolt.

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

with the marking.
NOTE
11 Grease and adjust the brake pedal, see Brake pedal, checking
and adjusting page 3.
VDRF03.02GB
23
NOTE
13 On machines with manual sliding cab. Secure the cab in the rearmost position with the cab locks.
14 Turn on the main electric power and start the engine. Run the engine at idling speed.
15 Test the brakes a couple of times.
16 Check that the brake valve's connections are sealed tightly.
17 Bleed the wheel brakes' brake cylinders, see Wheel brakes,
bleeding page 29.
000270
A. Location, lock handle

B. Lock pin
C. Lock handle for securing cab
VDRF03.02GB
24
4 Brakes 4.3.6 Drive axle block
4.3.6
Drive axle block
Drive axle block, description
page
10
1
1
2
3
3
5
4
5
6
The drive axle block has a measuring outlet for brake pressure and for
measuring back pressure in the disc brakes cooling circuit.
The drive axle block has a bypass valve which guides 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.
The drive axle block houses two switches: brake light NO (normally
open) switch (S216), see Switch normally open (NO), brake lights, description page 26, and declutch NO switch (S220-2), see section 2
Transmission, group 2.8.2 Normally open (NO) switch, declutch.
000439
The drive axle block distributes oil flow and brake pressure to the right
and left-hand wheel brakes. The drive axle block is located on a bracket above the drive axle differential.
1. Brake cooling connection, return from wheel brake

2. Brake cooling connection, return to cooler
3. Brake cooling connection, to wheel brake
4. Brake cooling connection from accumulator
charging valve
5. Brake cylinder connection, to wheel brake
6. Brake pressure connection, from brake valve
7. NO switch, declutch (S220-2)
9. Measuring outlet, brake pressure
10. Measuring outlet, brake cooling back pressure
VDRF03.02GB
4 Brakes 4.3.7 NC switch, brake fluid pressure
4.3.7
25
NC switch, brake fluid pressure
NC switch, brake oil pressure, description
page
The brake oil pressure NC switch (S204) detects the pressure in the
accumulators. The NC switch is located on the accumulator charging
valve on the lifting beam in front of the gearbox in the engine
compartment.
When the pressure in the feed circuit is high enough to ensure braking
of the machine, the sensor closes an electric circuit. This is used to
warn for pressure-drop in the brake system. The sensors opening
pressure is chosen so that there is pressure for another eight brake
applications without additional feed from the pump after the light has
gone off.
The brake oil pressure NC switch (S204) is supplied voltage by Control
unit, frame front (D797-F). When the pressure increases above the
cut-off pressure, the voltage signal to Control unit, frame front
(D797-F) is cut off.
000435
The signal can be checked from the diagnostic menu, see tab
8 Control system , group 8.4.5.4 HYD, menu 4.
page
Brake oil pressure NC switch, adjustment
NOTE
B Safety.
1 Operate and warm up the machine until the oil reaches operating
temperature, at least 50 C.
B Safety.
accumulator pressure on the accumulator charging valve.
6 Start the engine and fully charge the accumulators (the accumulator charging valve changes to cooling).
7 Stop the engine and turn the starter key to position I.
8 Brake several times, stop when the warning lamp for low brake
pressure comes on.
9 Read off the accumulator pressure. The pressure should be
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.
VDRF03.02GB
26
4 Brakes 4.3.8 NO (normally open) switch, brake lights
11 Repeat steps 6-10 until the warning lamp comes on at 11.5 MPa.
12 Seal the adjusting screw with locking fluid.
B Safety.
measuring outlet.
NOTE
4.3.8
NO (normally open) switch, brake

lights
Switch normally open (NO), brake lights, description
page
The brake light NO switch controls brake light activation when the machine brakes. The switch is located on the drive axle block which sits
on a bracket above the drive axle differential.
The brake light NO switch (S216) is supplied voltage by and sends a
voltage signal to Control unit, frame front (D797-F). When the pressure increases above the closing pressure, a voltage signal is sent to
Control unit, frame front (D797-F).
000439
The signal can be checked from the diagnostic menu, see tab 8 Control system , group 8.4.5.4 HYD, menu 4.
page
Brake light NO switch, checking
NOTE
B Safety.
1 Operate and warm up the machine until the brake fluid reaches
operating temperature, at least 50 C.
3 Brake and check that the brake light comes on.
VDRF03.02GB
4 Brakes 4.3.8 NO (normally open) switch, brake lights
27

B Safety.
brake pressure on the distribution block.
7 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.
BRAKE LIGHT PRESS. indicates status for the brake light contact. 1 = Activated contact (brakes applied).
000144
DIAG HYD
4(6)
PRESSURE SWITCHES
BRAKE PRESSURE
X
BRAKE LIGHT PRESS. X
DECLUTCH PRESSURE
X
9 Press down the brake pedal slowly until the brake light is activated or the status of the input signal changes. Keep the pedal in this
position and check the pressure on the pressure gauge.
The status can be changed and the brake light should come on
when the pressure is approx. 0.2 MPa.
10 Stop the engine
B Safety.
measuring outlet.
NOTE
VDRF03.02GB
28
4 Brakes 4.3.9 Wheel brake
4.3.9
Wheel brake
Wheel brake, description
page
The wheel brakes brake the machine during operation and are located
on the drive axle between the drive axle housing and hub reduction.
000015
The wheel brake uses so-called wet disc brakes (WDB). Wet disc
brakes require minimal maintenance and have a long service life due
to effective cooling. Maintenance requirements are minimised since oil
circulates in the brake system and prevents corrosion.
The wheel brakes have two main sections - disc assembly and brake
cylinder. The disc assembly performs the braking. The brake cylinder
presses the discs in the disc assembly together during braking.
000016
Wheel hub and brake, cross-section

1. Disc assembly
2. Brake cylinder
VDRF03.02GB
4 Brakes 4.3.9 Wheel brake
29
Wheel brakes, bleeding
page
NOTE
B Safety.
I M P OR TA NT
Both the brake cylinder and disc brake must be bled
after work where the brake system is opened or after
work on the wheel brake.
Brake cylinder
2 Place a ring spanner on the bleed nipple and connect a transparent hose to the bleed nipple.
Lead the other end of the hose down into a collection container.
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
approx. 7 metres long. Therefore, allow at least two litres of
oil to pass through the air bleeder nipple when bleeding to
ensure that no air pockets remain in the system.
Bleed nipple, brake cylinder, on top of the drive axle at
the wheel hub's inner short side (left-hand side).
5 Close the bleed nipple.

6 Move the spanner and hose and repeat steps 14 on the other
side.
Disc brake
NOTE
Disc brake ventilation is vital to correct cooling of the discs.
1 Start the engine and allow it to idle. Wait until the brake accumulators are fully loaded and the accumulating charging valve has
switched to brake cooling.
2 Remove the bleed screw of the disc brake and let oil flow out of
the hole until it is free of air bubbles. Refit the bleed screw.
3 Repeat steps 1-3 on the other wheel.
Bleed nipple, disc brake, on top of the drive axle at the

wheel hubs inner short side (left-hand side).
VDRF03.02GB
30
4 Brakes 4.3.9.1 Disc assembly
Wheel brake, replacement
page
See supplier documentation, drive axle.
4.3.9.1
Disc assembly
Disc assembly, description
page
The disc assembly consists of several thin metal discs fixed alternately
to the wheel brake housing and to the hub reduction housing. The
discs are mounted on splines, which allows them to move laterally.
Oil circulates between the discs cooling them, thus the name wet disc
brake. The oil is the same as in other parts of the brake system.
000008
Braking is effected by the brake cylinder pressing together the discs.

This creates friction between the discs that are fixed to the axle and
those fixed to the hub reduction.
Disc assembly
4.3.9.2
Brake cylinder
Brake cylinder, description
page
The brake cylinder is integrated in the wheel brake and consists of a

metal ring (cylinder) with two seal rings. The seals have lateral support
from a bevel on the cylinder and a bevel on the wheel brake housing.
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 assembly.
Brake cylinder
4.3.10
page
Pipes and hoses
Piped and hoses, description

See section 10 Common hydraulics , group 10.5.1 Pipes and hoses.
VDRF03.02GB
4 Brakes 4.5 Parking brake system
4.5
31
Parking brake system
Parking brake system, function description
page
D5
5
12
D790-2
D790-1
D797-F
7
D8
C3
D10
8
Pa 10
ACC
C1
3
H
006402
11
Pos
Explanation
Signal description
Reference

P = 19 0.5 MPa
The brake fluid filter cleans dirt from the

oil.

circuit.
The accumulators store oil pressure.
See pressure plate on left

frame beam.
Accumulator, description page 16
Switch parking brake (S107) activates

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 7, U = 0 V

page 13
Conn 1, U = 2228 V
Switch in home position:

system , group 8.4.5.5 HYD, menu 5
Conn 1, U = 0 V
Conn 7, U = 2228 V

release or apply parking brake on the
CAN bus.

error code.

VDRF03.02GB
32
Pos
Explanation
Signal description
Reference
Control unit, frame front (D797-F) activates the parking brake solenoid valve
(Y642).
U = 24 V

Solenoid valve parking brake (Y642) affects the valve slide which drains pressure in the parking brake calliper to tank.
Pump pressure.
The brake calliper is drained of pressure

and the spring applies the parking
brake.
0 MPa
Parking brake unit, description page 34
10
The parking brake NC switch (S200)

closes the circuit when the pressure decreases.
Applied parking brake:
Parking brake NC switch, description page

37

Solenoid valve parking brake, description

page 33
Conn 1: U = 24 V
Conn 2: U = 0 V
Released parking brake:

Conn 1: U = 24 V
Conn 2: U = 24 V
11
Control unit, frame front (D797-F) transmits parking brake applied on the CAN
bus.
Checked by control system, error shown with error code.

12
The KIT control unit (D790-2) activates

the parking brake indicator light (508).

4.5.1
page
Brake fluid pump
Brake fluid pump, general

See group 4.3.1 Brake fluid pump.
4.5.2
page
Brake fluid filter
Brake fluid filter, general

See Brake fluid filter, description page 45.
VDRF03.02GB
4 Brakes 4.5.3 M-valve parking brake
4.5.3
33
M-valve parking brake
Solenoid valve parking brake, description
page
The parking brake solenoid valve (Y642) activates the parking brake.
The solenoid valve is fitted on the accumulator charging valve, which
is fitted on the lifting beam in front of the gearbox in the engine compartment, see Accumulator charging valve, description page 13.
The solenoid valve opens a connection between the accumulators and
the parking brake calliper at activation. This means that the parking
brake calliper is pressurised and the parking brake is disengaged.
When the voltage feed to the solenoid valve is cut off, the connection
between the accumulators and parking brake calliper is terminated. Instead, a connection between the parking brake calliper and tank is
opened and the parking brake applied. This means that the parking
brake is applied if the machine loses electrical power or if the brake
system becomes depressurised.
The solenoid valve is supplied with voltage by Control unit, frame front
(D797-F) on activation.
000437
page
Solenoid valve parking brake, checking
D ANGER
The machine may start to roll. Risk of crushing.
Block the wheels so that the machine cannot start to
roll when the parking brake is released.
1 Start the engine and run the engine at idling speed until the warning lamp for brake pressure goes out and the accumulator charging valve changes to cooling.
2 Turn off the engine and turn the start key to position I.
3 Release the parking brake with switch parking brake and check
that the parking brakes brake caliper releases. The brake caliper
should be able to move.
4 Activate the parking brake with the parking brake switch and
check that the parking brakes brake caliper is applied.
VDRF03.02GB
34
4 Brakes 4.5.4 Parking brake unit
4.5.4
Parking brake unit
Parking brake unit, description
page
The parking brake unit keeps the machine stationary when parked.
The parking brake unit is located on the drive axle input shaft between
the propeller shaft and drive axle.
The parking brake acts on the propeller shaft via a disc mounted on
the drive axle input shaft and a brake calliper with dry brake pads
mounted in a bracket on the drive axle.
NOTE
005121
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.
page
Parking brake unit, checking and adjustment (drive

axle alternative Kessler)
D ANGER
The machine may start to roll.
Risk of crushing.
1 Start the engine and run up hydraulic pressure until the accumulators are fully charged and the accumulator charging valve
switches to cooling.
2 Turn off the engine and turn the start key to position I.
3 Release the parking brake.
4 Check that the parking brake caliper can move on the bracket.
5 Check that the brake disc is free from oil and dirt.
VDRF03.02GB
4 Brakes 4.5.4.1 Parking brake caliper
35
6 Remove the cover from the brake caliper.
7 Undo the lock nut.

8 Adjust the adjustment screw so that the brakes are applied.
9 Turn back the adjusting screw so that the clearance between pad
and disc is 0.5 0.1 mm.
10 Tighten lock nut.
NOTE
To avoid turning the adjustment screw as well it must be
held still when tightening the lock nut.
11 Refit the cover to the caliper.
12 Test the operation of the parking brake.
4.5.4.1
Parking brake caliper
Brake calliper, description
page
The brake calliper has a spring section and a hydraulic section. The
spring section applies the brake while the hydraulic section is used to
release the brake. This means that the parking brake is applied if the
brake system loses pressure. This, in turn, means that the machine is
braked if a serious fault arises.
000020
1. Brake pads
2. Release cylinder
3. Return spring
4. Slackening screw
5. Adjusting washer
VDRF03.02GB
36
4 Brakes 4.5.4.2 Parking brake pads
4.5.4.2
page
Parking brake pads
Brake pads, description

The brake pads consist of a metal plate with friction material (lining).
page
Brake pads, replacement
D ANGER
The machine may start to roll.
Risk of crushing.
1 Machine in service position and wheels blocked, see section
B Safety.
2 Remove the cover from the brake caliper.
3 Undo the lock nut.

4 Slacken the adjusting screw to release the brake pads.
5 Remove the split pin and undo the nut on one of the attaching
bolts holding the parking brake calliper in place.
VDRF03.02GB
4 Brakes 4.5.4.3 Parking brake disc
37
6 Pull the attaching bolt out so that the brake pads can be angled
out and removed.
NOTE
The bolt does not need to be removed.
7 Remove the parking brake pads.
8 Clean the brake disc with methylated spirit.
9 Install new parking brake pads.
10 Press the attaching bolt back.
11 Fit the nut and a new split pin.
12 Adjust the parking brake, see Parking brake unit, checking and
adjustment (drive axle alternative Kessler) page 34.
4.5.4.3
Parking brake disc
Brake disc, description
page
The brake disc is mounted on the drive axle input shaft. The drive axles gear ratio amplifies the braking force.
4.5.5
Parking brake NC switch
Parking brake NC switch, description
page
The parking brake NC switch (S200) detects whether the parking

brake is applied or released. The NC switch is fitted on the accumulator charging valve, which is fitted on the lifting beam in front of the
gearbox in the engine compartment, see Accumulator charging valve,
description page 13.
Break-contact 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.
The parking brake NC switch (S200) is supplied voltage by, and sends
a voltage signal to, Control unit, frame front (D797-F). When the pressure increases above the cut-off pressure, the voltage signal to Control unit, frame front (D797-F) is cut off.
000436
NOTE
Gears cannot be engaged when the parking brake is applied.
4.5.6
page
Pipes and hoses

VDRF03.02GB
38
4 Brakes 4.8 Temperature control, cleaning and brake oil
4.8
Temperature control,
cleaning and brake oil
Temperature control, cleaning and brake oil,

page
11
D795
D797-F
D8
D10
C4
C1
3
P
5
1
7
C
10
006403
8
C
Pos
Explanation
Signal description
Reference

P = 19 0.5 MPa
The brake oil filter cleans the oil.

circuit.
Max. 0.1 MPa

page 13
The oil cools the wheel brake.
The bypass valve in the distribution

block leads oil past the drive axle if the
back pressure through the wheel brake
is too high.
Drive axle block, description page 24
The cooler cools the oil.
The thermo-bypass valve leads oil past

the cooler if the temperature is low.
approx. 50 C
Thermal bypass valve, description page 42
The temperature sensor (B762) detects

and oil temperature and sends Control
unit, frame front (D797-F) a voltage signal proportional to the oil temperature.
R = 25 k at 20 C
Brake fluid temperature sensor, description

page 43
VDRF03.02GB

4 Brakes 4.8.1 Brake fluid tank
39
Pos
Explanation
Signal description
Reference

transmits the oil temperature information on the CAN bus.

error code.

10
When the oil is hot, Control unit, frame

front (D797-F) activates the cooling fan
(M674) and increases airflow through
the cooler.
U = 24 V with activated
fan
Cooling fan, description page 42
If temperature is high, the KID control

unit (D795) activates the high brake fluid
temperature warning in the display.

error code.
11
Activates at 65 C

Deactivates at 55 C
4.8.1
Brake fluid tank
Brake fluid tank, description
page
The brake fluid tank stores the brake system fluid and is located on the
left side of the machine in front of the fuel tank.
The brake system is separate from other hydraulics and has its own
tank and oil filter. This makes it possible to keep additives out of the
brake system fluid.
Brake fluid is filled directly to the tank. A drain plug is located at the
bottom of the tank. Hatches on top of the tank facilitate internal
cleaning.
The tank is equipped with a filtered breather that allows volume changes in the tank, due to temperature variations and use. See Breather filter, description page 44.
000012
The tank has a sight glass for checking oil level.
VDRF03.02GB
40
4 Brakes 4.8.2 Tank heater
4.8.2
Tank heater
Tank heater, safety
page
C AUTION
High voltage.
The tank heater is connected to high voltage
(110 - 400 V).
Installation and reconnection of the tank heater may
only be performed by personnel authorised for work
with high voltage.
Tank heater, description
page
The brake fluid tank can be equipped with a tank heater, which heats
the brake fluid in the tank and sits in a flange on the front short side of
the tank. The tank heater is designed for cold-climate usage.
001872
The tank heater is operated with high voltage. Heater output is adapted through different connections and adaptation to different operating
voltage - 110, 230 or 400 V AC. Higher voltage generates higher heater output.
The tank heater can be equipped with an adjustable thermostat which
maintains a constant temperature level. The thermostat is mounted directly on the heating coil and can be adjusted using the control on the
terminal box. The recommended temperature setting is 20 30 C.
4.8.3
page
Brake fluid pump
Brake fluid pump, general

See group 4.3.1 Brake fluid pump.
4.8.4
page
Accumulator charging valve, general

See 4.3.3 Accumulator charging valve.
4.8.5
page
Drive axle block
Drive axle block, description

See Drive axle block, description page 24.
4.8.6
page
Wheel brake
Wheel brake, general

See 4.3.9 Wheel brake and drive axle supplier documentation.
VDRF03.02GB
4 Brakes 4.8.7 Oil cooler
4.8.7
41
Oil cooler
page
The oil cooler cools the brake system fluid in order to maintain brake
performance. The oil cooler is found inside the side panel on the left
side behind the front wing.
The brake system uses a flow-through cooler with electric cooling fan.
The brake system fluid is cooled when it passes the cooler. Openings
in the frame panel allow air to pass through the cooler.
000010
The cooling fan is screwed onto the cooler. See Cooling fan, description page 42.
page
Brake system oil cooler, replacement
NOTE
B Safety.
2 Drain the brake fluid tank; see Brake system fluid, changing page
46.
3 Mark up and disconnect hydraulic hoses from the cooler. Let the
oil in the cooler drain into the collection container.
NOTE
contamination.
4 Disconnect the cabling from the cooling fan.
5 Remove the attaching bolts and lift away the cooler.
6 Transfer the cooling fan to the new cooler.
7 Install the cooler.
8 Connect the cabling to the cooling fan.
9 Connect the hydraulic hoses to the cooler.
1. Cooling fan
2. Connector
3. Radiator
NOTE
Check that the O-rings are intact and fitted correctly.
VDRF03.02GB
42
4 Brakes 4.8.8 Cooling fan
10 Fill the brake fluid tank; see Brake system fluid, changing page
46. The fluid level should be visible in the sight glass.
4.8.8
Cooling fan
Cooling fan, description
page
The cooling fan (M674) is a suctioning electronic fan. The fan suctions
air from the outside of the machine through the cooler and increases
airflow through the oil cooler as needed. The cooling fan is mounted
inside the cooler inside the side panel behind the left drive wheel.
The cooling fan (M674) is supplied voltage by Control unit, frame front
(D797-F). The cooling fan is activated when oil temperature is 65 C
in the brake oil tank and the fan is deactivated when oil temperature is
55 C.
000009
4.8.9
Thermal bypass valve
Thermal bypass valve, description
page
When the oil is cold, the thermo-bypass value guides the oil past the
cooler directly to the tank. The thermo-bypass valve is found inside the
brake fluid tank at the hose connections to and from the cooler.
000023
The thermo-bypass valve is a temperature-regulated bimetal valve

that is open at low temperatures and completely closed at 50 C.
VDRF03.02GB
4 Brakes 4.8.10 Sensor brake oil temperature
43
Thermo-bypass valve, replacement
page
NOTE
B Safety.
B Safety.
46.
4 Remove the thermo-bypass valve located inside the hydraulic oil
tank.
NOTE
Note how the valve is fitted.
5 Fit in reverse order.
4.8.10
Sensor brake oil temperature
Brake fluid temperature sensor, description
page
The brake fluid temperature sensor (B762) detects the temperature of

the brake system fluid. The sensor is mounted on the rear short side
of the brake fluid tank and therefore takes the accumulated heat in the
brake system fluid into account.
The brake fluid temperature sensor (B762) is supplied voltage by Control unit, frame front (D797-F) and sends the control unit a voltage signal proportional to temperature.
001091
page
Brake fluid temperature sensor, replacement
NOTE
B Safety.
46.
3 Disconnect the wiring from the fluid temperature sensor.
4 Remove the fluid temperature sensor.
NOTE
5 Connect the cabling to the sensor.
VDRF03.02GB
44
4 Brakes 4.8.11 Breather filter
6 Fill the brake fluid tank; see Brake system fluid, changing page
46. The fluid level should be visible in the sight glass.
4.8.11
Breather filter
Breather filter, description
page
The breather filter cleans the air that passes the tanks breather upon
volume changes arising due to temperature variations and use. The
breather filter is located in a holder on the top of the brake fluid tank.
000017
The breather filter is a paper insert filter. The filter removes moisture
and dust from the air passing through the tanks breather.
page
Breather filter, replacement

1 Clean the area around the break tank breather filter.
2 Remove the cover from the filter holder.
Remove the centre screw and lift away the cover.
3 Remove the old filter insert.
4 Clean the filter holder.
NOTE
Take care so as not to contaminate the tank.
5 Fit a new filter insert.
1. Brake system fluid filler orifice
2. Breather filter, brake fluid tank
VDRF03.02GB
6 Refit the cover on the filter holder.
4 Brakes 4.8.12 Brake fluid filter
4.8.12
45
Brake fluid filter
Brake fluid filter, description
page
The brake fluid filter eliminates contaminants from the fluid in the brake
system. The filter is secured on a mounting in front of the gearbox under the lifting beam.
The brake system fluid filter is a high-pressure filter with removable filter insert. It is located between the pump and accumulator charging
valve. The fluid is cleaned when it is forced through the (glass-fibre)
material of the filter insert before reaching the accumulator charging
valve.
A bypass valve located between the intake and outlet protects the insert. If resistance through the filter surface becomes too great, the bypass valve opens a passage past the insert. The bypass function
opens if the oil is viscous (cold or too low/high viscosity) or if the filter
insert is clogged with dirt.
NOTE
000018
When the filter is clogged, the oil is directed past the filter without
cleaning. Therefore, it is very important to replace the filter at the
prescribed interval.
page
Brake fluid filter, replacement
NOTE
B Safety.
I M P OR TA NT
The filter protects the brake system against contaminants. It is vital that new contaminants do not enter
the brake system during filter replacement.

2 Depressurise the hydraulic and brake systems; see section
B Safety.
NOTE
Leave the valves open during replacement.
VDRF03.02GB
46
4 Brakes 4.8.13 Pipes and hoses
3 Remove the drain plug on the underside of the filter.

Let the oil run out. Wait a moment since it runs out slowly.
4 Remove the filter holder.
NOTE
The filter holder is heavy. Detach it carefully.
5 Remove the filter insert.
NOTE
Note the location of the O-rings.
6 Clean the filter holder.
7 Fit the O-rings on the filter insert and filter holder. Lubricate the
O-rings with brake fluid.
8 Fit the new filter insert on the filter mounting.
9 Fit the filter holder and drain plug.
000018
10 Close the valves opened for draining the pressure in the hydraulic
system.
11 Start the engine and check the filter holder for leaks.
4.8.13
page
Pipes and hoses

4.8.14
page
Brake system fluid
Brake system fluid, general

See section F Technical data.
page
Brake system fluid, changing
NOTE
B Safety.
2 Depressurise the hydraulic and brake systems; see section
B Safety.
3 Remove the filler cap and drain the brake fluid tank.
4 Remove the drain plug and allow the last of the fluid drain into a
receptacle.
5 Fit the drain plug, using a new gland washer.
6 Fill brake fluid until the fluid level is in the middle of the sight
glass. For volume and grade, see section F Technical data.
1. Brake system fluid filler orifice
VDRF03.02GB
7 Fit the filler cap.
5 Steering
5 Steering
Table of Contents 5 Steering

mm mm mm mm mm mm
5
Steering........................................................................................................... 3
5.1
5.1.2
Mini-wheel .............................................................................................. 3
5.1.3
Joystick .................................................................................................. 4
5.2
Power assisted system ............................................................................... 6
5.2.1
Hydraulic oil pump ............................................................................... 13
5.2.2
Priority valve ........................................................................................ 14
5.2.3
Steering valve ...................................................................................... 20
5.2.4
Steering cylinder .................................................................................. 23
5.2.5
Steering axle cradle ............................................................................. 26
5.2.6
Link arm ............................................................................................... 27
5.2.7
Wheel spindle ...................................................................................... 27
5.2.8
Wheel hub ............................................................................................ 27
5.2.9
Shuttle valve ........................................................................................ 27
5.2.10
Control valve mini-wheel/joystick control ............................................. 28
5.2.11
Shuttle valve, mini-wheel/lever steering .............................................. 31
5.2.12
Steering angle sensor .......................................................................... 32
5.2.13
Pipes and hoses .................................................................................. 32
VDRF03.02GB
VDRF03.02GB
5 Steering
5 Steering
5 Steering
mm mm mm mm mm mm
5.1
5.1.2
Mini-wheel
Mini-wheel, description
page
On machines with mini-wheel, the machine is steered with an electric

control. A directional valve pressurises the steering cylinder.
The mini-wheel controls are integrated in the left armrest. The controls
consist of two rotary potentiometers and three switches to activate the
mini-wheel, select direction of travel and activate the horn.
NOTE
The mini-wheel is deactivated if the standard steering wheel is
used.
Mini-wheel or lever steering can only be activated at speeds
below 3 km/h.
Mini-wheel
000583
Rotary potentiometers transmit a 0-5 V signal for one revolution. The

potentiometers have phase displacement to determine the direction of
turning. The rotary potentiometers are supplied voltage by the cab
control unit (D790-1) and send it a voltage signal proportional to the
turn to indicate steering deflection.
1. Mini-wheel
2. Travel direction selector (F / N / R)
3. Switch, mini-wheel activation
4. Acoustic signal
5. Armrest
The relationship between the deflection of the mini-wheel and that of

the wheels can be set to 31 different settings - from linear to extremely
progressive. It is also possible to set how steering deflection is to be
adapted based on machine speed. This is done via the diagnostic
menus; see section 8 Control system , group 8.5.1 Initiation.
The signals can be read from the diagnostic menu, see section 8 Control system , group 8.4.11.4 EL-STEERING, menu 1.
Switch, mini-wheel activation

The mini-wheel switch (position 3) activates steering with the miniwheel. The switch is supplied voltage by and sends a voltage signal to
Travel direction selector

The travel direction selector is used to choose direction of travel (forward or reverse) when the mini-wheel is activated. The switch is supplied voltage by and sends a voltage signal to the cab control unit
(D790-1).
VDRF03.02GB
5 Steering 5.1.3 Joystick
Acoustic signal
The acoustic signal is used to activate the signal horn when the miniwheel is activated. The switch is supplied voltage by and sends a voltage signal to the cab control unit (D790-1).
5.1.3
Joystick
Joystick, description
page
On machines with joystick, the machine is steered with an electric control. A directional valve actuates the steering cylinder.
The joystick is integrated in the left armrest. The controls consist of a

sliding potentiometer and three switches to activate lever steering, select direction of travel and activate the horn.
NOTE
Lever steering is deactivated if the standard steering wheel is
used.
Mini-wheel or lever steering can only be activated at speeds below 3 km/h.
Joystick
The sliding potentiometer is supplied voltage by the cab control unit

(D790-1) and sends it a voltage signal proportional to movement to indicate steering deflection.
000900
1. Joystick
2. Travel direction selector (F / N / R)
3. Switch, joystick activation
4. Acoustic signal
5. Armrest
The relationship between the deflection of the joystick and that of the
wheels can be set to 31 different settings - from linear to extremely
adapted based on machine speed. This is done via the diagnostic
menus; see section 8 Control system , group 8.5.1 Initiation.
Joystick position (left, centre, right) can be calibrated with the diagnostic menus; see section 8 Control system , group 8.5.2.2 Calibrate
steering.
Switch, joystick activation

The joystick activation switch (position 3) activates steering with the
joystick. The switch is supplied voltage by and sends a voltage signal
to the cab control unit (D790-1).
VDRF03.02GB
5 Steering 5.1.3 Joystick
Travel direction selector

The travel direction selector is used to choose direction of travel (forward or reverse) when lever steering is activated. The switch is supplied voltage by and sends a voltage signal to the cab control unit
(D790-1).
Acoustic signal
The acoustic signal is used to activate the horn when the lever steering
is activated. The switch is supplied voltage by and sends a voltage signal to the cab control unit (D790-1).
VDRF03.02GB
5 Steering 5.2 Power assisted system
5.2
Power assisted system
Power assisted system, function description

(hydraulic oil pump alternative Rexroth)
page
2
PP
C1
LS
CF
P
LS
007428
Pos
Explanation
Signal description
Reference
The hydraulic oil pumps pump oil to the

priority valve.
See pressure plate on

left frame beam.
Section 10 Common hydraulics, group

10.4.2 Axial piston pump with variable displacement
The priority valve prioritises pressure supply to the steering valve over the working
hydraulics. The priority valve also transmits a control signal to the hydraulic oil
pump 3 and 4.

error code.
Priority valve, description (hydraulic oil

pump alternative Rexroth) page 14
The shuttle valve selects the strongest

load signal to the main pump if hydraulic
functions are activated at the same time
as the steering wheel is turned.

error code.

10.5.3 Shuttle valve
The steering wheel is turned and acts on

the steering valve's input shaft.
The steering valve pumps pressurised oil

to the steering cylinder and transmits a
load signal to the main pumps.
Steering valve, description page 20
The steering cylinder turns the wheels.
Steering cylinder, description page 23

VDRF03.02GB
Power assisted system, function description

(hydraulic oil pump alternative Sauer-Danfoss)
page
2
PP
C1
LS
CF
P
LS
007428
Pos
Explanation
Signal description
Reference
The hydraulic oil pump 2 pumps oil to

the priority valve.

frame beam.

10.4.2 Axial piston pump with variable
displacement
The priority valve prioritises pressure

supply to the steering valve over the
working hydraulics. The priority valve
also transmits a control signal to the
hydraulic oil pump 2.

error code.
Priority valve, description (hydraulic oil


load signal to the main pump if hydraulic
functions are activated at the same time
as the steering wheel is turned.

error code.


The steering valve pumps pressurised

oil to the steering cylinder and transmits
a load signal to the main pumps.
Steering valve, description page 20

VDRF03.02GB
Joystick control/mini-wheel, function

description (hydraulic oil pump alternative
Rexroth)
page
Mini-wheel or lever steering is a steering option that makes it possible

to steer the machine with an electric control.
The relationship between the deflection of the control and that of the
adapted based on machine speed. This is done via the initiation menus; see section 8 Control system, group 8.5.1 Initiation.
NOTE
The mini-wheel/lever steering is deactivated if the standard steering wheel is used.
Mini-wheel or lever steering can only be activated at speeds
below 3 km/h.
Condition
Reference value
Reference
Lever steering
activated
Voltage signal from switch miniwheel/joystick control.
Mini-wheel, description page 3 or Joystick, description page 4
Steering wheel
stationary
No signal from sensor steering

wheel movement.
Sensor, steering wheel movement, description page 32
Speed
Below 3 km/h (at engagement)
Safety switch
Not activated
Section 11 Common electrics, group 11.2.3 Safety switch
VDRF03.02GB
Diagnostic menu, see section 8 Control system , group 8.4.11.4

EL-STEERING, menu 2
1
D1
D12
11
13
D790-2
D797-O
12
2
D790-1
D790-3
D4
D3
8
C7
PP
P
LS
CF
LS
5, 9
TP
LS
T1
L
7
006404
10
Pos
Explanation
Signal description
Reference
The joystick switch or mini-wheel switch

sends a voltage signal to the cab control
unit (D790-1).
Signal 1, U = 0.5 - 4.5 V
Mini-wheel, description page 3 or Joystick,

description page 4
Signal 2, U = 0.5 - 4.5 V

(mini-wheel only)
On machines with Combi attachment

the signal is sent to the cab control unit
option (D790-3).
2

the desired steering deflection on the
CAN bus.

system , group 8.4.11.4 EL-STEERING,
menu 1
Checked by control system; error indicated with

error code.

I = 350550 mA

11.5.3.4 Control unit, frame option

the cab control unit option (D790-3)
sends steering deflection on the CAN
bus.
3
Control unit, frame option (D797-O) supplies voltage to the solenoid valve for
steering right (Y636R) or the solenoid
valve for steering left (Y636L).

menu 4 and 5
VDRF03.02GB
10
Pos
Explanation
Signal description
Reference
The solenoid valve, steering right

(Y636R) or solenoid valve, steering left
(Y636l) pressurises the steering slide in
the solenoid valve for lever steering or
mini-wheel.
Control valve for lever steering or miniwheel, description page 28
The solenoid valve for lever control or

mini-wheel sends a load signal to shuttle
valve, steering.

load signal to hydraulic oil pump 3 and 4
if hydraulic functions are activated at the
same time as the steering wheel is
turned.
Shuttle valve for mini-wheel or lever control,

description page 31
Hydraulic oil pumps 3 and 4 pump oil

from the hydraulic oil tank.

frame beam.

displacement

also transmits a control signal to the hydraulic oil pump 3 and 4.

frame beam.
Priority valve page 14
The slide changes position and pressurises the steering cylinder.
10
11

12
Sensor steering axle sends a voltage

signal to Control unit, cab (D790-1).
U = 24 V

menu 4 and 5
D12: Diagnostic menu, see section 8 Control system , group 8.4.11.4 EL-STEERING,
menu 3
13

the stop steering on the CAN bus.

error code.

Hydraulic diagram, joystick control
VDRF03.02GB
11
Joystick control/mini-wheel, function

description (hydraulic oil pump alternative
Sauer-Danfoss)
page
Mini-wheel or lever steering is a steering option that makes it possible

to steer the machine with an electric control.
The relationship between the deflection of the control and that of the
adapted based on machine speed. This is done via the initiation menus; see section 8 Control system, group 8.5.1 Initiation.
NOTE
The mini-wheel/lever steering is deactivated if the standard steering wheel is used.
Mini-wheel or lever steering can only be activated at speeds below 3 km/h.
Condition
Reference value
Reference
Lever steering
activated
Voltage signal from switch miniwheel/joystick control.
Mini-wheel, description page 3 or Joystick, description page 4
Steering wheel
stationary
No signal from sensor steering

wheel movement.
Speed
Below 3 km/h (at engagement)
Safety switch
Not activated
Section 11 Common electrics, group 11.2.3 Safety switch
Diagnostic menu, see section 8 Control system , group 8.4.11.4

EL-STEERING, menu 2
VDRF03.02GB
12
1
D1
D12
11
13
D790-2
D797-O
12
2
D790-1
D790-3
D4
D3
8
C7
PP
P
LS
CF
LS
5, 9
TP
LS
T1
L
7
006404
10
Pos
Explanation
Signal description
Reference
The joystick switch or mini-wheel switch

unit (D790-1).
Signal 1, U = 0.5 - 4.5 V
Mini-wheel, description page 3 or Joystick,

description page 4
Signal 2, U = 0.5 - 4.5 V

(mini-wheel only)

the signal is sent to the cab control unit
option (D790-3).
2

the desired steering deflection on the
CAN bus.

menu 1

error code.

I = 350550 mA


the cab control unit option (D790-3)
sends steering deflection on the CAN
bus.
3
Control unit, frame option (D797-O) supplies voltage to the solenoid valve for
steering right (Y636R) or the solenoid
valve for steering left (Y636L).
VDRF03.02GB

menu 4 and 5
5 Steering 5.2.1 Hydraulic oil pump
13
Pos
Explanation
Signal description
Reference
The solenoid valve, steering right

(Y636R) or solenoid valve, steering left
(Y636l) pressurises the steering slide in
the solenoid valve for lever steering or
mini-wheel.
The solenoid valve for lever control or

mini-wheel sends a load signal to shuttle
valve, steering.

load signal to hydraulic oil pump 2 if hydraulic functions are activated at the
same time as the steering wheel is
turned.

description page 31
Hydraulic oil pump 2 pumps oil from the

hydraulic oil tank.

frame beam.


also transmits a control signal to the hydraulic oil pump 2.

frame beam.
Priority valve page 14
The slide changes position and pressurises the steering cylinder.
10
11

12
Sensor steering axle sends a voltage

U = 24 V

menu 4 and 5
D12: Diagnostic menu, see section 8 Control system , group 8.4.11.4 EL-STEERING,
menu 3
13

the stop steering on the CAN bus.

error code.

5.2.1
page
Hydraulic oil pump
Hydraulic oil pump, general (hydraulic oil pump

Steering is supplied oil by the hydraulic oil pumps 3 and 4, see section
10 Common hydraulics , group 10.4 Pumps.
VDRF03.02GB
14
5 Steering 5.2.2 Priority valve
Hydraulic oil pump, general (hydraulic oil pump

page
Steering is supplied oil by the hydraulic oil pump 2, see section

10 Common hydraulics , group 10.4 Pumps.
5.2.2
Priority valve
Priority valve, description (hydraulic oil pump

page
The priority valve divides the oil flow from the main pump 3 and 4 so
that there is always oil to the steering valve. The residual flow goes to
working hydraulics.
The priority valve is load sensing and pilot pressure compensating.
Load sensing means that the valve adapts the control signal to the
steering valves 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.
001016
The priority valve has a built-in pressure limiter on the load signal. The
pressure limiter maximises the load signals pressure.
Steering pressure, checking (hydraulic oil pump

page
NOTE
B Safety.
1 Operate and warm up the machine so that the hydraulic oil reaches operating temperature, 50 C.
C
000475
3 Depressurising removed.
Operating menu, hydraulic oil temperature
VDRF03.02GB
15
4 Connect the pressure gauge to the measuring outlet for hydraulic

oil pump 3 or 4.
5 Start the engine and increase engine speed to approx. 1200 rpm.
Measuring outlet, hydraulic oil pumps

1. Hydraulic oil pump 1
6 Turn the steering wheel fully and read pump pressure during
steering wheel movement. Compare this to the steering pressure
on the hydraulics plate. The max. pressure measured on the
pump should be 1.5 MPa more than the steering pressure on the
hydraulics plate.
MPa

power.
MPa
measuring outlet.
MPa
MPa
MPa
MPa
MPa
MPa
MPa
920643.0024
001033
MPa
VDRF03.02GB
16
Priority valve, description (hydraulic oil pump

page
The priority valve divides the oil flow from the main pump 2 so that
there is always oil to the steering valve. The residual flow goes to
working hydraulics.
The priority valve is load sensing and pilot pressure compensating.
Load sensing means that the valve adapts the control signal to the
steering valves 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.
011345
The priority valve has a built-in pressure limiter on the load signal. The
pressure limiter maximises the load signals pressure.
VDRF03.02GB
17
Steering pressure, checking (hydraulic oil pump

page
NOTE
B Safety.
1 Operate and warm up the machine so that the hydraulic oil reaches operating temperature, 50 C.
000475
C
4 Connect the pressure gauge to the measuring outlet for hydraulic

oil pump 2.
5 Start the engine and increase engine speed to approx. 1200 rpm.
Measuring outlet, hydraulic oil pumps

6 Turn the steering wheel fully and read pump pressure during
steering wheel movement. Compare this to the steering pressure
on the hydraulics plate. The max. pressure measured on the
pump should be 1.5 MPa more than the steering pressure on the
hydraulics plate.
MPa
MPa
power.
MPa
measuring outlet.
MPa
MPa
MPa
MPa
MPa
MPa
MPa
MPa
A49195.0400
VDRF03.02GB
18
page
Priority valve, replacement
NOTE
B Safety.
B Safety.
power.
4 Mark up and detach the hydraulic hoses from the priority valve.
NOTE
5 Remove the priority valve attaching bolts.
6 Release the priority valve from the collection block.
7 Remove the priority valve.
8 Transfer the connection adapters to the new priority valve.
NOTE
Transfer one connection at a time so that the marking is not
mixed up.
9 Connect the new priority valve to the collection block.
C AUTION
Do not tighten the hydraulic connection between priority valve and collection block before all other connections and attaching bolts are fitted.
Stresses in the priority valve may result in incorrect
function.
10 Fit the priority valve attaching bolts.

11 Connect the hydraulic hoses to the priority valve.
12 Check that the collection block is not pressing against the priority
valve.
13 Tighten the hydraulic connection between priority valve and collection block.
VDRF03.02GB
19
NOTE
15 Close the relief valve for top lift.
C AUTION
010475

Check that the relief valve for top lift is closed before
starting the engine.
Relief valve for top lift, the figure shows a closed valve.
16 Start the engine and check that the hydraulic connections at the
priority valve are sealed.
17 Check the oil level in the hydraulic oil tank with the lift cylinders
fully down and the extension cylinder fully in. The oil level should
be in the centre of the level glass. Top up if necessary, for grade
see section F Technical data.
C AUTION
Overfilling of oil, leakage, and environmental damage.
The hydraulic oil level is checked with the boom completely lowered and retracted.
18 Check steering pressure, see Steering pressure, checking (hydraulic oil pump alternative Rexroth) page 14.
VDRF03.02GB
20
5 Steering 5.2.3 Steering valve
5.2.3
Steering valve
Steering valve, description
page
The steering valve is a "progressive, 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.
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 guides oil to the steering
cylinder. The gear pump ensures that the oil flow fed to the cylinder is
proportional to the steering wheel angle.
001082
There are double shock and anti-cavitation valves in the steering

valve. The shock valves protect the hydraulics against pressure spikes
which can arise from impacts on the steering wheels. The anti-cavitation valves (non-return valves) protect against vacuum on the pistons
rear side, which can lead to cavitation.
VDRF03.02GB
page
21
Steering valve, replacement
NOTE
B Safety.
1 Remove the cover plates over the engine compartment.
2 Slide the cab forward so that the control valve is accessible from
below.
B Safety.
power.
1. Water valve
2. Steering valve
6 Detach the steering valve from the brake pedal.
Remove the steering valve attaching bolts and lower the steering
valve.
7 Mark up and detach the hydraulic hoses from the steering valve.
NOTE
8 Remove the steering valve.
9 Transfer the connection adapters to the new steering valve.
NOTE
Transfer one at a time so that the marking is not mixed up.
10 Connect the hydraulic hoses to the steering valve in accordance
with the marking.
NOTE
11 Connect the new steering valve to the brake pedal.
Place the steering valve and check that the steering wheel shafts
splines enter straight in the steering valves slot. Install the attaching bolts.
VDRF03.02GB
22
12 On machines with manual sliding cab:

Lock the cab in its rearmost position with both locking catches.
000270
A. Location, lock handle

B. Lock pin
NOTE
C AUTION
010475

VDRF03.02GB
5 Steering 5.2.4 Steering cylinder
23

16 Check that the connections on the steering valve are sealed.
17 Steer very carefully a few times right - left, to bleed the steering
valve and steering cylinder.
C AUTION
5.2.4
Steering cylinder
Steering cylinder, description
page
The steering cylinder acts on the wheels via the link arms. The steering cylinder is a double-acting hydraulic cylinder.
001446
1. Wheel hub
2. Wheel spindle
3. Link arm
4. Steering axle
5. Suspension
6. Steering cylinder
7. Rear mounting
8. Counterweight
VDRF03.02GB
24
page
Steering cylinder, replacement
NOTE
B Safety.
1 Park the machine with the wheels fully turned so that the steering
cylinder can be lifted out to one side.
B Safety.
4 Disconnect the link arms from the steering cylinder.
5 Mark up and disconnect the hydraulic hoses from the steering
cylinder.
NOTE
1. Link arm mounting

2. Hydraulic connection
6 Remove the steering cylinders attaching bolts.
7 Change the steering cylinder. Lift aside the steering cylinder.
NOTE
The steering cylinder is heavy, use lifting equipment.
8 Support the new steering cylinder so that the holes in the attaching bolts are lined up directly opposite the holes in the steering
axle.
9 Fit and lubricate the steering cylinder attaching bolts. Tighten
them crosswise in steps until 680 Nm is achieved.
10 Transfer parts to the new steering cylinder.
Attaching bolts steering cylinder.
NOTE
VDRF03.02GB
25
11 Fit the link arms to the steering cylinder.

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

2. Hydraulic connection
NOTE
C AUTION
010475

VDRF03.02GB
26
5 Steering 5.2.5 Steering axle cradle
C AUTION
page
Hydraulic cylinders, repairs

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

See section 6 Suspension, group 6.2.1 Steering axle cradle.
VDRF03.02GB
5 Steering 5.2.6 Link arm
5.2.6
27
Link arm
Link arm, description
page
The link arm transfers the lateral movement of the steering cylinder to
turning the wheel spindles.
The setting of the steering wheels cannot be adjusted. If the link arms
are deformed in a way that changes the setting of the steering wheels,
they must be replaced.
001446
The link arms must be turned to the right direction, otherwise they can
be damaged by the rims with large wheel angles.
1. Wheel hub
2. Wheel spindle
3. Link arm
4. Steering axle
5. Suspension
7. Rear mounting
8. Counterweight
5.2.7
page
Wheel spindle
Wheel spindle, general

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

See section 6 Suspension , group 6.2.3 Wheel hub.
5.2.9
page
Shuttle valve
Shuttle valve, description

See section 10 Common hydraulics , group 10.5.3 Shuttle valve.
VDRF03.02GB
28
5 Steering 5.2.10 Control valve mini-wheel/joystick control
5.2.10
Control valve mini-wheel/joystick

control
Control valve for lever steering or mini-wheel,

description
page
1
6
On machines with joystick control or mini-wheel, steering cylinder displacement is regulated by the control valve for joystick control or miniwheel. The control valve is located on the inside of the right frame
member in front of the engine. The control valve is regulated by Control unit, frame option (D797-O).
The control valve is an electro-hydraulically controlled, proportional
and pressure-compensated directional valve. Electrically controlled
pressure reducing valves convert electrical 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 flow limits so that several functions can be activated
simultaneously.
002205
Valve slide, steering
1. Load signal (LS)

2. Pressure supply (P)
3. Tank return (T)
4. Connection, steering cylinder (B)
5. Tank return (TP)
6. Connection, steering cylinder (A)
The valve slide controls the direction and steering angle by controlling
the hydraulic pressure to the steering cylinder.
The valve slide is controlled by servo valve right and servo valve left.
Servo valve right

Servo valve right controls servo pressure to valve slide, steering, so
that it controls oil pressure for steering right.
Servo valve right regulates electrically with the solenoid valve steering
right (Y636R), which is activated by Control unit, frame option
(D797-O).
Servo valve left

Servo valve left controls servo pressure to valve slide, steering, so that
it controls oil pressure for steering left.
Servo valve left regulates electrically with the solenoid valve steering
left (Y636L), which is activated by Control unit, frame option (D797-O).
VDRF03.02GB
29
Control valve for joystick control or mini-wheel,

replacement
page
NOTE
B Safety.
B Safety.
3 Mark up and detach the hydraulic hoses from the control valve.
NOTE
6
Plug all connections immediately to protect the hydraulic

4 Mark up and detach the wiring from the control valve.
5 Remove the control valve.
Remove the attaching bolts and lift away the valve. Place the
valve on a clean and protected surface.
6 Transfer parts to the new control valve.
NOTE
002205
Check that the O-rings on the hydraulic connections are intact and in place.
1. Load signal (LS)

3. Tank return (T)
5. Tank return (TP)
NOTE
Transfer one adapter component at a time so that the marking is not mixed up.
7 Mark up the servo valves on the new control valve.
8 Fit the valve.
9 Connect the wiring to the control valve in accordance with the
marking.
10 Connect the hydraulic hoses to the control valve in accordance
with the marking.
NOTE
VDRF03.02GB
30
NOTE
C AUTION
010475

14 Check the function.
C AUTION
Air in the hydraulic system may cavitate and result in
product damage.
Activate the steering carefully and drive a couple of
times with lowest possible speed to avoid cavitation.
C AUTION
VDRF03.02GB
5 Steering 5.2.11 Shuttle valve, mini-wheel/lever steering
5.2.11
31
Shuttle valve, mini-wheel/lever

steering

description
page
Machines with lever steering or mini-wheel have an extra shuttle valve

for the control signal cables of the hydraulic oil pumps. The shuttle
valves are fitted on the bracket for oil filling and dipsticks between engine and transmission.
The shuttle valve forwards the control signal from the control valve to
the main pumps.
2
3
002203
Shuttle valves on attachment plate between engine

and transmission
1. Shuttle valve, frame option
2. Shuttle valve lifting / steering
3. Shuttle valve joystick control/mini-wheel
4. Shuttle valve lifting / attachment
VDRF03.02GB
32
5 Steering 5.2.12 Steering angle sensor
5.2.12
Steering angle sensor
Sensor, steering wheel movement, description
page
The steering angle sensor (B770) detects if the steering wheel is

turned and sends a signal to the KIT control unit (D790-2). This is used
to disengage joystick control or the mini-wheel. The sensor is located
by the steering axle inside the panels. The sensor is tripped by an indicator ring on the steering axle with four lobes. The location of the
sensor and lobes spacing means that small steering wheel movements can be detected.
002628
1. Indicator ring
2. Sensor steering wheel movement (B770)
page
Position sensor, checking and adjustment

See section 7 Load handling.
5.2.13
page
Pipes and hoses

VDRF03.02GB
6 Suspension
6 Suspension
Table of Contents 6 Suspension

mm mm mm mm mm mm
6
Suspension..................................................................................................... 3
6.2
Suspension ................................................................................................. 3
6.2.1
Steering axle cradle ............................................................................... 5
6.2.2
Wheel spindle ........................................................................................ 7
6.2.3
Wheel hub ............................................................................................ 11
6.3
Tyres and rims .......................................................................................... 16
6.3.1
Tyres .................................................................................................... 18
6.3.2
Rims ..................................................................................................... 19
6.3.3
Nut, washer and clamp ........................................................................ 20
VDRF03.02GB
VDRF03.02GB
6 Suspension
6 Suspension
mm mm mm mm mm mm
6 Suspension
6.2
page
Suspension
Bushing steering axle mounting, changing
D ANGER
Steering axle and machine are very heavy.
It is not permissible to go under a machine which has
been lifted by a jack or similar. For machine weights,
please refer to section F Technical data.
power.
3 Remove the counterweights on the rear of the machine.
NOTE
Mark the locations of the counterweights so that they can be
refitted at the same spot. This is important for the machines
stability.
4 Support under the steering axle so that it cannot fall over.
5 Connect lifting equipment to the rear of the machine and take up
the slack so that the steering axles mounts are relieved.
NOTE
Do not lift so much that the wheels are off the ground.
6 Remove the shafts holding the steering axle.
7 Lift the machine up so that the frame is lifted away from the axle.
8 Support the machine under the frame.
9 Move the steering axle so that the mountings can be accessed.
NOTE
If needed, disconnect the cabling for the sensors on the
steering axle.
The illustration shows rear attachment.
VDRF03.02GB
6 Suspension 6.2 Suspension
10 Remove the washers that hold the bushing in place.

11 Press out the bushing.
12 Clean the bearing surfaces on the steering axle.
The illustration shows front mounting.

13 Assemble the parts of the bushing and press in the new bushing.
Lubricate the bushing with grease in order to simplify installation.
C AUTION
The bearing halves must be mounted horizontally.
14 Fit the washers that hold the bushing in place. Use locking fluid
and tighten the bolts to a torque of 45 Nm.
Parts of bushing steering axle
1. Inner race
2. Bearing halves
15 Move the steering axle into place under the frame.

16 Grease and install the pins by the steering axles mounts.
17 Remove the lifting equipment from the machine.
18 Fit the counterweights.
NOTE
Make sure that all counterweights are refitted and that they
are fitted in the exact same location as before. The stability
of the machine is affected if the counterweights are
changed.
VDRF03.02GB
6 Suspension 6.2.1 Steering axle cradle
6.2.1
Steering axle cradle, description
page
The steering axle is pendulum suspended with a double-acting steering cylinder. The construction comprises a minimum of moving parts
to minimise service points and simplify maintenance.
001446
The frame suspension comprises maintenance-free parts. The rear

suspension is designed with a leading knee which is used to indicate
too low load on the steering axle, a so-called mechanical overload system, see section 8 Control system , group 8.2.1 Overload System.
1. Wheel hub
2. Wheel spindle
3. Link arm
4. Steering axle
5. Front mounting
7. Rear mounting
8. Counterweight
page
Steering axle cradle, replacement
D ANGER
Steering axle and machine are very heavy.
It is not permissible to go under a machine which has
been lifted by a jack or similar. For machine weights,
please refer to section F Technical data.
1 Clean the steering axle and its surrounding area.
B Safety.
power.
VDRF03.02GB
6 Suspension 6.2.1 Steering axle cradle
5 Remove the counterweights on the rear of the machine.
NOTE
Mark the locations of the counterweights so that they can be
refitted at the same spot. This is important for the machines
stability.
6 Connect the lifting equipment to the rear section of the machine.
7 Tension the lifting equipment, do not lift so high that the wheels
start to hang.
8 Support the machines rear section.
9 Detach the wiring from the overload sensor (applies only to machines with mechanical overload system).
10 Detach the hydraulic hoses from the steering cylinder.
NOTE
contamination.
11 Remove the shafts holding the steering axle.
12 Lift the machine up so that the frame is lifted away from the axle.
13 Lift out the steering axle.
C AUTION
The steering axle may start to roll.
Crushing injury!
Make sure that the steering axle does not start
uncontrolled movement.
14 Adjust the support so that the machine is secured in the new position.
15 Lift the steering axle into place underneath the frame.
16 Remove the support under the frame.
17 Lower the rear of the machine.
18 Fit the shafts at the steering axle mountings.
19 Connect the hydraulic hoses to the steering cylinder.
NOTE
Check that the O-rings are intact and that they are fitted correctly.
20 Attach the wiring to the overload sensor (applies only to machines with mechanical overload system).
VDRF03.02GB
6 Suspension 6.2.2 Wheel spindle
21 Remove the lifting equipment from the machine.

22 Fit the counterweights.
NOTE
Make sure that all counterweights are refitted and that they
are fitted in the exact same location as before. The stability
of the machine is affected if the counterweights are
changed.
6.2.2
Wheel spindle
Wheel spindle, description
page
The wheel spindle is the link between steering axle and wheel hubs
which means that the wheels can be turned.
6
7
010483
1. Wheel spindle
2. Spindle bolt
3. Seal
4. Slide bearing washer
5. Cover
6. Spindle bolt bearing
7. Thrust bearing
8. Lock screw
page
Spindle bolt bearing, replacement

1 Clean the wheel spindle and its surrounding area.
2 Lift the machine under the steering axle at the wheel in question.
Support the steering axle in a suitable way.
3 Remove the steering wheel in question.
VDRF03.02GB
4 Detach the link arm from the wheel spindle.
Remove the lock screw and then remove the axle. Move the link
arm aside.
5 Position a lifting strap inside the hub to secure the spindle.

6 Remove the covers at the spindle bolts upper and lower bearing.
004516
7 Remove the grease between the cover and spindle bolt.
1. Shaft, link arm

2. Cover (upper)
3. Cover (lower)
8 Remove the spindle bolts upper and lower lock screw.
Remove the nut and the lock screw.
9 Adjust the lifting equipment to relieve the load on the wheel
spindle.
10 Remove the spindle bolt.

Pull the spindle bolt up, using a sliding hammer or the like connected to the threaded hole in the centre of the spindle bolt.
11 Remove the wheel spindle.
Place the wheel spindle on a soft surface.
12 Remove the thrust bearings from the steering axle.
13 Press out the old bearing bushings. Note how the old bearing
bushings are fitted so that the new ones can be positioned the
same way with the space in the same place.
14 Clean the surfaces inside the steering axle.
15 Press in the new bearing bushings. Make sure that the space
ends up at the same spot as before.
004517
NOTE
The upper bearing bushing must protrude (4.5-4.8 mm) so
that it is level with the thrust bearings slotted washer.
1. Wear washer, thrust bearing
VDRF03.02GB
16 Fit new thrust washers on the steering axle. Only fit three bolts in
the manner illustrated. The fourth bolt cannot be fitted until the
wheel spindle is in place. Only tighten the bolts slightly (5-10 Nm)
so that the thrust bearings are secured in position.
Thoroughly coat the bearing bushings with grease. For grade,
NOTE
Be sure to position the nuts as illustrated.
011152
17 Fit new O-rings on the wheel spindle.

Pull the O-ring toward the hub.
18 Lift the wheel spindle into place on the steering axle.
19 Coat the wear surface of the lower wear washer with lubricating
grease and align the bearing between the wheel spindle and the
lower thrust washer. Use a rubber mallet to get the bearing to the
right position. Check that the bearing is centred in the wheel spindle by looking in the spindle from below.
011163
20 Coat the wear surface of the upper wear washer with lubricating
grease and align the bearing between the wheel spindle and the
upper thrust washer. Use a rubber mallet to get the bearing to the
right position. Check that the bearing is centred in the wheel spindle by looking in the spindle from above.
21 Fit the spindle bolt.

Coat the spindle bolt with lubricating grease and press it into
place.
NOTE
Check that the spindle bolt is turned so that the holes for the
guide screws align with the holes in the wheel spindle. It is
important that the spindle bolt is perfectly seated before the
lock screws are fitted. It is not possible to "tighten" the spindle bolt into place.
VDRF03.02GB
10
22 Fit the lock screws and tighten with the lock nuts. Tighten to
250 Nm (oiled screw).
23 Coat the space between the wheel spindle and steering axle with
lubricating grease.
24
Position the O-rings.
25 Fit the remaining bolts to the thrust bearings wear washer as illustrated. Tighten to 25 Nm (oiled screw).
004517
1. Wear washer, thrust bearing

26 Fit the upper cover and the lower cover.
27 Lubricate the upper and lower bearings of the spindle bolt with lubricating grease.
28 Rock the wheel spindle back and forth a few times to even out the
grease. Check that resistance is uniform.
29 Connect the link arm to the wheel spindle.
Lubricate the link arm bearings with grease.
3
1. Cover (upper)
2. Shaft, link arm
3. Cover (lower)
VDRF03.02GB
004516
30 Fit the wheel.

31 Remove the support and lower the steering wheel.
32 Test-run the machine and test the steering. Check also that the
machine feels stable when driving straight ahead.
6 Suspension 6.2.3 Wheel hub
6.2.3
11
Wheel hub
Wheel hub, description
page
The wheel hub holds the wheel in place and allows the wheel to rotate.
001443
1. Hub nut with locking washer

2. Outer wheel bearing
3. Hub
4. Inner wheel bearing
5. Seal
6. Support ring
page
Wheel bearing, replacement

1 Lift the machine under the steering axle by the wheel in question.
Support securely under the steering axle.
2 Remove the steering wheel in question.
3 Clean the hub cover and its surrounding area.

4 Remove the hub cover.
5 Wipe away grease from hub cover and hub nuts. Handle it as environmentally hazardous waste.
VDRF03.02GB
12
6 Secure the hub with a lifting strap.

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

Remove the outer bearing inner race and pull the hub from the
axle.
11 Remove the inner bearing from the wheel spindle.
VDRF03.02GB
13
12 Remove the seal from the hub.

13 Remove the bearings outer races from the hub.
Use a drift and press out the bearing races.
14 Clean the hub and smear the inside with universal grease "EP2".
15 Fit new bearing races in the hub.
Use a drift and press in the bearing races. Never tap directly on
the bearings.
NOTE
Fit the outer bearings with the larger diameter outward.
16 Fit a new seal on the inside with the seal lip turned out.
Press in a new seal in the hub. Use a suitable round plate, the
seal does not tolerate impacts from a hammer.
NOTE
Turn the seal correctly.
17 Install the inner bearings inner race and rollers on the wheel
spindle. Pack the bearing with universal grease "EP2".
18 Fill the empty space in the hub with universal grease "EP2".
VDRF03.02GB
14
19 Fit the hub on the wheel spindle.
20 Install the outer bearing, protecting washer, and bearing nut.

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

A. Lubricate the thread and the side of the nut facing the
bearing with oil (SAE 80W/140).
B. Tighten the nut to 250 Nm (oiled screw).
C. Rotate the hub 10 revolutions.
D. Angle tighten the nut 45.
E. Rotate the hub 10 revolutions.
F.
Angle tighten the nut 45.
23 Grease the lock 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.
VDRF03.02GB
15
25 Fit the bearing casing and fill it with grease.

26 Grease the wheel bearing with grease through the grease nipple.
Lift the seal rings lip with a small screwdriver to facilitate the escape of air. Grease until grease comes out at the seal.
27 Fit the wheel.
28 Remove the support and lower the steering wheel.
VDRF03.02GB
16
6 Suspension 6.3 Tyres and rims
6.3
page
Tyres and rims
Tyres and rims, safety
D ANGER
Always block the wheels on the side of the axle that is
not going to be worked on before positioning the jack.
Always secure the jack to prevent it from sliding out
of position.
Deflate the tyre before removal. Otherwise the conical
ring and locking clips can loosen and shoot out when
the pressure is changed. With double wheel fitting
both tyres must be deflated!
Do not release air through the valve if the tyre or rim
is damaged. Drill a hole in the tread to release the air.
Damaged tyres may explode.
Never stand directly in front of the wheel when deflating or inflating. The conical ring and locking clips can
loosen and shoot out when the pressure is changed.
Never install damaged tyres or rims.
It's prohibited to repair rims with welding.
It's prohibited to operate the machine if one of the
tyres is flat.
Wheels, tyres and rims are dimensioned and selected
for each machine type so that maximal wheel loads
and travel speeds are not exceeded. For this reason it
is forbidden to change tyre dimension, tyre brand,
tyre type, rim type or rim brand without approval from
Cargotec.
VDRF03.02GB
6 Suspension 6.3 Tyres and rims
17
C AUTION
When removing wheels, the wheel nuts should be left
in place after loosening. If the wheel nuts are removed
immediately, the wheel may release from the hub.
When removing drive wheels, make sure that the
wheels are secured in position when the spacer rings
are removed. If the wheels move they may displace
the spacer rings, with crushing injuries as a result.
When installing drive wheels, ensure that the clamps
clamp straight on the spacer ring.
Wheel nuts should be check-tightened after 4-5
operating hours.
Always follow the tyre manufacturers or other approved instructions when changing tyres.
Never use a steel hammer to install or remove rim
components. Instead, use a lead, brass or plastic
mallet.
Keep the tyre pressure at the prescribed level. Insufficient tyre pressure impairs stability and reduces the
machines capacity.
Remove penetrating objects, such as crushed glass,
pieces of wood and metal filings.
Check if tyre wear is abnormal. This could indicate a
mechanical fault. Rectify faults immediately and
change damaged tyres.
VDRF03.02GB
18
6 Suspension 6.3.1 Tyres
6.3.1
Tyres
Tyres, description
page
The tyres are the point of contact between the machine and the
ground. These absorb unevenness and provide suspension.
002027
The drive axle is subject to major forces during operation. If each tyres
rolling circumference differs, the stresses on the drive axle increase.
For this reason it is important that the tyres on the drive axle have
equal wear and correct air pressure.
Spare and replacement tyres must be from a manufacturer approved
by Cargotec.
002026
Front wheels
Rear wheels
page
Tyre replacement
D ANGER
Changing tyres is complicated and dangerous work.
FATAL DANGER!
Leave tyre work to authorised personnel/ tyre
company.
The wheel rims must be checked when tyres are changed. See Maintenance manual DRF 400450 section 6 Suspension.
VDRF03.02GB
6 Suspension 6.3.2 Rims
6.3.2
19
Rims
Rim, description
page
The rim is split to make it possible to fit a tyre, the rim consists of the
following parts.
Rims
Rim bead seat
Rim flange
Lock ring
Lock lugs
Hub plate
001444
1. Lock ring
2. Rim flange
3. Tapered rim bead seat
4. O-ring
5. Rims
6. Rim flange
7. Wheel nut
8. Wheel clamp
VDRF03.02GB
20
6 Suspension 6.3.3 Nut, washer and clamp
6.3.3
Nut, washer and clamp
Nut, washer and clamp, description
page
The rim is attached to the wheel hub with nuts and clamps.
The number of nuts and clamps varies depending on the type of drive
axle and steering axle used.
001444
1. Lock ring
2. Rim flange
3. Tapered rim bead seat
4. O-ring
5. Rims
6. Rim flange
7. Wheel nut
8. Wheel clamp
VDRF03.02GB
page
21
Wheel bolt, replacing

2 Raise the machine with a jack positioned under the steering axle.
3 Remove the steering wheel, see Maintenance Manual DRF
400-450 section 6 Suspension.
4 Knock out the bolt with a sledge hammer.

5 Replace the bolt.
VDRF03.02GB
22
VDRF03.02GB
7 Load handling
7 Load handling
Table of Contents 7 Load handling

mm mm mm mm mm mm
7
Load handling................................................................................................. 5
7.1
7.1.1
Control lever .......................................................................................... 7
7.1.2
Switch, lock twistlocks ........................................................................... 9
7.1.3
Switch, automatic spreading ................................................................ 10
7.1.5
Switch, stop at 30' or 35' ...................................................................... 10
7.2
Lifting/lowering ......................................................................................... 11
7.2.1
7.2.2
Servo filter ............................................................................................ 16
7.2.3
Pressure reducer ................................................................................. 16
7.2.4
Accumulator servo circuit ..................................................................... 18
7.2.5
Control valve lift, lower and extension ................................................. 20
7.2.6
Shuttle valve ........................................................................................ 22
7.2.7
Valve block lift cylinder ........................................................................ 23
7.2.8
Lift cylinder ........................................................................................... 27
7.2.9
Sensor hydraulic pressure lift cylinder ................................................. 32
7.2.10
Lift boom .............................................................................................. 35
7.2.11
Sensor, boom angle ............................................................................. 35
7.2.12
Pipes and hoses .................................................................................. 35
7.2.16
Sensor, attachment damping ............................................................... 36
7.3
Extension .................................................................................................. 37
7.3.1
7.3.2
Servo filter ............................................................................................ 44
7.3.3
Pressure reducer ................................................................................. 44
7.3.4
Accumulator servo circuit ..................................................................... 45
7.3.5
Control valve lift, lower, extension ....................................................... 45
7.3.6
Shuttle valve ........................................................................................ 46
7.3.7
Valve block, extension cylinder ............................................................ 47
7.3.8
Extension cylinder ................................................................................ 47
7.3.9
Valve block, pump relief ....................................................................... 51
7.3.10
Lift boom .............................................................................................. 53
7.3.11
Sensor, boom length ............................................................................ 55
7.3.12
Pipes and hoses .................................................................................. 55
7.4
Side shift ................................................................................................... 56
7.4.1
7.4.2
Valve block, top lift hydraulics .............................................................. 58
7.4.3
Control valve attachment ..................................................................... 59
7.4.4
Shuttle valve ........................................................................................ 63
7.4.5
Side shift cylinder ................................................................................. 64
7.4.6
Side shift frame .................................................................................... 65
7.4.7
Main beam, attachment ....................................................................... 69
7.4.8
Relief valve, attachment ...................................................................... 69
7.4.9
Pipes and hoses .................................................................................. 70
7.5
Spreading ................................................................................................. 71
VDRF03.02GB
7 Load handling
7.5.1
7.5.2
7.5.3
7.5.4
7.5.5
7.5.6
7.5.7
7.5.8
7.5.9
7.5.10
7.5.11
7.5.12
7.5.13
7.6
7.6.1
7.6.2
7.6.3
7.6.4
7.6.5
7.6.6
7.6.7
7.6.8
7.6.9
7.6.10
7.6.11
7.6.12
7.7
7.7.1
7.7.2
7.7.3
7.7.4
7.7.5
7.7.6
7.7.7
7.7.8
7.7.9
7.7.10
7.7.11
7.8
7.8.1
7.8.2
7.8.3
7.8.4
7.8.5
7.8.6
7.8.7
7.8.8
VDRF03.02GB
Hydraulic oil pump ................................................................................ 78

Control valve attachment ...................................................................... 78
Shuttle valve ......................................................................................... 78
Valve block, spreading motor ............................................................... 79
Spreading motor ................................................................................... 79
Spreader chains ................................................................................... 83
Spreader beam ..................................................................................... 91
Main beam, attachment ........................................................................ 93
Position sensor, spreading ................................................................... 93
Relief valve, attachment ....................................................................... 93
Pipes and hoses ................................................................................... 93
Buzzer, automatic spreading 20'-40' .................................................... 94
Rotation ..................................................................................................... 95
Hydraulic oil pump ................................................................................ 99
Control valve attachment .................................................................... 100
Shuttle valve ....................................................................................... 100
Valve block, rotation motor ................................................................. 101
Rotation motor unit ............................................................................. 102
Rotation yoke ..................................................................................... 105
Ring gear ............................................................................................ 108
Side shift frame .................................................................................. 109
Sensor, rotation stop .......................................................................... 110
Relief valve, attachment ..................................................................... 110
Pipes and hoses ................................................................................. 110
Tilt ........................................................................................................... 111
Hydraulic oil pump .............................................................................. 116
Valve block, top lift hydraulics ............................................................ 116
Damping block, tilt .............................................................................. 117
Lock valve, tilt ..................................................................................... 119
Shuttle valve ....................................................................................... 120
Tilt cylinder ......................................................................................... 121
Lift boom ............................................................................................. 121
Rotation yoke ..................................................................................... 121
Relief valve, attachment ..................................................................... 121
Pipes and hoses ................................................................................. 121
Levelling .................................................................................................. 122
Hydraulic oil pump .............................................................................. 126
Valve block, top lift hydraulics ............................................................ 126
Shuttle valve ....................................................................................... 128
Overcentre valve, levelling ................................................................. 128
Valve block, levelling cylinders ........................................................... 128
Levelling cylinders .............................................................................. 129
Side shift frame .................................................................................. 129
7 Load handling
7.8.9
7.8.10
7.9
7.9.1
7.9.2
7.10
7.10.1
7.10.2
7.10.3
7.10.4
Relief valve, attachment ....................................................................

Pipes and hoses ................................................................................
Load carrier ............................................................................................
Twistlocks ..........................................................................................
Lifting jacks ........................................................................................
Other functions .......................................................................................
Support jacks .....................................................................................
Weight indicator .................................................................................
Container counter ..............................................................................
Synchronised lift ................................................................................
129
129
130
130
144
172
172
181
187
192
VDRF03.02GB
VDRF03.02GB
7 Load handling
7 Load handling
7 Load handling
mm mm mm mm mm mm
Position sensor, checking and

adjustment
page
8
12, 13
11
11
10
14
15
008212
16
1. Sensor, boom length
5. Sensor, twistlocks
2. Sensor, rotation stop
6. Spreading sensor
3. Sensor, contact
7. Sensor, end position

damping
4. Sensor, steering wheel 8. Sensor, steering axle
movement
13. Sensor, clamping position

9. Sensor, support jacks up
10. Sensor, support jacks down 14. Sensor, knee
11. Sensor, lifting jacks
12. Sensor, contact
15. Sensor, lowered cab

16. Sensor, overheight-jacks up
VDRF03.02GB
7 Load handling
3 Check that the distance between the position sensor and

indicator is 41 mm. Adjust if necessary.
C-C
41 mm
C-C
2 Check that the sensor in question is free of damage and dirt.
I M P OR TA NT
41 mm
Adjusting position sensor - indicator
VDRF03.02GB
008209
41 mm
It is very important that the bolt head on the steering

axle sensor is in right front of the centre of the sensor
and that the bolt head is turned so that the edge is
parallel with the top of the sensor.
7 Load handling 7.1 Controls and instruments
7.1
7.1.1

Control lever
Control lever, description
page
The control lever (S815) is used to control the boom and attachment.
The lever sends a voltage signals to the cab control unit (D790-1).
The control lever has three or four potentiometer-controlled functions

and six on/off functions.
3
4
Lifting/lowering
Lifting/lowering is controlled by moving the control lever forward (lower

boom) or rearward (lift boom). See Lifting/lowering, function description page 11.
Control system , group 8.4.8.1 BOOM, menu 1.
5
6
000442
Extension
1. Tilt lock (S815-T3.1)

2. Levelling lock (S815-T3.2)
3. Rotation (S815-P3)
4. Side shift right (S815-T1.2)
5. Side shift left (S815-T1.1)
6. Opening of twistlocks (S815-T2) upon full contact
7. Tilt (S815-P4)
8. Pistol trigger (S815-T4): Activates weighing
,
changes function of side shift to spreading out
(S815-T1.2) and spreading in (S815-T1.1) as well as
lift to synchronised lift
Extension is controlled by moving the control lever right (boom out) or

left (boom in). See Extension, function description (hydraulic oil pump
alternative Rexroth) page 37.
Sideshift or spreading
When switch (position 4) is pressed down sideshift right is activated,
and when switch (position 5) is pressed down sideshift left is activated.
See Side shift, function description page 56.
If the pistol trigger (position 8) is pressed in at the same time as side
shift right (position 4), spreading out is activated. If the pistol trigger
(position 8) is pressed in at the same time as side shift left (position 5),
spreading in is activated. See Spreading, function description page
71.
Control system , group 8.4.9.2 ATTACH, menu 2.
Rotation
When the potentiometer (position 3) is pressed down on the left side
rotation clockwise is activated, and when right side is pressed in rotation anticlockwise is activated. See Rotation, function description page
95.
VDRF03.02GB
7 Load handling 7.1.1 Control lever
Opening of twistlocks
When the switch (position 6) is activated, the twistlocks are opened if
the conditions for such are fulfilled. See Twistlocks, function description page 130.
As an option the machine can be equipped with sensors on the
attachment that activate damping when the attachment is approaching
a container.
Tilt
When the top edge of the potentiometer (position 7) is pressed down,

tilt out is activated. When the bottom edge is pressed down, tilt in is
activated. See Tilt control, function description page 114.
Tilt lock
When the switch (position 1) is pressed down, the tilt lock is activated.
The light in the switch remains lit while the lock is active. See Tilt locking, function description page 112.
The signal can be checked from the diagnostic menu; see section 8
Levelling
When the rotation potentiometer (position 3) is pressed down on the

left side at the same time as the pistol trigger (position 8) is pressed in
then levelling right is activated. When the right side is pressed down at
the same time as the pistol trigger is pressed in, levelling left is activated. See Hydraulic levelling, function description page 122.
Levelling lock
When the switch (position 2) is pressed down, the levelling lock is activated. The indicator light in the switch remains lit while the lock is active. See Levelling lock, function description page 125.
VDRF03.02GB
7 Load handling 7.1.2 Switch, lock twistlocks
Pistol trigger
The pistol trigger (position 8) activates weighing if the machine is
equipped with a weight indicator. See Weight indicator, description
page 181.
The pistol trigger also changes the function of other buttons of the control lever.
If side shift is activated at the same time as the pistol trigger is pressed
in, spreading is activated. See Spreading, function description page
71.
If lift is activated at the same time as the pistol trigger is pressed
in, synchronised lift is activated if the machine is equipped with this option. See Synchronised lift, function description page 192.
7.1.2
Switch, lock twistlocks
Switch, lock twistlocks, description
page
000443
The switch for lock twistlocks (S1001) controls locking of twistlocks.

The switch has three positions: two fixed and one rocker with the following functions.
1.
Automatic locking of the twistlocks at full contact and released

parking brake.
2.
Twistlocks open (off).
3.
Manual locking of the twistlocks at full alignment and released

parking brake (rocker switch).
Twistlocks are opened with the switch on the control lever, see Control
lever, description page 7.
The switch is supplied voltage by and sends a voltage signal to the KIT
control unit (D790-1).
VDRF03.02GB
10
7 Load handling 7.1.3 Switch, automatic spreading
7.1.3
Switch, automatic spreading
Switch automatic spreading, description
page
Switch, automatic spreading (S1012) activates automatic spreading.

When the switch is depressed, spreading automatically goes to the
next position (20, 30 or 40 feet) if spreading is activated with the control lever.
000444
The switch is supplied with voltage from and sends a voltage signal to
the cab control unit (D790-1) when the switch is activated.
WARN IN G
Risk of crushing and product damage!
Automatic spreading is stopped by activating spreading in the opposite direction or deactivating the function with the switch.
7.1.5
Switch, stop at 30' or 35'
Switch, stop at 30 or 35, description
page
Switch, stop at 30 or 35 (S1004) activates 30 and 35 foot stop. When

the switch is depressed the function for spreading is changed from
2040 to stop at 30.
35
30-
000447
The switch is supplied voltage by and sends a voltage signal to the KIT
VDRF03.02GB
7 Load handling 7.2 Lifting/lowering
7.2
11
Lifting/lowering
Lifting/lowering, function description
page
Condition
Reference value
Reference
Safety switch
Disengaged

Emergency stop switch voltage
Twistlocks
Locked or unlocked, not intermediate position
Twistlocks, description page 137
Overload system
Boom up: passive

Boom down: passive or bypass activated
Section 8 Control system , group 8.2.1 Overload

system
Boom down: no alignment
Twistlocks, function description page 130
Bypassed or boom height lower than height

limitation
Section 8 Control system, group 8.2.4 Height

limitation
Contact
Height limitation
D1
1
2, 4
D790-1
3
D794
D797-F
D791-1
D797-R
D18
24
13, 18
D23
D22
D3
D17
11 C10
12
PSS
PP
10
D13 14
19
PSL
A1
VA
B1
C-M
22
23
16, 21
Pa
CP
LS
8
C9
C+
C+M
Pa
17
15, 20
010492
VDRF03.02GB
12
Pos
Explanation
Signal description
Reference
Control lever (S815-P1) sends the cab

proportional to lever movement.
Lower: US815/P1 = 0.52.0 V
Control lever, description page 7
Zero position: US815/P1 =

Control system group 8.4.8.1 BOOM,
menu 1
2.0-3.0 V
Lift: US815/P1 = 3.04.5 V
0.5 V is the fastest lowering
speed and 4.5 V is the fastest
lift speed. Lower voltages than
0.5 V and higher voltages than
4.5 V are used to detect malfunctions in cabling and controls.
Control unit, cab (D790-1) transmits the

request for Boom up or Boom down with
the speed information on the CAN bus.

Control unit, frame front (D797-F) activates Servo valve, lift (Y6005) or Servo
valve, lower (Y6004).
I = 380650 mA


are request for increased engine speed
on the CAN bus.

The engine control unit (D794) increases

engine speed.

Servo valve, lift (Y6005) or Servo valve,

lower (Y6004) pressurises the control
valves lift slide with servo pressure.
Control valve lift, lower and extension

page 20
The control valves lift slide changes position and pressurises valve block, lift cylinder and sends a load signal to the
hydraulic oil pumps.

page 20
The shuttle valve forwards the strongest

load signal if several functions are activated simultaneously.
Section 10 Common hydraulics,

group 10.5.3 Shuttle valve
The hydraulic oil pumps pump oil from the

hydraulic oil tank.

frame beam.
Section 10 Common hydraulics,

group 10.4.2 Axial piston pump with
variable displacement
10
The pressure reducer reduces the oil

pressure from the hydraulic pumps to servo pressure for the control valve.

frame beam.
Pressure reducer, description page

16
VDRF03.02GB

menu 4 and 8.4.8.5 BOOM, menu 5

13
Pos
Explanation
Signal description
Reference
11
The accumulator stores servo pressure.

The non-return valve in the pressure reducer makes it possible to store the pressure when the engine is shut off.

frame beam.
Accumulator servo circuit, description

page 18
12
The servo filter cleans the servo oil before

the control valve.
Servo filter, description page 16
13
With boom down Control unit, frame front

(D797-F) activates Servo valve, blocking
right (Y6001) and Servo valves, blocking
left (Y6002).
U = 24 V

With boom down Servo valve, blocking

right (Y6001) and Servo valve, blocking
left (Y6002) act on the blocking valves in
the valve blocks for left and right lift cylinder respectively.
With boom up the blocking valves in the

valve blocks are opened for left and right
lift cylinder respectively by the hydraulic
pressure from the control valve.
Lift cylinder valve block, description

page 23
14
15

Control system, group 8.4.8.2
BOOM, menu 2

page 23
BOOM, menu 2
With boom down the blocking valve opens

so that the pressure from the lift cylinder
can be released.
16
The lift cylinders piston side is pressurised and the boom is lifted.
Lift cylinder, description page 27
17
Regeneration
UB768-L1/1 = 5 V
The lift cylinder hydraulic pressure sensor, piston side left (B768-L1) sends Control unit, frame front (D797-F) a voltage
signal proportional to oil pressure.
UB768-L1/2 = 0 V
Lift cylinder hydraulic pressure sensor, description page 32
NOTE
Regeneration is not possible in the
proximity of end position or in the
event of overload.
18
19
UB768-L1/5 = 0.5-4.5 V
Regeneration is activated
when the pressure in the lift
cylinders is 8.5 MPa. Regeneration is stopped if the pressure
reaches 18.5 MPa.
Control unit, frame front (D797-F) activates solenoid valve, regeneration right
(Y6051) and solenoid valve, regeneration
left (Y6052) if the pressure is sufficiently
low for regeneration.
U = 24 V
The regeneration servo valve pressurised

the regeneration valve.

Control system, group 8.4.10.3 OP,
menu 3

BOOM, menu 3

page 23
VDRF03.02GB
14
Pos
Explanation
Signal description
Reference
20
The regeneration valve changes position

and directs oil from the rod side of the lift
cylinder to the piston side.

page 23
21
Lift speed increases.
22
Damping
Section 8 Control system, group

8.2.1.5 Sensor, boom angle
When the beam is approx. 4 from an end

position then damping is activated.

Sensor, boom angle (B771) sends a voltage signal proportional to the boom angle
to Control unit, frame rear (D797-R) requesting damping on the CAN bus.
23

BOOM, menu 8
U = 0-10 V
Container damping
Sensor, attachment damping (B796)
sends a voltage signal proportional to the
container distance to Control unit, attachment (D791-1).
24

Control system, group 8.4.9.22 ATTACH, menu 22
Container damping
Sensor, attachment damping, description page 36
When the voltage signal from Sensor, attachment damping (B796) is equivalent to
the set limit for damping then Control unit,
attachment (D791-1) requests damping
on the CAN bus.

11.5.3.5 Control unit, attachment
Control system, group 8.4.9.22 ATTACH, menu 22
VDRF03.02GB
7 Load handling 7.2.1 Hydraulic oil pump
page
15
Lowering speed, checking
D ANGER
The lowering speed must correspond. If speed lowering is too high there is a risk of rollover.
The machine must absolutely not be operated before
lowering speed is verified.
1 Operate the machine and hydraulics until the hydraulic oil reaches the operating temperature of 50 C.
2 Lift a container weighing 35-45 tonnes.
3 Move the machine away to a level and a safe place.
NOTE
It is important that the ground is level and without gradient.
4 Retract the boom fully and lift to maximum.
5 Note the time for how long it takes to lower from the top position
until the container is about 20 cm from the ground.
Lowering should take 18-21 seconds.
6 If the time does not correspond then contact Cargotec for further
instructions.
7.2.1
page
Hydraulic oil pump
Hydraulic oil pump, general

See section 10 Common hydraulics , group 10.4.2 Axial piston pump
with variable displacement.
VDRF03.02GB
16
7 Load handling 7.2.2 Servo filter
7.2.2
Servo filter
Servo filter, description
page
The servo filter protects the control valves servo circuits against contaminants. The servo filter is located in the front edge of the lifting
beam on the right of the engine compartment, between the pressure
reducer and the control valve for lift, lower and extension.
The servo filter is a low-pressure filter with detachable filter insert. The
oil is cleaned when it passes through the filter inserts filter material.
000534
The filter insert is pressed against the upper section of the filter housing by a spring. Rubber gaskets seal between the insert and filter
housing. If the back pressure through the filter is too great the insert is
pressed down so that the oil passes by the insert. This occurs if the oil
is viscous (cold or incorrect viscosity) or if the filter insert is clogged.
7.2.3
Pressure reducer
Pressure reducer, description
page
1
7
6
The pressure reducer reduces the pressure from hydraulic oil pumps
to servo pressure for the control valve. The pressure reducer is located
to the right on the lifting beam in the engine compartment fitted together with the accumulator for servo pressure.
Servo pressure is stored in an accumulator. A built-in non-return valve
prevents pressure leakage from the accumulator when the machine is
not in use.
000432
1. Servo pressure accumulator

2. Servo pressure test outlet
3. Pressure feed from servo filter
4. Return to tank
5. Servo pressure to control valve
6. Servo pressure adjusting screw.
7. Pressure reducer
VDRF03.02GB
7 Load handling 7.2.3 Pressure reducer
17
Servo pressure, checking and adjustment
page
NOTE
Read the instructions for oil before working; see section B Safety.
1 Operate and warm up the machine so that the hydraulic oil is at
operating temperature, at least 50 C. As an alternative, operate
until the cooling fan is activated.
000475
C

on the pressure reducing valve.
4 Start the engine and check the servo pressure. Compare with the
pressure plate.
MPa
Turn the steering wheel or activate a load handling function to activate the hydraulic oil pumps. The servo pressure is higher than
the standby pressure of the hydraulic oil pumps.
MPa
MPa
MPa
MPa
MPa
MPa
MPa
MPa
920643.0024
001029
MPa
The appearance of the pressure plate may vary, but

the symbols are the same.
VDRF03.02GB
18
7 Load handling 7.2.4 Accumulator servo circuit
5 If necessary, adjust the pressure with the adjusting screw. Loosen the lock nut and turn the adjusting screw.
NOTE
If the servo pressure is too high, a load handling function
must be activated so that servo pressure is used from the
accumulator for a reduction on the adjusting screw to be
seen on the pressure gauge. Sometimes the engine has to
be shut off between the checks.
Clockwise: reduce pressure.
Counter-clockwise: increase pressure.
measuring outlet.
7.2.4
Accumulator servo circuit
page
The accumulator stores pressurised oil and ensures that there is servo
pressure for activating control valve functions. The accumulator is located to the right on the lifting beam in the engine compartment.
The accumulator is a diaphragm type and is divided into two spaces
by a diaphragm. One side of the diaphragm is pressurised with nitrogen gas. The other side is pressurised by hydraulic oil which compacts
the nitrogen gas.
001095
Furthest up on the accumulator is a test outlet for checking gas pressure and filling gas.
page
Accumulator servo circuit, replacement
NOTE
B Safety.
B Safety.
VDRF03.02GB
19
3 Detach the accumulator from its mounting.

4 Replace the accumulator.
NOTE
C AUTION
010475

C AUTION
VDRF03.02GB
20
7 Load handling 7.2.5 Control valve lift, lower and extension
7.2.5
Control valve lift, lower and extension, description

(model year -2008)
page
The control valve controls the speed and direction of lift and extension.
The control valve is located on a bracket in the space between the lifting beam and front axle.
9
8
7
3
4
The valve has two sections - one for the lift function and one for boom
extension. The sections have many similarities, but are described separately under the respective function. For extension, see Control valve
lift, lower, extension page 45. Electric servo valves control the flow
from the valve.
The control valve is a proportional valve that is controlled by servo
valves. This means that both volume and direction of the flow from the
valve can be adjusted and that the valve can also send a control signal
to the variable pumps.
000529
Electrically controlled pressure reducing valves (servo valves) convert

electrical current into a low hydraulic pressure that is proportional to
the current, known as the servo pressure. The servo pressure acts on
the spring-centred control slide in the control valve for the function in
question and thereby controls the main flow.
1. Servo valve, boom out (Y6006)

2. Servo valve, boom in (Y6007)
3. Servo valve, lower (Y6004)
4. Servo valve, lift (Y6005)
5. Connection, rod side, right lift cylinder (B2)
6. Connection, piston side, right lift cylinder (A1)
7. Connection, feed from hydraulic oil pumps (P)
8. Connection, rod side, extension cylinder (B1)
9. Connection, piston side, extension cylinder (A1)
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 direction and flow of oil to the lift cylinder.
Servo valve, lift

The lift servo valve controls servo pressure to the lift slide so that it
controls oil pressure for lifting. The valve is controlled electrically with
the lift solenoid valve (Y6005), which is activated by Control unit, frame
front (D797-F).
The signals can be checked from the diagnostic menu, see section
8 Control system , group 8.4.8.4 BOOM, menu 4.
Servo valve, lower

The lower servo valve controls servo pressure to the lift slide so that it
controls oil pressure for lowering. The valve is controlled electrically
with the lower solenoid valve (Y6004), which is activated by Control
unit, frame front (D797-F).
VDRF03.02GB
7 Load handling 7.2.5 Control valve lift, lower and extension
21

(model year 2009-)
page
1
2
010490

The control valve controls the speed and direction of lift and extension.
The control valve is located on a bracket in the space between the lifting beam and front axle.
The valve has two sections - one for the lift function and one for boom
extension. The sections have many similarities, but are described separately under the respective function. For extension, see Control valve
lift, lower, extension page 45. Electric servo valves control the flow
from the valve.
The control valve is a proportional valve controlled by servo valves.
This means that both volume and direction of the flow from the valve
can be adjusted and that the valve can also send a control signal to
the variable pumps.
Electrically controlled pressure reducing valves (servo valves) convert
electrical current into a low hydraulic pressure that is proportional to
the current, known as the servo pressure. The servo pressure acts on
the spring-centred control 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 direction and flow of oil to the lift cylinder.
Servo valve, lift

The lift servo valve controls servo pressure to the lift slide so that it
controls oil pressure for lifting. The valve is controlled electrically with
the lift solenoid valve (Y6005), which is activated by Control unit, frame
front (D797-F).
Servo valve, lower

The lower servo valve controls servo pressure to the lift slide so that it
controls oil pressure for lowering. The valve is controlled electrically
with the lower solenoid valve (Y6004), which is activated by Control
VDRF03.02GB
22
page
7 Load handling 7.2.6 Shuttle valve
Control valve lift, lower and extension, replacement
D ANGER
After replacing control valve lift, lower and extension or parts of the
valve, lowering speed must be checked. See Lowering speed, checking page 15.
7.2.6
page
Shuttle valve

VDRF03.02GB
7 Load handling 7.2.7 Valve block lift cylinder
7.2.7
23
Valve block lift cylinder
page
1
2
The lift cylinder valve block directs oil to the lift cylinder and is mounted
directly on the lower part of the lift cylinder. The valve block comprises
the blocking valve, regeneration valve, non-return valve and shock
valve.
3
Blocking valve
4
5
6
9
7
8
The blocking valve prevents unwanted lowering and angling of the lift
cylinders. The blocking valve holds the load by ensuring that the connection to the lift cylinders piston side is closed. (The pressure passes
through a restriction as blocking pressure and holds the valve slide
closed.)
Servo valve blocking actuates the blocking valve. The servo valve is
controlled electrically with Solenoid valve, blocking left (Y6002) and
Solenoid valve, blocking right (Y6001), which are activated by Control
000473
Regeneration valve
1. Connection, rod side, lift cylinder (C-)

2. Solenoid valve regeneration (Y6051 or Y6052)
3. Pressure feed connection (VA)
4. Connection tank (T)
5. Pressure sensor, piston side (C+M)
6. Draining servo valves (D)
7. Shock valve
8. Solenoid valve blocking (Y6001 or Y6002)
9. Pressure sensor, rod side (C-M)
The regeneration valve directs oil from the rod side of the cylinder back
to the piston side. This allows the oil to be re-used during lifting. For
more information on regeneration see Lifting/lowering, function description page 11. The regeneration valve is regulated by the regeneration servo valve.
The regeneration servo valve actuates the regeneration valve. The
servo valve is regulated electrically with solenoid valve, regeneration
right (Y6051) or solenoid valve, regeneration left (Y6052), which are
activated by Control unit, frame front (D797-F).
Shock valve
The shock valve protects the hydraulic system against pressure surges which can occur when operating with a load. The shock valve
opens a connection between the lift cylinder piston side and tank if the
pressure becomes too high.
Non-return valve
The non-return valve prevents oil from going the wrong way during regeneration.
VDRF03.02GB
24
page
Lift cylinder valve block, replacing
NOTE
B Safety.
B Safety.
power.
4 Mark up and detach the wiring from the valve block.
5 Remove the wirings clamping at the valve block.
6 Mark up and detach the hydraulic hoses from the valve block.
NOTE
VDRF03.02GB
25
7 Remove the valve block from the lift cylinder.

Remove the attaching bolts and lift away the valve block.
8 Transfer the connection adapters, sensors and servo valves to
the new valve block.
NOTE
NOTE
Transfer one part at a time so that the marking is not mixed
up.
9 Fit the new valve on the lift cylinder.
NOTE
10 Connect the hydraulic hoses to the valve block in accordance

with the marking.
NOTE
VDRF03.02GB
26
11 Connect the cable harness to the valve block in accordance with

the marking.
12 Clamp the cable harness as before.
NOTE
C AUTION
010475

VDRF03.02GB
7 Load handling 7.2.8 Lift cylinder
27
16 Activate the lift carefully.
C AUTION
product damage.
Activate the functions carefully and operate at the
lowest possible speed a couple of times to avoid
cavitation.
17
Check for leaks.
C AUTION
19 Check the lowering speed, see Lowering speed, checking page

15.
7.2.8
Lift cylinder
Lift cylinder, description
page
The lift cylinders lift and lower (angle) the lift boom. The lift cylinders
are located between boom and frame in the front edge of the machine,
one on the right and one on the left-hand side.
Each lift cylinder houses a valve block that controls pressurization and
regeneration of the lift cylinder.
001096
The lift cylinder is equipped with guide bearings both in the cylinder
end and the piston rod mounting. The piston rod mounting is threaded
in the piston rod and locked with a lock nut.
The lift cylinders are connected in parallel and are supplied from the
lift, lower and extension control valve, see Control valve lift, lower and
extension page 20.
VDRF03.02GB
28
page
Lift cylinder, replacement
D ANGER
Fatal danger, risk of crushing!
Be certain to compensate for the lift cylinders support of the boom by lifting the booms leading edge
with the lifting equipment.
A lift cylinder weighs approx. 2 tonnes. Use wooden
blocks as protection between cab and lift cylinder
when the lift cylinder is lowered or lifted.
The boom may move when the shafts are removed.
Make sure that the shafts are unloaded. Stand to the
side of the boom mounting so that the mounting protects in the event of movement.
1 Move the cab into the front position.

3 Depressurise the hydraulic and brake systems, section B Safety.
power.
5 Connect the lifting equipment at the front edge of the boom.
6 Lift the boom at the front edge so that the bearings on the lift cylinders are unloaded.
VDRF03.02GB
29
7 Mark up and detach the hydraulic hoses from the lift cylinder.
8 Attach lifting equipment to the lift cylinder.
9 Remove the upper shaft for the lift cylinder.

10 Unload the lower bearing of the lift cylinder.
11 Remove the lower shaft for the lift cylinder.
12 Lift away the lift cylinder.
13 Fit new bearing races in the lift cylinder.
14 Lubricate the lift cylinders bearing races and the holes for the
shafts in the frame and the boom with plenty of aluminium paste.
NOTE
The bearings are only lubricated during replacement.
15 Lift the new lift cylinder into place.
16 Fit the shafts for the lift cylinder.
VDRF03.02GB
30
17 Connect the hydraulic hoses to the lift cylinder.

NOTE
C AUTION
010475

21 Carefully activate the lift function.
C AUTION
product damage.
lowest possible speed a couple of times to avoid cavitation.
22 Check for leaks.
VDRF03.02GB
31
C AUTION
24 Check the lowering speed, see Lowering speed, checking page

15.
page

VDRF03.02GB
32
7 Load handling 7.2.9 Sensor hydraulic pressure lift cylinder
7.2.9
Sensor hydraulic pressure lift

cylinder
Lift cylinder hydraulic pressure sensor, description
page
The lift cylinder hydraulic pressure sensor measures the pressure in

the lift cylinders and is located on the lift cylinder valve block.
Pressure is measured to determine if regeneration can be activated. A
sensor measures the pressure on the piston side of the left lift cylinder.
If the machine is equipped with the fixed scale option then an extra
pressure sensor is used, on the piston side for the right lift cylinder.
1
If the machine is equipped with the electrical dynamic scale option
then two pressure sensors are used, one for the rod side and one for
the piston side on right and left-hand lift cylinders respectively (a total
of four pressure sensors).
001097
The sensors are supplied with power by, and send a voltage signal
proportional to the hydraulic oil pressure, to Control unit, frame front
(D797-F).
8 Control system , group 8.4.10.3 OP, menu 3.
1. Sensor, hydraulic pressure lift cylinder, piston side,

left (B768-L1)
Sensor, hydraulic pressure lift cylinder, piston
side, right (B768-R1)
2.
Sensor, hydraulic pressure lift cylinder, rod
side, left (B768-L2)
Sensor, hydraulic pressure lift cylinder, rod side,
right (B768-R2)
page
Lift cylinder hydraulic pressure sensor, replace
NOTE
B Safety.
B Safety.
3 Detach the cable harness from the lift cylinder hydraulic pressure
sensor.
4 Remove the lift cylinder hydraulic pressure sensor.
NOTE
VDRF03.02GB
33
5 Fit the new sensor.
NOTE
6 Connect the cable harness to the hydraulic pressure sensor.
7 Clamp the cable harness as before.
NOTE
C AUTION
010475

VDRF03.02GB
34
11 Activate the lift carefully.
C AUTION
product damage.
12 Check that the hydraulic connections of the valve block do not

leak and the lifting/lowering works correctly.
C AUTION
14 Check the function of the sensor from the diagnostic menu. See
section 8 Control system, group 8.4.10.3 OP, menu 3.
DIAG OP
3(x)
PRESENT INPUT SIGNAL
LIFT CYL LE
RI
CX.XXV X.XXV
C+
X.XXV X.XXV
Raise the boom and check that the sensor is sending values. The
value should be approximately the same as from the sensor on
the second lift cylinder (RI/LE).
C008213
C+
VDRF03.02GB
7 Load handling 7.2.10 Lift boom
7.2.10
35
Lift boom
Lift boom, description
page
The lift boom lifts the load. The rear section of the boom is secured into
the frame with two bearing-mounted shafts. In the front edge is the lift
attachment and in the centre on each side of the boom are lift cylinders
which are secured with bearing-mounted shafts. The lift cylinders angle the boom and raise the front section of the boom in this way. The
lift boom is available in several versions depending on reach and load
capacity.
The boom consists of outer boom and inner boom manufactured in
high-strength steel with a minimum number of welds to provide maximum strength.
The inner boom runs in the outer boom and can be extended longitudinally with the extension cylinder. There are slide plates between inner boom and outer boom which reduce the friction between them.
The slide plates are located in the front edge of the outer boom and
the rear edge of the inner boom.
Running along the left-hand side is a cable chain for hydraulic hoses
and cables between outer and inner boom.
9
1. Outer boom
2. Inner boom
3. Tilt cylinder right side
4. Mounting, attachment
5. Tilt cylinder left side
6. Extension cylinder
7.2.11
page
001239
7. Lift cylinder
8. Mounting, lift cylinder
9. Rear boom mounting
Sensor, boom angle
Sensor, boom angle, general

See section 8 Control system, group 8.2.1.5 Sensor, boom angle.
7.2.12
page
Pipes and hoses

VDRF03.02GB
36
7 Load handling 7.2.16 Sensor, attachment damping
7.2.16
Sensor, attachment damping
Sensor, attachment damping, description
page
010491
Sensor, attachment damping (B769) is an ultrasonic sensor that detects whether there is anything under the attachment. The sensor is fitted in the lower edge in the centre of the attachments side shift frame.
VDRF03.02GB
The sensors are supplied with power by, and send a voltage signal
proportional to the distance to the object under the attachment to Control unit, attachment (D791-1).
7 Load handling 7.3 Extension
7.3
37
Extension
Extension, function description (hydraulic oil

pump alternative Rexroth)
page
Condition
Reference value
Reference
Safety switch
Disengaged
Section 11 Common electrics, group 11.5.1.4 Emergency stop

switch voltage
Overload system
Boom out: passive
Section 8 Control system , group 8.2.1 Overload system

Section 8 Control system, group 8.2.3 Load centre limitation
Load centre limitation
Bypassed or the attachment

is within the limit for the load
centre limitation.
Bypassed or boom height
lower than height limitation
Section 8 Control system, group 8.2.4 Height limitation
Height limitation
D1
2, 4
D790-1
D794
5
Pa 18
D797-F
3,19
12
6
C11 13
11
D6
PS
PP
D797-R
D14
D18
14, 20
D20
15
21
LS
24
PL
D24
A1
VA
A1
VA
B1
VB
16, 22
CC+
17, 23
8
9
D3
C10
006406
10
VDRF03.02GB
38
Pos
1
Explanation
Signal description
Reference
Control lever (S815-P2) sends the cab

proportional to lever movement.
Boom in: US815/P2 =
0.5-2.0 V

menu 1

2.03.0 V
Boom out: US815/P2 =
3.0-4.5 V
0.5 V is the fastest retraction
extension speed. Lower voltages than 0.5 V and higher
voltages than 4.5 V are used
to detect malfunctions in wiring and controls.
Control unit, cab (D790-1) transmits the

request for boom out or boom in with the
speed information on the CAN bus.


Control unit, frame front (D797-F) activates Servo valve, boom out (Y6006) or
Servo valve, boom in (Y6007).
I = 380-650 mA

page 20
menu 6 and 8.4.8.7 BOOM, menu 7 and
8.4.8.2 BOOM, menu 2
During retraction of the boom Control

unit, frame rear (D797-R) activates Solenoid valve pump relief (Y6062).
4

are request for increased engine speed
on the CAN bus.


The engine control unit (D794) increases engine speed.


Servo valve, boom out (Y6006) or Servo

valve, boom in (Y6007) pressurises the
control valves extension slide with servo pressure.

page 20
The control valves extension slide

changes position and pressurises valve
block, extension cylinder and sends a
load signal to the hydraulic oil pumps.

page 20
When the boom is retracted the valve

block, pump relief load signal, drains to
two of the hydraulic oil pumps to the tank
so that only two pumps generate pressure.
Valve block, pump relief, description (hydraulic oil pump alternative Rexroth)
page 51

load signal if several functions are activated simultaneously.

VDRF03.02GB

Pos
39
Explanation
Signal description
Reference
10
The hydraulic oil pumps pump oil from

the hydraulic oil tank.

frame beam.

displacement
11
The pressure reducer reduces pressure

from the hydraulic oil pumps to servo
pressure.

frame beam.
Pressure reducer, description page 16
12
Servo pressure is stored in the accumulator. The non-return valve in the pressure reducer makes it possible to store
the pressure when the engine is shut off.

frame beam.

page 18
13
The servo filter filters the oil before the

control valve.
14
For boom in Control unit, frame rear

(D797-R) activates Servo valve, blocking extension (Y6050).
U = 24 V
Valve block extension cylinder, description page 47
15
For boom in Servo valve, blocking extension (Y6050) actuates the blocking
slide in valve block, extension cylinder.
16
For boom out the blocking slide is

opened in valve block, extension cylinder by the hydraulic pressure from the
control valve.

Control system, group 8.4.8.2 BOOM,
menu 2
For boom in the blocking valve opens

and releases pressure from the extension cylinder.
17
Extension cylinder extends or retracts

the boom.
Extension cylinder, description page 47
18
Regeneration
UB768-L1/1 = 5 V
The lift cylinder hydraulic pressure sensor, piston side left (B768-L1) sends
Control unit, frame front (D797-F) a voltage signal proportional to the cylinder
pressure in the lift cylinders.
UB768-L1/2 = 0 V
Lift cylinder hydraulic pressure sensor,

description page 32
UB768-L1/3 = 0.54.5 V

menu 3
19
Control unit, frame front (D797-F) sends

information about the pressure in the lift
cylinders.


20
Control unit, frame rear (D797-R) activates Servo valve, regeneration

(Y6046), if the pressure is low enough
for regeneration.
U = 24 V

Control system, group 8.4.8.3 BOOM,
menu 3
VDRF03.02GB
40
Pos
Explanation
Signal description
Reference
21
Servo valve, regeneration (Y6046) pressurises the regeneration valve.
22
The regeneration valve changes position and directs oil from the rod side of
the lift cylinder to the piston side.
23
Extension speed increases.
24
Damping
Section 8 Control system, group 8.2.1.6

Sensor, boom length
When the extension is about 0.4 m from

the end position damping is activated.
Mechanical overload system:

menu 1,

Sensor, boom length (B769-3 or B7694) sends a voltage signal to Control unit,
frame rear (D797-R) which sends damping on the CAN bus.
Mechanical overload system with analogue position sensors or Electronic

overload system:

overload system:

menu 4 and 8.4.10.6 OP, menu 6
Sensor, boom length (B777) sends a

voltage signal proportional to the boom
extension to Control unit, frame rear
(D797-R) that sends damping on the
CAN bus.
VDRF03.02GB
41

pump alternative Sauer-Danfoss)
page
Condition
Reference value
Reference
Safety switch
Disengaged

switch voltage
Overload system
Boom out: passive

Section 8 Control system, group 8.2.3 Load centre limitation
Bypassed or the attachment

is within the limit for the load
centre limitation.
Height limitation
D1
2, 4
D790-1
D794
5
Pa 18
D797-F
3,19
12
6
C11 13
11
D6
PS
PP
D797-R
D14
D18
14, 20
D20
15
21
LS
24
PL
D24
A1
VA
A1
VA
B1
VB
16, 22
CC+
17, 23
8
9
D3
C10
006406
10
VDRF03.02GB
42
Pos
1
Explanation
Signal description
Reference
Control lever (S815-P2) sends the

cab control unit (D790-1) a voltage
signal proportional to lever
movement.
Boom in: US815/P2 = 0.5-2.0 V

system group 8.4.8.1 BOOM, menu 1
2.0-3.0 V
Boom out: US815/P2 =
3.0-4.5 V
0.5 V is the fastest retraction
extension speed. Lower voltages than 0.5 V and higher
voltages than 4.5 V are used
to detect malfunctions in wiring and controls.
Control unit, cab (D790-1) transmits

the request for boom out or boom in
with the speed information on the
CAN bus.


Control unit, frame front (D797-F) activates Servo valve, boom out
(Y6006) or Servo valve, boom in
(Y6007).
I = 380-650 mA
Control valve lift, lower and extension page

20
system, group 8.4.8.6 BOOM, menu 6,
8.4.8.7 BOOM, menu 7 and 8.4.8.2
BOOM, menu 2
During retraction of the boom Control

unit, frame rear (D797-R) activates
Solenoid valve pump relief (Y6062).
4
The cab control unit (D790-1) transmits are request for increased engine
speed on the CAN bus.


The engine control unit (D794) increases engine speed.


Servo valve, boom out (Y6006) or

Servo valve, boom in (Y6007) pressurises the control valves extension
slide with servo pressure.

20
The control valves extension slide

changes position and pressurises
valve block, extension cylinder and
sends a load signal to the hydraulic oil
pumps.

20
When the boom is retracted the valve

block, pump relief load signal, drains
to one of the hydraulic oil pumps to
the tank so that only one pump generates pressure.
Valve block, pump relief, description (hydraulic oil pump alternative Sauer-Danfoss]
page 52
VDRF03.02GB

system, group 8.4.8.6 BOOM, menu 6 and
8.4.8.7 BOOM, menu 7
Pos
43
Explanation
Signal description
Reference
The shuttle valve forwards the strongest load signal if several functions are
activated simultaneously.

10
The hydraulic oil pumps pump oil


frame beam.

11
The pressure reducer reduces pressure from the hydraulic oil pumps to
servo pressure.

frame beam.
Pressure reducer, description page 16
12
Servo pressure is stored in the accumulator. The non-return valve in the

pressure reducer makes it possible to
store the pressure when the engine is
shut off.

frame beam.
Accumulator servo circuit, description page

18
13
The servo filter filters the oil before

the control valve.
14
For boom in Control unit, frame rear

(D797-R) activates Servo valve,
blocking extension (Y6050).
U = 24 V
Valve block extension cylinder, description

page 47
15
For boom in Servo valve, blocking extension (Y6050) actuates the blocking slide in valve block, extension
cylinder.

page 47
16
For boom out the blocking slide is

opened in valve block, extension cylinder by the hydraulic pressure from
the control valve.

page 47
D14: Diagnostic menu, see section 8 Control system, group 8.4.8.2 BOOM, menu 2
For boom in the blocking valve opens

and releases pressure from the extension cylinder.
17
Extension cylinder extends or retracts

the boom.
18
Regeneration
UB768-L1/1 = 5 V
The lift cylinder hydraulic pressure

sensor, piston side left (B768-L1)
sends Control unit, frame front (D797F) a voltage signal proportional to the
cylinder pressure in the lift cylinders.
UB768-L1/2 = 0 V
UB768-L1/3 = 0.54.5 V
D18: Diagnostic menu, see section 8 Control system, group 8.4.10.3 OP, menu 3

sends information about the pressure
in the lift cylinders.


19
VDRF03.02GB
44
Pos
Explanation
Signal description
Reference
Control unit, frame rear (D797-R) activates Servo valve, regeneration

(Y6046), if the pressure is low enough
for regeneration.
U = 24 V

page 47
21
Servo valve, regeneration (Y6046)

pressurises the regeneration valve.

page 47
22
The regeneration valve changes position and directs oil from the rod side
of the lift cylinder to the piston side.

page 47
23
Extension speed increases.
24
Damping

Sensor, boom length
20
D20: Diagnostic menu, see section 8 Control system, group 8.4.8.3 BOOM, menu 3
When the extension is about 0.4 m

from the end position damping is activated.

D24: Diagnostic menu, see Workshop
Manual section 8 Control system, group
8.4.10.1 OP, menu 1

Sensor, boom length (B769-3 or
B769-4) sends a voltage signal to
which sends damping on the CAN
bus.
Mechanical overload system with analogue

position sensors or Electronic overload
system:
and 8.4.10.6 OP, menu 6

overload system:
voltage signal proportional to the
boom extension to Control unit, frame
rear (D797-R) that sends damping on
the CAN bus.
7.3.1
page
Hydraulic oil pump

7.3.2
page
Servo filter
Servo filter, description

See Servo filter, description page 16.
7.3.3
page
Pressure reducer
Pressure reducer, description

See Pressure reducer, description page 16.
VDRF03.02GB
7.3.4
45
page
See Accumulator servo circuit, description page 18.
7.3.5
Control valve lift, lower, extension

(model year -2008)
page
The control valve has two sections: one for the lift function and one for
boom extension. The sections have many similarities but are described separately for each function.
9
8
7
For general information on the control valve, refer to Control valve lift,
lower and extension page 20.
Extension slide
The extension slide controls direction (in or out) and oil flow to valve
block extension cylinder.
3
Servo valve, boom out
Servo valve boom out, controls servo pressure to the extension slide
so that it controls oil pressure for extension.
Servo valve boom out is controlled electrically with Solenoid valve
boom out (Y6006) which is activated by Control unit, frame front
(D797-F).
000529

Servo valve, boom in

Servo valve boom in, controls servo pressure to the extension slide so
that it controls oil pressure for boom retraction.
Servo valve boom in is controlled electrically with Solenoid valve boom
in (Y6007) which is activated by Control unit, frame front (D797-F).
Shock valve, extension

Two shock valves protect the hydraulic system against surges which
can occur when operating on uneven ground or when stopping.
The shock valve opens a connection between the extension cylinder
piston side and tank if the pressure becomes too high.
VDRF03.02GB
46

(model year 2009-)
page
The control valve has two sections: one for the lift function and one for
boom extension. The sections have many similarities but are described separately for each function.
For general information on the control valve, refer to Control valve lift,
lower and extension page 20.
Extension slide
The extension slide controls direction (in or out) and oil flow to valve
block extension cylinder.
010490
Servo valve, boom out

Servo valve boom out, controls servo pressure to the extension slide
so that it controls oil pressure for extension.
Servo valve boom out is controlled electrically with Solenoid valve
boom out (Y6006) which is activated by Control unit, frame front
(D797-F).
Servo valve, boom in

Servo valve boom in, controls servo pressure to the extension slide so
that it controls oil pressure for boom retraction.
Servo valve boom in is controlled electrically with Solenoid valve boom
in (Y6007) which is activated by Control unit, frame front (D797-F).
Shock valve, extension

Two shock valves protect the hydraulic system against surges which
can occur when operating on uneven ground or when stopping.
The shock valve opens a connection between the extension cylinder
piston side and tank if the pressure becomes too high.
7.3.6
page
Shuttle valve

VDRF03.02GB
7 Load handling 7.3.7 Valve block, extension cylinder
7.3.7
47
Valve block, extension cylinder
page
Valve block extension cylinder directs pressure to the extension cylinder. The valve block is located at the rear edge of the extension cylinder in the lift boom and contains a blocking valve, regeneration valve,
and non-return valve.
Blocking valve
1
7
6
5
The blocking valve prevents unwanted lowering. The valve holds the
load by keeping the connection to the extension cylinders piston side
closed. The pressure passes through a restriction providing a blocking
pressure and holds the valve slide closed.
Solenoid valve blocking (Y6050) actuates the blocking valve. Solenoid

valve, blocking extension (Y6050) which is activated by Control unit,
000474
Regeneration valve
1. Connection, rod side, (C-)

2. Draining (D)
3. Solenoid valve regeneration (Y6046)
4. Connection control valve (VB)
5. Connection control valve (VA)
6. Connection control valve (VA)
7. Solenoid valve blocking (Y6050)
The regeneration valve directs oil from the rod side back to the piston
side. This allows the oil to be re-used during extension. For more information on regeneration see Extension, function description (hydraulic oil pump alternative Rexroth) page 37 or Extension, function
description (hydraulic oil pump alternative Sauer-Danfoss) page 41.
The regeneration valve is regulated by the regeneration servo valve.
Solenoid valve, extension (Y6046) pressurises the regeneration valve.
Solenoid valve, extension (Y6046) is activated by Control unit, frame
rear (D797-R).
7.3.8
page
Extension cylinder
Extension cylinder, description

The extension cylinder forces out and pulls in the inner boom. The extension cylinder is located in the lift boom. The rear section is secured
in the outer boom, the front section is secured in the inner boom. On
the extension cylinder is a valve block which controls pressurising of
the cylinder and regeneration for boom out.
The extension cylinder piston rod end is designed as a lug with a
flange which is secured on the piston rod with hexagonal bolts.
VDRF03.02GB
48
page
7 Load handling 7.3.8 Extension cylinder
Extension cylinder, replacement
NOTE
Safety.
Removal
2 Operate the boom out until the inspection holes in the side of the
inner boom become accessible.
B Safety.
4 Remove the lock rings and press out the shaft for the front cylinder mounting in the inner boom.
5
Machine with analogue sensor boom length.

Remove the sensor for boom length from the boom, see section
8 Control systems, group 8.2.1.6 Sensor boom length.
6 Mark up and detach the hydraulic hoses from the extension

cylinder.
NOTE
Plug all hydraulic connections immediately.
7 Mark up and detach the wiring from the valve block on the extension cylinder.
8 Remove the valve block from the extension cylinder.
NOTE
9 Remove the lock rings and press out the outer shafts for the rear
cylinder mountings in the outer boom.
10 Connect lifting equipment to the rear extension cylinder
mounting.
11 Tighten the extension cylinder carefully. When the cylinder has
come out slightly connect a second lifting device that is moved
forward on the lift cylinder during the entire disassembly in order
to stabilise the lifting.
12 Place the cylinder on wooden blocks.
Outer shafts extension cylinder
VDRF03.02GB
13 Transfer parts to the new extension cylinder.
49
Installation
14 Clean and lubricate all bearing surfaces with lubricating grease.
15 Measure how far the old extension cylinder is extended and extend the new cylinder to the same length.
NOTE
If this is not carried out then the front cylinder mounting will
not reach far enough forward.
16 Lift the extension cylinder into place.
C AUTION
Use the dual lifting devices to achieve balance during
the lifting. The front should be positioned behind the
support at the front edge of the cylinder so that it can
be slid into the boom.
17 Fit the shaft at the front cylinder mounting in the inner boom.
NOTE
Lubricate the shaft with lubricating grease before
installation.
18 Fit the lock rings on the shaft.
19 Fit the shafts at the rear cylinder mountings.
NOTE
Lubricate the shaft with lubricating grease before
installation.
20 Fit the lock rings on the shafts.
21 Fit the valve block on the extension cylinder.
NOTE
22 Connect the hydraulic hoses and the wiring to the extension
cylinder.
23
Machine with analogue sensor boom length.

Fit the sensor for boom length, see section 8 Control system,
group 8.2.1.6 Sensor boom length.
VDRF03.02GB
50
NOTE
C AUTION
010475

C AUTION
28 Calibrate the sensor for boom length, see section 8 Control system, group 8.5.2.1 Calibrate SCALE steps 9 - 12.
page

VDRF03.02GB
7 Load handling 7.3.9 Valve block, pump relief
7.3.9
51
Valve block, pump relief
Valve block, pump relief, description (hydraulic oil

page
5
6
10
For boom in, only a small oil flow is required. Solenoid valve pump relief (Y6062) drains the control signal for hydraulic oil pump 2, to the
tank. This results in only one pump unit building up pressure, which reduces the use of engine power and thus fuel consumption. If other
functions are activated at the same time, the pressure signal will pass
through the shuttle valve, see section 10 Common hydraulics, group
10.5.3 Shuttle valve. The load signal goes to the pumps that are needed. The valve block is located standing on the bracket for the oil filling
point between the engine and transmission.
Solenoid valve, pump relief (Y6062) is supplied with voltage by Control
unit, frame rear (D797-R) on activation.
003623
1. Solenoid valve, engagement of hydraulic pressure

(Y6003)
2. Pressure signal to hydraulic oil pump 2
3. Valve block, top lift hydraulics
4. Tank drain
5. Pressure signal in, from shuttle valve
6. Valve block, pump relief
8. Solenoid valve, pump relief (Y6062)
9. Tank drain
10. Pressure signal in, from shuttle valve 1
VDRF03.02GB
52
7 Load handling 7.3.9 Valve block, pump relief
Valve block, pump relief, description (hydraulic oil

pump alternative Sauer-Danfoss]
page
5
6
10
For boom in, only a small oil flow is required. Solenoid valve pump relief (Y6062) drains the control signal for hydraulic oil pump 2, to the
tank. This results in only one pump unit building up pressure, which reduces the use of engine power and thus fuel consumption. If other
functions are activated at the same time, the pressure signal will pass
through the shuttle valve, see the Workshop Manual, section 10 Common hydraulics, group 10.5.3 Shuttle valve. The load signal goes to
the pumps that are needed. The valve block is located standing on the
bracket for the oil filling point between the engine and transmission.
Solenoid valve, pump relief (Y6062) is supplied with voltage by Control
unit, frame rear (D797-R) on activation.
003623

(Y6003)
4. Tank drain
9. Tank drain
VDRF03.02GB
7.3.10
page
53
Lift boom
Lift boom, general

See Lift boom, description page 35.
page
Slide plates, lift boom, replacement
NOTE
When adjusting the side-mounted slide plates, it is important to
check the clearance for the whole travel of the boom and that the
inner boom is centred in the outer boom.
Front slide plates

1 Move the boom to the lowest position with the inner boom extended approx. 50 cm.
2 Remove the cover plate for the side-mounted slide plates and remove the spacer plates and slid plate.
4 Check the clearance between the boom and slide plate, the clearance should be 1 mm, adjust with spacer plates as required.
NOTE
1. Side-mounted slide plates
2. Lower slide plates
Inner boom must be centred in the outer boom.

5 Remove the lock screws and the slide plates brackets, and pull
out the upper slide plates and the spacer plates.
6 Unload the lower slide plates, lift the inner boom at the front edge
and use wooden shims.
WARN IN G
Secure the inner boom relative to the outer boom with
wooden blocks.
7 Remove the lock screws, slide plates brackets and pull out the
lower slide plates.
8 Transfer the nuts for the lock screws for the lower slide plates to
the new slide plates.
9 Fit the new lower slide plates, lock screws and brackets.
10 Remove the wooden blocks and ease down the inner boom so
that it rests on the lower slide plates.
11 Transfer the nuts for the lock screws for the upper slide plates to
12 Fit the new slide plates, spacer plates, lock screws and brackets.
VDRF03.02GB
54
13 Check the clearance between the boom and stop at the front
edge/top edge of the boom, the clearance must be max. 2 mm,
adjust the slide plates with spacer plates if necessary.
Check attachment levelling

14 Park the machine on level ground.
15 Lower the boom fully and centre the attachment.
16 Measure the distance between the extension beam and the
ground on the right and left-hand sides of the attachment.
A
Measuring points, levelling, attachment
008217
The difference between the dimensions for right (A) and left (B)
sides must not be more than 50 mm at 20' position, or 100 mm
for 40' position.
Check both the dimensions with the boom fully retracted and fully
extended.
17 If necessary, adjust the lower slide plates so that the attachment
is straight.
Rear slide plates

18 Start the engine and operate the boom inwards completely (fully
retracted).
19 Remove the cover plate for the side-mounted slide plates and remove the spacer plates and slid plate.
21 Check the clearance between the boom and slide plate, the clearance should be 1 mm, adjust with spacer plates as required.
22 Unload the lower slide plates, use wooden shims.
1. Upper slide plates

2. Side-mounted slide plates
3. Lower slide plates
WARN IN G
wooden blocks.
23 Remove the cover plates, spacer plates and the lower slide
plates.
24 Fit new slide plates, spacer plates and cover plate.
25 Unload the upper slide plates, use wooden shims.
WARN IN G
wooden blocks.
VDRF03.02GB
7 Load handling 7.3.11 Sensor, boom length
55
26 Remove the lock screws, the slide plates brackets and pull out
the upper slide plates and the spacer plates.
27 Transfer the nuts for the lock screws for the upper slide plates to
28 Fit the new slide plates, spacer plates, lock screws and brackets.
29 Check the clearance between the outer and inner boom, the
clearance should be max. 2 mm, adjust the slide plates with
spacer plates as required.
004874
Lubrication
Sliding surfaces, boom

30 Operate the inner boom outwards completely and lubricate the
sliding surfaces inside the outer boom and on the inner boom with
white lubricating paste.
31 Operate the boom in and out about 10 times and stop with the
boom fully out.
32 Wipe away excess lubricating paste at the slide plates and on
sliding surfaces.
7.3.11
page
Sensor, boom length
Sensor, boom length, general

See section 8 Control system, group 8.2.1.3 Sensor, boom length.
7.3.12
page
Pipes and hoses

VDRF03.02GB
56
7 Load handling 7.4 Side shift
7.4
Side shift
Side shift, function description
page
Condition
Reference
value
Reference
Safety switch
Disengaged
Section 11 Common electrics, group 11.5.1.4 Emergency stop switch voltage
D1
2
D790-1
3
D3
D797-R
D791-1
D7
C6
P1
10
4
T1
006407
C6
6
Pos
Explanation
Signal description
Reference
The control lever (S815-T1.1) sends a

voltage signal to the cab control unit
(D790-1).
Left: US815-T1.1 = 24 V
Right: US815-T1.2 = 24 V

system, group 8.4.9.2 ATTACH, menu 2
The cab control unit (D790-1) transmits side shift left or right on the CAN
bus.

Cab control unit
Control unit, frame rear (D797-R) activates the solenoid valve, engagement
of hydraulics for top lift (Y6003).
U = 24 V

Control unit, frame rear
Solenoid valve, engagement of hydraulics for top lift (Y6003) opens and
pressurises valve block lift cylinder and
sends a load signal to hydraulic oil
pump 2.
VDRF03.02GB

system, group 8.4.5.6 HYD, menu 6
Valve block, top lift hydraulics, description

page 58
57
Pos
Explanation
Signal description
Reference
The shuttle valve forwards the strongest load signal to the hydraulic oil
pumps if several functions are activated simultaneously.
Section 10 Common hydraulics, group 10.5.3

Shuttle valve
Hydraulic oil pump 2 pumps oil from


frame beam.

Axial piston pump with variable displacement
Control unit, attachment (D791-1) activates the servo valve for side shift left
(Y6020) or servo valve for side shift
right (Y6021).
U = 24 V

Control unit, attachment
The servo valve for side shift left

(Y6020) or servo valve for side shift
right (Y6021) pressurises the side shift
slide in the attachment control valve.
The control valves side shift slide

changes position and pressurizes the
side shift cylinders.
Attachment control valve, description page

59
10
The side shift cylinders push the main

beam in sideways in relation to the
side shift frame.
Side shift cylinder, description page 64


59
Hydraulic diagram, top lift

Hydraulic diagram, top lift, tilt lock and controllable tilt
Hydraulic diagram, combi yoke
Hydraulic diagram, top lift, tilt lock and controllable tilt and hydraulic
levelling
7.4.1
page
Hydraulic oil pump

VDRF03.02GB
58
7 Load handling 7.4.2 Valve block, top lift hydraulics
7.4.2
Valve block, top lift hydraulics
page
5
6
10
The valve block for top lift hydraulics is an electrically controlled valve.
It leads an unloaded constant pressure as the load signal to the hydraulic oil pumps when attachment functions are activated. The valve
block is positioned horizontally on the bracket for the oil filling point between the engine and transmission.
When the solenoid valve is activated, pressure is routed from the top
hydraulics supply through a shuttle valve to the hydraulic oil pumps for
steering. A restriction before the valve block ensures that pressure for
control of the hydraulic oil pumps does not become too high. When the
solenoid valve is not activated, the load signal is drained to the tank
and the inlet from the top hydraulics supply is closed.
003623
The valve is controlled electrically with Solenoid valve, engagement

hydraulic pressure (Y6003) which is activated by Control unit, frame
rear (D797-R).

(Y6003)
4. Tank drain
9. Tank drain
VDRF03.02GB
Control system , group 8.4.5.6 HYD, menu 6.
7 Load handling 7.4.3 Control valve attachment
7.4.3
59
Control valve attachment
Attachment control valve, description
page
1 2 3 4 5 6 7 8 9 10
11
28
12
27
26
13
25
001098
24
23 22 21 20 19 18 17 16 15 14
16. Connection to side shift cylinder
1. Solenoid valve, tilt out (Y6010)
17. Connection to side shift cylinder

2. Solenoid valve, tilt in (Y6011)
18. Connection to rotation motor
3. Solenoid valve rotation clockwise (Y6008)
19. Connection to rotation motor
4. Solenoid valve rotation anticlockwise (Y6009)

5. Solenoid valve, side shift right (Y6021)
6. Solenoid valve, side shift left (Y6020)
7. Solenoid valve, spreading out (Y6018)
20. Connection to tilt cylinder

21. Connection to tilt cylinder
22. Connection to levelling cylinder
8. Solenoid valve, spreading in (Y6019)

9. "Lock twistlocks" solenoid valve (Y6040)
10. "Open twistlocks" solenoid valve (Y6039)
11. Drain to tank
12. Connection to lock cylinder
23. Connection to levelling cylinder

24. Test outlet, feed pressure to control valve
25. Feed from hydraulic oil pump 2
26. Return to tank (through tank filter)
13. Connection to lock cylinder
27. Solenoid valve, levelling right (Y6035)
14. Connection to spreader motor
28. Solenoid valve, levelling left (Y6036)
15. Connection to spreader motor

Side shift is controlled by a separate section of the attachment control
valve.
The attachment control valve controls hydraulic functions on the attachment. The control valve is located at the centre rear of the attachment. Electric servo valves control the flow from the valve.
VDRF03.02GB
60

servo 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 main flow.
The control valve has built-in supply of pilot pressure. This means that
the valve has built-in pressure reduction which converts feed pressure
to servo pressure for the various functions. Supply of pilot pressure is
common for all functions. This reduces pressure variations due to long
hoses and reduces the number of hoses to the valve.
The control valve has the following sections:
Side shift
Spreading
Rotation
Twistlocks
Controllable tilt
Hydraulic levelling
Side shift slide

The valve slide controls side shift direction and speed.
The valve slide is controlled by a servo valve for side shift right and a
servo valve for side shift left.
Servo valve, side shift left

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

The servo valve for side shift right directs pressure to the side shift
slide so that the side shift slide opens and pressurises the side shift
cylinders.
The servo valve for side shift is controlled electrically by the solenoid
valve for side shift right (Y6021), which is activated by the attachment
control unit (D791-1). The servo valve directs servo pressure to the
side shift slide in proportion to the control current to the solenoid valve.
VDRF03.02GB
page
61
Attachment control valve, replacement
NOTE
B Safety.
B Safety.
NOTE
6 Transfer the connection adapters to the new control valve.
NOTE
NOTE
Transfer one adapter at a time so that the marking is not
mixed up.
8 Fit the valve.
Lift the valve into place and fit the attaching bolts.
marking.
with the marking.
NOTE
VDRF03.02GB
62
NOTE
C AUTION
010475
14 Check that the valve's hydraulic connections are sealed.
15 Check that the attachment is working.
C AUTION
product damage.
C AUTION
VDRF03.02GB
63
Attachment control valve, checking hydraulic

pressure
page
NOTE
Read the instructions for oil before working; see section B Safety.
1 Operate and warm up the machine so that the hydraulic oil is at
operating temperature, at least 50 C. As an alternative, operate
until the cooling fan is activated.
C
000475

3 Connect a pressure gauge to measuring outlet PL on the attachment control valve.
008226
4 Start the engine and run it at idling speed. Check the pressures
in the attachments different functions by letting each function go
to its end-position and then reading off the pressure gauge.
Function
Pressure
Side shift
16.0 MPa
Spreading
12.0 MPa
Rotation
15.0 MPa
15.0 MPa
Tilt control
Measuring outlet, control valve, attachment
15.5 MPa
Levelling
Twistlocks
Same as feed pressure.
Overheight jacks, lowering

Lifting jacks, knee in/out
Lifting jacks, jack up/down
Lifting jacks, clamping
10.0 MPa
10.0 MPa
13.0 MPa
13.0 MPa
measuring outlet.
7.4.4
page
Shuttle valve

VDRF03.02GB
64
7 Load handling 7.4.5 Side shift cylinder
7.4.5
Side shift cylinder
Side shift cylinder, description
page
The side shift cylinders are two cross connected hydraulic cylinders
which extend the attachments main beam laterally in relation to the
sideshift frame. The side shift cylinders are located along the front and
rear of the attachment and are used to centre the loads centre of
gravity.
1
10
9
8
2
3
001500
1. Side shift frame

2. Side shift cylinder
3. Position sensor, spreading
4. Sensor alignment
5. Twistlock
6. Twistlock sensor
7. Lock cylinder, twistlocks
8. Spreading boom
9. Spreading motor
10. Main beam, attachment
page

VDRF03.02GB
7 Load handling 7.4.6 Side shift frame
7.4.6
65
Side shift frame
Side shift frame, description
page
The attachment is secured in the boom with the rotation yoke. The side
shift frame is located under the rotation yoke. The attachments main
beam is located in the side shift frame. The main beam can be extended laterally in relation to the side shift frame with two hydraulic cylinders. Inside the main beam are two spreader beams which can be
extended in and out with a hydraulic motor.
The position of the attachment can be adjusted laterally by moving the

main beam in relation to the side shift frame. The main beam runs on
slide pates in the sides and in the bottom. The side shift cylinders secure the lateral position.
000526
The side shift frame is available in two versions:
1. Main beam
2. Ring gear
3. Rotation motor unit
4. Rotation yoke
5. Control valve attachment
6. Side shift frame
Standard top lift. The side shift frame allows the main beam to be
levelled 5. Side shift 800 mm.
Pile-slope top lift

The side shift frame is located in the rotation yoke with four hydraulic cylinders which mean that the levelling can be controlled
for adaptation to angled containers. Side shift 800 mm.Side shift
frame, description page 129
VDRF03.02GB
66
page
Slide plates, side shift frame, replacement

1 Undo the cover plates attaching bolt and remove the cover plate.
2 Remove the spacer plates and slide plate.
3 Repeat steps 1 - 3 on the other slide plates.
4 Measure the distance between the edge of the cover plate and
the attachments main beam slide surface on all slide plates.
5 Centre the boom so that the distance between the attachments
main beam and edge is the same on all slide plates.
6 Fit the new slide plate.

7 Check the slide plates clearance by measuring the distance between the slide plate and the edge of the cover plate. The clearance between the attachments main beam and slide plates must
be 1 mm.
8 Fit the spacer plates until the distance is correct.
VDRF03.02GB
67
9 Fit the cover plate.

10 Repeat steps 7 - 10 on the other slide plates.
004875
Lubrication
Sliding surfaces, attachment

11 Lubricate the sliding surfaces of the attachment with white lubricating paste.
12 Operate full side shift from right to left approx. 10 times.
sliding surfaces.
VDRF03.02GB
68
page
Lower slide plates, side shift frame, replacement

1 Position axle stands or similar under the attachments spreader
booms and lower the attachment on the stands so that the side
shift frames lower slide plates are released.
D ANGER
Place spacers between the crossmember and the attachments main boom for both crossmembers.
3 Remove the attaching bolts and remove the slide plates.

4 Install new slide plates.
5 Remove the spacer.
7 Lift the attachment and remove the stands.
Lubrication
004875
The illustration shows a crossmember
Slide plates, attachment

9 Operate full side shift from right to left approx. 10 times.
sliding surfaces.
VDRF03.02GB
7 Load handling 7.4.7 Main beam, attachment
7.4.7
69
Main beam, attachment
Attachment main beam, description
page
The main beam attachment is located in the side shift frame. The main
beam contains equipment for spreading (spreader beams, hydraulic
motor, chains, slide plates and sensors). On the attachments main
beam are also the control valves for the attachments hydraulic
functions.
000526
1. Main beam
2. Ring gear
4. Rotation yoke
6. Side shift frame
7.4.8
Relief valve, attachment
Attachment relief valve, description
page
002269
The attachment relief valve opens the connection between the attachments pressure supply and the tank. This is used to drain the pressure
in the attachment hoses prior to work on the hydraulic system. The relief valve is located at the rear of the lifting beam in front of the
transmission.
VDRF03.02GB
70
7 Load handling 7.4.9 Pipes and hoses
7.4.9
page
Pipes and hoses

VDRF03.02GB
7 Load handling 7.5 Spreading
7.5
71
Spreading
Spreading, function description
page
Condition
Reference value
Reference
Safety switch
Disengaged
Section 11 Common electrics, group 11.5.1.4 Emergency stop switch

voltage
Twistlocks
Unlocked or bypass activated
Passive
Overload system
Section 8 Control system, group 8.2.2 Bypassing
D1
+
D790-1
3
D797-R
2
D791-1
D12
7, 13
D7
D3
8, 14
C6
12
P1
11, 16
T1
9, 15
C6
10
006408
Pos
Explanation
Signal description
Reference
The control lever (S815-T1.x and

S815-T4) sends a voltage signal to the
Spreading: US815-T4 = 24 V
Out: US815-T1.2 = 24 V

In: US815-T1.1 = 24 V
2
The cab control unit (D790-1) transmits a signal on the CAN bus.
Checked by control system, error shown with error

code.

VDRF03.02GB
72
Pos
Explanation
Signal description
Reference
U = 24 V

Solenoid valve, engagement of hydraulics for top lift (Y6003) opens and
pumps.
The shuttle valve forwards the strongest load signal to the hydraulic oil
pumps if several functions are activated simultaneously.



frame beam.

The attachment control unit (D791-1)

activates the servo valve for spreading
out (Y6018) or spreading in (Y6019).
I = 350600 mA

The servo valve for spreading out

(Y6018) or spreading in (Y6019) pressurizes the spreader slide in the attachments control valve.
The control valves spreader slide

changes position and directs pressure
to the spreader motor.

59
10
The motor valve block directs the pressure to the motor and prevents the motor from pumping (rotating faster than
supplied pressure).
Spreader motor valve block, description

page 79
11
The motor drives the chains that extend or retract the spreader beams.
Spreader motor, description page 79
12
The sensor for end position 20-40

(B769) sends a voltage signal to the attachment control unit (D791-1).
Sensor directly opposite indicator plate: U > 24 V
Position sensor spreading, description

page 93

reduces control current to the servo
valve for spreading out (Y6018) or
spreading in (Y6019).
13
VDRF03.02GB


page 58

and 8.4.9.14 ATTACH, menu 14

59
D12: Diagnostic menu, see section 8 Control system, group 8.4.9.5 ATTACH, menu 5

73
Pos
Explanation
Signal description
Reference
14
The servo valve for spreading out

(Y6018) or spreading in (Y6019) reduces pressure to the spreader slide in
the attachments control valve.

78
15
The control valves spreader slide

changes position and reduces pressure to the spreader motor.

78
16
The speed of the spreader motor is reduced.
Spreader motor, description page 79


levelling
VDRF03.02GB
74
Spreading 30 stop, function description
page
Condition
Reference value
Reference
Safety switch
Disengaged
Section 11 Common electrics, group 11.5.1.4 Emergency stop switch

voltage
Twistlocks
Unlocked or bypass
activated
Passive
Overload system
D2
35
30-
+
D1
D790-1
D791-1
6, 8
D5
D7
006409
D8
Pos
Explanation
Signal description
Reference
The switch for stop at 30-35 (S1004)

sends a voltage signal to the cab control unit (D790-1).
Switch in ON position:
Switch, stop at 30 or 35, description page

10
Conn 1: U = 0 V
Conn 5: U = 24 V
Switch in OFF position:

Conn 1: U = 24 V
Conn 5: U = 24 V
2
The control lever (S815-T1.2 and

S815-T4) sends a voltage signal to the
Spreading: US815-T4 = 24 V
Out: US815-T1.2 = 24 V

In: US815-T1.1 = 24 V
3

spreading 30 on the CAN bus.

code.

Spreading is activated in the same way

as steps 311 of normal spreading.
Spreading, function description page 71
VDRF03.02GB
75
Pos
Explanation
Signal description
Reference
When spreading approaches the 30

position, the end position 30 sensor
(B777-3) sends a voltage signal to the
attachment control unit (D791-1).
Sensor directly opposite indicator plate: U = 24 V

page 93

dampens the speed the same way as
in steps 1316 of normal spreading.
When spreading is in the 30 position,

the 20-40 end position sensor (Y769)
sends a voltage signal.

page 93
Spreading is interrupted by the attachment control unit (D791-1) cutting of

current to the servo valve for spreading
out (Y6018) or spreading in (Y6019).
U=0V



78

levelling
VDRF03.02GB
76
Automatic spreading 20-40 foot, function

description
page
Condition
Reference value
Reference
Safety switch
Not activated
Twistlocks
Unlocked or bypass
activated
Overload system
Passive
Section 8 Control system, group 8.2.1.1 Mechanical overload system
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
D2
1
+
D790-1
D795
D791-1
4, 5, 8, 11 D10
D7
D5
6
D4
10
006884
D1
Pos
Explanation
Signal description
Reference
1.
The control lever (S815-T1.2 and

S815-T4) sends a voltage signal
Spreading: US815/T4 = 24 V
Out: US815/T1.2 = 24 V

In: US815/T1.1 = 24V

2.
The switch for automatic spreading 20-40 (S199-2) sends a voltage signal to the cab control unit
(D790-1).
US199-2/2 = 0 V
US199-2/5 = 24 V
Switch automatic spreading, description page

10

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.
VDRF03.02GB

code.

Cab control unit
77
Pos
Explanation
Signal description
Reference
4.
The attachment control unit

(D791-1) activates spreading the
same way as in steps 2-11 of normal spreading.

(D791-1) activates the automatic
spreading buzzer (H9003).
Buzzer active: U = 24 V
The automatic spreading buzzer

(H9003) generates an acoustic
warning signal.
When spreading approaches the

30' position, the end position 30
sensor (B777-3) sends a voltage
signal to the attachment control
unit (D791-1).
Position sensor spreading, description page 93
8.

(D791-1) dampens the spreading
in the same way as in position 1316 of normal spreading.
When automatic spreading is active, the KID control unit (D795)

activates the Automatic spreading
event menu.

KID control unit
10.
When spreading is at the 20' position, 30' position or 40' position,

the 20-40 end position sensor
(B769) sends a voltage signal to
the attachment control unit
(D791-1).
Position sensor spreading, description page 93

(D791-1) cuts off control current to
the servo valve for spreading out
(Y6018) or spreading in (Y6019).
I = 0 mA
Attachment control valve, description page 78
5.
6.
7.
11.

system, group 8.4.9.13 ATTACH, menu 13 and
8.4.9.14 ATTACH, menu 14
Buzzer for automatic spreading 20-40, description page 94

Buzzer for automatic spreading 20-40, description page 94


D4: Diagnostic menu, see section 8 Control system, group 8.4.9.13 ATTACH, menu 13 and
levelling
VDRF03.02GB
78
7.5.1
page
Hydraulic oil pump

7.5.2
page

See Valve block, top lift hydraulics, description page 58.
7.5.3
page

Spreading is regulated by a separate section in the attachments control valve. For a more detailed description of the valve and component
locations, see Attachment control valve, description page 59.
Spreader slide
The valve slide controls the direction and speed of spreading. The
valve slide is controlled by a servo valve for spreading out and a servo
valve for spreading in.
Servo valve, spreading out

The servo valve for spreading out directs pressure to the spreader
slide so that it opens and pressurizes the spreader motor.
The servo valve is controlled electrically by the solenoid valve for
spreader out (Y6018), which is activated by the attachment control unit
(D791-1). The servo valve directs servo pressure to the spreading
slide in proportion to the control current to the solenoid valve.
Servo valve, spreading in

The servo valve for spreading in directs pressure to the spreader slide
so that it opens and pressurizes the spreader motor.
The servo valve is controlled electrically by the solenoid valve for
spreader in (Y6019), which is activated by the attachment control unit
(D791-1). The servo valve directs servo pressure to the spreading
page

See Attachment control valve, replacement page 61.
7.5.4
page
Shuttle valve

VDRF03.02GB
7 Load handling 7.5.5 Valve block, spreading motor
7.5.5
79
Valve block, spreading motor
Spreader motor valve block, description
page
The spreader motor valve block regulates the oils direction to the
spreader motor. The valve block sits on the spreader motor all the way
out out to the left on the front side of the attachments main beam.
The valve block maintains a balance between supply and spreading
speed. Balance means that the valve block prevents the motor from
pumping oil, i.e. rotates faster than the supply of oil allows. The
spreading valve block contains overcentre valves that block the outlet
if pressure on the outlet side is higher than pressure on the inlet side.
II
001004
Hydraulic diagram, spreader motor valve block
7.5.6
Spreading motor
Spreader motor, description
page
Via two chains, the spreader motor moves the spreader beams in and
out in the attachments main beam. The spreader motor sits all the way
out out to the left on the front side of the attachments main beam.
1
10
The hydraulic motor is integrated with a planetary gear that reduces

speed and makes the motor more powerful. A valve block with two
overcentre valves is located on the hydraulic connections and prevents the motor from rotating faster than the supplied hydraulic
pressure.
9
8
2
3
001500
1. Side shift frame

4. Sensor alignment
5. Twistlock
6. Twistlock sensor
8. Spreading boom
9. Spreading motor
VDRF03.02GB
80
page
7 Load handling 7.5.6 Spreading motor
Spreader motor, replacement
NOTE
B Safety.
2 Remove the cover on the left side of the attachments main beam.
3 Start the engine and run spreading out until the chain tensioners
are visible in the inspection holes.
B Safety.
power.
7 Measure and note the chain tensioners length to attain the correct chain tension when refitting.
8 Slacken the chain tensioner on the engine side and remove the
chain from the tensioner.
9 Remove the protective plate from over the spreader motor.
VDRF03.02GB
81
10 Mark up and detach the hydraulic hoses from the valve block of
the spreader motor.
11 Remove the spreader motor assembly.
12 Transfer the valve block to the new motor assembly.
NOTE
13 Clean the contact surfaces between the planetary gear and the
attachments main beam.
14 Fit the motor unit. Tighten the bolts crosswise in steps until
117 Nm is achieved.
15 Attach the hydraulic hoses to the valve block.
VDRF03.02GB
82
16 Connect the spreader chain to the chain tensioner. Check that

the chain runs straight in the hydraulic motor sprocket.
17 Tension the chain tensioner to the same degree as before.
19 Check that the hydraulic connections are sealed tightly.
20 Check that spreading is working.
21 Fit the protective plate over the motor.
22 Grease the spreader chain with lubricating grease.
23 Fit the cover plates on the attachments main beam.
NOTE
C AUTION
010475

C AUTION
VDRF03.02GB
7 Load handling 7.5.7 Spreader chains
7.5.7
83
Spreader chains
Spreader chains, description
page
The spreader chains move the extension beams in and out of the attachments main beam. The force from the spreading motor is transferred to extension beams via two chains. The chains run inside the
attachment between the extension beams.
The chains are fastened crosswise with one end at the bottom of one
extension beam and the other end along the side of the other extension beam.
000472
Openings in the sides of the extension beams and the attachments

main beam make it possible to access the chains for maintenance
purposes.
Principle diagram, spreader chains

page
Spreader chains, checking

1 Before adjustment, the clearance between the slide plates and
extension beams must be checked so that the chain mountings
are not damaged. See Maintenance manual, section 7 Load handling, group 7.5.8 Spreader beam.
20-foot position
2 Start the engine, run spreading in to the 20-foot position and
switch off the engine.
3 Check that both spreader beams are against the 20-foot stop and
that the distance between the spreader beam and spreader motor mounting is at least 3 mm.
4 Check the C-C measurement between the twistlocks.
C-C 20 feet: 58533 mm.
If the 20-foot setting is correct proceed to step 8.
VDRF03.02GB
84
5 If necessary, adjust the distance by moving washers between the

right and left 20-foot stop. Do not change the number of washers.
NOTE
Note the distance the stop was adjusted.
Run spreading out a little to make it possible to move the
washers.
C AUTION
20-foot stop
Incorrect chain tension.

Risk of damage to the attachment.
If the 20-foot stop is adjusted, the spreader chains
must be adjusted by the same amount.
6 Remove the cover plate on the attachments main beam.
7 If the 20-foot stop is adjusted, the spreader chains must be

adjusted by the same amount, see step 14.
NOTE
005105
Check the vertical position of the chain tensioner so that the

chain runs straight to the sprocket.
VDRF03.02GB
85
40-foot position
8 Start the engine, run spreading out to the 40-foot position and
switch off the engine.
9 Check the C-C measurement between the twistlocks.
C-C 40 feet: 119853 mm.
If the 40-foot setting is correct proceed to step 11.
10 Adjust the 40-foot stop if necessary.
Chain tension
11 Start the engine and run spreading out to the 40-foot position.
005106
12 Wait 2 minutes and then check the tension of the chains.
40-foot stop
815 mm
13 Use suspension scales and measure how far the chain moves
when pulled outward with a force of 100 N at 815 mm from the
main beams internal reinforcement collar as illustrated.
100 N
Standard attachment: X = 8-13 mm.

Overheight attachment: X = 5-6 mm.
815mm
100 N
010486
100 N
0N
14 Adjust chain tension if necessary.

Start the engine and operate spreading outwards until the chain
tensioners are visible in the inspection holes (approx. 250 mm).
Adjust the chains, hold the chain tensioner in place with a
spanner so that the chain does not rotate during adjustment.
NOTE
Adjust max. 2 mm on the chain tightener at a time.
15 Repeat steps 1114 until the chains have the correct tension.
VDRF03.02GB
86
16
If the machine is equipped with a 30 or 35-foot stop, start the engine, run spreading out to the 30 or 35-foot position, switch off the
engine and check the C-C measurement between the twistlocks.
C-C 30 feet: 89183 mm
C-C 35 feet: 104883 mm
I M P OR TA NT
Check the distance at stop from both 20 and 40.
17 Grease the spreader chain with lubricating grease.

Spreader chain, replacement
page
1 Park the machine with the attachment as far down as possible.

2 Remove the cover plate on the attachments main beam.
3 Start the engine and run spreading out until the chain tensioners
are visible in the inspection holes.
005105
VDRF03.02GB
87
5 Slacken the chain tensioner of the chain in question and remove

it from the tensioner.
NOTE
005105
Measure and note the chain tensioners length to attain the

correct chain tension when refitting.
6 Remove the sprocket of the chain in question.
NOTE
Note the location of the spacer ring.
If the sprocket on the engine side must be removed, fist remove
the spreader motor. See Spreader motor, replacement page 80.
7 Pull the chain out through the sprocket hole so that the chain runs
along the spreader beam.
8 Temporarily fasten the chain along the cable rack to prevent the
chain from being pinched.
VDRF03.02GB
88
9 Pull out the spreader beam.

Use a machine or the like to pull the spreader beam out of the attachments main beam. Stop when the spreader beam is close to
the 40-foot stop.
NOTE
Support the spreader beam to minimise breaks. If necessary, remove the upper slide plates to reduce resistance.
10 Remove the boom stop from the attachments main beam.

11 Remove the hydraulic hoses clamping on the attachments main
beam.
12 Detach the cable rack from the attachments main beam. Support
the cable rack so that it is not damaged.
13 Pull out the spreader beam until the chain mounting becomes
accessible.
14 Detach the chain from the spreader beam and cable rack.
15 Connect the new chain to the spreader beam.
VDRF03.02GB
89
16 Fasten the chain along the cable rack so that it runs straight along
the spreader beam.
17 Grease the chain with lubricating grease.
18 Slide in the spreader beam so that the extension stop can be

fitted.
19 Fit the extension stop.
20 Connect the cable rack to the attachments main beam.
21 Fit the hydraulic hoses clamping on the attachments main
beam.
22 Slide in the spreader beam until it is extended the same amount
as the other one. This facilitates fitting of the chains.
23 Detach the chain from the cable rack and insert it through the
sprocket hole.
24 Fit the sprocket. The spacer ring should sit on the underside of
the sprocket.
If the rotation motor has been removed, refit it. See Spreader motor, replacement page 80.
NOTE
Check that the chain runs straight in the sprockets.
VDRF03.02GB
90
25 Connect the chain to the chain tensioner.
NOTE
005105
Use a new split pin.
26 Lubricate the sprocket bearings with grease.

27 Tension the spreader chain to the same degree as before.
Tighten the lock nut.
28 If the slide plates have been removed, refit them.
30 Check that spreading is working properly.
31 Stop the engine
32 Check chain tension. See Spreader chains, checking page 83.
VDRF03.02GB
7 Load handling 7.5.8 Spreader beam
7.5.8
91
Spreader beam
Spreader beam, description
page
The spreader beams are the part of the attachment that grip the container. Two spreader beams run along the main beam. The spreader
beams are slid in and out via the spreader motor and spreader chains.
1
10
The spreader beam houses twistlocks. See Twistlocks, description

page 137.
9
8
2
3
001500
1. Side shift frame

4. Sensor alignment
5. Twistlock
6. Twistlock sensor
8. Spreading boom
9. Spreading motor
page
Slide plates, extension beam, replacement

2 Take the strain off the glide plate in question.
The pressure can be relieved from the slide plates by raising the
outer edge of the extension beam or inserting wedges to alter the
position of the extension beam in the attachments main beam.
The photo depicts the inner slide plates of the

VDRF03.02GB
92
7 Load handling 7.5.8 Spreader beam
3 Remove the attaching bolts for the glide plates bracket.

4 Remove the guide plates guide pin.
5 Pull out the glide plate with spacer plate and bracket.
The photo depicts the inner slide plates of the

6 Position the new slide plate.
Check the clearance between the extension beam and the slide
plate. Clearance should be max. 1 mm with all slide plates fitted.
Use a spacer plate to adjust the clearance.
7 Fit the slide plate bracket and guide screw.
004875
Lubrication
9 Run spreading completely in and out approximately 10 times and
check the spreading function.
sliding surfaces.
11 Try to lift a container and check the extension beams clearance
in the attachments main beam.
VDRF03.02GB
7 Load handling 7.5.9 Main beam, attachment
7.5.9
93
page
See Attachment main beam, description page 69.
7.5.10
Position sensor, spreading
page
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 on the top left side of the attachments main beam.
The end position sensor (B769) indicates the end position of 20 and
40-foot containers. The sensor detects the spreader beam end positions via two indicator plates on the top of the spreader beams. The
sensor is used to activate damping.
With the 30-foot stop option, there is an extra sensor - position sensor
(B779) - and two indicator plates. The sensor is used to activate the
30-foot stop.
The sensors are supplied power by and send a 24 V signal to the attachment control unit (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.
003165
8 Control system , group 8.4.9.5 ATTACH, menu 5.
1. Indicator plate 20
2. Sensor, damping 20 and 40, Stop 30
3. Sensor, damping 30
4. Indicator plate, 30 or 35
5. Indicator plate 40
page

See Position sensor, checking and adjustment page 5.
7.5.11
page

See Attachment relief valve, description page 69.
7.5.12
page
Pipes and hoses

VDRF03.02GB
94
7 Load handling 7.5.13 Buzzer, automatic spreading 20'-40'
7.5.13
page
Buzzer, automatic spreading 20'-40'
Buzzer for automatic spreading 20-40, description
The buzzer for automatic spreading 20'-40' (H9003) is fitted on the

boom nose on machines with automatic spreading 20'-40'. The buzzer
is activated during automatic spreader movement.
VDRF03.02GB
7 Load handling 7.6 Rotation
7.6
95
Rotation
Rotation, function description
page
Condition
Reference
value
Reference
Safety switch
Disengaged
Overload system
Passive
D1
1
2
D790-1
3
D797-R
D791-1
7
D8
D4
8
C6
P1
T1
11, 12
4
C6
10
006410
VDRF03.02GB
96
Pos
Explanation
Signal description
Reference

signal proportional to lever
movement.
Anticlockwise: US815/P3 =

0.52.0 V
2.03.0 V

Clockwise: US815/P3 =
3.0-4.5 V
0.5 V and 4.5 V represent
the maximum rotation
speed. Lower voltages
than 0.5 V and higher
voltages than 4.5 V are
used to detect malfunctions in wiring and
controls.
2
Control unit, cab (D790-1) transmits

clockwise rotation or anticlockwise
rotation on the CAN bus.

Cab control unit

activates the solenoid valve, engagement of hydraulics for top lift
(Y6003).
U = 24 V

Solenoid valve, engagement of hydraulics for top lift (Y6003) opens

and pressurises valve block lift cylinder and sends a load signal to the
hydraulic oil pumps.
The shuttle valve forwards the

strongest load signal to hydraulic oil
pump 2 if several functions are activated simultaneously.

Shuttle valve


frame beam.

Control unit, attachment (D791-1)

activates servo valve, rotation
clockwise or servo valve, rotation
anticlockwise.
I = 435650 mA

Servo valve, rotation clockwise

(Y6008) or servo valve, rotation anticlockwise (Y6009) pressurise the
rotation slide in the attachment control valve.
VDRF03.02GB

Valve block, top lift hydraulics, description page

58
D4: Diagnostic menu, see section 8 Control system, group 8.4.5.6 HYD, menu 6

97
Pos
Explanation
Signal description
Reference
The rotation slide in the attachment

control valve changes position and
controls the pressure to the hydraulic motor valve block.
10
The hydraulic motor valve block

controls the pressure to both
motors.
Valve block rotation motor, description page 101
11
The hydraulic motors disc brakes

are disengaged.
Rotation motor unit, description page 102
12
The hydraulic motors rotate the

attachment.
Rotation motor unit, description page 102

levelling
VDRF03.02GB
98
Rotation stop, function description
page
Rotation stop is used to avoid rotating the attachment into the boom in
the raised position.
Condition
Reference
value
Reference
Safety switch
Disengaged
Overload system
Passive
D2
D1
D790-1
D795
D791-1
D5
006411
D6
Pos
Explanation
Signal description
Reference
The rotation stop switch

(S1014) sends a voltage signal to the cab control unit
(D790-1).
US1014/1 = 0 V
US1014/5 U = 24 V


US1014/1 = 24 V
US1014/5 U = 24 V
2
Control lever (S815-P3) sends

the cab control unit (D790-1) a
voltage signal proportional to
lever movement.
Anticlockwise: US815/P3 = 0.52.0 V

Zero position: US815/P3 = 2.03.0 V
Clockwise: US815/P3 = 3.04.5 V
0.5 V is the minimum rotation speed
and 4.5 V is the maximum rotation
speed. Lower voltages than 0.5 V
and higher voltages than 4.5 V are
used to detect malfunctions in cabling and controls.
VDRF03.02GB
99
Pos
Explanation
Signal description
Reference
Control unit, cab (D790-1)

transmits clockwise rotation to
stop or anticlockwise rotation
to stop on the CAN bus.
Checked by control system, error


Rotation is activated in the

same way as steps 312 of
normal rotation.
Rotation, function description page 95
Sensor rotation stop (B7225)

sends a voltage signal to the
attachment control unit
(D791-1).
Sensor directly opposite indicator

plate: U = 24 V
Sensor rotation stop, description page 110
The rotation is stopped by the

attachment control unit (D7911) cutting off the current to the
servo valve, rotation clockwise
(Y6008) or servo valve, rotation anticlockwise (Y6009).
When rotation stop has been

achieved the KID control unit
(D795) activates the event
menu for rotation stop.


100

levelling
7.6.1
page
Hydraulic oil pump

7.6.2
page

VDRF03.02GB
100
7.6.3
page

Rotation is regulated by a separate section in the attachments control
valve. For a general description of the valve and component locations,
see Attachment control valve, description page 59.
Rotation slide
The valve slide controls the direction and speed of rotation. The valve
slide is controlled by servo valve, rotation clockwise and servo valve,
rotation anticlockwise.
Servo valve, rotation clockwise

Servo valve, rotation clockwise controls pressure to the rotation slide
so that the rotation slide opens and pressurises the rotation motors.
Servo valve, rotation clockwise is controlled electrically by solenoid
valve, rotation clockwise (Y6008), which is activated by the attachment control unit (D791-1). The servo valve directs servo pressure to
the rotation slide in proportion to the control current to the solenoid
valve.
Servo valve, spreading anticlockwise

Servo valve, rotation anticlockwise controls pressure to the rotation
slide so that the rotation slide opens and pressurises the rotation
motors.
Servo valve, rotation anticlockwise is controlled electrically by solenoid valve, rotation anticlockwise (Y6009), which is activated by the attachment control unit (D791-1). The servo valve directs servo
pressure to the rotation slide in proportion to the control current to the
solenoid valve.
page

7.6.4
page
Shuttle valve

VDRF03.02GB
7 Load handling 7.6.5 Valve block, rotation motor
7.6.5
101
Valve block, rotation motor
Valve block rotation motor, description
page
Valve block, rotation motor controls pressure to the rotation motors.

The valve block is located on one of the rotation motors.
The valve block provides a controlled rotation by preventing the load
from pulling away and provides faster rotation than the hydraulic motor. The valve block contains a shuttle valve and overcentre valves.
1
2
1
2
000530
1. Hydraulic motor rotation

2. Disc brake
3. Planetary gear
4. Gear wheel
5. Rotation yoke
6. Ring gear
7. Side shift frame
VDRF03.02GB
102
7 Load handling 7.6.6 Rotation motor unit
7.6.6
Rotation motor unit
Rotation motor unit, description
page
The rotation motors rotate the attachment in relation to the boom. The
motors are located along the front pf the attachments rotation yoke.
The motors work against the ring gear between the rotation yoke and
the side shift frame. The rotation motor unit consists of hydraulic motor, disc brake and planetary gear which are built together into one
unit.
The hydraulic motor is located on the disc brake housing. Between the
motor and the discs is a gear wheel.
1
2
The disc brake prevents accidental rotation. The disc brake is applied
with springs and is disengaged when the hydraulic pressure is built up
to rotate the yoke.
1
2
The planetary gear reinforces the output in the motor and disc brake.
The planetary gear changes the motor speed down so that motor power is greater.
000530

2. Disc brake
3. Planetary gear
4. Gear wheel
5. Rotation yoke
6. Ring gear
7. Side shift frame
VDRF03.02GB
page
103
Rotation motor unit, replacement
NOTE
B Safety.
B Safety.
3 Mark up and detach the hydraulic hoses from the motor.
NOTE
4 Remove the hydraulic motors attaching bolts.
5 Lift away the rotation motor unit. Position the motor unit so that
the pinion and planetary gear are not damaged.
6 Clean the contact surfaces on the motor unit and rotation yoke.
7 Lift the new motor unit into place.
8 Fit the motor unit. Tighten the bolts crosswise in steps until
117 Nm is achieved.
VDRF03.02GB
104
9 Connect the hydraulic hoses to the motor and brake in accordance with the marking.
NOTE
NOTE
C AUTION
010475

13 Check that the hydraulic connections are sealed tightly.
14 Check that the rotation is working.
VDRF03.02GB
7 Load handling 7.6.7 Rotation yoke
105
C AUTION
7.6.7
Rotation yoke
Rotation yoke, description
page
The rotation yoke is a part of the attachment which connects the attachment to the boom. The rotation yoke is secured on the inner boom
with two shafts which run in bearing equipped attaching lugs. In the
bottom of the rotation yoke is the ring gear with lead-through bolts.
Using the rotation motors which act on the ring gear the remaining
parts of the attachment can be rotated in relation to the lift boom.
000526
The rotation yokes mounting in the lift boom facilitates longitudinal

motion (so-called tilt). The oscillating motion is dampened by two hydraulic cylinders which are secured between the upper yoke and the
upper edge on the inner boom.
1. Main beam
2. Ring gear
4. Rotation yoke
6. Side shift frame
VDRF03.02GB
106
Rotation yoke, replacement
page
1 Clean the attachment and boom nose.

2 Release the attachment from the boom.
3 Remove the rotation motors from the rotation yoke.
4 Fit the lifting equipment on the rotation yoke.
5 Remove the pipes for ring gear lubrication.
The illustration shows removed rotation yoke and ring

gear.
6 Remove the rotation yoke attaching bolts.
7 Lift away the rotation yoke.
8 Clean the contact surfaces on the ring gear.
9 Remove the plastic plugs and clean the threads and holes on the
new rotation yoke, clean the contact surface against the ring
gear.
10 Transfer parts to the new rotation yoke.
Grease cups
Mounting shafts
11 Transfer the lifting equipment to the new rotation yoke.

12 Lift the new rotation yoke into place.
NOTE
Align the position against that of the ring gear so that the lubrication lines can be fitted.
13 Grease the rotation yokes mounting shafts with lubricating
grease and fit them in the rotation yoke.
VDRF03.02GB
107
14 Tighten the rotation yokes attaching bolts to a torque of 331 Nm.
15 Fit the pipes for the ring gear lubrication lines.

16 Lubricate the ring gear with lubricating grease.
Rotate the yoke during lubrication it so that the grease is distributed evenly.
17 Rotate the yoke so that it is straight.
18 Fit the rotation motors. See Rotation yoke, description page 105.
NOTE
If necessary, rotate the rotation yoke so that the rotation motors gear wheel aligns against the ring gear.
19 Connect the attachment to the boom.
20 Start the motor and check that the rotation is working.
21 Clean the attachment.
completely down and the extension cylinder completely in. The
oil level should be in the top of the level glass. Top up as needed.
C AUTION
Overfilling of oil.
Leakage and environmental damage.
VDRF03.02GB
108
7 Load handling 7.6.8 Ring gear
7.6.8
Ring gear
Ring gear, description
page
The ring gear is the joint between the rotation yoke and the side shift
frame. The ring gear consists of gear wheel, bearings and mounting
parts. The unit is bolted into the rotation yoke and side shift frame.
1
2
1
2
000530

2. Disc brake
3. Planetary gear
4. Gear wheel
5. Rotation yoke
6. Ring gear
7. Side shift frame
VDRF03.02GB
109
Ring gear, replacement
page
1 Remove the rotation yoke, see Rotation yoke, replacement page

106.
2 Remove the lubricating pipes from the ring gear.
NOTE
Note down the locations of the lubricating pipes to facilitate
fitting.
gear.
3 Remove the attaching bolts between the ring gear and the side
shift frame.
4 Lift away the ring gear.
5 Clean the contact surfaces on the side shift frame and ring gear.
6 Lift the new ring gear into place.
NOTE
Rotate it so that the connections for the lubricating pipes are
in the same positions as before.
7 Lubricate the inner attaching bolts with lubricating grease and fit
them. Tighten the bolts crosswise in turns to a torque of 331 Nm.
8 Fit the rotation yoke, see Rotation yoke, replacement page 106.
9 Fit the lubricating pipes to the ring gear.
10 Lubricate the ring gear with lubricating grease.
11 Start the motor and check the function of the rotation.

gear.
completely down and the extension cylinder completely in. The
oil level should be in the top of the level glass. Top up as needed.
C AUTION
Overfilling of oil.
Leakage and environmental damage.
7.6.9
page
Side shift frame

See Side shift frame, description page 65.
VDRF03.02GB
110
7 Load handling 7.6.10 Sensor, rotation stop
7.6.10
page
Sensor, rotation stop
Sensor rotation stop, description

Sensor rotation stop (B7225) indicates when rotation is 25 from the
centre position and is used to activate rotation stop. The sensor is located on a bracket on the left side of the rotation yoke and detects 25
towards the rotation yokes mechanical stop.
The sensors are supplied with voltage and send 24 V signal to the attachment control unit (D791-1) when the raised parts pass the sensor.
page

7.6.11
page

7.6.12
page
Pipes and hoses

VDRF03.02GB
7 Load handling 7.7 Tilt
7.7
111
Tilt
Tilt damping, function description
page
2
A
C1C2+
C
B
C1+
C2-
000461
Pos
Explanation
Signal description
Reference
Hydraulic oil pump 2 pumps oil.

left frame beam.

The tilt damping block distributes oil to the

tilt cylinders.
Damping block tilt, description page 117
The tilt cylinders suppress the attachments

movements.
Tilt cylinder, description page 121
VDRF03.02GB
112
Tilt locking, function description
page
D1
D790-1
D795
D797-R
D791-1
D3
11
7
D7
C1C2+
10
4
B
C1+
C2-
C6
006412
Pos
Explanation
Signal description
Reference

(D790-1).
US815-T3.1 = 24 V


tilt locking on the CAN bus.

error code.

Cab control unit
Control unit, frame rear (D797-R) activates the solenoid valve, engagement of
hydraulics for top lift (Y6003).
U = 24 V

page 58
Solenoid valve, engagement of hydraulics for top lift (Y6003) opens and pressurises valve block lift cylinder and
pumps.

load signal to the hydraulic oil pumps if
several functions are activated simultaneously.
VDRF03.02GB



page 58

Shuttle valve
113
Pos
Explanation
Signal description
Reference

hydraulic oil tank.

left frame beam.

The attachment control unit (D791-1) activates the servo valve, tilt lock (Y6012).
Float position: U = 24 V

Lock position: U = 0 V

8
Lock valve tilt, description page 119
Servo valve, tilt lock (Y6012) pressurises the lock valve in the attachment control valve.
The lock valve changes position and

blocks the connections to the tilt cylinders.
10
The tilt cylinders lock the attachments

inclination.
11
When tilt locking is activated, the KID

control unit (D795) shows the tilt locking
event menu.


When tilt locking is activated, the machines speed is limited to max. 5 km/h.
levelling
VDRF03.02GB
114
Tilt control, function description
page
Condition
Reference
value
Reference
Safety switch
Disengaged
Overload system
Passive
D1
1
D790-1
3
D791-2
D797-F
D791-1
7
D7
D3
10
11 D10
8
C6
P1
13
T1
C6
C1C2+
C1+
C2-
12
013027
Pos
Explanation
Signal description
Reference

signal proportional to lever movement.
Tilt out: US815/P4 = 0.52.0 V


2.0-3.0 V
Tilt in: US815/P4 = 3.04.5 V


transmits tilt in or tilt out on the
CAN bus.


Cab control unit

activates the solenoid valve, engagement of hydraulics for top lift
(Y6003).
U = 24 V

VDRF03.02GB

115
Pos
Explanation
Signal description
Reference
Solenoid valve, engagement of

hydraulics for top lift (Y6003)
opens and pressurises valve block
lift cylinder and sends a load signal to the hydraulic oil pumps.

page 58
The shuttle valve forwards the

strongest load signal to the hydraulic oil pumps if several functions are activated simultaneously.

Shuttle valve
Hydraulic oil pump 2 pumps oil


frame beam.

The attachment control unit option

(D791-2) activates servo valve, tilt
out (6010) or servo valve, tilt in
(Y6011).
I = 400650 mA

Control unit, attachment option or section 11
Common electrics, group 11.5.3.8 Control
unit, attachment right jack pair


Machine with lifting jacks

The attachment control unit right
jack pair (D791-4) activates servo
valve, tilt out (6010) or servo
valve, tilt in (Y6011).
8

120
The servo valve for tilt out (Y6010)

or tilt in (Y6011) pressurises the tilt
slide in the attachments control
valve.
The control valves tilt slide changes position and pressurises the
damping block.

120
10

(D791-1) activates the servo
valve, tilt lock (Y6012).
Float position: U = 24 V

Servo valve, tilt lock (Y6012) pressurises the lock valve in the attachment control valve.
12
The lock valve changes position

and directs oil crosswise to the tilt
cylinders.
Damping block tilt, description page 117
13
The tilt cylinders change the attachments inclination.
11

Lock position: U = 0 V



VDRF03.02GB
116
levelling
Tilt damping, adjustment
page
NOTE
B Safety.
NOTE
Tilt damping may need to be adjusted after running-in due to mechanical tolerances.
1 Engine at idling speed.
2 Raise the boom without a load and check that the attachment is
suspended horizontally throughout the lifting movement.
3 Adjust tilt damping as required by adjusting the screws on the
damping block. Adjust both screws by the same amount.
Clockwise: increase damping.

Anticlockwise: decrease damping.
4 Lift a loaded container, test drive, and brake, check that the container does not swing uncontrollably. If necessary, adjust the
damping in accordance with Step 3.
005350
5 Start the machine and check that the function is working

satisfactorily.
1. Adjusting screws
7.7.1
page
Hydraulic oil pump

7.7.2
page

VDRF03.02GB
7 Load handling 7.7.3 Damping block, tilt
7.7.3
117
Damping block, tilt
Damping block tilt, description
page
The damping block contains restrictions which create resistance to the

tilt cylinders movements, which in turn dampen the attachments oscillations. The damping block is located in the centre of the boom nose.
The damping block is supplied with oil via the return from the attachments control valve. The feed means that the cylinders are always
filled with oil. Precisely adjusted restrictions mean that the feed does
not affect the tilting. The constant feed means that the tilt cylinders do
not need bleeding after work on tilting.
000535
The damping block contains two shock valves which protect the valve
against surges.
1. Damping block
2. Tilt cylinder
page
Damping block tilt, replacement
NOTE
B Safety.
B Safety.
3 Mark up and detach the hydraulic hoses from the valve block.
NOTE
4 Remove the valve block from the boom.
VDRF03.02GB
118
7 Load handling 7.7.3 Damping block, tilt
5 Transfer the connection adapters to the new valve. Transfer one

adapter at a time so that the marking is not mixed up.
NOTE
6 Fit a new valve block to the boom nose.
The illustration shows the damping block with controllable tilt.

7 Connect the hydraulic hoses to the damping block in accordance
with the marking.
NOTE
NOTE
C AUTION
010475

VDRF03.02GB
7 Load handling 7.7.4 Lock valve, tilt
119
10 Start the machine and check seal integrity and function.

Check both tilt and attachment functions.
C AUTION
7.7.4
page
Lock valve, tilt
Lock valve tilt, description
On machines with tilt lock, there are two solenoid valves on the damping blocks return lines. When the solenoid valves are activated the
connection between the cylinders is blocked and locks the tilt position.
The lock valves are located on the damping block.
Solenoid valve tilt (Y6012) is supplied with voltage by Control unit, attachment option (D791-2) when tilt lock is not activated.
VDRF03.02GB
120
7.7.5
page
Controllable tilt is regulated by a separate section in the attachments

control valve. For a general description of the valve and component locations, see Attachment control valve, description page 59.
Tilt slide
The valve slide controls the direction and speed of attachment tilting.
The valve slide is controlled by servo valve, tilt in and servo valve, tilt
out.
Servo valve, tilt out

Servo valve tilt out controls pressure to the tilt slide so that the tilt slide
opens and pressurises the tilt cylinders.
The servo valve tilt out is controlled electrically by the solenoid valve
for tilt out (Y6010), which is activated by Control unit, attachment option (D791-2). The servo valve directs servo pressure to the tilt slide in
proportion to the control current to the solenoid valve.
Servo valve, tilt in

Servo valve tilt in controls pressure to the tilt slide so that the tilt slide
opens and pressurises the tilt cylinders.
The servo valve tilt in is controlled electrically by the solenoid valve for
tilt in (Y6011), which is activated by Control unit, attachment option
(D791-2). The servo valve directs servo pressure to the tilt slide in proportion to the control current to the solenoid valve.
The signal can be checked from the diagnostic menu; see section
page

7.7.6
page
Shuttle valve

VDRF03.02GB
7 Load handling 7.7.7 Tilt cylinder
7.7.7
121
Tilt cylinder
Tilt cylinder, description
page
The piston rod bracket is welded to the piston rod, which is threaded
in the piston head and locked with a lock screw. The cylinder head is
threaded in the cylinder pipe.
000535
The tilt cylinders are located between the inner booms front edge and
the rotation yokes upper section. The two cylinders are positioned diagonally and can therefore effectively dampen or control tilt motion.
1. Damping block
2. Tilt cylinder
page

7.7.8
page
Lift boom
Lift boom, general

See Lift boom, description page 35.
7.7.9
page
Rotation yoke
Rotation yoke, general

See group 7.6.7 Rotation yoke.
7.7.10
page

7.7.11
page
Pipes and hoses

VDRF03.02GB
122
7 Load handling 7.8 Levelling
7.8
Levelling
Hydraulic levelling, function description
page
Condition
Reference
value
Reference
Safety switch
Disengaged
Overload system
Passive
D1
1
2
D790-1
3
D791-2
D791-3
D797-R
7 9
D8
D9
D4
10
C6
14
P1
T1
11
C6
12
13
006888
Pos
Explanation
Signal description
Reference
Control lever (S815-P3) transmits a voltage signal proportional to lever movement while control lever S815-T4 sends
voltage to the cab control unit (D790-1).
Levelling right: US815/P3

= 0.52.0 V
Zero position: US815/P3
= 2.03.0 V

Levelling left: US815/P3

= 3.04.5 V
US815/T4 = 24 V
VDRF03.02GB
123
Pos
Explanation
Signal description
Reference

levelling left or right on the CAN bus.
Checked by control
system, error shown
with error code.

Cab control unit
U = 24 V

Solenoid valve, engagement of hydraulics for top lift (Y6003) opens the connection between the pumps and the
attachments control valve.


Shuttle valve

hydraulic oil tank.

left frame beam.

Control unit, attachment option

(D791-2) or activates solenoid valve,
levelling (Y6034).
U = 24 V

unit, attachment left jack pair


page 58
Machine with combi attachment

Control unit, attachment left jack pair

(D791-3) activates solenoid valve, levelling (Y6034).
8
The levelling control valve opens a connection to the levelling cylinders in the
levelling cylinders valve block.
Levelling cylinders valve block, description

page 128
Control unit, attachment option

(D791-2) or control unit attachment, left
jack pair (D791-3) activates servo valve,
levelling right (Y6035) or servo valve
levelling left (Y6036).
I = 400650 mA

unit, attachment left jack pair
The servo valve for levelling right

(Y6035) or levelling left (Y6036) is actuates the levelling slide in the attachment
control valve.
The control valves levelling slide

changes position and pressurises the
levelling overcentre valve.
10
11


127

127
VDRF03.02GB
124
Pos
Explanation
Signal description
Reference
12
The overcentre valve opens and directs

pressure to the levelling cylinders valve
block.
Overcentre valve, levelling, description page

128
13
The levelling cylinders valve block directs pressure on to the levelling cylinders.

page 128
14
The levelling cylinders lock the attachments inclination.
Levelling cylinders, description page 129

levelling
VDRF03.02GB
125
Levelling lock, function description
page
Condition
Reference
value
Reference
Safety switch
Disengaged
D1
D790-1
D795
D797-F
D791-2
D791-3
10
D8
D4
8
C6
P1
9
4
T1
5
C6
006889
Pos
Explanation
Signal description
Reference

(D790-1).
US815-T3.1 = 24 V


levelling lock on the CAN bus.

error code.

Cab control unit
U = 24 V

page 58


VDRF03.02GB
126
Pos
Explanation
Signal description
Reference
Solenoid valve, engagement of hydraulics for top lift (Y6003) opens the connection between the pumps and the
attachments control valve.

page 58


Shuttle valve
The hydraulic oil pumps pump oil from


left frame beam.

Control unit, attachment option (D791-2)

stops activation solenoid valve, levelling
(Y6034).
U=0V

page 128


Machine with combi attachment.

(D791-3) stops activation solenoid
valve, levelling (Y6034).
8

page 128
The levelling control valve (Y6034)

blocks the connections to the levelling
cylinders in the levelling cylinders valve
block.
The levelling cylinders change the attachments inclination.
Levelling cylinders, description page 129
10
When tilt lock is activated, event menu

shows tilt lock.


When levelling lock is activated, the machines speed is limited to max. 5 km/h.
levelling
7.8.1
page
Hydraulic oil pump

7.8.2
page

VDRF03.02GB
7.8.3
page
127

Hydraulic levelling is regulated by a separate section in the attachment
Levelling slide
The valve slide controls the direction and speed of attachment levelling.
The valve slide is controlled by the servo valve for levelling right
(Y6035) and levelling left (Y6034).
Servo valve, levelling right

The servo valve for levelling right controls pressure to the levelling
slide so that it opens and pressurises the levelling cylinders.
The servo valve levelling right is controlled electrically by the solenoid
valve for levelling right (Y6035), which is activated by Control unit, attachment option (D791-2). The servo valve directs servo pressure to
the tilt slide in proportion to the control current to the solenoid valve.
Servo valve, levelling left

The servo valve for levelling left controls pressure to the levelling slide
so that it opens and pressurises the levelling cylinders.
The servo valve levelling left is controlled electrically by the solenoid
valve for levelling left (Y6036), which is activated by Control unit, attachment (D791-2). The servo valve directs servo pressure to the tilt
Passive levelling
The servo valves open a connection to the tank, in addition, hydraulic
oil can flow between right and left-hand side levelling cylinders, from
piston sides to rod sides, in accordance with inclination.
Active levelling
Levelling is monitored by the sequence valves in the valve block levelling cylinder, which close when the feed pressure is high enough to
set all cylinders in bottom position. Following which, hydraulic oil is fed
to the rod sides on one sides cylinders and the side lifts. When levelling, the other side will thus always be in its lowest position. This always gives maximal levelling travel.
page

VDRF03.02GB
128
7.8.4
Shuttle valve
page
7.8.5
Overcentre valve, levelling
Overcentre valve, levelling, description
page
The overcentre valve ensures that the levelling cylinders are completely extended. The valve is located to the right of the attachment
control valve on the rear edge of the side shift frame under the levelling
cylinders valve block.
Passive levelling
The over-centre valves allow flow of hydraulic oil between right and left
levelling cylinders, from piston sides to rod sides, in accordance with
inclination.
Active levelling
001062
The over-centre valves close when the feed pressure is high enough
to put all levelling cylinders in bottom position. Then, hydraulic oil is
supplied through the levelling cylinder valve block to the rod sides on
one sides (right or left) cylinders and the side lifts. When levelling, the
other side will thus always be in its lowest position. This always gives
maximal levelling travel.
7.8.6
Valve block, levelling cylinders
page
The levelling cylinders valve block directs pressure from the attachment control valve to the levelling cylinders. The valve block comprises lock valves that block the levelling when the levelling lock is
activated or if the machine is without power. The valve sits to the right
of the attachment control valve on the rear edge of the side shift frame
above the overcentre valve for levelling.
Lock valve
The lock valve is opened by Solenoid valve levelling (Y6034). When
the lock valve is closed the oil is blocked to and from the levelling cylinders, and levelling is blocked. Solenoid valve levelling (Y6034) is
supplied with voltage by Control unit, attachment option (D791-2) or
Control unit, attachment right jack pair (D791-4).
001061
VDRF03.02GB
7 Load handling 7.8.7 Levelling cylinders
7.8.7
129
Levelling cylinders
Levelling cylinders, description
page
001860
On machines with hydraulic levelling there are four hydraulic cylinders

between the sideshift frames parts, see Side shift frame, description
page 129.
page
7.8.8
Side shift frame
page
The sideshift frame is available in two different versions, see Side shift
frame, description page 65.
Mechanical levelling
5
2. Side shift frame upper section
3. Levelling cylinder
4. Side shift frame lower section
001932
The sideshift frame is larger than the attachments main beam. The
main beam can move freely between the slide plates. This allows approx. 5 levelling.
Hydraulic levelling
The sideshift frame is split in two. There are four levelling cylinders between the two sections, see Levelling cylinders, description page 129.
The outer section is secured in the rotation yoke via the ring gear. The
inner part holds the attachments main beam. The main beam slides
on slide plates. The hydraulic cylinders stroke makes levelling of the
main beam possible, approx. 5. With hydraulically controlled levelling,
the angle of the main beam attachment can be controlled with the control lever.
7.8.9
page

7.8.10
page
Pipes and hoses

VDRF03.02GB
130
7 Load handling 7.9 Load carrier
7.9
Load carrier
7.9.1
Twistlocks
Twistlocks, function description
page
Condition
Reference value
Reference
Safety switch
Disengaged
Contact
Full contact or bypass

activated
Overload system
Passive
D1
D18
7, 20
8
D790-1
D790-2
D797-R
D791-1
5, 21
D795
D2
9
4, 6, 13,18, 19
D13
D3
D8
14
D17
P1
T1
10
C12
17
C12
16
15
11
006890
12
Pos
Explanation
Signal description
Reference
The switch for locking the twistlocks

(S1003) (automatic mode) sends a voltage signal to the cab control unit (D7901).
U = 24 V

VDRF03.02GB

7 Load handling 7.9.1 Twistlocks
131
Pos
Explanation
Signal description
Reference
The control lever (S815-T2) sends a

(D790-1) for opening twistlocks.
US815/T2 = 24 V

system , group 8.4.9.3 ATTACH, menu 3
If Switch, lock twistlocks (S1003) is in

manual position no signal is needed
from the control lever to open twistlock.
The sensor for front left alignment
(7202L), sensor for front right alignment
(7202R), sensor for rear left alignment
(Y7203L) and sensor for rear right alignment (Y7203R) send a voltage signal to
the attachment control unit (D791).
Sensor directly opposite

indicator plate: U = 24 V
Sensor alignment, description page 140
The attachment control unit (D791)

transmits alignment on the CAN bus.

error code.

The KID control unit (D795) activates

the alignment event menu.

The attachment control module (D791)

activates the alignment indicator light on
the booms light panel.
U = 24 V

system group 8.4.9.10 ATTACH, menu 10
The KIT control module (D790-2) activates the alignment indicator light on the
cab light panel.


"open twistlocks" or "lock twistlocks" on
the CAN bus.

error code.

Cab control unit
U = 24 V

sends a load signal to hydraulic oil
pump 2.
11


Shuttle valve
12

hydraulic oil tank.

left frame beam.

10



page 58
VDRF03.02GB
132
Pos
Explanation
Signal description
Reference
13
The attachment control unit (D791) activates the "open twistlocks" servo valve
(Y6039) or "lock twistlocks" servo valve
(Y6040).
U = 24 V

The "open twistlocks" servo valve

(Y6039) or "lock twistlocks" servo valve
(Y6040) pressurises the twistlocks slide
with servo pressure.
15
The control valves twistlocks slide

changes position and pressurises the
locks cylinders.

135
16
The lock cylinders rotate the twistlocks.
Lock cylinder, description page 136
17
The "unlocked twistlocks" sensor

(B7204) or the "locked twistlocks" sensor (B7205) sends a signal to the attachment control unit (D791).

Sensor twistlocks, description page 141
18
The attachment control unit (D791) supplies voltage to the "unlocked twistlocks"
indicator light (H562) or the "locked
twistlocks" indicator light (H563) on the
booms light panel.
U = 24 V

19
The attachment control unit (D791)

transmits "twistlocks unlocked" or "twistlocks locked" on the CAN bus.

error code.

20
The KIT control unit (D790-2) supplies

voltage to the "unlocked twistlocks" indicator light or the "locked twistlocks" indicator light on the cab light panel.

21

the twistlocks event menu.

14


135


levelling
VDRF03.02GB
133
Overheight jacks, function description
page
Condition
Reference
value
Reference
Safety switch
Not activated
Overload system
Passive
Section 8 Control system, group 8.2.1.1 Mechanical overload system
Twistlocks
Open
13
1
2
D790-1
D797-R
D791-2 7
D3
12
C6
P1
A
11
T1
10
9
5
008218
C6
6
Pos
Explanation
Signal description
Reference
1.
The overheight jacks switch (S1031) sends

a voltage signal to the cab control unit
(D790-1).
U = 24 V
2.
Control unit cab (D790-1) sends a message

to lower overheight jacks on the CAN bus.
Checked by control
system, error shown
with error code.

3.
Control unit, frame rear (D797-R) activates

the solenoid valve, engagement of hydraulics for top lift (Y6003).
U = 24 V

page 58
D3: Diagnostic menu, see section 8 Control system, group 8.4.5.6 HYD, menu 6
VDRF03.02GB
134
Pos
7 Load handling 7.9.1.1 Hydraulic oil pump
Explanation
Signal description
Reference
4.
Solenoid valve, engagement of hydraulics

for top lift (Y6003) opens and pressurises
valve block top lift hydraulics and sends a
load signal to hydraulic oil pump 2.

page 58
5.

load signal to the hydraulic oil pump 2 if several functions are activated simultaneously.

6.
Hydraulic oil pump 2 pumps oil from the hydraulic oil tank.

left frame beam.

7.
Control unit, attachment option (D791-2) activates the servo valve overheight jacks up
(Y6070) or servo valve overheight jacks
down (Y6071).
U = 24 V

135
8.
Servo valve overheight jacks up (Y6070) or

servo valve overheight jack down (Y6071)
pressurises the overcentre valve for overheight jacks.
U = 24 V

135
9.
Overcentre valve opens and pressurises hydraulic cylinder overheight jacks.
Overcentre valve (product alternative overheight jacks) page 142
10.
Hydraulic cylinder overheight jacks lowers

the overheight jacks.
Hydraulic cylinder, overheight jacks page

142
11.
Sensor overheight jacks up left (B7231-L) or

sensor overheight jacks up right (B7231-R)
sends a voltage signal to Control unit, attachment option (D791-2).
Sensor directly opposite indicator plate: U =

24 V
Sensor, overheight-jacks page 143
12.
Control unit, attachment option (D791-2) activates the indicator lamp for overheight
jacks up (H5001).
Overheight jacks up: U

= 24 V

11.5.3.6 Control unit, attachment option
Indicator light, overheight jacks up (H5001)

illuminates when the jacks are completely
raised.
Overheight jacks up: U

= 24 V
13
Overheight jacks
down: U = 0 V
Overheight jacks
down: U = 0 V
7.9.1.1
page
Hydraulic oil pump

7.9.1.2
page

VDRF03.02GB
7 Load handling 7.9.1.3 Control valve attachment
7.9.1.3
page
135

Twistlocks are regulated by a separate section in the attachments
Twistlocks slide, description

The valve slide controls the direction and the lock cylinder.
The valve slide is controlled by two servo valves, lock twistlocks and
open twistlocks.
"Lock twistlocks" servo valve, description

The "lock twistlocks" servo valve directs pressure to the twistlocks
slide so that the slide opens and pressurises the lock cylinders.
The servo valve lock twistlocks is controlled electrically by the solenoid
valve for lock twistlocks (Y6040), which is activated by Control unit, attachment (D791-1). The servo valve directs servo pressure to the
twistlocks slide in proportion to the control current to the solenoid
valve.
"Open twistlocks" servo valve, description

The "open twistlocks" servo valve directs pressure to the twistlocks
slide so that the slide opens and pressurises the lock cylinders.
The servo valve open twistlocks is controlled electrically by the solenoid valve for open twistlocks (Y6041), which is activated by Control
unit, attachment (D791-1). The servo valve directs servo pressure to
the twistlocks slide in proportion to the control current to the solenoid
valve.
page

7.9.1.4
page
Shuttle valve

VDRF03.02GB
136
7 Load handling 7.9.1.5 Lock cylinder
7.9.1.5
Lock cylinder
Lock cylinder, description
page
000539
The lock cylinder pulls the lock mechanism so that the twistlocks are
rotated. Two lock cylinders - one in the right and one in the left spreader beam - pull the lock mechanism. The lock cylinders are located in
the centre of the spreader beams longitudinal section.
page
7.9.1.6
Lock mechanism
Lock mechanism, description
page
The lock mechanism transfers the force of the lock cylinders to the
twistlocks. Two lock mechanisms - one in the right and one in the left
spreader beam - actuate the twistlocks. The lock mechanism runs
along the longitudinal section of the spreader beam between the twistlocks.
001863
The lock mechanism consists of a rod with two spherical plain bearings in the end. The rod is fastened in levers that rotate the twistlocks.
A retaining lug for the lock cylinder sits in the centre of the rod.
VDRF03.02GB
7 Load handling 7.9.1.7 Twistlocks
7.9.1.7
137
Twistlocks
Twistlocks, description
page
WARN IN G
Dropped load.
Twistlocks hold the load during load handling and

therefore it is very important that twistlocks are
checked according to instructions and are replaced at
the slightest sign of damage or wear.
Fatal danger!
Twistlocks secure the load and are located in the corners of the
spreader beams longitudinal part.
000536
Twistlocks are manufactured from high-strength steel according to international standards. The lift pins are marked with serial numbers.
Twistlocks are connected in pairs via a linkage system to a hydraulic
cylinder which in turn is controlled via a section in the attachments
control valve. Inductive sensors send signals when the twistlocks are
locked and unlocked, respectively.
1. Lock mechanism
2. Sensor alignment
3. Contact pin
4. Lift pin
5. Lock guide
VDRF03.02GB
138
page
Twistlock, replacement
2 Depressurise the brake and hydraulic systems, see section B
Safety.
3 Clean the twistlocks and the surrounding area.
4 Detach the centre nut of the twistlocks.
5 Tap on the nut so that the lift pin releases from the wedge.
6 Hold the lift pin while removing the centre nut.
WARN IN G
Dropped component.
Risk of pinch injury or product damage.
Twistlock weighs approx. 30 kg.
7 Remove the centre nut and lift away the twistlock.
8 Coat a new lift pin with grease and position it in the guide pin.
9 Place the lift pin and guide pin in the extension beam. Place the
guide pin so that the grease cup is accessible through the holes
in the extension beam.
NOTE
Do not forget the washer between the extension beam and
guide pin.
10 Position the wedge, bearing, lever, new locking washers and

new lock nuts on the lock pin.
Apply lubricating grease to the parts before fitting.
11 Check the positions of the parts and that the twistlock can move.
12 Tighten the lock nut to a torque of 300 Nm.
13 Lubricate the guide pin, lever and bearing arrangement with lubricating grease.
14 Check that the twistlock mechanism can move.
15 Turn on the main electric power and start the machine.
16 Check that the twistlock is working.
VDRF03.02GB
139
Twistlock, replacement (product alternative Collet type)
page
1 Machine in service position, see section B Safety in the Workshop Manual.

2 Depressurise the hydraulic systems, See section B Safety in the
Workshop Manual.
3 Clean the twistlocks and the surrounding area.
4 Slacken the screws of the clamp holding the twistlocks in place.
5 Hold the twistlock while removing the clamp halves.
WARN IN G
Dropped component.
Risk of pinch injury or product damage.
009958
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 twistlock can move.
9 Tighten the screws of the clamp halves.
10 Lubricate the twistlock and lock mechanism with lubricating
grease.
11 Check that the twistlock mechanism can move.
12 Turn on the main electric power and start the machine.
009958
13 Check that the twistlock is working.
VDRF03.02GB
140
7 Load handling 7.9.1.8 Sensor alignment
7.9.1.8
Sensor alignment
Sensor alignment, description
page
The alignment sensors detect when the attachment has contact with
the container. Four inductive sensors - one at each twistlock at the far
corner of the longitudinal section of the spreader beam - 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 above 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 containers corner boxes means the sensors stop
sending signals when the attachment is lifted.
001451
The sensors are supplied voltage by and send a 24 V signal to the attachment control unit (D791) when the indicator pin is pressed in.
Alignment sensor, checking
page

2 Check that the indicator pins in the corner boxes can freely move
up and down. The indicator pins must spring down when they are
not loaded.
3 Check that the sensor is free of damage and dirt.
4 Start the machine.
000360
5 Lower the attachment to a container and check that all twistlocks

indicate contact - filled circles in the alignment event menu - and
that the alignment indicator lamp illuminates.
Event menu, alignment
6 Lift the attachment slightly so that contact is just broken (unfilled

circles in the alignment event menu or alignment indicator lamp
goes out).
7 Check more must indicator pin movement is required to detect
contact. The movement must be 34 mm.
8 Adjust sensor position if necessary. See Position sensor, checking and adjustment page 5.
page

VDRF03.02GB
7 Load handling 7.9.1.9 Twistlock sensor
7.9.1.9
141
Twistlock sensor
Sensor twistlocks, description
page
001452
Twistlocks sensors detect when the twistlocks are locked or unlocked.

Four inductive position sensors - two in each spreader beam - detect
the position of the lock mechanism. The sensors are located at the
lock cylinder in the centre of the longitudinal section of the spreader
beam.
Both sides function the same way independently of one another. An
indicator plate is located on the lock mechanism at the lock cylinder.
When the lock mechanism is in the position that locks the twistlocks,
one of the sensors sends a signal to the attachment control unit
(D791). When the lock mechanism is in the position that unlocks the
twistlocks, the other sensor sends a signal to the attachment control
unit (D791). No signals are sent if the lock mechanism stops midway.
The sensors are supplied voltage by and send a 24 V signal to the attachment control unit (D791) when the indicator plate is in front of the
sensor.
page

7.9.1.10
page

7.9.1.11
page
Pipes and hoses

VDRF03.02GB
142
7 Load handling 7.9.1.12 Overcentre valve
7.9.1.12
Overcentre valve
Overcentre valve (product alternative overheight jacks)
page
1
The overcentre valve prevents the overheight jacks lowering under
their own weight.
008219
1. Hydraulic cylinder, overheight jacks

2. Overcentre valve, overheight jacks
3. Sensor, overheight jacks up
(B7231-L and B7231-R)
7.9.1.13
Hydraulic cylinder, overheight jacks
Hydraulic cylinder, overheight jacks
page
1
The hydraulic cylinder lowers the overheight jacks. The hydraulic cylinder is controlled by a separate section in the attachment control
valve, see Attachment control valve, description page 78.
008219

(B7231-L and B7231-R)
page

VDRF03.02GB
7 Load handling 7.9.1.14 Sensor, overheight-jacks
7.9.1.14
143
Sensor, overheight-jacks
Sensor, overheight-jacks
page
1
Sensor, overheight jacks up, detects when the jacks are completely
raised.
Sensor, overheight jacks up left (B7231-L) detects the position of the

left jack pair and sends a voltage signal to Control unit, attachment option (D791-2) when the jack pair is fully folded up.
008219
Sensor, overheight jacks up right (B7231-R) detects the position of the

left jack pair and sends a voltage signal to Control unit, attachment option (D791-2) when the jack pair is fully folded up.

(B7231-L and B7231-R)
page

VDRF03.02GB
144
7 Load handling 7.9.2 Lifting jacks
7.9.2
Lifting jacks
Raising/lowering of front lifting jacks, function

description
page
Condition
Reference
value
Reference
Safety switch
Disengaged
20
1, 29
D1
25
21, 22
D21
26, 27
T1
D26
P1
19
D28
2
D790-1
D797-R
D791-4
D791-3
3, 18, 23
24
D23
D18
D13
D8
3, 8, 13, 28
14
P1
T1
D16
D4
5
16, 17
D11
15
11, 12
C7
7
013028
10
VDRF03.02GB
145
Pos
Explanation
Signal description
Reference
The switch for lowering the front jacks

(S1006) sends a voltage signal to the
U = 24 V
Control unit cab (D790-1) sends front

lifting jacks down or up on the CAN bus.


(D791-3) and Control unit, attachment
right jack pair (D791-4) send activate
top hydraulics on the CAN bus.

11.5.3.7 Control unit, attachment left jack
pair and section 11 Common electrics,
group 11.5.3.8 Control unit, attachment right
jack pair
U = 24 V

sends a load signal to hydraulic oil pump
2.



hydraulic oil tank.

frame beam.


(D791-3) activates solenoid valve front
knee out left (Y6056L).
U = 24 V

pair

system , group 8.4.11.1 COMBI, menu 1


page 58

9
Control valve, lifting jacks, description page

160
Solenoid valve front knee out left

(Y6056L) pressurises hydraulic cylinder
knee left front.
10
Hydraulic cylinder knee left front lowers

knee left front.
Hydraulic cylinder knee/clamp, description

page 165
11
Sensor front knee left (B7217L) sends a

voltage signal to Control unit, attachment left jack pair (D791-3) when the
knee is lowered.
U = 24 V
Sensor knee, description page 166


VDRF03.02GB
146
Pos
Explanation
Signal description
Reference
12
Sensor front knee left (B7217L) stops

sending a signal to Control unit, attachment left jack pair (D791-3).
U=0V

jack down left (Y6013L) when sensor
front knee left (B7217L) stops sending a
signal.
U = 24 V
Solenoid valve front jack down left

(Y6013L) pressurises Hydraulic cylinder
jack left front.
15
Hydraulic cylinder jack left front lowers

jack left front.
Hydraulic cylinder, jack, description page

168
16
Sensor front jack left (B7219L) sends a

signal to Control unit, attachment left
jack pair (D791-3) when the jack is lowered.
U = 24 V
Sensor, lifting jacks, description page 168
Sensor front jack left (B7219L) stops

U=0V
Control unit, attachment right jack pair

knee out right (Y6056R) when sensor
front jack left (B7219L) stops sending a
signal.
U = 24 V
Solenoid valve front knee out right

(Y6056R) pressurises hydraulic cylinder
knee right front.
20
Hydraulic cylinder knee right front lowers knee right front.

page 165
21
Sensor front knee right (B7217R) sends

a voltage signal to Control unit, attachment right jack pair (D791-4) when the
knee is lowered.
U = 24 V
Sensor front knee right (B7217R) stops

sending a signal to Control unit, attachment right jack pair (D791-4).
U=0V
13
14
17
18
19
22
VDRF03.02GB

pair

160


11.5.3.8 Control unit, attachment right jack
pair

160


147
Pos
Explanation
Signal description
Reference
23

jack down right (Y6013R) when sensor
front knee right (B7217R) stops sending
a signal.
U = 24 V

pair
24
Solenoid valve front jack down right

(Y6013R) pressurises Hydraulic cylinder jack right front.

160
25
Hydraulic cylinder jack right front lowers

jack right front.

168
26
Sensor front jack right (B7219R) sends

a signal to Control unit, attachment right
U = 24 V
Sensor front jack right (B7219R) stops

sending a signal to Control unit, attachment right jack pair (D791-4) when the
jack has reached the end position.
U=0V

(D791-4) activates indicator lamp front
jack down (H580).
U = 24 V
27
28



pair
29
When the switch is released, activation of all solenoid valves is interrupted. Solenoid valves remain activated even
after the movement has been completed in order for it to be possible to complete the movement if the button is released when the lifting jack is in an intermediate position.
VDRF03.02GB
148
Raising/lowering of rear lifting jacks, function

description
page
Condition
Reference
value
Reference
Safety switch
Disengaged
D32
32
20
31
1, 33
21
D21 22
D1
D26
25
30
26
27
A
P1
D30
T1
D23
24
2
D790-1
D791-4
29
19
3, 18, 23, 28 D18

D29
D797-R
D8
D791-3 3, 8, 13, 28
14
D5
29
D13
P1
T1
D16
16
17
30
15
C
7
6
11
D11 12
31
10
32
013029
D32
VDRF03.02GB
149
Pos
Explanation
Signal description
Reference
The rear jacks switch (S1007) sends a

(D790-1).
U = 24 V
Control unit cab (D790-1) sends rear lifting jacks down or up on the CAN bus.

error code.


right jack pair (D791-4) send activate top
hydraulics on the CAN bus.

error code.

jack pair
U = 24 V

Solenoid valve, engagement of hydraulics for top lift (Y6003) opens and pressurises valve block lift cylinder and sends a



hydraulic oil tank.

left frame beam.


(D791-3) activates solenoid valve rear
knee out left (Y6058L).
U = 24 V

pair



page 58

9

160
Solenoid valve rear knee out left

(Y6058L) pressurises hydraulic cylinder
knee left rear.
10
Hydraulic cylinder knee left rear lowers

knee left rear.

page 165
11
Sensor rear knee left (B7218L) sends a

voltage signal to Control unit, attachment
left jack pair (D791-3) when the knee is
lowered.
U = 24 V

D11: Diagnostic menu, see section 8 Control system , group 8.4.11.1 COMBI, menu 5
VDRF03.02GB
150
Pos
Explanation
Signal description
Reference
12
Sensor rear knee left (B7218L) stops

U=0V

jack down left (Y6014L), sensor rear knee
left (B7218L) stops sending a signal.
U = 24 V
Solenoid valve rear jack down left

(Y6014L) pressurises Hydraulic cylinder
jack left rear.
15
Hydraulic cylinder jack left rear lowers

jack left rear.

168
16
Sensor rear jack left (B7220L) sends a

signal to Control unit, attachment left jack
pair (D791-3) when the jack is lowered.
U = 24 V
Sensor rear jack left (B7220L) stops

sending a signal to Control unit, attachment left jack pair (D791-3) when sensor
rear jack left (B7220L) stops sending a
signal.
U=0V

knee out right (Y6058R).
U = 24 V
13
14
17
18
pair
D13: Diagnostic menu, see section 8 Control system , group 8.4.11.1 COMBI, menu
12

160
D13: Diagnostic menu, see section 8 Control system , group 8.4.11.1 COMBI,
menu 12


pair
12
19

160
Solenoid valve rear knee out right

(Y6058R) pressurises hydraulic cylinder
knee right rear.
20
Hydraulic cylinder knee/right rear lowers

knee right rear.

page 165
21
Sensor rear knee right (B7218R) sends a

voltage signal to Control unit, attachment
right jack pair (D791-4) when the knee is
lowered.
U = 24 V
VDRF03.02GB
12
151
Pos
Explanation
Signal description
Reference
22
Sensor rear knee right (B7218R) stops

sending a signal to Control unit, attachment right jack pair (D791-4) when the
knee reaches the end position.
U=0V

jack down right (Y6014R) when sensor
rear knee right (B7218R) stops sending a
signal.
U = 24 V
Solenoid valve rear jack down right

(Y6014R) pressurises Hydraulic cylinder
jack right rear.
25
Hydraulic cylinder jack right rear lowers

jack right rear.

168
26
Sensor rear jack right (B7220R) sends a

signal to Control unit, attachment right
U = 24 V
Sensor rear jack right (B7220R) stops

sending a signal to Control unit, attachment right jack pair (D791-4).
U=0V
When both rear lifting jacks are completely lowered Control unit, attachment left
jack pair (D791-3) activates solenoid
valve operating position left (Y6053L) and
solenoid valve clamping left (Y6054L).
U = 24 V
23
24
27
28
12
Solenoid valve operating position left

(Y6053L) closes the connection between
control valve and hydraulic cylinder
clamping left front.

160
12

jack pair
D29: Diagnostic menu, see section 8 Control system group 8.4.11.1 COMBI, menu
15 and 8.4.11.1 COMBI, menu 16
At the same time Control unit, attachment

right jack pair (D791-4) activates Solenoid
valve operating position right (Y6053R)
and Solenoid valve clamping right
(Y6054R).
29

pair
Solenoid valve operating position right

(Y6053R) closes the connection between
control valve and hydraulic cylinder
clamping right front.

160
D29: Diagnostic menu, see section 8 Control system group 8.4.11.1 COMBI, menu
15 and 8.4.11.1 COMBI, menu 16
VDRF03.02GB
152
Pos
Explanation
Signal description
Reference
30
Solenoid valve clamping left (Y6054L)

pressurises hydraulic cylinder clamp left
rear.

160
15
Solenoid valve clamping right (Y6054R)

pressurises hydraulic cylinder clamp right
rear.
31
Hydraulic cylinder clamp presses knee

down and thus presses the rear lifting
jacks forward.

page 165
32
Sensor operating position left (B7212L)

sends a voltage signal to Control unit, attachment left jack pair (D791-3) and sensor operating position right (B7212R)
sends a voltage signal to Control unit attachment right jack pair (D791-4) when
the jack pair is in the operating position.

Sensor operating position, description page

165
33
When the switch is released, activation of all solenoid valves is interrupted. Solenoid valves remain activated even
after the movement has been completed in order for it to be possible to complete the movement if the button is released when a lifting jack is in an intermediate position.
VDRF03.02GB
153
Clamp with left jacks, function description
page
Condition
Reference
value
Reference
Safety switch
Disengaged
Lifting jacks
Lowered
Raising/lowering of front lifting jacks, function description page 144

Raising/lowering of rear lifting jacks, function description page 148
22
15
20
14
17 22
D1
D20
D22
P1
D17
D22
T1
D21
2, 25
D12
D790-1
D791-4
D797-R
D791-3
D4
D8
13
3, 12, 18, 21
D795
3, 8, 23
24
9
D23
P1
T1
A
D22
D16
D19
22 19
16
11
22
006894
D22
6
10
Pos
Explanation
Signal description
Reference
The switch for clamp/release jacks

(S1008) sends a voltage signal to the cab
U = 24 V

The cab control unit (D790-1) sends

clamp or release jacks on the CAN bus.
Checked by control
system, error shown
with error code.

Cab control unit
VDRF03.02GB
154
Pos
Explanation
Signal description
Reference

right jack pair (D791-4) send activate top
hydraulics on the CAN bus.
Checked by control
system, error shown
with error code.

Control unit, attachment left jack pair and section 11 Common electrics, group 11.5.3.8
U = 24 V

Solenoid valve, engagement of hydraulics for top lift (Y6003) opens and pressurises valve block lift cylinder and sends a


Shuttle valve

hydraulic oil tank.

left frame beam.


(D791-3) activates solenoid valve clamp
left (Y6054L) or solenoid valve clamp release left (Y6055L).
U = 24 V

Solenoid valve clamp left (Y6054L) or solenoid valve clamp release left (Y6055L)
front and hydraulic cylinder clamp left
rear.
10
Hydraulic cylinder knee and clamp left

front act on knee left front so that left lifting
jacks clamp or release.

page 165
11
Hydraulic cylinder knee and clamp left

rear act on knee left rear so that left lifting

page 165
12

(D791-4) activates solenoid valve clamp
right (Y6054R) or solenoid valve clamp
release right (Y6055R).
U = 24 V

Solenoid valve clamp left (Y6054L) or solenoid valve clamp release left (Y6055L)
front and hydraulic cylinder clamp left
rear.
13
VDRF03.02GB


page 58


160


160
155
Pos
Explanation
Signal description
Reference
14
Hydraulic cylinder knee and clamp right

front act on knee left front so that left lifting

page 165
15
Hydraulic cylinder knee and clamp right

rear act on knee left rear so that left lifting

page 165
16
Sensor clamping position front jack left

(B7215L) sends a voltage signal to Control unit, attachment left jack pair
(D791-3).
U = 24 V
Sensor, clamping position, description page

171
Sensor clamping position front jack right

(B7215R) sends a voltage signal to Control unit, attachment right jack pair
(D791-4).
U = 24 V

(D791-4) activates indicator light clamping position front jack (H578).
U = 24 V
Sensor clamping position rear jack left

(B7216L) sends a voltage signal to Control unit, attachment left jack pair
(D791-3).
U = 24 V
Sensor clamping position rear jack right

(B7216R) sends a voltage signal to Control unit, attachment right jack pair
(D791-4).
U = 24 V

(D791-4) activates indicator light clamping position rear jack (H579).
U = 24 V
When lifting is started, Sensor alignment

front jack left (B7213L) and Sensor alignment rear jack left (B7214L) send a signal
to Control unit, attachment left jack pair
(D791-3). Sensor alignment front jack
right (B7213R) and Sensor alignment rear
jack right (B7214R) send a signal to Control unit, attachment right jack pair
(D791-4).
U = 24 V
17
18
19
20
21
22


171

171

171
If it takes longer than 4 seconds between

the first sensors signal until all sensors
send signals, the lift function is blocked.
VDRF03.02GB
156
Pos
Explanation
Signal description
Reference
23

(D791-3) activates the alignment indicator light for the respective lifting jack.
U = 24 V

24
The KID control unit (D795) activates the

event menu for alignment bottom lift.

25
When more than two sensors indicate

alignment or clamping position, speed
limitation is activated.
Checked by control
system, error shown
with error code.
Section 8 Control system, group 8.2.5 Speed

limitation

Lifting jacks, checking and adjusting
page
If necessary, the lifting jacks can be operated manually, step by step

with the diagnosis menu Extra\\Combi menu 17, see section 8 Control
system, group 8.4.11.1 COMBI.
1 Start key in position I.
2 Check that all sensors have voltage. The LED on the sensor
should illuminate when the sensor indicates.
3 Check the distance between all sensors and their target surface,
the distance will be 4 1 mm when the sensor is in the centre of
the lug.
Sensor knee and Sensor jack should only be active during the
movement, not in the two end positions.
4 Check that the attachment hangs horizontally, adjust the tilt function if necessary.
5 Fully lower all jacks.
6 Check that the jacks are vertical in the lateral direction.
7 If necessary, adjust the position on the lowering cylinders rod
mounting by turning the piston.
After adjustment, the target surfaces for the jack sensors may
need to be precisely adjusted.
NOTE
Loosen the lock nuts on the piston head before adjustment.
90
8 Check the c-c measurement between right and left lifting jacks,
the measurement should be approximately 4876 mm at the bottom of the jacks.
90
008205
c-c = 4876 mm
Attachment, seen from the front
VDRF03.02GB
157
9 Operate the lifting jacks to clamping position.

10 Check that the lifting jacks are tilted 8.0 towards each other in
the longitudinal direction.
11 If necessary, adjust the position on the clamping cylinders rod
mounting by turning the piston.
After adjustment, the target surfaces for the knee sensors may
need to be precisely adjusted.
NOTE
8,0
Loosen the lock screws in the piston head before adjustment.
007458
8,0
Clamping position, max. retracted jacks

12 Operate the lifting jacks apart from clamping position.
13 Check that the rear lifting jacks are tilted 1.5 outwards (reverse).
14 Check that the front lifting jacks are tilted 9.0 outwards (forward).
1,5
007459
9,0
Clamping position, max. extended jacks.
VDRF03.02GB
158
15 Press the top of the rear lowering button, the rear lifting jacks
should move to operating position. (Operate clamping position
apart to return to end position in order to test the operating position again.)
16 Check that the lifting jacks stop at 1.0 inwards (forward).
007460
1,0
Operating position, rear jacks
001856
17 Adjust the position by moving the sensor clamping position

laterally.
Sensor, operating position

18 Press in the alignment lugs on a lifting jack one at a time and
check that the respective alignment indicator light is working.
008200
If the light does not illuminate when the lug is pressed in, check
the lamp and alignment sensor, see Sensor alignment, description page 170.
Indicator lights, alignment
VDRF03.02GB
159
19 Press in the contact surfaces on the front and rear lifting jacks
and check that the indicator light for clamping position alignment
for the respective jack pair is working.
When both contact surfaces are pressed in the indicator light for
clamping position front and rear should illuminate.
008201
If the light does not illuminate when the contact surfaces are
pressed in, check the lamp and clamping position sensor, see
Sensor, clamping position, description page 171.
Indicator lights, clamping position
008202
20 Check that the indicator light for front jacks lowered is illuminated
when the front lifting jacks are lowered.
Indicator light, front jacks down

21 Operate the front lifting jacks up and check the indicator light for
front jacks lowered is switched off when the jacks are raised, and
that the indicator light for front jacks raised illuminates when the
front lifting jacks are completely raised.
008204
22 Checks that the working lights on the attachment switch between

lighting the twistlocks and lighting the lifting jacks on the right and
left side when the rear lifting jacks on each respective side are
raised and lowered.
Indicator light, front jacks up
7.9.2.1
page
Hydraulic oil pump

7.9.2.2
page

VDRF03.02GB
160
7 Load handling 7.9.2.3 Control valve, lifting jacks
7.9.2.3
Control valve, lifting jacks
Control valve, lifting jacks, description
page
10
23
11
22
12
21
20
13
19
14
18
15
17
000467
16
1. Solenoid valve, rear knee out (Y6058)

2. Solenoid valve, rear knee in (Y6059)
3. Solenoid valve, clamp (Y6054)
4. Solenoid valve, clamp release (Y6055)
5. Solenoid valve, front knee in (Y6057)
6. Solenoid valve, front jack up (Y6060)
7. Solenoid valve, front jack down (Y6013)
8. Solenoid valve, front knee out (Y6056)
9. Drain to tank
10. Connection, hydraulic cylinder for front jack
11. Connection, hydraulic cylinder for front knee
12. Connection, hydraulic cylinder for front jack
13.Connection, hydraulic cylinder for front knee
14. Connection, hydraulic cylinder for clamping
15. Connection, hydraulic cylinder for rear knee
16. Connection, hydraulic cylinder for rear jack
17. Feed from hydraulic oil pumps
18. Tank return (through filter)
19. Connection, hydraulic cylinder for rear jack
20. Connection, hydraulic cylinder for rear knee
21. Connection, hydraulic cylinder for clamping
22. Solenoid valve, rear jack down (Y6014)
23. Solenoid valve, rear jack up (Y6061)
The lifting jacks are controlled by two control valves: one for the left
jack pair and one for the right jack pair. The control valves are controlled by separate control units: Control unit, attachment left jack pair
(D791-3) and Control unit, attachment right jack pair (D791-4). The
control valves are fitted crosswise (left front and right rear, respectively) on the bracket for the knee on the attachments main beam.
The control valves are identical and have five sections each:
Raising/lowering of front knee
Raising/lowering of front jacks
Raising/lowering of rear knee
Raising/lowering of rear jacks
Clamping position

have flow limits so that several functions can be activated
simultaneously.
Valve slide front knee

The valve slide controls the direction and speed of front knee lowering
by controlling the hydraulic pressure to hydraulic cylinder knee and
clamp.
The valve slide is controlled by servo valve, front knee out and servo
valve, front knee in.
Servo valve front knee out

Servo valve front knee out, controls servo pressure to valve slide front
knee so that it controls oil pressure for front knee out.
Servo valve front knee is controlled electrically with Solenoid valve
front knee out (Y6056) which is activated by Control unit, attachment
left jack pair (D791-3) or Control unit, attachment right jack pair (D7914), depending on if it is the right or left jack.
8 Control system , group 8.4.11.1 COMBI, menu 10.
Servo valve front knee in

Servo valve front knee in, controls servo pressure to valve slide front
knee so that it controls oil pressure for front knee in.
Servo valve front knee is controlled electrically with Solenoid valve
front knee in (Y6057) which is activated by Control unit, attachment left
jack pair (D791-3) or Control unit, attachment right jack pair (D791-4),
depending on if it is the right or left jack.
VDRF03.02GB
161
Valve slide front jack

The valve slide controls the direction and speed of front jack lowering
by controlling the hydraulic pressure to hydraulic cylinder, jack.
The valve slide is controlled by servo valve front jack down and servo
valve front jack out.
Servo valve front jack down

Servo valve front jack down, controls servo pressure to valve slide
front jack so that it controls oil pressure for jack lowering.
Servo valve front jack is controlled electrically with Solenoid valve front
jack down (Y6013) which is activated by Control unit, attachment left
Servo valve front jack up

Servo valve front jack up, controls servo pressure to valve slide front
jack so that it controls oil pressure for jack raising.
Servo valve front jack is controlled electrically with Solenoid valve front
jack up (Y6060) which is activated by Control unit, attachment left jack
pair (D791-3) or Control unit, attachment right jack pair (D791-4), depending on if it is the right or left jack.
8 Control system, group 8.4.11.1 COMBI, menu 11.
Valve slide clamp

Valve slide clamp controls the direction and speed of clamping with the
jack pair by controlling the hydraulic pressure to hydraulic cylinder
knee and clamp.
The valve slide is controlled by servo valve clamp and servo valve
clamp release.
Servo valve clamp

Servo valve clamp, controls servo pressure to valve slide clamp so
that it controls oil pressure for clamping.
Servo valve clamp is controlled electrically with Solenoid valve clamp
in (Y6054) which is activated by Control unit, attachment left jack pair
(D791-3) or Control unit, attachment right jack pair (D791-4), depending on if it is the right or left jack pair.
VDRF03.02GB
162
Servo valve clamp release

Servo valve clamp release, controls servo pressure to valve slide
clamping position so that it controls oil pressure for clamp release.
Servo valve clamp release is controlled electrically with Solenoid valve
clamp release in (Y6055) which is activated by Control unit, attachment left jack pair (D791-3) or Control unit, attachment right jack pair
(D791-4), depending on if it is the right or left jack pair.
Valve slide rear knee

The valve slide controls the direction and speed of rear knee lowering
by controlling the hydraulic pressure to hydraulic cylinder knee and
clamp.
The valve slide is controlled by servo valve, rear knee out and servo
valve, rear knee in.
Servo valve rear knee out

Servo valve rear knee out, controls servo pressure to valve slide rear
knee so that it controls oil pressure for knee out.
Servo valve rear knee out is controlled electrically with Solenoid valve
rear knee out (Y6058) which is activated by Control unit, attachment
left jack pair (D791-3) or Control unit, attachment right jack pair (D7914), depending on if it is the right or left knee.
Servo valve rear knee in

Servo valve rear knee in, controls servo pressure to valve slide knee
so that it controls oil pressure for knee in.
Servo valve rear knee in is controlled electrically with Solenoid valve
rear knee in (Y6059) which is activated by Control unit, attachment left
depending on if it is the right or left knee.
Valve slide rear jack

The valve slide controls the direction and speed of rear jack lowering
by controlling the hydraulic pressure to hydraulic cylinder, jack.
The valve slide is controlled by servo valve rear jack down and servo
valve rear jack out.
VDRF03.02GB
7 Load handling 7.9.2.4 Shuttle valve
163
Servo valve rear jack down

Servo valve rear jack down, controls servo pressure to valve slide front
jack so that it controls oil pressure for jack lowering.
Servo valve rear jack down is controlled electrically with Solenoid
valve rear jack down (Y6014) which is activated by Control unit, attachment left jack pair (D791-3) or Control unit, attachment right jack
pair (D791-4), depending on if it is the right or left jack.
Servo valve rear jack up

Servo valve rear jack up, controls servo pressure to valve slide rear
jack so that it controls oil pressure for jack raising.
Servo valve rear jack up is controlled electrically with Solenoid valve
rear jack up (Y6061) which is activated by Control unit, attachment left
page

7.9.2.4
page
Shuttle valve

VDRF03.02GB
164
7 Load handling 7.9.2.5 Valve, operating position
7.9.2.5
Valve, operating position
Valve operating position, description
page
The valve for operating position cuts off the pressure to the front hydraulic cylinder for clamping. The valve is located on the attachments
main beam by the hydraulic cylinder knee and clamp.
When the valve is activated, it cuts the hydraulic connection between
Control valve, attachment lifting jacks and hydraulic cylinder knee and
clamp front. This results in only the rear lifting jack being angled forward.
Solenoid valve operating position (Y6053L/R) is activated by Control
unit, attachment left jack pair (D791-3) or Control unit, attachment right
jack pair (D791-4), depending on if it is the right or left jack.
001849
7.9.2.6
page
The brackets for knee and hydraulic cylinder knee and clamp are located on the attachments main beam.
7.9.2.7
Knee
Knee, description
page
The knee is located between the attachments main beam and lifting
jack. There are four knees, one at each lifting jack. The knee enables
folding in and clamping with the jacks. The knee is controlled by hydraulic cylinder knee and clamp.
001851
Located on the knee joint is an indicator ring which is turned with the
lifting jack. The indicator ring is used together with Sensor, knee, to determine whether the jack is raised, in intermediate position or lowered.
VDRF03.02GB
7 Load handling 7.9.2.8 Hydraulic cylinder knee and clamp
7.9.2.8
165
Hydraulic cylinder knee and clamp
page
Hydraulic cylinder knee and clamp has two pistons in separate cylinders. There are four hydraulic cylinders, one at each lifting jack. The
hydraulic cylinder is located between attachment and knee. One of the
hydraulic cylinders pistons folds the knee joint out. The other piston
clamps with the lifting jacks by angling the knee joint further.
001852
1. Hydraulic cylinder, clamp

2. Hydraulic cylinder, knee
page
7.9.2.9
Sensor, operating position
Sensor operating position, description
page
The sensor for operating position senses the position of the rear lifting
jacks hydraulic cylinder for knee and clamp. This is used to indicate
operating position for the rear lifting jacks. There are two sensors, one
on each side (right and left).
Sensor, operating position left (B7212L/R) provides a voltage signal
when the rear hydraulic cylinder lowering knee/clamp is in its inner end
position. The signal is used to stop activation of the solenoid valve for
operating position when the rear lifting jack is lowered.
001856
page

VDRF03.02GB
166
7 Load handling 7.9.2.10 Sensor, knee
7.9.2.10
Sensor, knee
Sensor knee, description
page
Sensor knee senses the position of the knee joint, this is used to control lowering of the jacks. There are four sensors, one by each knee.
Sensor front knee (B7217) and Sensor rear knee (B7218) give voltage
signals when the knee is between either end-position. The signal goes
to 0 V when end-position is reached. This applies both when retracting
and extending. The signal is used to activate the next step in the sequence. If the signal does not go to 0 V, the jack is not lowered.
001853
8 Control system , group 8.4.11.1 COMBI, menu 4 5.
page

VDRF03.02GB
7 Load handling 7.9.2.11 Lifting jacks
7.9.2.11
167
Lifting jacks
Lifting jacks, description
page
The lifting jacks grip around/under the load. In the lower end of the
jacks there are lifting shoes. The lifting jacks are raised and lowered
with the hydraulic cylinder for lifting jacks.
001866
Located on the lifting jacks joint is an indicator ring which is turned

with the lifting jack. The indicator ring is used together with Sensor,
jack, to determine whether the jack is raised, in intermediate position
or lowered.
VDRF03.02GB
168
7 Load handling 7.9.2.12 Hydraulic cylinder, jack
7.9.2.12
Hydraulic cylinder, jack
Hydraulic cylinder, jack, description
page
001855
Hydraulic cylinder lifting jack is located between knee and lifting jack.
The hydraulic cylinder raises and lowers the lifting jacks.
page
7.9.2.13
Sensor, lifting jacks
Sensor, lifting jacks, description
page
Sensor, lifting jacks, senses the position of the lifting jacks, this is used
to control lowering of the jacks. There are four sensors, one by each
lifting jack.
Sensor front jack (B7219) and Sensor rear lifting jack (B7220) give
voltage signals when the lifting jacks are between either end-position.
The signal goes down to 0 V when end-position is reached. This applies both when raising and lowering. The signal is used to activate the
next step in the sequence. If the signal does not go to 0 V, the knees
are not lowered.
001859
page

VDRF03.02GB
7 Load handling 7.9.2.14 Lifting shoe
7.9.2.14
169
Lifting shoe
Lifting shoe, description
page
The lifting shoe is located at the lower end of the lifting jacks. The lifting
shoe grips under the load. At each lifting shoe there are two sensors.
Sensor alignment senses when the lifting shoe has contact with the
load from above, see Sensor alignment, description page 170. Sensor
clamping position senses when the lifting shoe has horizontal contact
with the load, see Sensor, clamping position, description page 171.
001857
1. Indicator pin, clamping position sensor

2. Indicator pin, alignment sensor
3. Lifting shoe
VDRF03.02GB
170
7 Load handling 7.9.2.15 Sensor alignment
7.9.2.15
Sensor alignment
Sensor alignment, description
page
The sensor for alignment (B7213L/R or B7214L/R) senses when the

lifting shoe has contact with the load from above. The sensor is located
behind the lifting shoe and senses the position on a linkage. The linkage is affected by a pin in the middle of the lifting shoe which is
pressed down when the load is positioned correctly in the lifting shoe.
001858
1. Sensor clamping position (B7215L/R or B7216L/R)

2. Sensor alignment (B7213L/R or B7214L/R)
page

VDRF03.02GB
7 Load handling 7.9.2.16 Sensor, clamping position
7.9.2.16
171
Sensor, clamping position
Sensor, clamping position, description
page
The sensor for clamping position (B7215L/R or B7216L/R) senses

when the lifting shoe has horizontal contact with the load. The sensor
is located behind the lifting shoe and is activated by a bolt mounted on
a spring-loaded plate on the lifting shoe.
Control system , group 8.4.11.1 COMBI, menu 2.
001858
1. Sensor clamping position (B7215L/R or B7216L/R)

2. Sensor alignment (B7213L/R or B7214L/R)
page

7.9.2.17
page

7.9.2.18
page
Pipes and hoses

VDRF03.02GB
172
7 Load handling 7.10 Other functions
7.10
Other functions
7.10.1
Support jacks
Support jacks, function description
page
Condition
Reference value
Reference
Safety switch
Disengaged
Section 10 Common hydraulics, group 10.4.2 Axial piston pump with variable displacement
Parking brake
Released
Section 4 Brakes, group 4.5 Parking brake system
Transmission
Neutral position
Section 2 Transmission
Machine stationary
Speed = 0 km/h
D1
D13
1
2, 13
D790-1
D794
12
D4
C8
11
D795
D797-O
4
D3
5
10
7
C8
T
A
T1
013030
LS
Pos
Explanation
Signal description
Reference
The support jacks switch (S1013) sends a

voltage signal to the cab control unit (D7901).
U = 24 V
The cab control unit (D790-1) sends front

support jacks down or up on the CAN bus.
Checked by control
system, error shown
with error code.
VDRF03.02GB

system , group 8.4.11.3 SUPPORT JACKS,
menu 1

7 Load handling 7.10.1 Support jacks
173
Pos
Explanation
Signal description
Reference
Sensor support jacks up (B7222) or Sensor

support jacks down (B7021) sends a voltage signal to Control unit, frame option
(D797-O).
Support jacks up or
down: U = 24 V
Sensor, support jacks up, description page

179
Support jacks in intermediate position: U =

0V
Sensor, support jacks down, description

page 180

menu 2
Control unit, frame option (D797-O) activates the Solenoid valve support jacks
down (Y6064) or Solenoid valve support
jacks up (Y6063) and sends the status for
the support jacks position on the CAN bus.
U = 24 V
Solenoid valve support jacks down (Y6064)

or Solenoid valve support jacks up (Y6063)
pressurises the support jacks slide in Control valve, option frame.
Control valve, option frame sends a load

signal to shuttle valve, option frame and
pressurises valve block, support jacks cylinder.
Control valve, option frame, description

page 174
The shuttle valve sends pressure signal on

to hydraulic oil pumps 1 & 2

Hydraulic oil pumps 1 & 2 pump oil from the

hydraulic oil tank.

left frame beam.

Valve block support jacks pressurises hydraulic cylinder support jacks.
Valve block, support jacks, description page

180
10
The hydraulic cylinder lowers or raises the

support jack.
Hydraulic cylinder, support jacks, description

page 178
11
Control unit KID (D795) activates the event

menu for support jacks and blocks shifting
from neutral position.

12
Control unit, engine (D794) sends engine

speed on the CAN bus. If the engine speed
is higher than 1000 rpm then the cab control
unit (D790-1) activates automatic lowering
of support jacks.
Checked by control
system, error shown
with error code.


menu 3

page 174
menu 3
VDRF03.02GB
174
Pos
Explanation
Signal description
Reference
13
The cab control unit (D790-1) activates the

indicator light for support jacks down.
U = 24 V

menu 4
When support jacks are lowered the cab

control unit (D790-1) changes the load
curve (limit for overload protection systems).
When support jacks are raised the cab control unit (D790-1) allows shifting from neutral position.
7.10.1.1
Hydraulic oil pump
page

7.10.1.2
Control valve, option frame
page
1
6
On machines with support jacks, the lowering/raising of support jacks

is controlled by a separate section in the control valve frame option.
The control valve is fitted on a bracket at the front end in the engine
compartment.
The control valve is controlled by Control unit, frame option (D797-O).
Control valve, option frame is made up of several sections, each section controls one function. The following functions are controlled by
control valve, option frame.
000624
1. Load signal (LS)

3. Tank return (T1)
5. Tank return (TP)
Support jacks
Sliding cab/Cab lift
Cab tilt

have flow limits so that several functions can be activated simultaneously.
Valve slide, support jacks

The valve slide controls the direction and speed of support jack lowering by controlling the hydraulic pressure to hydraulic cylinder, support
jacks.
The valve slide is controlled by servo valve, support jacks up and servo valve, support jacks down.
VDRF03.02GB
7 Load handling 7.10.1.2 Control valve, option frame
175
Servo valve, support jacks down

Servo valve, support jacks up controls servo pressure to valve slide
support jacks so that it controls oil pressure for support jacks up.
Servo valve support jacks down regulates electrically with the solenoid
valve support jacks down (Y6064), which is activated by Control unit,
frame option (D797-O).
Control system , group 8.4.11.3 SUPPORT JACKS, menu 3.
Servo valve, support jacks up

Servo valve, support jacks down controls servo pressure to valve slide
support jacks so that it controls oil pressure for support jacks down.
Servo valve support jacks up regulates electrically with the solenoid
valve support jacks up (Y6063), which is activated by Control unit,
page
Control valve, option frame, replacement
NOTE
Safety.
Safety.
VDRF03.02GB
176
NOTE
6

NOTE
000624
1. Load signal (LS)

3. Tank return (T1)
4. Connection, hydraulic cylinder (B)
5. Tank return (TP)
6. Connection, hydraulic cylinder (A)
NOTE
up.
8 Fit the valve.
marking.
with the marking.
NOTE
NOTE
VDRF03.02GB
177
C AUTION
010475

C AUTION
product damage.
C AUTION
VDRF03.02GB
178
7 Load handling 7.10.1.3 Hydraulic cylinder, support jacks
7.10.1.3
Hydraulic cylinder, support jacks
Hydraulic cylinder, support jacks, description
page
Hydraulic cylinder support jacks lowers the support jack up and down.
The hydraulic cylinder is located between support jacks and frame.
2
3
4
001870
1. Hydraulic cylinder, support jacks

2. Sensor, support jacks up (B7222)
3. Upper bracket
4. Support jacks
5. Support foot
6. Lower bracket
7. Sensor, support jacks down (B7221)
7.10.1.4
Support jacks
Support jacks, description
page
The support jack consists of linkage and support. The linkage is designed so that it locks automatically when it is loaded from below in its
lowered position.
The support jack is secured in the frame and in the drive axles attaching bolts.
3
4
001870

3. Upper bracket
4. Support jacks
5. Support foot
6. Lower bracket
VDRF03.02GB
7 Load handling 7.10.1.5 Sensor, raised support jacks
7.10.1.5
179
Sensor, raised support jacks
Sensor, support jacks up, description
page
1
2
3
4
Sensor, support jacks up (B7222) is located under hydraulic cylinder,

support jacks and senses when the support jack is raised. There is a
sensor for each support jack. The sensor indicates when the support
jack is fully raised. This is used to control the support jacks event
menu.
Sensor, support jacks up (B7222) sends a voltage signal to Control
unit, frame option (D797-O) when the support jack is completely
raised.
001870

3. Upper bracket
4. Support jacks
5. Support foot
6. Lower bracket
page

VDRF03.02GB
180
7 Load handling 7.10.1.6 Sensor, lowered support jacks
7.10.1.6
Sensor, lowered support jacks
Sensor, support jacks down, description
page
1
2
3
4
Sensor, support jacks down (B7221) is located under the support

jacks upper mounting and detects when the support jack is lowered.
A sensor is fitted on each support jack. This is used to control the support jacks and the activation of the indicator light for support jacks
down.
Sensor, support jacks down (B7221) sends a voltage signal to Control
unit, frame option (D797-O) when the support jack is completely lowered.
001870

3. Upper bracket
4. Support jacks
5. Support foot
6. Lower bracket
page

7.10.1.7
page
Pipes and hoses

7.10.1.8
page
Shuttle valve, option
Shuttle valve, option description

See section 10 Common hydraulics, group 10.5.3 Shuttle valve.
7.10.1.9
page
Valve block, support jacks
Valve block, support jacks, description

Valve block, support jacks is located by the hydraulic cylinders and
contains a blocking valve which protects against accidental raising
and lowering of the support jacks.
VDRF03.02GB
7 Load handling 7.10.2 Weight indicator
7.10.2
page
181
Weight indicator
Weight indicator, description
The weight indicator uses Sensor hydraulic pressure lift cylinder

(B768) and sensor boom angle to calculate the load. For more information about sensors, see section 8 Control system , group 8.2.1
Overload system.
The pressure sensors can be checked from the diagnostic menu, see
tab 8 Control system , group 8.4.5.3 HYD, menu 3.
Fixed scale (only model year -2008)

The fixed scale weighs the load in a preset position on the boom by
measuring the pressure on the piston side in the lift cylinders. The
boom angle for the measuring position is indicated by a rod and marking on the left lift cylinder. The boom length for the measuring position
is indicated with an extra Sensor boom length (Position sensor boom
length 60 cm).
Dynamic scale
The dynamic scale weighs the load regardless of boom position. The
weight is calculated as a function of boom angle, boom length and the
pressure in the lift cylinders. The dynamic scale uses Sensor, hydraulic pressure lift cylinder, Sensor, boom angle (analogue sensor) and
Sensor, boom length (analogue sensor).
VDRF03.02GB
182
Weight indicator, function description (product

alternative fixed scale) (only model year -2008)
page
Condition
Reference
value
Reference
Safety switch
Disengaged
D1
1
3, 4
D790-1
D795
D797-R 11 D797-F
D5
D10
5
>
D791-1
D10
Pa
10
7, 12
Pa
D8
8
006896
Pos
Explanation
Signal description
Reference
The pistol trigger on the control lever

unit (D790-1).
US815/T4 = 24 V

weighing activated on the CAN bus.

error code.

Boom lowered to measuring position

(when the boom is in measuring position
boom lowering is interrupted
automatically).
Lifting/lowering, function description page 11
The boom is operated to 60 cm extension

(when the boom is in measuring position
boom extension is interrupted
automatically).

Sensor, boom angle (B771) sends a voltage signal proportional to boom angle to
Control unit, frame rear (D797-R).
U = 0.5-4.5 V

Sensor, boom angle
Control unit, frame rear (D797-R) transmits boom angle on the CAN bus.

error code.
VDRF03.02GB


system, group 8.4.10.4 OP, menu

system, group 8.4.10.4 OP, menu
183
Pos
Explanation
Signal description
Reference
The KID control unit (D795) activates the

event menu fixed scale (flashing).

Sensor, boom length 60 cm (B7224)

sends a signal to the attachment control
unit (D791-1).
U = 24 V

Sensor, boom length

transmits Boom length 60 cm on the CAN
bus.

error code.
Sensor, hydraulic pressure lift cylinder

piston side left (B768-L1) and Sensor hydraulic pressure lift cylinder piston side
right (B768-R1) send a voltage signal to
U = 0.5 - 4.5 V
11
Control unit, frame front (D797-F) transmits weight information on the CAN bus.

error code.

12
The KID control unit (D795) updates the

weight information in the display (fixed
glow).

10


VDRF03.02GB
184
Weight indicator, function description (product

alternative dynamic scale)
page
Condition
Reference
value
Reference
Safety switch
Disengaged
D795
D797-F
D797-R
D2
D4
6
Pa
Pa
Pa
Pa
3,5
<
006897
D6
D790-1
Pos
Explanation
Signal description
Reference
Operating menu dynamic scale is shown

in the display.

voltage signal proportional to boom
length to Control unit, frame rear
(D797-R).
U = 0.5-4.5 V

Sensor, boom length
Control unit, frame rear (D797-R) transmits boom length information on the CAN
bus.

Sensor, boom angle (B771) sends a voltage signal proportional to boom angle to
Control unit, frame rear (D797-R).
U = 0.5-4.5 V

Sensor, boom angle
Control unit, frame rear (D797-R) transmits boom angle information on the CAN
bus.
VDRF03.02GB

system, , group 8.4.10.4 OP, menu 4


185
Pos
Explanation
Signal description
Reference
Sensor hydraulic pressure lift cylinder

piston side left (B768-12), Sensor hydraulic pressure lift cylinder rod side left
(B768-11), Sensor hydraulic pressure lift
cylinder piston side right (B768-10) and
rod side right (B768-13) send voltage signals proportional to the hydraulic pressure to Control unit, frame front
(D797-F).
U = 0.5-4.5 V
Control unit, frame front (D797-F) calculates and sends the weight on the CAN
bus. The weight is calculated by a machine-unique load curve based on sensor
values for boom angle, boom length and



system, group 8.4.10.3 OP, menu 3
NOTE
The load curve is unique for each
machine.
8

weight information in the display.
Printer, description
page
Printer is an option for the dynamic scale function that makes it possible to save weights and print lists of saved weights.
The printer is connected to the KID control unit (D795) and is fitted on
a dashboard panel on the right side of the steering wheel.
004907
The printer is controlled by the printer operating menu in the display,

where the driver selects the weights to be saved and what should be
printed.
Printer location
VDRF03.02GB
186
7 Load handling 7.10.2.1 Sensor hydraulic pressure lift cylinder
7.10.2.1
page
Sensor hydraulic pressure lift cylinder, general

See Lift cylinder hydraulic pressure sensor, description page 32.
7.10.2.2
page
Sensor, boom angle
Sensor, boom angle, general

See section 8 Control system, group 8.2.1.2 Sensor, boom angle.
7.10.2.3
page
Sensor, boom length
Sensor, boom length, general

See section 8 Control system, group 8.2.1.3 Sensor, boom length.
VDRF03.02GB
7 Load handling 7.10.3 Container counter
7.10.3
page
187
Container counter
Container counter, description
The container counter counts the number of lifted containers. The

counter has two counters that can be reset separately. The container
counter counts in different ways depending on whether the top lift
(twistlocks) or bottom lift (lifting jacks) is used.
Top lift
The container counter counts lifting when contact disappears with
locked twistlocks and twistlocks are not opened within 8 seconds.
Bottom lift
The container counter counts lifting when the clamp function is activated and lifting is started and unloading clamping position is not activated within 10 seconds.
VDRF03.02GB
188
Container counter, function description (product

alternative top lift)
page
Condition
Reference
value
Reference
Safety switch
Disengaged
1, 4, 7
D1
10
D790-1
D795
D797-R
D791-1
3, 6, 9
D2
5
006898
2, 8
D5
Pos
Explanation
Signal description
Reference
The attachment is positioned over a

container with the functions 7.2 Lifting/
lowering and 7.3 Extension.

system, group 8.4.8.1 BOOM, menu 1

(Y7203L) and sensor for rear right alignment (Y7203R) send a voltage signal to
the attachment control unit (D791-1).
Sensor directly opposite indicator plate: U

= 24 V

Checked by control
system, error shown
with error code.

Twistlocks are rotated to the locked position and are closed with the 7.9.1
Twistlocks function.
The sensor for lock twistlocks left

(B7205L) and sensor for lock twistlocks
right (B7205R) send a voltage signal to
the attachment control unit (D791-1).

= 24 V
Sensor twistlocks, description page 141
VDRF03.02GB


189
Pos
Explanation
Signal description
Reference

transmits "locked twistlocks" on the
CAN bus.
Checked by control
system, error shown
with error code.

The container is lifted with the function

7.2 Lift and lower.

(Y7203L) and sensor for rear right alignment (Y7203R) stop sending a voltage
signal to the attachment control unit
(D791-1).
U=0V

transmits no alignment on the CAN bus.
Checked by control
system, error shown
with error code.

10
If the twistlocks remain locked for 8 seconds, the cab control unit (D790-1) adds
one lift to the container counter.

Cab control unit

VDRF03.02GB
190
Container counter, function description (product

alternative bottom lift)
page
Condition
Reference
value
Reference
Safety switch
Disengaged
Section 11 Common electrics , group 11.5.1.4 Emergency stop voltage (15E)
2, 7
D4
D3
D1
D2
10
D790-1
D791-4 6, 9
5
D5
D8
006899
6, 9 D791-3
D5
D8
8
5
D795
Pos
Explanation
Signal description
Reference
The attachments rear lifting jacks fold are

lowered to operating position with the function 7.9.2 Lifting jacks.
Raising/lowering of rear lifting jacks, function

description page 148
The attachment is positioned over a container with the functions 7.2 Lifting/lowering and 7.3 Extension.


system , group 8.4.8.1 BOOM, menu 1
The front lifting jacks are lowered with the

function 7.9.2 Lifting jacks.
Raising/lowering of front lifting jacks, function

description page 144
The lifting jacks clamp around the container with the function 7.9.2 Lifting jacks.
Clamp with left jacks, function description

page 153
VDRF03.02GB
191
Pos
Explanation
Signal description
Reference
Sensor clamping position front jack left

(B7215L) and sensor clamping position
rear jack left (B7216L) send a voltage signal to Control unit, attachment left jack pair
(D791-3).

= 24 V

171
Sensor clamping position front jack right

(B7215R) and sensor clamping position
rear jack right (B7216R) send a voltage
signal to Control unit, attachment right jack
pair (D791-4).
(D791-3) and Control unit, attachment right
jack pair (D791-4) send clamping position,
lifting jacks on the CAN bus.
Checked by control
system, error shown
with error code.

The container is lifted with the function 7.2

Lift and lower.
Sensor alignment front jack left (B7213L)

and sensor alignment rear jack left
(B7214L) send a voltage signal to Control
unit, attachment left jack pair (D791-3).

= 24 V


Sensor alignment front jack right (B7213R)

and sensor alignment rear jack right
(B7214R) send a voltage signal to Control
unit, attachment right jack pair (D791-4).
9

Checked by control
system, error shown
with error code.

10
If clamping position remains active for 10

seconds, the cab control unit (D790-1)
adds one bottom lift to the container
counter.

VDRF03.02GB
192
7 Load handling 7.10.4 Synchronised lift
7.10.4
Synchronised lift
Synchronised lift, function description
page
Condition
Reference value
Reference
Safety switch
Disengaged

switch voltage

Height limitation
1
D1
+
2, 6
D790-1
D795
D797-R
D797-F
D4
<
006900
D3
Pos
Explanation
Signal description
Reference
The control lever sends for lift or lower and pistol trigger voltage signal to
Lower: US815/P1 = 0.52.0 V

Lift: US815/P1 = 3.04.5 V

24 V

system , group 8.4.8.1 BOOM, menu 1 and
Pistol trigger: US815/T4 =
The cab control unit (D790-1) transmits synchronised lift on the CAN
bus.


Sensor, boom angle (B771) sends a

voltage signal to Control unit, frame
rear (D797-R).
U = 0.5-4.5 V
Section 8 Control system, group 8.2.1.5 Sensor, boom angle

voltage signal to Control unit, frame
rear (D797-R).
U = 0.5-4.5 V

transmits length and angle information on the CAN bus.

VDRF03.02GB

system , group 8.4.10.1 OP, menu 1
Section 8 Control system, group 8.2.1.6 Sensor, boom length

193
Pos
Explanation
Signal description
Reference
The cab control unit (D790-1) control

the functions 7.2 Lifting/lowering
and 7.3 Extension at the same time
so that the lifting movement is
vertical.

VDRF03.02GB
194
VDRF03.02GB
8 Control system
8 Control system
Table of Contents 8 Control system

mm mm mm mm mm mm
8
Control system ............................................................................................... 3
8.1
8.1.4
Switch, bypass of load centre and height limitation ............................... 4
8.1.10
Error code menu .................................................................................... 4
8.2
Monitoring ................................................................................................... 7
8.2.1
Overload system .................................................................................... 7
8.2.2
Bypass ................................................................................................. 15
8.2.3
Load centre limitation ........................................................................... 16
8.2.4
Height limitation ................................................................................... 16
8.2.5
Speed limitation ................................................................................... 17
8.2.6
Service indicator .................................................................................. 17
8.4
Diagnostics ............................................................................................... 18
8.4.1
CAN/POWER ....................................................................................... 20
8.4.2
LIGHTS ................................................................................................ 40
8.4.3
CAB ..................................................................................................... 53
8.4.4
CLIMATE ............................................................................................. 62
8.4.5
HYD ..................................................................................................... 70
8.4.6
ENGINE ............................................................................................... 75
8.4.7
TRANSM .............................................................................................. 82
8.4.8
BOOM ................................................................................................ 101
8.4.9
ATTACH ............................................................................................ 109
8.4.10
OP ...................................................................................................... 132
8.4.11
EXTRA ............................................................................................... 137
8.4.13
RMI .................................................................................................... 166
8.5
Setup ...................................................................................................... 169
8.5.1
Initiation ............................................................................................. 169
8.5.2
Calibration .......................................................................................... 196
VDRF03.02GB
VDRF03.02GB
8 Control system
8 Control system
mm mm mm mm mm mm
page
8 Control system
Control system, general
In many cases the machines functions are controlled electrically. The
signals that control the machine are monitored to warn the operator or
limit the machines functions in case 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 machines monitoring functions that

warn the operator or limit the machines 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 machines display.
Settings is the tool for setting and adapting the machines functions.
The software creates the functions in the control system.
VDRF03.02GB
8 Control system 8.1 Controls and instruments
8.1
8.1.4

Switch, bypass of load centre and
height limitation
Switch, bypass height limitation, description
page
Switches bypass height limitation (S1015) bypasses height limitation

and makes it possible to raise the boom above the limit for height limitation, See Height limitation, description page 16.
008216
The switch is supplied with voltage from and sends a voltage signal to
the Control unit, cab (D790-1) when the switch is activated.
8.1.10
Error code menu
Error code menu, description
page
The control systems display is divided into four fields that show information (see figure to the left).
C
D
E
000389
Field B: Error code level shown with a symbol.
Field C: Indicates error code.
Field D: Indicates type of error.
Field E: Indicates which function is affected by error code.
The book symbol means that there's information in the operator's

manual.
Field B: Error code level

The control system gives error code information in three levels which
are indicated with a symbol in the lower left corner (B) on the display
unit.
Indicates a serious malfunction that may affect operator safety or

cause machine breakdown. The error code must be taken care of
immediately. Stop working with the machine and contact service
immediately.
E
000350
The error code is shown automatically on the display.
VDRF03.02GB
Warning
Indicates machine malfunction that should be taken care of as
soon as possible. After finished work shift with the machine, contact service as soon as possible.
E
000351
Stop
8 Control system 8.1.10 Error code menu
Information
Information to the operator that something should be taken care
of as soon as possible, e.g., defective light bulb. Take action to fix
the cause of the error code as soon as possible.
The error code is stored in the error code list under operating
menu for service.
000352
Field C: Error code number

The control system gives error codes from three sub-systems:
Machine:
Shown with error code number XXX on display.
E
000389
XXX/YY
Engine:
Shown with error code number XXX/YY on display.
NOTE
If several error codes come from the engine, the error code
level is shown for the most serious error code.
013390
XX/YY
Transmission:
Shown with error code number XX/YY on display.
D
013391
Field D: Type of error
1.
Too high/too low temperature.
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
VDRF03.02GB
8 Control system 8.1.10 Error code menu
Field E: Affected function
1.
Attachment
2.
Rotation of attachment
3.
Side shift-attachment
4.
Length adjustment attachment
5.
Levelling attachment
6.
Twistlocks
7.
Tilt attachment
8.
Bottom lift-attachment
9.
Bottom lift-attachment, clamping position
10. Bottom lift-attachment, jacks up/down
10
11
11. Boom up/down
12
12. Boom in/out

13. Pressure sensor lift cylinder (overload system, OP)
13
14
14. Overload system
15
15. Support jacks up/down

16. Hydraulic functions
16
17
17. Brake system
18
18. Steering
19. Engine
20. Transmission
19
20
21
21. Central lubrication

22. Control unit
23. Hardware-related error
22
23
24
24. Cab
25. Air conditioning system
26. Fuel system
25
26
27
27. Headlights
28. Windscreen wipers
29. Battery voltage
29
30. Bulb for lighting
30
000397
28
VDRF03.02GB
8 Control system 8.2 Monitoring
8.2
Monitoring
8.2.1
Overload system
8.2.1.1
Mechanical overload system
Mechanical overload system, function description (model

year-2008)
3, 10
D795
4
D4
D793
2, 5, 7, 9 D797-R
1
D1
D6
>
006413
page
Pos
Explanation
Signal description
Reference
Sensor, steering axle load (B7221)

sends a voltage signal to Control unit,
frame rear (D797-R) if the load on the
steering axle is low.
Normal: U = 24 V
Sensor, steering axle load, description page

11
Control unit, frame rear (D797-R) sends

"Overload forward" on the CAN bus.

error code.

Control unit KID (D795) shows Event

menu, overload forward.

Position sensor boom length 1.5 m

(B777) sends a voltage signal to Control
unit, frame rear (D797-R) if the booms
extension is less than 1.5 m.
Extension less than

1.5 m: U = 24 V
Sensor, boom length, description (position

sensor) page 13
Extension more than

1.5 m: U = 0 V


"boom length under 1.5m" on the CAN
bus.

error code.

Sensor, boom angle (B771) sends a

voltage signal proportional to boom angle to Control unit, frame rear (D797-R).
UB771/1 = 5 V
Sensor, boom angle, description (angle sensor) page 12
Overload: U = 0 V

UB771/2 = 0 V
UB771/3 = 0.5 - 4.5 V


"boom angle" on the CAN bus.

error code.


bus.

error code.

VDRF03.02GB
8 Control system 8.2.1.2 Mechanical overload system with analogue position sensors
Pos
Explanation
Signal description
Reference
If both Position sensors, beam length

1.5 m (B777) send a voltage signal and
the boom angle is over 35 while the
machine is operated faster than 10 km/h
then Control unit, frame rear (D797-R)
sends "Overload on steering axle" on
the CAN bus.

error code.

10

the Event menu for overload on steering
axle.

8.2.1.2
Mechanical overload system with

analogue position sensors
Mechanical overload system with analogue position

sensors, function description (model year-2008)
page
3, 8
D795
D793
D797-R
D4 2, 7
D5
1
D1
<
006414
Pos
Explanation
Signal description
Reference
Sensor, steering axle load (B7221)

sends a voltage signal to Control unit,
frame rear (D797-R) if the load on the
steering axle is low.
Normal: U = 24 V
Sensor, steering axle load, description page

11

"Overload forward" on the CAN bus.

error code.

Control unit KID (D795) activates Event

menu, overload forward.

Sensor, boom length (R777) sends a

(D797-R).
UB777/1 = 5 V
Sensor, boom length, description (analogue

sensor) page 14
VDRF03.02GB
Overload: U = 0 V

UB777/2 = 0 V
UB777/3 = 0.5 - 4.5 V

8 Control system 8.2.1.3 Electrical overload system
Pos
Explanation
Signal description
Reference
Sensor, boom angle (R771) sends a

angle to Control unit, frame rear
(D797-R).
UB771/1 = 5 V
Sensor, boom angle, description (angle sensor) page 12

bus.

error code.

If boom length is less than 1.5 m and

boom angle is greater than 35 while
the machine is operated faster than
10 km/h then Control unit, frame rear
(D797-R) sends "Overload on steering
axle" on the CAN bus.

error code.


the Event menu for overload on steering
axle.

UB771/2 = 0 V

UB771/3 = 0.5 - 4.5 V
8.2.1.3
Electrical overload system
Electrical overload system, function description (standard

model year 2009-)
page
D795
5, 8
D797-R
D797-F
D793
D4
D3
3
<
D1
1
Pa
Pa
006415
Pos
Explanation
Signal description
Reference
Sensor, hydraulic pressure lifting cylinder left (B768-L1 and B768-L2) transmits a voltage signal proportional to the
pressure in the left-hand lift cylinder to
UB768-XX/1 = 5 V

Sensor, hydraulic pressure lift cylinder
UB768-XX/2 = 0 V
UB768-XX/3 = 0.5 - 4.5 V

Sensor, hydraulic pressure lifting cylinder right (B768-R1 and B768-R2) transmits a voltage signal proportional to the
pressure in the right-hand lift cylinder to
VDRF03.02GB
10
8 Control system 8.2.1.3 Electrical overload system
Pos
Explanation
Signal description
Reference

pressure information on the CAN bus.

error code.


(D797-R).
UB777/1 = 5 V

Sensor, boom length
UB777/2 = 0 V
UB777/3 = 0.5 - 4.5 V

Alternatively, Sensor, boom length

(B777) may have a position sensor for
none or maximum boom extension.
4

Sensor, boom angle
Sensor, boom angle (BR771) sends a

angle to Control unit, frame rear
(D797-R).
UB771/1 = 5 V
Control unit, frame front (D797-F) calculates and sends the weight, which is calculated and compared with a machine
unique load curve based on the sensor
values for boom angle, boom length and

error code.

UB771/2 = 0 V
UB771/3 = 0.5 - 4.5 V

NOTE
The load curve is unique for each
machine.
If the load is high then Control unit,
frame front (D797-F) sends Overload
forward on the CAN bus.
6

the event menu for overload, depending
on the load situation.


bus.

error code.

In the event of overload on the steering

axle the speed is limited gradually with
the increasing load.

error code
VDRF03.02GB
8 Control system 8.2.1.4 Sensor, steering axle load
8.2.1.4
11
Sensor, steering axle load
Sensor, steering axle load, description
page
Sensors, steering axle load (B7221L and B7221R) detect when the
steering axles rear suspension decompresses. The sensors are fitted
on each side of the steering axles rear suspension.
Sensors, steering axle load, are inductive position sensors that are
supplied with voltage and send a voltage signal to Control unit, frame
rear (D797-R).
005122
The sensor signals can be checked from the diagnostic menu, see
section 8 Control system , group 8.4.10.1 OP, menu 1.
Location, Sensor, steering axle load (B7221L and

B7221R)
page
Sensor, steering axle load, replacement
page

2 Replace the sensor.
3 Adjust sensor position, see section 7 Load handling.
4 Turn on the main electric power and turn the ignition key to position I.
005122
5 Check the overload system, see section 8 Control system, group

8.2.1 Overload System.
VDRF03.02GB
12
8 Control system 8.2.1.5 Sensor, boom angle
8.2.1.5
Sensor, boom angle
Sensor, boom angle, description (angle sensor)
page
The booms angle is measured by a sensor that senses the booms angle in relation to the frame. The sensor consists of a sensor housing,
potentiometer and arm. The sensor housing is mounted on the boom.
The arm is connected to the frame and turns the potentiometer when
the boom is angled.
The sensor is supplied with voltage by and sends a signal proportional
to the angle to Control unit, frame rear (D797-R).
001093
Sensor, boom angle (B771)

page
Sensor, boom angle, replacement (angle sensor)

4 Calibrate Sensor, boom angle, see Weight indicator, calibration
(product alternative fixed scale) (only model year -2008) page
198 or Weight indicator, calibration (product alternative dynamic
scale) page 200.
5 Check that the end position damping is working in both outer and
inner end positions.
VDRF03.02GB
8 Control system 8.2.1.6 Sensor, boom length
8.2.1.6
13
Sensor, boom length
Sensor, boom length, description (position sensor)
page
Sensor, boom length specifies the booms extension and is available

in two versions, position sensors or analogue sensors. Standard is
three inductive position sensors. As an option there is an extra position
sensor for fixed scale (60 cm extension).
Two inductive sensors, Sensor, damping boom in (B769-3) and Sensor, damping boom out (769-4), are used to control the damping of
boom in and boom out. The sensors are located on the right-hand side
of the lift booms outer part.
The sensors are supplied with voltage by and send a negative signal
(grounding) to Control unit, frame rear (D797-R) when the booms indicator plate passes the sensor. Each sensor has an LED that is activated when sensors sense the indicator plate. The LEDs can be used
to check the sensors function.
1
2
001203
3
4
1. Position sensor, damping boom in (B769-3)
2. Position sensor 1.5 m (B777)
3. Position sensor, damping boom out (B769-4)
4. Position sensor, boom length 60 cm (B7224)
Position sensor damping extension sends a signal when the boom is

close to outer and inner end positions, this is used to activate damping,
see section 7 Load handling , group 7.3 Extension . The signal can be
checked from the diagnostic menu, see section 8 Control system ,
group 8.4.8.8 BOOM, menu 8.
Position sensor boom length 1.5 m (B777) sends a signal when the
booms extension is 1.5 m. This signal is used for the overload system
on the steering axle. The signal can be checked from the diagnostic
menu, see section 8 Control system , group 8.4.10.1 OP, menu 1.
Position sensor boom length 60 cm (B7224) sends a signal when the
booms extension is in position for weighing on machines with fixed
scale, see section 7 Load handling , group 7.10.2 Weight indicator .
page

page
Sensor, boom length (position sensor), replacement

3 Adjust sensor position, see section 7 Load handling.
4 Check that the end position damping is working in both outer and
inner end positions.
VDRF03.02GB
14
8 Control system 8.2.1.7 Sensor hydraulic pressure lift cylinder
Sensor, boom length, description (analogue sensor)
page
Sensor, boom length (R777) senses the lift booms extension and is
located in the rear edge of the boom on the left-hand side.
The sensor is connected to a spring-loaded wire that is connected to
a rotary potentiometer via a gearbox. The wire is connected to the inner boom. When the boom is extended, the wire acts on the potentiometer and the signal is changed.
The sensor is supplied with voltage by and sends a voltage signal proportional to the length to Control unit, frame rear (D797-R).
000471
Sensor, boom length (R777)

page
Sensor, boom length (analogue sensor), replacement

4 Calibrate the sensor, see Weight indicator, calibration (product
alternative dynamic scale) page 200.
5 Check that the end position damping is working in both the outer
and the inner end positions.
8.2.1.7
page
Sensor hydraulic pressure lift cylinder, general

See section 7 Load handling, group 7.2.9 Sensor, hydraulic pressure
lift cylinder.
VDRF03.02GB
8 Control system 8.2.2 Bypass
8.2.2
page
15
Bypass
Bypassing, description
When the overload system engages and turns off the hydraulic controls, it may take place in a situation where it is necessary to bypass
the safety system.
Bypass is activated with a switch, there are between one and three
switches depending on the machines equipment:
Switch, bypass
Switch, bypass height limitation
Switch rotation stop
Bypassing the safety system makes the following possible:
lower load at overload
locking and opening twistlocks without full alignment
spread 20-40 with locked twistlocks
bottom lift without full alignment
manual control of the recirculation damper for ECC or EHC
release of parking brake in case of malfunction of Switch, parking

brake or Sensor, operator in seat
lift above height limitation
rotation past rotation stop
load handling past limitation for load centre limitation.
lift, lower and extension with active error on the overload system
selection of travel direction in case of malfunction of Sensor, operator in seat, speed is limited to 10 km/h
D ANGER
Bypassing the safety systems results in a risk of tipping. Use at your own risk.
VDRF03.02GB
16
8 Control system 8.2.3 Load centre limitation
8.2.3
Load centre limitation, description
000358
page
Event menu, load centre limitation.
Load centre limitation prevents the load from coming too close to the
machine. The load centre limitation is controlled by the control system
with signals from Sensor, boom angle, see Sensor, boom angle, description (angle sensor) page 12 and Sensor, boom length, see Sensor, boom length, description (analogue sensor) page 14. For
example, this is used in connection with cab lift to prevent the container damaging the cab.
For details about lift, lower and extension, see section 7 Load handling, group 7.2 Lifting/lowering and section 7 Load handling, group
7.3 Extension.
Load centre limitation reaches its limit, synchronised lift is activated
(see section 7 Load handling, group 7.10.4 Synchronised lift) this
function can be temporarily disengaged using Switch, bypass (see Bypassing, description page 15).
Load centre limitation values can be checked from the diagnostic
menu, see 8 Control system , group 8.4.10.5 OP, menu 5.
8.2.4
page
Height limitation
Height limitation, description
Height limitation is a part of the control system and prevents the machine lifting higher than a preset height, without the operator being informed.
Height limitation is controlled by the control system with signals from
Sensor, boom angle, and Sensor, boom length. When boom angle
and extension indicate that permitted height is reached, lift and extension are blocked and display information height limitation is activated.
For details about lift, lower and extension, see section 7 Load handling, group 7.2 Lifting/lowering and section 7 Load handling, group
7.3 Extension.
Height limitation can be temporarily disengaged using Switch, bypass
of load centre and height limitation (S1015), see Switch, bypass height
limitation, description page 4.
Height limitation values can be checked from the diagnostic menu, see
VDRF03.02GB
8 Control system 8.2.5 Speed limitation
8.2.5
17
Speed limitation
Speed limitation, description
page
Speed limitation prevents the machines speed from exceeding preset value by limiting gear position and engine rpm.
Speed limitation is set via the initiation menu; see section 8 Control
system , group 8.5.1.5 INIT DRIVE-TRAIN, menu 9.
8.2.6
Service indicator
Service indicator, resetting
page
000056
2 First navigate to the service menu and press Enter.
3 Enter the code for service indicator reset.

Code is obtained from Cargotec Support.
000060
1 23
4 5
The code determines which service menu shall be activated

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

with the plus or minus key.
VDRF03.02GB
18
8 Control system 8.4 Diagnostics
8.4
Diagnostics
Diagnostic test, general
page
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 menu figures content and which functions that can be
controlled.
009268
DIAGNOSIS
CAN/POWER LIGHTS CAB
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
The diagnostic test is divided into the following groups:
Voltage feed and communication for the Control system, CAN/

POWER, description page 20.
Lighting, LIGHTS, description page 40.
Cab functions, CAB, description page 53.
Air conditioning, CLIMATE, description page 62.
Hydraulic functions, HYD, description page 70.
Engine, ENGINE, description page 75.
Transmission, TRANSM, description page 82.
Boom functions, BOOM, description page 101.
Attachment functions, ATTACH, description page 109.
Overload system, OP, description page 132.
Optional functions, EXTRA, description page 137.
Bottom lift, COMBI, menu 1 page 137.
Hydraulic sliding/vertically adjustable cab, SLIDING-CAB,

menu 1 page 154.
Support jacks, SUPPORT-JACKS, menu 1 page 158
Mini-wheel or lever steering, EL-STEERING, menu 1 page

161
RMI (Remote Machine Interface), RMI, description page 166
Diagnostic menu, description
page
7
6
DIAG CAB
FRONT WIPER
SWITCH (1-3)
OUTPUT
FEEDBACK
Diagnostic tests show how the control units interpret input signals as
well as which signals that the control units send.
2(10)
2
11
0
004856
1. DIAG = Diagnostic menus

2. Menu group
3.Menu number
4.Total number of menus in the loop
5.Signal value
6.Variable
7. Menu heading
VDRF03.02GB
8 Control system 8.4 Diagnostics
DIAG
Indicates that diagnostic tests are selected.
Menu group
Indicates which menu group is selected, these groups are:
19
CAN/POWER, description page 20.

LIGHTS, description page 40.
CAB, description page 53.
CLIMATE, description page 62.
HYD, description page 70.
ENGINE, description page 75.
TRANSM, description page 82.
BOOM, description page 101.
ATTACH, description page 109.
EXTRA, description page 137.
Menu number
Number of current menu. Every menu group consists of several menus in a loop.
Number of
menus
Total number of menus in the group.
Variable
The signal that is measured. Different signals are designated in different ways:
SWITCH: a digital input signal, e.g., a switch.
OUTPUT: a digital output signal, e.g., feed to a motor.
INPUT: an analogue input signal, e.g., from a sensor.
REFERENCE: status for an analogue output signal.
REQUIRED: triggered output signal for a control current
FEEDBACK: either feedback signal from a motor or measured current on the minus side for an analogue
output signal.
Signal value
Measurement value or status for signal for variable. On the same row there are different types that are
interpreted in different ways.
SWITCH: 1 or 0 where 1 means closed circuit.
OUTPUT: two characters where the first number is 1 if the output signal is active. The second number is
status for the circuit, 1=circuit OK, 0=open circuit or short-circuiting.
INPUT: numerical value corresponding to the signal.
REFERENCE: two characters where the first number is 1 if the input signal is active. The second number
is status for the circuit, 1=circuit OK, 0=open circuit or short-circuiting.
REQUIRED: numerical value corresponding to the signal.
FEEDBACK: numerical value corresponding to the signal.
Menu heading
Description of the function for which the menu reads signals.
VDRF03.02GB
20
8 Control system 8.4.1 CAN/POWER
8.4.1
CAN/POWER
CAN/POWER, description
page
This group handles redundant voltage feed to control units and CAN
bus communication.
Confirm selection with function key for Enter.
009268
DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
8.4.1.1
CAN/POWER, menu 1
PRESENT REDCAN STATUS, COMMUNICATION MODE
page
Description: Indicates communications status for the redundant CANbus.

Circuit diagram: 003177
DIAG CAN/POWER
1(20)
PRESENT REDCAN STATUS
COMMUNICATION MODE X
NUMBERS OF UNITS
X
SEGMENT ERROR
X
Connection: Function: 11.6.2 Redundant CAN-bus

Signal value:
3
Ok.
Segment check
Error.
PRESENT REDCAN STATUS, NUMBER OF UNITS
DIAG CAN/POWER
1(20)
NUMBERS OF UNITS
X
SEGMENT ERROR
X
003177
page
Description: Indicates the number of nodes on the redundant CAN bus

that should be on the machine in question, excluding Control unit, cab
(D790-1) and Control unit, KID (D795). (Control unit, transmission
(D793) and Control unit, engine (D794) are connected to a separate
CAN bus and are therefore not counted).
Circuit diagram: Circuit CAN BUS opt. frame KDU group 11.6, Circuit
CAN BUS ATT group, 11.6
Signal value:
X
VDRF03.02GB
Number of nodes that should be in the machine. Number of

nodes dependent on installed options.
8 Control system 8.4.1.2 CAN/POWER, menu 2
21
PRESENT REDCAN STATUS, SEGMENT ERROR
page
Description: Indicates if there is open circuit on the redundant CAN

bus. And if there is, where the first open circuit is. If there is open circuit, it is indicated with a number that corresponds to the incorrect segment on the redundant CAN bus.
003177
DIAG CAN/POWER
1(20)
NUMBERS OF UNITS
X
SEGMENT ERROR
X
Signal value:
0
No open circuit.
>0
If X is separated from 0, the first segment is indicated as

missing contact. A 1 means that the first segment is incorrect,
that is, that contact between first and second control unit is
cut off.
To see which control units are installed on the machine along
with their order, use diagnostic menu CAN/POWER, menu 2,
see PRESENT REDCAN STATUS, RED.CON.CITIES page
21.
8.4.1.2
CAN/POWER, menu 2
PRESENT REDCAN STATUS, RED.CON.CITIES
page
Description: Indicates which control units have contact with the cab
control unit (D790-1) via the redundant CAN bus. Note that certain
control units are optional and may not be installed on the machine.
000087
DIAG CAN/POWER
2(20)
RED.CON.CITIES
XYXYXYXY
1234ROFD
Connection:
D790-1: K13:4, K13:5, K13:7 and K13:8
D795: K1:10, K1:11, K1:12 and K1:13
D797-F, D797-R, D797-O, D791-1, D791-2, D791-2, D791-3,
D797-4: K2:2, K2:3, K2:4 and K2:5
Function: 11.5.3.1 Control unit, cab, 11.5.3.2 Control unit, frame front,
11.5.3.3 Control unit, frame rear, 11.5.3.4 Control unit, frame option,
11.5.3.5 Control unit, attachment, 11.5.3.6 Control unit, attachment
option, 11.5.3.7 Control unit, attachment left jack pair, 11.5.3.8 Control
unit, attachment right jack pair, 11.5.3.12 Control unit KID, 11.6.2 Redundant CAN bus
VDRF03.02GB
22
Signal value:
1
Communication with the node is OK.
No communication and/or there is some node error.

Position 1: Control unit, attachment (D791-1)
Position 2: Control unit, attachment option (D791-2)
Position 3: Control unit, attachment left jack pair (D791-3)
Position 4: Control unit, attachment right jack pair (D791-4)
Position R: Control unit, frame rear (D797-R)
Position O: Control unit, frame option (D797-O)
Position F: Control unit, frame front (D797-F)
Position D: Control unit, KID (D795)
8.4.1.3
CAN/POWER, menu 3
PRESENT DRIVE-TRAIN CAN BUS STATUS, ENGINE
page
Description: Indicates status for engine in drivetrains CAN bus.

engine Volvo 1240&1250, group 1.0, Circuit engine Cummins
group 1.0
000088
DIAG CAN/POWER
3(20)
PRESENT DRIVE-TRAIN
CAN BUS STATUS
ENGINE
X
TRANSMISSION
X
Connection:
Volvo TWD1240VE: CAN J1939 from D790-1/K13:1 and K13:2 to
D794/1 and 2
Volvo TAD1250VE: CAN J1939 from D790-1/K13:1 and K13:2 to
D794/1 and 2
Cummins QSM11: CAN J1939 from D790-1/K13:1 and K13:2 to
D794/46 and 37
Function: 11.6.3 Communication
Signal value:
1
NOTE
The cable harness for CAN bus drivetrain 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.
VDRF03.02GB
23
PRESENT DRIVE-TRAIN CAN BUS STATUS,

TRANSMISSION
page
Description: Indicates status for transmission in drivetrains CAN bus

Dana TE 32000 group 2.0, Circuit Dana TE 32000FF group 2.0
000088
DIAG CAN/POWER
3(20)
PRESENT DRIVE-TRAIN
CAN BUS STATUS
ENGINE
X
TRANSMISSION
X
Connection: CAN J1939 from D790-1/K13:1 and K13:2 to D793/L2

and M2
Function: 11.6.3 Communication
Signal value:
1
NOTE
The cable harness for CAN bus drivetrain 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.
8.4.1.4
CAN/POWER, menu 4
IGNITION, KEY IN
page
Description: Indicates if ignition is on (key in ignition).
4(X)
X
XY
XY
Circuit diagram: Circuit Power group 11.5

Connection: signal from S150/15 to D790-1/K11:1
006859
DIAG CAN/POWER
INGNITION
KEY IN
RELAY K315-1
RELAY K315-2
Function: 11.5.1.3 Ignition voltage

Signal value:
1
Input signal active.
No signal.
VDRF03.02GB
24
IGNITION, RELAY K315-1
page
Description: Control current to Relay ignition voltage (K315-1),

15-voltage.
4(X)
X
XY
XY

006859
DIAG CAN/POWER
INGNITION
KEY IN
RELAY K315-1
RELAY K315-2
Connection: signal from D790-1/K10:10 to K315-1/86

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
page
Description: Control current to Relay ignition voltage (K315-2), 15-voltage.
4(X)
X
XY
XY

006859
DIAG CAN/POWER
INGNITION
KEY IN
RELAY K315-1
RELAY K315-2

Signal value:
00
01

10
11

as this can only be detected when the output signal is
missing.
VDRF03.02GB
8.4.1.5
25
CAN/POWER, menu 5
EMERGENCY STOP, SW
page
Description: Indicates if switch, control switch, is activated.

006860
DIAG CAN/POWER
5(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
No signal.
EMERGENCY STOP, RELAY K3009-1
page
Description: Status for control current to Relay K2, for emergency stop
switch voltage (K3009-1), 15E voltage.
006860
DIAG CAN/POWER
5(X)
RELAY K3009-1
XY
FEEDBACK
X
RELAY K3009-2
XY

Signal value:
00
01

10
11

missing.
EMERGENCY STOP, FEEDBACK
page
Description: Feedback signal from emergency stop switch voltage relay (K3009-1); indicates that relay is working normally.
006860
DIAG CAN/POWER
5(X)
RELAY K3009-1
XY
FEEDBACK
X
RELAY K3009-2
XY
Connection: signal from K3009-1/87 via F58-3/8 to digital in D790-1/

K11:13
Signal value:
1
No signal.
VDRF03.02GB
26
EMERGENCY STOP, RELAY K3009-2
page
Description: Status of control current to emergency stop switch voltage relay (K3009-2), 15E-voltage.
006860
DIAG CAN/POWER
5(X)
RELAY K3009-1
XY
FEEDBACK
X
RELAY K3009-2
XY

Signal value:
00
01

10
11

missing.
8.4.1.6
CAN/POWER, menu 6
790-1 CAB, POWER
page
Description: Ignition voltage (15) to cab control unit (D790-1).

000091
DIAG CAN/POWER
6(20)
790-1 CAB
POWER
XX.XXV
5V REF
X.XXV
Connection: 15-voltage from K315-1/87 via F54/4 and F58-5/1 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
page
Description: Reference voltage 5 V to controls in cab.

Circuit diagram: Circuit Climate system group 9.4 (contact 1, 2), Circuit
Drivetrain group 1.1 (contact 3), Circuit Joystick group 7.1 (contact 4)
000091
DIAG CAN/POWER
6(20)
790-1 CAB
POWER
XX.XXV
5V REF
X.XXV
Connection:
1.
signal from digital out D790-1/K4:5 to Y672/10 and Y673/10
2.
signal from digital out D790-1/K5:11 to S118/1, S 139/1 and

S117/1
3.
signal from digital out D790-1/K5:13 to B690-1/1 and B697/1
4.
signal from digital out D790-1/K7:2 to S815/9
Function: 9.4 Heating, ventilation and air conditioning (contact 1

and 2); 1 Engine and 2 Transmission (contact 3); 7 Load handling
(contact 4)
Signal value: X.XXV = 5.00 V, Important that the signal value is stable
(not varying).
VDRF03.02GB
8.4.1.7
27
CAN/POWER, menu 7
790-1 CAB, 24V SENSOR SUPPLY
page
Description: 24 V voltage feed to components in cab.

Circuit diagram:
003178
DIAG CAN/POWER
7(20)
790-1 CAB
24V SENSOR SUPPLY XY
24V SUPPLY,RPM>500 XY
1.
Circuit Wiper group 9.5
2.
Circuit Extra equipment group 9.1, Circuit Drivetrain group 2.1,

Circuit Cab drivers seat group 9.3, Circuit Lighting group 9.6, Circuit Working lights group 9.6 and Circuit Extra Sensor Instr. group
9.1
3.
Circuit Joystick group 7.1
4.
Circuit Power group 11.5, Circuit Brake group 4.0, Circuit Bypass
group 8.2, Circuit Sliding/Vertically adjustable Cab group 9.10,
Circuit Hyd Support jacks group 7.10, Circuit Twistlocks group
7.9, Circuit Spreading Sensor group 7.5, Circuit Extra equipment
group 9.1
5.
Circuit Combi Att group 7.9
6.
7.
Circuit Sliding/Vertically adjustable Cab group 9.10
8.
Circuit Alarm, audible signals group 9.7
9.
Circuit Wiper group 9.5
10. Circuit Wiper group 9.5

Connection:
1.
signal from digital out D790-1/K4:14 to M650-1/53a
2.
signal from digital out D790-1/K5:1 to S199-1/5, S199-3/5, S1994/5, S220-2/1, S143/5, S100/5, S110/5, S105-3/5, S105-2/5,
S105-1/5
3.
4.
signal from digital out D790-1/K8:16 to S250/11, S107/5, S1005/

5, S1015/5, S1014/5, S177/3, S1013/3, S1003/3, S1003/4,
S1004/5, S199-2/5
5.
signal from digital out D790-1/K9:1 to S1006/3, S1007/3, S1008/3
6.
signal from digital out D790-1/K9:7 not connected
7.
signal from digital out D790-1/K10:1 to B769-2/1
8.
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
VDRF03.02GB
28
Function:
1.
9.5.5 Wiper motor front
2.
2.0 Transmission, 9.3 Seat, 9.6 Lighting
3.
7.1.1 Control lever
4.
11.5.1.4 Emergency stop voltage, 4.5 Parking brake system, 8.2.2

Bypass, 9.10.4 Sliding cab, 9.10.5 Vertically adjustable cab,
7.10.1 Support jacks, 7.9.1 Twistlocks
5.
7.9.2 Lifting jacks
6.
7.
9.10.4 Sliding cab, 9.10.5 Vertically adjustable cab
8.
9.3.10 Sensor operator in seat
9.
9.5.7 Wiper motor rear
10. 9.5.6 Wiper motor roof

Signal value:
01

No output signal. It can also be a short circuit in the circuit as
this fault can only be detected when the output signal is active.
10
Output signal active, short-circuit. It can also be open circuit

as this cannot be detected.
11

Output signal active, circuit OK or open circuit. Open circuit
cannot be detected.
790-1 CAB, 24V SUPPLY, RPM >500
page
Description: Voltage feed at engine speed is higher than 500 rpm.

Circuit diagram: Circuit Sensor instr. group 9.1
003178
DIAG CAN/POWER
7(20)
790-1 CAB
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

missing.
VDRF03.02GB
8.4.1.8
29
CAN/POWER, menu 8
797-F FRAME, POWER
page
Description: Ignition voltage (15) to Control unit, frame front (D797-F).

000093
DIAG CAN/POWER
8(20)
797-F FRAME
POWER
XX.XXV
RED.POWER
Le X Ri X
EME STOP POWER
X
Connection: 15 voltage from K315-1/87 via F54/4 and F58-2/1 to

D797-F/K2:1, D797-F/K2:9 and D797-F/K2:10
797-F FRAME, RED. POWER
page
Description: Redundant voltage to Control unit, frame front (D797-F).

Circuit diagram: Circuit CAN BUS opt. frame KDU group 11.6
Connection:
000093
DIAG CAN/POWER
8(20)
797-F FRAME
POWER
XX.XXV
RED.POWER
Le X Ri X
EME STOP POWER
X
Le: redundant feed to D797-F/K2:7

Ri: redundant feed to D797-F/K2:8
Function: 11.5.1.2 Redundant voltage feed of control units
Signal value:
1
Feed active.
No feed.
797-F FRAME, EME STOP POWER
page
Description: Emergency stop voltage to Control unit, frame front

(D797-F).
000093
DIAG CAN/POWER
8(20)
797-F FRAME
POWER
XX.XXV
RED.POWER
Le X Ri X
EME STOP POWER
X
Connection: 15E-voltage from K3009-1787 via K3009-2/87 and

F58-3/2 to D797-F/K2:11
Signal value:
1
Feed active.
No feed.
VDRF03.02GB
30
8.4.1.9
CAN/POWER, menu 9
797-F FRAME, 24V SENSOR SUPPLY
page
Description: Voltage feed 24 V to sensors connected to Control unit,

frame front (D797-F) (pressure switches).
Circuit diagram: Circuit Brake system group 4.0, Circuit Drivetrain
group 2.1, Circuit Lighting group 9.6
000094
DIAG CAN/POWER
9(20)
797-F FRAME
5V REF
X.XXV
Connection: signal from digital out D797-F/K1:39 to S, 200, S204,

S216 and S220
Function: 9.6.4 Brake light, 2.2.6 NO (normally open) switch declutch,
4.3.7 NO (normally open) switch brake pressure, 4.3.8 NO (normally
open) switch brake light 4.5.5 NO (normally open) switch parking
brake
Signal value:
00
01

10
11

797-F FRAME, 5V REF
page
Description: Reference voltage 5 v to sensors connected to Control

unit, frame front (D797-F) (voltage feed to pressure sensors).
Circuit diagram: Circuit OP + Scale group 8.2
Connection: digital out from 797-F/K1:8 to B768-R1, B768-R2,
B768-L1 and B768-L2
000094
DIAG CAN/POWER
9(20)
797-F FRAME
5V REF
X.XXV
Function: 7.2.9 Sensor hydraulic pressure lift cylinder

Signal value: X.XXV = 5.00 V. Important that signal value is stable (not
varying).
8.4.1.10
CAN/POWER, menu 10
797-R FRAME, POWER
page
Description: Ignition voltage (15) to Control unit, frame rear (D797-R).

Circuit: Circuit Power group 11.5
000095
DIAG CAN/POWER 10(20)

797-R FRAME
POWER
XX.XXV
RED.POWER
Le X Ri X
Connection: 15 voltage from K315-1/87 via F54/4 and F58-2/3 to

D797-R/K2:1 and D797-R/K2:9
VDRF03.02GB
31
797-R FRAME, RED. POWER
page
Description: Redundant voltage to Control unit, frame rear (D797-R).

Connection:
Le: redundant feed to D797-R/K2:7
000095

797-R FRAME
POWER
XX.XXV
RED.POWER
Le X Ri X
Ri: redundant feed to D797-R/K2:8

Signal value:
1
Feed active.
No feed.
8.4.1.11
CAN/POWER, menu 11
797-R FRAME, 24V SENSOR SUPPLY
page
Description: Voltage feed 24 V to sensors connected to Control unit,

000096

797-R FRAME
5V REF
X.XXV
Connection: digital out from D797-R/K1:2 to B7221

Function: 8.2.1.1 Sensor, steering axle load
Signal value:
00
01

10
11

missing.
797-R FRAME, 5V REF
page
Description: Reference voltage 5 V to sensors connected to Control

unit, frame rear (D797-R).
000096

797-R FRAME
5V REF
X.XXV
Connection: digital out from 797-R/K1:8 to B771/1 and B777/1

Function: 8.2.1.2 Sensor, boom angle (angle sensor), 8.2.1.3 Sensor,
boom length (analogue sensor)
Signal value: X.XXV = 5.00 V. Important that signal value is stable (not
varying).
VDRF03.02GB
32
8.4.1.12
CAN/POWER, menu 12
797-O FRAME, POWER
page
Description: Ignition voltage (15) to Control unit frame option

(D797-O).
000097

797-O FRAME
POWER
XX.XXV
RED.POWER
Le X Ri X
EME STOP POWER
X

Connection: 15-voltage from K315-1/30 via F54/4 and 58-2/4 to
D797-O/K2:10
797-O FRAME, RED. POWER
page
Description: Redundant voltage to Control unit frame option (D797-O).

000097

797-O FRAME
POWER
XX.XXV
RED.POWER
Le X Ri X
EME STOP POWER
X
Connection:
Le: redundant feed to D797-O/K2:7
Ri: redundant feed to D797-O/K2:8
Signal value:
1
Feed active.
No feed.
797-O FRAME, EME STOP POWER
page
Description: Emergency stop voltage (15E) to Control unit frame option (D797-O).
000097

797-O FRAME
POWER
XX.XXV
RED.POWER
Le X Ri X
EME STOP POWER
X

Connection: 15E-voltage from K3009-1/87 via K3009-2/87 and F58-3/
4 to D797-O/K2:11
Signal value:
VDRF03.02GB
Feed active.
No feed.
8.4.1.13
33
CAN/POWER, menu 13
797-O FRAME, 24V SENSOR SUPPLY
page
Description: Battery voltage to sensor.

000098

797-O FRAME
5V REF
X.XXV
Circuit diagram: Circuit Hyd Support jacks group 7.10, Circuit Tiltable
cab group 9:10
Connection: digital out D797-O/K1:9 to B7222L, B7222R, B7223L,
B7223R
Function: 7.10.1.5 Sensor, raised support jacks, 7.10.1.6 Sensor, lowered support jacks
Signal value:
00
01

10
11

790-O FRAME, 5V REF
page
Description: not connected


797-O FRAME
5V REF
X.XXV
Connection: digital out from D797-O/K1:8, not connected

Function: Signal value: -
8.4.1.14
CAN/POWER, menu 14
795 DISPLAY, RED. POWER
page
Description: Redundant voltage to KID control unit (D795).
DIAG CAN/POWER
795 DISPLAY
14(20)
Le X Ri X
000099
Connection:
RED.POWER
Le: redundant feed to D790/K1:8

Ri: redundant feed to D790/K1:7
Signal value:
1
Feed active.
No feed.
VDRF03.02GB
34
8.4.1.15
CAN/POWER, menu 15
793 TRANSMISSION, POWER
page
Description: Battery voltage (30) to transmission control unit (D793).

Circuit diagram: Circuit Power group 11.5, Circuit Dana TE 32000
group 2.0, Circuit Dana TE 32000FF group 2.0
000100

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/A1

Function: 11.5.1.1 Battery voltage (30)
793 TRANSMISSION, IGNITION POWER
page
Description: Ignition voltage (15) to transmission control unit (D793).

Circuit diagram: Circuit Power group 11.5, Circuit Dana TE 32000
group 2.0, Circuit Dana TE 32000FF group 2.0
000100

793 TRANSMISSION
POWER
XX.XXV
Connection: 15-voltage from K315/87 via F54/4 and F58-2/5 to D793/

S2
793 TRANSMISSION, SENSOR SUPPLY
page
Description: voltage feed to sensors on transmission, reference voltage of 5 V.

Circuit diagram: Circuit Dana TE 32000 group 2.0, Circuit Dana TE
32000FF group 2.0
000100

793 TRANSMISSION
POWER
XX.XXV
Connection:
Dana: 5V analogue Ref from D793/M1 to S221/1
Dana full flow: 5V analogue Ref from D793/M1 to S2210/1
Function: 2.9 Control system, transmission
Signal value: XX.XXV = voltage on connection. The signal value
should be 8 V, stable (not vary).
8.4.1.16
CAN/POWER, menu 16
791-1 ATTACHMENT, POWER
page
Description: Battery voltage to Control unit, attachment (D791-1).

00003179

791-1 ATTACHMENT
POWER
XX.XXV
RED.POWER
Le X Ri X
Connection: 15E voltage from K3009-1/87 via K3009-2/87, F58-3/1

and F52-1 to D791-1/K2:1, K2:9, K2:10, K2:11
VDRF03.02GB
35
791-1 ATTACHMENT, RED. POWER
page
Description: Redundant voltage feed to attachment control unit

(D791-1).
00003179

791-1 ATTACHMENT
POWER
XX.XXV
RED.POWER
Le X Ri X
Connection:
Le: redundant voltage feed to D791/K2:7
Ri: redundant voltage feed to D791/K2:8
Signal value:
1
Feed active.
No feed.
8.4.1.17
CAN/POWER, menu 17
page
Description: Battery voltage to Control unit, attachment option

(D791-2).
000102

791-2 ATTACHMENT
POWER
XX.XXV
RED.POWER
Le X Ri X
Circuit diagram: Circuit Power group 11.5, Circuit Power att. group
11.5
and F52-1 to D791-2/K2:1, K2:11
page
Description: Redundant voltage to Control unit, attachment option

(D791-2).
000102

791-2 ATTACHMENT
POWER
XX.XXV
RED.POWER
Le X Ri X
Connection:
Le: redundant feed to D791-2/K2:7
Ri: redundant feed to D791-2/K2:8
Signal value:
1
Feed active.
No feed.
VDRF03.02GB
36
8.4.1.18
CAN/POWER, menu 18
page
Description: Battery voltage to Control unit, attachment left jack pair

(D791-3).
000103

791-3 ATTACHMENT
POWER
XX.XXV
RED.POWER
Le X Ri X
Circuit diagram: Circuit Power group 11.5, Circuit Combi Att group 7.9
and F52-2 to D791-3/K2:1, K2:11
should be 22-30V (battery voltage).
page
Description: Redundant voltage to Control unit, attachment left jack

pair (D791-3).
000103

791-3 ATTACHMENT
POWER
XX.XXV
RED.POWER
Le X Ri X
Connection:
Signal value:
1
Feed active.
No feed.
8.4.1.19
CAN/POWER, menu 19
page
Description: Battery voltage to Control unit, attachment right jack pair

(D791-4).
000104

791-4 ATTACHMENT
POWER
XX.XXV
RED.POWER
Le X Ri X
Circuit diagram: Circuit Power group 11.5, Circuit Combi Att group 7.9
and F52-2 to D791-4/K2:1, K2:11
should be 22-30V (battery voltage).
VDRF03.02GB
37
page
Description: Redundant voltage to Control unit, attachment right jack

pair (D791-4).
000104

791-4 ATTACHMENT
POWER
XX.XXV
RED.POWER
Le X Ri X
Connection:
Signal value:
1
Feed active.
No feed.
8.4.1.20
CAN/POWER, menu 20
24V SENS. SUP 791-1
page
Description: Voltage feed to position sensors connected to Control

unit, attachment (D791-1).
Circuit diagram: Circuit Spreading Valves group 7.5
003180

24V SENS.SUP 791-1 XY
Connection: digital out from D791/K1:10 to B769, B777-3, B7224,

B7225, B7202L, B7202R, B7203L, B7203R, B7204L, B7204R,
B7205L and B7205R
Function: 7.5.10 Position sensor spreading, 7.6.10 Sensor rotation
stop, 7.9.1.8 Sensor alignment, 7.9.1.9 Sensor twistlocks, 8.2.1.6
Sensor, boom length
Signal value:
00
01

10
11

missing.
VDRF03.02GB
38
24V SENS. SUP 791-2
page
Description: Voltage feed to position sensors connected to Control

unit, attachment (D791-2).
003180

Circuit diagram: Circuit Over Height group 7.9

Connection: digital out from D791/K1:10 to B7231L and B7231R
Function: 7.9.1 Twistlocks
Signal value:
00
01

10
11

missing.
24V SENS. SUP 791-3
page
Description: Battery voltage to position sensor for left jack pair on combi attachment.
003180

Circuit diagram: Circuit Combi Att group 7.9

Connection: digital out from D791-3/K1:26 to B7212L, B7213L,
B7214L, B7215L, B7216L, B7217L, B7218L, B7219L and B7220L
Function: 7.9.2.9 Sensor operating position, 7.9.2.10 Sensor knee,
7.9.2.13 Sensor lifting jacks, 7.9.2.15 Sensor alignment, 7.9.16 Sensor clamping position
Signal value:
00
01

10
11

missing.
VDRF03.02GB
39
24V SENS. SUP 791-4
page
Description: Battery voltage to position sensor for right jack pair on

combi attachment.
003180


Connection: digital out from D791-4/K1:26 to B7212R, B7213R,
B7214R, B7215R, B7216R, B7217R, B7218R, B7219R and B7220R
Function: 7.9.2.9 Sensor operating position, 7.9.2.10 Sensor knee,
7.9.2.13 Sensor lifting jacks, 7.9.2.15 Sensor alignment, 7.9.16 Sensor clamping position
Signal value:
00
01

10
11

missing.
8.4.1.21
CAN/POWER, menu 21
REDCAN STATUS CHECK
page
Description: Control function from the redundant CAN bus. Control

unit, attachment (D791-1) creates a virtual fault in the redundant CAN
bus in order to determine whether all control units have contact and
are connected in the right order. The control system indicates the fault
by numbering the cables between the control units (segments) from 1
onwards. Segment 1 is always between Control unit, cab (D790-1)
and Control unit, attachment(D791-1). 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
006861
DIAG CAN/POWER
21(X)
REDCAN STATUS CHECK
PRESS ENTER
X
CAN R
D791-3
CAN R
CAN L
CAN L
4
5
CAN R
D791-1
CAN L
D790-1
1
CAN R
D791-2
CAN R
D790-2
CAN R
D797-R
Function: 11.6.2 Redundant CAN-bus

Signal value:
D795
CAN L
CAN R
CAN L
9
6
CAN L
Connection:
CAN L
No errors.
>0
X > 0, the number indicates incorrect segment. Use circuit diagram to find the incorrect segment.
7
CAN L
CAN R
D797-O
CAN L
CAN R
D797-F
006883
D791-4
Segment numbering with maximum number of control

units. Control units marked with dashes are optional.
VDRF03.02GB
40
8 Control system 8.4.2 LIGHTS
8.4.2
LIGHTS
LIGHTS, description
page
This group covers lighting.

012083
DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
8.4.2.1
LIGHTS, menu 1
WORKING LIGHT CAB, SWITCH
page
Description: Signal from switch working lights cab roof.

Circuit diagram: Working lights group 9.6
Connection: from S105-1/1 to digital in D790-1/K6:10
000107
DIAG LIGHTS
1(13)
WORKING LIGHT CAB
SWITCH
X
OUTPUT
LE XY RI XY
Function: 9.6 Lighting system

Signal value:
1
No signal.
WORKING LIGHT CAB, OUTPUT
page
Description: Voltage feed to working lights cab roof.

Connection:
LE: digital out from D790-1/K2:7 to E404-1L
000107
DIAG LIGHTS
1(13)
WORKING LIGHT CAB
SWITCH
X
OUTPUT
LE XY RI XY
RI: digital out from D790-1/K2:6 to E404-1R

Function: 9.6.9 Working lights cab
Signal value:
01

No output signal. It can also be a fault in the circuit as this fault
can only be detected when the output signal is active.
10
Output signal active, short-circuiting or open circuit.
11

Output signal active, circuit OK.
VDRF03.02GB
8 Control system 8.4.2.2 LIGHTS, menu 2
8.4.2.2
41
LIGHTS, menu 2
WORKING LIGHT ATTACH, SWITCH
page
Description: Signal from switch working lights attachment.

Connection: signal from S105-2/1 to digital in D790-1/K6:2
012084
DIAG LIGHTS
2(13)
WORKING LIGHT ATTACH
SWITCH
X
OUTPUT
LE XY RI XY
OPT OUTPUT (2X)
XY

Signal value:
1
No signal.
WORKING LIGHT ATTACH, OUTPUT
page
Description: Voltage feed to working light, attachment, feed.

Connection:
LE: digital out from D791/K1:15 to E404-2L
012084
DIAG LIGHTS
2(13)
SWITCH
X
OUTPUT
LE XY RI XY
OPT OUTPUT (2X)
XY
RI: digital out from D791/K1:1 to E404-2R

Function: 9.6.11 Working lights attachment
Signal value:
00
01

10
11

missing.
VDRF03.02GB
42
WORKING LIGHT ATTACH, OPT OUTPUT (2X)
page
Description: Voltage feed to the extra working lights on the

attachment.
012084
DIAG LIGHTS
2(13)
SWITCH
X
OUTPUT
LE XY RI XY
OPT OUTPUT (2X)
XY
Circuit diagram: Circuit Extra Wor.li. Att group 9.6

Connection: digital out from D791/K1:42 to E404-4R and E404-4L
Function: 9.6.11 Working lights attachment
Signal value:
00
01

10
11

missing.
8.4.2.3
LIGHTS, menu 3
WORKING LIGHT BOOM, SWITCH
page
Description: Signal from switch working light boom.
VDRF03.02GB

Connection: from S105-3/1 to digital in D790-1/K6:3
000109
DIAG LIGHTS
3(13)
WORKING LIGHT BOOM
SWITCH
X
OUTPUT
LE XY RI XY
OPTIONAL OUTPUT
XX

Signal value:
1
No signal.
43
WORKING LIGHT BOOM, OUTPUT
page
Description: Voltage feed to working light boom.

Connection:
LE: digital out from D797-R/K1:1 to E404-3L
000109
DIAG LIGHTS
3(13)
WORKING LIGHT BOOM
SWITCH
X
OUTPUT
LE XY RI XY
OPTIONAL OUTPUT
XX
RI: digital out from D797-R/K1:15 to E404-3R

Function: 9.6.10 Working light boom
Signal value:
00
01

10
11

missing.
WORKING LIGHT BOOM, OPTIONAL OUTPUT
page
Description: Voltage feed to extra working lights on the boom.

Circuit diagram: Circuit Extra Wor.li. Boom group 9.6
000109
DIAG LIGHTS
3(13)
WORKING LIGHT BOOM
SWITCH
X
OUTPUT
LE XY RI XY
OPTIONAL OUTPUT
XX
Connection: digital out from D790-1/K10:8, via relay K304/87 to

H404-5L and H404-5R
Function: 9.6.10 Working light boom
Signal value:
00
01

10
11

missing.
VDRF03.02GB
44
8.4.2.4
LIGHTS, menu 4
MAIN LIGHT, SWITCH
page
Description: Signal from headlights switch.
4(13)
Circuit diagram: Circuit Lighting group 9.6
Connection: from S100/1 to digital in D790-1/K6:5

000110
DIAG LIGHTS
MAIN LIGHT
SWITCH

Signal value:
1
No signal.
8.4.2.5
LIGHTS, menu 5
PRESENT OUTPUT SIGNAL, SIDE F
page
Description: Voltage feed to side lights front.

Connection:
LE: digital out from D797-F/K1:25 to H416-1
000111
DIAG LIGHTS
5(13)
PRESENT OUTPUT SIGNAL
SIDE-F
LE XY RI XY
SIDE-R
LE XY RI XY
REAR
LE XY RI XY
RI: digital out from D797-F/K1:29 to H417-1

Function: 9.6.2 Running lights
Signal value:
00
01

10
11

missing.
VDRF03.02GB
45
PRESENT OUTPUT SIGNAL, SIDE R
page
Description: Voltage feed to side lights rear.

Connection:
LE: digital out from D797-R/K1:7 to H416-2
000111
DIAG LIGHTS
5(13)
SIDE-F
LE XY RI XY
SIDE-R
LE XY RI XY
REAR
LE XY RI XY
RI: digital out from D797-R/K1:9 to H417-2

Function: 9.6.2 Running lights
Signal value:
00
01

10
11

missing.
PRESENT OUTPUT SIGNAL, REAR
page
Description: Voltage feed to rear lights.

Connection:
LE: digital out from D797-R/K1:10 to H412L
000111
DIAG LIGHTS
5(13)
SIDE-F
LE XY RI XY
SIDE-R
LE XY RI XY
REAR
LE XY RI XY
RI: digital out from D797-R/K1:25 to H412R

Function: 9.6.3 Rear lights
Signal value:
00
01

10
11

missing.
VDRF03.02GB
46
8.4.2.6
LIGHTS, menu 6
HEADLIGHTS, SWITCH
page
Description: Lighting headlights front, switch.

Connection: from S162/56A to digital in D790-2/K3:9
000112
DIAG LIGHTS
6(13)
HEAD LIGHTS
SWITCH
X
HEAD
LE XY RI XY
DIMMED
XY

Signal value:
1
No signal.
HEAD LIGHTS, HEAD
page
Description: Voltage feed to headlights, high beam. If the machine is

equipped with extra working lights front then they are connected in
parallel with the high beams.
000112
DIAG LIGHTS
6(13)
HEAD LIGHTS
SWITCH
X
HEAD
LE XY RI XY
DIMMED
XY
Circuit diagram: Circuit Lighting group 9.6 and Circuit Extra Wor.Li.
Frame group 9.6
Connection:
LE: digital out from D797-F/K1:1 to E402L (
E404-8L)
RI: digital out from D797-F/K1:15 to E402R (
E404-8R)
E404-7L and
E404-7R and
Function: 9.6.1 Headlights

Signal value:
00
01

10
11

missing.
VDRF03.02GB
47
HEAD LIGHTS, DIMMED
page
Description: Voltage feed to headlights, low beams.

Connection: digital out from D797-F/K1:42 to E400L and E400R
000112
DIAG LIGHTS
6(13)
HEAD LIGHTS
SWITCH
X
HEAD
LE XY RI XY
DIMMED
XY
Function: 9.6.1 Headlights

Signal value:
00
01

10
11

missing.
8.4.2.7
LIGHTS, menu 7
PRESENT INPUT SIGNAL, HAZARD SWITCH
page
Description: Signal from switch flashing hazard lights (Hazard).

Circuit diagram: Circuit Direction indicators, Hazard flashers,
group 9.7
000113
DIAG LIGHTS
7(13)
HAZARD SWITCH
X
FLASH.SW.
LE X RI X

Function: 9.7 Signalling system
Signal value:
1
No signal.
PRESENT INPUT SIGNAL, FLASH.SW.
page
Description: Signal from switch direction indicators.

group 9.7
000113
DIAG LIGHTS
7(13)
HAZARD SWITCH
X
FLASH.SW.
LE X RI X
Connection:
LE: from S161/1 to digital in D790-2/K8:9
RI: from S161/6 to digital in D790-2/K8:8
Signal value:
1
No signal.
VDRF03.02GB
48
8.4.2.8
LIGHTS, menu 8
PRESENT OUTPUT SIGNAL HAZARD/FLASHER, FRONT
page
Description: Voltage feed to direction indicators front.

group 9.7
000114
DIAG LIGHTS
8(13)
HAZARD/FLASHER
FRONT
LE XY RI XY
REAR
LE XY RI XY
Connection:
LE: digital out from D797-F/K1:9 to H422
RI: digital out from D797-F/K1:10 to H423
Function: 9.6.6 Direction indicators, 9.6.7 Flashing hazard lights
(Hazard)
Signal value:
00
01

10
11

missing.
PRESENT OUTPUT SIGNAL HAZARD/FLASHER, REAR
page
Description: Voltage feed to direction indicators rear.

group 9.7
000114
DIAG LIGHTS
8(13)
HAZARD/FLASHER
FRONT
LE XY RI XY
REAR
LE XY RI XY
Connection:
LE: digital out from D797-R/K1:29 to H426
RI: digital out from D797-R/K1:39 to H427
Function: 9.6.6 Direction indicators, 9.6.7 Flashing hazard lights
(Hazard)
Signal value:
00
01

10
11

missing.
VDRF03.02GB
8.4.2.9
49
LIGHTS, menu 9
ROTATING BEACON, SWITCH
page
Description: Signal from switch rotating beacon.
9(13)
X
XY

000115
DIAG LIGHTS
ROTATION BEACON
SWITCH
OUTPUT

Signal value:
1
No signal.
ROTATING BEACON, OUTPUT
page
Description: Voltage feed to rotating beacon.
9(13)
X
XY

Connection: digital out D790-1/K2:5 to H428
000115
DIAG LIGHTS
ROTATION BEACON
SWITCH
OUTPUT
Function: 9.6.8 Rotating beacon

Signal value:
01

10
11

8.4.2.10
LIGHTS, menu 10
PRESENT INPUT SIGNAL, BRAKE LIGHT SWITCH
page
Description: Signal from make-contact brake lights.

Connection: from S216/2 to digital in D797-F/K1:13
013260
DIAG LIGHTS
10(13)
BRAKE LIGHT SWITCH
X
REVERSE LIGHT SIGNAL X
Function: 4.3.8 Make-contact brake lights

Signal value:
1
No signal.
VDRF03.02GB
50
PRESENT INPUT SIGNAL, REVERSE LIGHT SIGNAL
page
Description: Signal from transmission control unit (D793) when reverse gear is activated.
013260
DIAG LIGHTS
10(13)
BRAKE LIGHT SWITCH
X
REVERSE LIGHT SIGNAL X
Connection: Function: 9.6.5 Back-up light

Signal value:
1
Input signal active. Output signal "reverse gear active" from

transmission control unit (D793).
No signal.
8.4.2.11
LIGHTS, menu 11
PRESENT OUTPUT SIGNAL, BRAKE LIGHT
page
Description: Voltage feed to brake lights.

Connection:
000117
DIAG LIGHTS
11(13)
BRAKE LIGHT LEXY RIXY
REVERSE LGT LEXY RIXY
REVERSE ALARM
XY

Function: 9.6.4 Brake lights
Signal value:
00
01

10
11

missing.
VDRF03.02GB
51
PRESENT OUTPUT SIGNAL, REVERSE LGT
page
Description: Voltage feed to brake lights.

Connection:
000117
DIAG LIGHTS
11(13)
REVERSE ALARM
XY

Function: 9.6.5 Back-up light
Signal value:
00
01

10
11

missing.
PRESENT OUTPUT SIGNAL, BACK-UP (REVERSE)

ALARM
page
Description: Voltage feed to back-up alarm.

Circuit diagram: Circuit Reverse alarm group 9.7
Connection: digital out from D797-R/K1:30 to H965
000117
DIAG LIGHTS
11(13)
REVERSE ALARM
XY
Function: 9.7.5 Back-up alarm

Signal value:
00
01

10
11

missing.
VDRF03.02GB
52
8.4.2.12
LIGHTS, menu 12
CAB LIGHT, MANUAL SWITCH
page
Description: Signal from switch lighting cab.
12(13)
X
X
XXX

Connection: from KIT, D790-2/K8:11 to digital in D790-1/K11:2
000118
DIAG LIGHTS
CAB LIGHT
MANUAL SWITCH
DOOR SWITCH
OUTPUT

Signal value:
1
No signal.
CAB LIGHT, DOOR SWITCH
page
Description: Signal from contact breaking door.
12(13)
X
X
XXX
000118
DIAG LIGHTS
CAB LIGHT
MANUAL SWITCH
DOOR SWITCH
OUTPUT
Connection: from S266LE or S266RE (connected in parallel) to digital

in D790-1/K11:3
Function: 9.10.2 Doors
Signal value:
1
No signal.
CAB LIGHT, OUTPUT
page
Description: Voltage feed to interior light cab.
12(13)
X
X
XXX

Connection: from D790-1/K11:6 to E434
000118
DIAG LIGHTS
CAB LIGHT
MANUAL SWITCH
DOOR SWITCH
OUTPUT
Function: 9.6.12 Interior lighting cab

Signal value: XXX = 0-255 = 0-24 V (255 means 24 V which corresponds to battery voltage).
8.4.2.13
LIGHTS, menu 13
SWITCH LIGHTS, OUTPUT
page
OUTPUT
13(13)
Circuit diagram: -
XXX
Connection: 000119
DIAG LIGHTS
SWITCH LIGHTS
Description: Voltage feed to background lights in switches, panels and

keys.
Function: 9.6.12 Interior lighting cab

Signal value:
VDRF03.02GB
50
Means 4-5 V.
170
Means 15-16 V.
8 Control system 8.4.3 CAB
8.4.3
53
CAB
CAB, description
page
This group covers functions in the cab.

012086
DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
8.4.3.1
CAB, menu 1
WASHER, SWITCH
page
Description: Signal from gear and multi-function lever switch washer.
1(X)
X
XY
XY
Circuit diagram: Circuit Wipers group 9.5

Connection: signal from S162/53C to digital in D790-2/K3:4
012087
DIAG CAB
WASHER
SWITCH
OUTPUT FRONT
OUTPUT REAR/ROOF
Function: 9.5 Wiping and cleaning of windows

Signal value:
1
No signal.
WASHER, OUTPUT
page
Description: Voltage feed to windscreen washer motor.
1(X)
X
XY
XY

Connection: digital out D790-1/K10:13 to M651-1 and M651-2
012087
DIAG CAB
WASHER
SWITCH
OUTPUT FRONT
OUTPUT REAR/ROOF
Function: 9.5.4 Washer motor and reservoir

Signal value:
01

10
11

VDRF03.02GB
54
8 Control system 8.4.3.2 CAB, menu 2
WASHER, OUTPUT REAR/ROOF
page
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.
1(X)
X
XY
XY
012087
DIAG CAB
WASHER
SWITCH
OUTPUT FRONT
OUTPUT REAR/ROOF

Connection: PWM out D790-1/K5:4 to M651-2
Function: 9.5.4 Washer motor and reservoir
Signal value:
00
01

10
11

missing.
8.4.3.2
CAB, menu 2
FRONT WIPER, SWITCH (1-3)
page
Description: Signal from multi-function lever switch wiper function.
2(10)
X
XY
X

Connection:
X = 1 Interval slow: signal from S162/J1 to digital in D790-2/K3:6
000122
DIAG CAB
FRONT WIPER
SWITCH (1-3)
OUTPUT
FEEDBACK
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
Signal value:
VDRF03.02GB
Long interval.
Normal interval.
Continuous operation.
55
FRONT WIPER, OUTPUT
page
Description: Voltage feed to wiper front.
2(10)
X
XY
X

Connection: digital out D790-1/K2:1 to M650-1/53
000122
DIAG CAB
FRONT WIPER
SWITCH (1-3)
OUTPUT
FEEDBACK
Function: 9.5.5 Wiper motor front

Signal value:
01

10
11

FRONT WIPER, FEEDBACK
page
Description: Signal from motor wiper front, indicates when wiper motion is completed.
2(10)
X
XY
X

000122
DIAG CAB
FRONT WIPER
SWITCH (1-3)
OUTPUT
FEEDBACK
Connection: 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).
No signal (home position).
8.4.3.3
CAB, menu 3
REAR WIPER, SWITCH
page
Description: Status of rear window wiper switch on KIT control unit

(D790-2).
3(10)
X
XY
X
DIAG CAB
REAR WIPER
SWITCH
OUTPUT
FEEDBACK
Connection: Function: 9.5 Wiping and cleaning of windows

Signal value:
1
Input signal active. Key for continuous/interval pressed down.
No signal.
VDRF03.02GB
56
REAR WIPER, OUTPUT
page
Description: Voltage feed to direction windscreen wiper rear.
3(10)
X
XY
X

Connection: digital out from D790-1/K2:4 to M650-2/53
000123
DIAG CAB
REAR WIPER
SWITCH
OUTPUT
FEEDBACK
Function: 9.5.7 Wiper motor rear

Signal value:
01

10
11

REAR WIPER, FEEDBACK
page
Description: Signal from motor windscreen wiper rear, indicates when

wiper motion is completed.
3(10)
X
XY
X

000123
DIAG CAB
REAR WIPER
SWITCH
OUTPUT
FEEDBACK

Function: 9.5.7 Wiper motor rear
Signal value:
1
8.4.3.4
CAB, menu 4
ROOF WIPER, SWITCH
page
Description: Signal from switch wiper roof.
VDRF03.02GB
4(10)
X
XY
X
Circuit diagram: Connection: 000124
DIAG CAB
ROOF WIPER
SWITCH
OUTPUT
FEEDBACK

Signal value:
1
Input signal active. Key for continuous/interval pressed down.
No signal.
57
ROOF WIPER, OUTPUT
page
Description: Voltage feed to wiper roof.
4(10)
X
XY
X

Connection: digital out D790-1/K10:14 to M650-3/53
000124
DIAG CAB
ROOF WIPER
SWITCH
OUTPUT
FEEDBACK
Function: 9.5.6 Wiper motor roof

Signal value:
00
01

10
11

missing.
ROOF WIPER, FEEDBACK
page
Description: Signal from motor wiper roof, indicates when wiper motion is completed.
4(10)
X
XY
X

000124
DIAG CAB
ROOF WIPER
SWITCH
OUTPUT
FEEDBACK

Function: 9.5.6 Wiper motor roof
Signal value:
1
8.4.3.5
CAB, menu 5
HORN, SWITCH
page
Description: Signal from switch horn.
5(10)
X
XY
X
Circuit diagram: Circuit Alarm, audible signals group 9.7

Connection: signal from S162/H to digital in D790-2/K3:2
013382
DIAG CAB
HORN
SWITCH
OUTPUT
SWITCH JOYSTICK
Function: 9.7 Signal system

Signal value:
1
No signal.
VDRF03.02GB
58
HORN, OUTPUT
page
Description: Voltage feed to horn.
5(10)
X
XY
X
013382
DIAG CAB
HORN
SWITCH
OUTPUT
SWITCH JOYSTICK
Connection: digital out D790-1/K11:11 to H850/8 (

horn, signal to relay K3016/86)
for compressor
Function: 9.7.1 Horn

Signal value:
01

10
11

SWITCH JOYSTICK
page
Description: Signal from the switch open twistlocks on the control lever. The signal is used to activate the horn when there is no alignment.
5(10)
X
XY
X
Circuit diagram: Circuit Joystick group 7.1

013382
DIAG CAB
HORN
SWITCH
OUTPUT
SWITCH JOYSTICK
Connection: signal from S815/20 to digital in D790-1/K7:15

Function: 9.7 Signal system
Signal value:
VDRF03.02GB
No signal.
8.4.3.6
59
CAB, menu 6
BUZZER
page
Description: Voltage feed to buzzer for alarm indication panel, feed.
6(10)
XY
X
X
X

Connection: digital out D790-1/K11:5 to H853/1
000126
DIAG CAB
BUZZER
SWITCH SEAT
ALARM
OP
Function: 9.3 Seat, 1 Engine, 8.2.1 Overload system

Signal value:
00
01

10
11

SWITCH SEAT
page
Description: Signal from sensor operator in seat.
6(10)
XY
X
X
X

000126
DIAG CAB
BUZZER
SWITCH SEAT
ALARM
OP
Function: 9.3.9 Sensor operator in seat

Signal value:
1
Input signal active. Operator in seat.
No signal. No operator in seat.
ALARM
page
6(10)
XY
X
X
X
Description: Status for alarm indication panel, warning from control

system.
DIAG CAB
BUZZER
SWITCH SEAT
ALARM
OP
Connection: Function: 8.1.2 Information display

Signal value:
1
Conditions for activation of buzzer from seat switch and parking brake are fulfilled
Conditions for activation of buzzer are not fulfilled.
VDRF03.02GB
60
OP
page
Description: Status for overload warning from the control system.
6(10)
XY
X
X
X

Connection: 000126
DIAG CAB
BUZZER
SWITCH SEAT
ALARM
OP
Function: 8.2.1 Overload system

Signal value: X = 1,
1
Conditions for activation of buzzer fulfilled, that is, overload

system is indicating.
Conditions for activation of buzzer are not fulfilled.
8.4.3.7
CAB, menu 7
FUEL, SENSOR VALUE
page
Description: Signal from sensor fuel level.
7(10)
XXXOHM
XXX
000127
DIAG CAB
FUEL
SENSOR VALUE
PROC
Connection: analogue rheostat signal from B757/1 signal to D797-R/

K2:15
Function: 1.2.2 Sensor fuel level
Signal value: XXXOHM = Current resistance value from sensor fuel
level in ohm.
FUEL, PROC
page
Description: the control systems interpretation of signal from fuel tank

sensor.
7(10)
XXXOHM
XXX

000127
DIAG CAB
FUEL
SENSOR VALUE
PROC
Connection: Function: 1.2.2 Sensor fuel level

Signal value: XXX = 0-100 = 0-100% = Fuel volume in tank.
8.4.3.8
CAB, menu 8
SEAT HEATER, SWITCH
page
8(10)
Description: Signal from seat heating switch.
X
XY
Circuit diagram: Circuit Cab drivers seat group 9.3

000128
DIAG CAB
SEAT HEATER
SWITCH
OUTPUT

Function: 9.3 Seat
Signal value:
VDRF03.02GB
No signal.
61
SEAT HEATER, OUTPUT
page
8(10)
Description: Control voltage to seat heating relay.
X
XY
Circuit diagram: Circuit Cab drivers seat group 9.3

000128
DIAG CAB
SEAT HEATER
SWITCH
OUTPUT
Connection: digital out D790-1/K10:7 to K383/86

Function: 9.3.3 Heating coil
Signal value:
00
01

10
11

8.4.3.9
CAB, menu 9
AUT. LUBRICATION CHASSIS, OUTPUT
page
OUTPUT
9(X)
Description: Voltage feed to central lubrication chassis. Central lubrication is only supplied with voltage when the machine is operating.
XY
006863
DIAG CAB
AUT LUBRICATION
CHASSI
Circuit diagram: Circuit Central lubrication group 9.14

Connection: digital out D797-F/K1:28 to M693-1
Function: 9.14 Central lubrication
Signal value:
00
01

10
11

missing.
VDRF03.02GB
62
8.4.3.10
CAB, menu 10
AUT. LUBRICATION ATTACHMENT, OUTPUT
page
OUTPUT
10(X)
Description: Central lubrication attachment, feed. Central lubrication is
only supplied with voltage when the machine is operating.
XY
006864
DIAG CAB
AUT LUBRICATION
ATTACHMENT
Circuit diagram: Circuit Central lubrication group 9.14

Connection: digital out D791/K1:14 to M693-2
Function: 9.14 Central lubrication
Signal value:
01

10
11

8.4.4
CLIMATE
CLIMATE, description
page
This group covers the cabs climate control system.

012088
DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
8.4.4.1
CLIMATE, menu 1
PRESENT INPUT SIGNAL, REQUIRED TEMP
page
Description: Set value for desired temperature.
VDRF03.02GB
Circuit diagram: Circuit Climate system group 9.4

Connection: signal from S139/3 to analogue in D790-1/K5:8
000132
DIAG CLIMATE
1(8)
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 C Preset temperature shown in
tenths of degrees and adjusted in increments of half degrees (200 =
20 C). Test by increasing or decreasing temperature with the temperature switch on the panel.
8 Control system 8.4.4.2 CLIMATE, menu 2
63
PRESENT INPUT SIGNAL, PRESENT TEMP
page
Description: Signal from sensor cab temperature.

Connection: signal from B775-1/2 to input D790-1/K4:8
000132
DIAG CLIMATE
1(8)
REQUIRED TEMP
XXX
PRESENT TEMP
XXX
Function: 9.4.17 Sensor cab temperature

Signal value: XXX = Cabs interior temperature in tenths of degrees
(200 = 20 C).
PRESENT INPUT SIGNAL, WATER VALVE FEEDB.
page
Description: Water valves position (opening in percent).

Connection: signal from Y673/9 to analogue in D790-1/K10:4
000132
DIAG CLIMATE
1(8)
REQUIRED TEMP
XXX
PRESENT TEMP
XXX
Function: 9.4.5 Water valve

Signal value: XXX = 0-100 = 0-100% = Water valves opening in %. 0
= Closed. 100 = Fully open.
8.4.4.2
CLIMATE, menu 2
TEMP COIL
page
CLIMATE
COIL
COOLANT
AMBIENT
DE-ICE
2(8)
XXX
XXX
XXX
XXX
Description: Temperature of the air out from the fan. The sensor is located in the air distributor.
000133
DIAG
TEMP
TEMP
TEMP
TEMP

Function: 9.4.16 Sensor temperature outlet fan
Signal value: XXX = Temperature of the air blown into the cab in tenths
of degrees (200 = 20 C).
TEMP COOLANT
page
CLIMATE
COIL
COOLANT
AMBIENT
DE-ICE
2(8)
XXX
XXX
XXX
XXX
Description: Coolant temperature, temperature of the engines coolant. Signal is retrieved from the engine via CAN bus drivetrain.
000133
DIAG
TEMP
TEMP
TEMP
TEMP
Connection: from engine via CAN bus, see PRESENT INPUT SIGNAL, COOLANT TEMP page 80.
Function: 1.7.9 Sensor coolant temperature
Signal value: XXX = Engine temperature in tenths of degrees (200 =
20 C).
TEMP AMBIENT
page
CLIMATE
COIL
COOLANT
AMBIENT
DE-ICE
2(8)
XXX
XXX
XXX
XXX
Description: Outdoor temperature. Heat radiation from engine and sun

may affect the value since the sensor is located on the rear of the cab
roof.
000133
DIAG
TEMP
TEMP
TEMP
TEMP
Connection: signal from B774/2 to input D790-1/K7:9

Function: 9.4.18 Sensor ambient temperature
Signal value: XXX = Outdoor temperature in tenths of degrees (200 =
20 C).
VDRF03.02GB
64
TEMP DE-ICE
page
Description: Temperature in refrigerant circuit.
CLIMATE
COIL
COOLANT
AMBIENT
DE-ICE
2(8)
XXX
XXX
XXX
XXX

000133
DIAG
TEMP
TEMP
TEMP
TEMP
Function: 9.4.12 Sensor temperature refrigerant

Signal value: XXX = Refrigerant temperature in tenths of degrees (200
= 20 C).
8.4.4.3
CLIMATE, menu 3
PRESENT INPUT SIGNAL, PRESSURE SWITCH
page
Description: Signal from refrigerant pressure switch.

Connection: signal from S246/2 to digital in D797-R/K1:37
Function: 9.4.10 Pressure switch
006865
DIAG CLIMATE
3(X)
PRESSURE SWITCH
X
OPT DOOR SWITCH
X
Signal value:
1
Input signal active. Press Ok.
No signal, too high or too low pressure.
PRESENT INPUT SIGNAL, OPT DOOR SWITCH
page
Description: Signal from the drivers door switch. On machines with the
option of automatic shutdown of AC with open door this signal is used
to control the shutdown.
006865
DIAG CLIMATE
3(X)
PRESSURE SWITCH
X
OPT DOOR SWITCH
X

Connection: signal from S266-LE or S266-RI to digital in D790-1/
K11:3
Signal value:
1
Input signal active. Door open.
No signal. Doors closed.
8.4.4.4
CLIMATE, menu 4
PRESENT INPUT SIGNAL, WATER VALVE
page
Description: Signal from water valve, the voltage is a measure of the

position.
000135
DIAG CLIMATE
4(8)
WATER VALVE
XX.XXV
DRAUGHT VALVE XX.XXV

Signal value: XX.XXV = 0.50 - 4.50 V
VDRF03.02GB
65
PRESENT INPUT SIGNAL, DRAUGHT VALVE
page
Description: Signal from the engine to the air distributor. Voltage is a

measure of the valves position.
000135
DIAG CLIMATE
4(8)
WATER VALVE
XX.XXV

Function: 9.4.14 Air distributor
Signal value: XX.XXV = 0.50 - 4.50 V
8.4.4.5
CLIMATE, menu 5
PRESENT INPUT SIGNAL, REQUIRED TEMP
page
Description: Signal from switch temperature. Voltage when switch is

pressed in voltage level indicates increase or decrease of the temperature.
000136
DIAG CLIMATE
5(8)
REQUIRED TEMP XX.XXV
REQ. DRAUGHT
XX.XXV
REQ. FAN SPEED XX.XXV

Signal value: XX.XXV 2.4 / 0 / 5.0 V = Increase / - / decrease.
PRESENT INPUT SIGNAL, REQ. DRAUGHT
page
Description: Signal from switch air distribution, voltage when switch is

pressed in. The voltage level indicates change of air control against
windscreen (up) or floor (down). The valves position changes in steps
between windscreen - floor.
000136
DIAG CLIMATE
5(8)
REQ. DRAUGHT
XX.XXV

Signal value: XX.XXV 2.4 / 0 / 5.0 V = Up / - / down.
PRESENT INPUT SIGNAL, FAN SPEED
page
Description: Signal from switch fan speed, switch controls increase or

decrease of fan speed. Speed is endless adjustable. The voltage level
indicates if the speed should be increased or decreased.
000136
DIAG CLIMATE
5(8)
REQ. DRAUGHT
XX.XXV

Function: 9.4 Heating, ventilation and climate control unit
Signal value: XX.XXV 2.4 / 0 / 5.0 V = Increase / - / decrease.
VDRF03.02GB
66
8.4.4.6
CLIMATE, menu 6
PRESENT OUTPUT SIGNAL, FAN SPEED
page
Description: Current control of fan motor, speed is controlled with

PWM-control of grounding (of fan motor).
000137
DIAG CLIMATE
6(8)
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
page
Description: Control voltage to motor for fresh air and recirculation

damper.
000137
DIAG CLIMATE
6(8)
FAN SPEED
XXX
RECIRKULATION
XY
COMPRESSOR
XY
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
page
Description: Voltage feed of AC compressors electromagnetic clutch.

Controls cut-in and cut-out of the compressor. Two outputs are connected in parallel to handle the current.
000137
DIAG CLIMATE
6(8)
FAN SPEED
XXX
RECIRKULATION
XY
COMPRESSOR
XY
Connection: digital out from D797-R/K1:34 and K1:35 to M645/1

Function: 9.4.7 Compressor
Signal value:
00
01

10
11

VDRF03.02GB
8.4.4.7
67
CLIMATE, menu 7
OUTPUT WATER VALVE, CLOCKWISE
page
Description: Voltage feed to water valve, for opening. The valve is connected to an H-bridge. The signal can only be diagnosed when the
valves position changes. The valves opening and closing is controlled by the climate control units 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(8)
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
000138
0V
Signal value: motor runs clockwise row 1: 11 11 row 2: 00 11

00
01

H-bridge
10
11

VDRF03.02GB
68
OUTPUT WATER VALVE, COUNTER-CLOCKWISE
page
Description: Voltage feed to water valve, for closing. The valve is connected to an H-bridge. The signal can only be diagnosed when the
valves position changes. The valves opening and closing is controlled by the climate control units 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(8)
OUTPUT WATER VALVE
CLOCKWISE
XY XY
24V

D790-1/K4:2 via R4 to Y673/6
000138
Signal value: motor runs counter-clockwise row 1: 00 11, row 2: 11 11
0V
00
01

H-bridge
10
11

8.4.4.8
CLIMATE, menu 8
OUTPUT DRAUGHT VALVE, CLOCKWISE
page
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 distributors position changes.
DIAG CLIMATE
8(8)
OUTPUT DRAUGHT VALVE
CLOCKWISE
XY XY

D790-1/K4:4 via R6 to Y672/6
24V

Signal value: motor runs clockwise row 1: 11 11, row 2: 00 11
00
01
0V
H-bridge
VDRF03.02GB
000139

10
11

69
OUTPUT DRAUGHT VALVE, COUNTER-CLOCKWISE
page
Description: Voltage feed to motor for the air distributor, rotation counter-clockwise. Motor is connected to an H-bridge. Signal can only be
diagnosed when the air distributors position changes.
DIAG CLIMATE
8(8)
CLOCKWISE
XY XY

D790-1/K4:4 via R6 to Y672/6
24V

Signal value: motor runs counter-clockwise row 1: 00 11, row 2: 11 11
00
01
0V
H-bridge
000139

10
11

VDRF03.02GB
70
8 Control system 8.4.5 HYD
8.4.5
HYD
HYD, description
page
This group covers the hydraulic functions.

009272
DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
8.4.5.1
HYD, menu 1
HYDRAULIC OIL, TEMP
page
Description: Signal from sensor hydraulic oil temperature.
1(6)
XXX
XY
Circuit diagram: Circuit Hydraulics group 10.0

Connection: signal from B776/1 for input D797-R/K2:13
000141
DIAG HYD
HYDRAULIC OIL
TEMP
FAN
Function: 10.6.3 Sensor, hydraulic oil temperature

Signal value: XXX = Temperature in tenths of degrees (200 = 20 C).
HYDRAULIC OIL, FAN
page
Description: Voltage feed cooling fan hydraulic oil.
1(6)
XXX
XY
Circuit diagram: Circuit Hydraulics group 10.0

Connection: digital out from D797-R/K1:14 to M668/1
000141
DIAG HYD
HYDRAULIC OIL
TEMP
FAN
Function: 10.6.4 Cooling fan

Signal value:
01

10
11

8.4.5.2
HYD, menu 2
BRAKE COOLANT OIL, TEMP
page
Description: Signal from sensor for oil temperature, brake system.
VDRF03.02GB
Circuit diagram: Circuit Brake system group 4.0

Connection: signal from B762/1 for input D797-F/K2:13
000142
DIAG HYD
2(6)
BRAKE COOLANT OIL
TEMP
XXX
FAN
XY
Function: 4.8.10 Sensor oil temperature, brake system

Signal value: XXX = Temperature in tenths of degrees (200 = 20 C).
8 Control system 8.4.5.3 HYD, menu 3
71
BRAKE COOLANT OIL, FAN
page
Description: Voltage feed to cooling fan for brake system fluid.

Connection: digital out from D797-F/K1:14 to M674/1
Function: 4.8.8 Cooling fan
000142
DIAG HYD
2(6)
BRAKE COOLANT OIL
TEMP
XXX
FAN
XY
Signal value:
01

10
11

8.4.5.3
HYD, menu 3
PRESSURE LIFTING CYL, C-
page
DIAG HYD
3(6)
PRESSURE LIFTING CYL
Le
Ri
CXXX
XXX
C+
XXX
XXX
Description: Pressure on the lift cylinders rod side (C-). For voltage
value, see OP, description page 132.
Connection: See PRESENT INPUT SIGNAL LIFT CYL LE RI, C- page
134
C-
Signal value: XXX = 0-250 = Hydraulic pressure 0 - 25 MPa. (255 =

incorrect signal.)
NOTE
You can quickly test the sensors by lifting max. and running the
lifting function against end-position (overflow). All 4 sensors (C+
and C-) will then show the same pressure 0.1 MPa.
000143
C+
VDRF03.02GB
72
PRESSURE LIFTING CYL, C+
page
Description: Pressure on the lift cylinders piston side (C+). For voltage
value, see OP, description page 132. The sensor on the right-hand lift
DIAG HYD
3(6)
PRESSURE LIFTING CYL
Le
Ri
CXXX
XXX
C+
XXX
XXX
cylinder is optional

Connection: See PRESENT INPUT SIGNAL LIFT CYL LE RI, C+
page 134
Signal value: XXX = 0-250 = Hydraulic pressure 0 - 25 MPa. (255 =
incorrect signal.)
C-
NOTE
You can quickly test the sensors by lifting max. and running the
lifting function against end-position (overflow). All 4 sensors (C+
and C-) will then show the same pressure 0.1 MPa.
000143
C+
8.4.5.4
HYD, menu 4
PRESSURE SWITCHES, BRAKE PRESSURE
page
Description: Signal from the NC switch for oil pressure, brake system.
Connection: signal from S204/2 to analogue in D797-F/K1:20
012403
DIAG HYDRAULIC
4(X)
PRESSURE SWITCHES
BRAKE PRESSURE
X
DECLUTCH PRESSURE
X
Function: 4.3.7 NC switch oil pressure, brake system

Signal value:
1
No signal.
PRESSURE SWITCHES, BRAKE LIGHT PRESS.
page
Description: Signal from make-contact brake lights.
VDRF03.02GB

Connection: from S216/2 to analogue in D797-F/K1:13
012403
DIAG HYDRAULIC
4(X)
PRESSURE SWITCHES
BRAKE PRESSURE
X
DECLUTCH PRESSURE
X
Function: 4.3.8 Make-contact brake lights

Signal value:
1
No signal.
73
PRESSURE SWITCHES, DECLUTCH PRESSURE
page
Description: Signal from NO switch declutch.

Circuit diagram: Circuit Drivetrain group 2.1
Connection: from S220-2/2 to analogue in D797-F/K1:41
012403
DIAG HYDRAULIC
4(X)
PRESSURE SWITCHES
BRAKE PRESSURE
X
DECLUTCH PRESSURE
X
Function: 2.8.2 NO switch, declutch

Signal value:
1
No signal.
8.4.5.5
HYD, menu 5
P-BRAKE, SWITCH
page
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

012404
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: 4.1.2 Switch parking brake
Signal value:
1/0
Open, parking brake released.
0/1
On, parking brake applied.
P-BRAKE, FEEDBACK SWITCH
page
Description: Signal from break-contact parking brake.
5(X)
X/Y
X
XY

Connection: signal from S200/2 analogue in D797-F/K1:27
012404
DIAG HYDRAULIC
P-BRAKE
SWITCH
FEEDBACK SWITCH
VALVE
Function: 4.5.5 NC switch, parking brake

Signal value:
1
No signal.
VDRF03.02GB
74
P-BRAKE, VALVE
page
Description: Voltage feed to Solenoid valve parking brake.
5(X)
X/Y
X
XY

Connection: digital out D797-F/K1:7 to Y642/1
012404
DIAG HYDRAULIC
P-BRAKE
SWITCH
FEEDBACK SWITCH
VALVE
Function: 4.5.3 Solenoid valve parking brake

Signal value:
00
01

10
11

8.4.5.6
HYD, menu 6
PRESENT OUTPUT SIGNAL, PRESSURE TO ATTACHM.

VALVE
page
Description: Voltage feed to Solenoid valve, engagement of hydraulics

for top lift.
Circuit diagram: Circuit Rotation, group 7.6
000146
DIAG HYD
6(6)
PRESSURE TO ATTACHM.
VALVE
XY
Connection: digital out D797-R/K1:31 to Y6003/1

Function: 7.4 Side shift, 7.5 Spreading, 7.6 Rotation, 7.7 Tilt, 7.8 Levelling 7.9.1 Twistlock, 7.9.2 Lifting jacks
Signal value:
00
01

10
11

VDRF03.02GB
8 Control system 8.4.6 ENGINE
8.4.6
75
ENGINE
ENGINE, description
page
This group covers engine functions.

012093
DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
8.4.6.1
ENGINE, menu 1
PRESENT INPUT SIGNAL, ACCELERATOR
page
Description: Signal from accelerator pedal.

Connection: signal from R690/2 to analogue in D790-1/K6:11
Function: 1 Engine
006866
DIAG ENGINE
1(X)
ACCELERATOR
X.XXV
REQUIRED SPD PROC XXX
REQUIRED SPD RPM XXXX
Signal value: X.XXV = 0.50-4.50 V
PRESENT INPUT SIGNAL, REQUIRED SPD PROC
page
Description: Required engine speed (in percent) which is sent from the
cab control unit (D790-1) to the engine control unit (D794) via the CAN
bus drivetrain.
DIAG ENGINE
1(X)
ACCELERATOR
X.XXV
Connection: Function: 1.9 Control system, engine

Signal value: XXXX = 0-100%
PRESENT INPUT SIGNAL, REQUIRED SPD TCU
page
Description: Required engine speed in rpm which is sent from Control

unit, transmission (D793) to the engine control unit (D794) via the CAN
bus drivetrain.
DIAG ENGINE
1(X)
ACCELERATOR
X.XXV

Signal value: XXXX = 0-2010 rpm
8.4.6.2
ENGINE, menu 2
PRESENT INPUT SIGNAL, ENGINE SPEED EDC
page
Description: Engine speed from engine control unit (D794) to the cab
control unit (D790-1) via the CAN bus drivetrain. The actual value for
engine speed.
DIAG ENGINE
2(X)
ENGINE SPEED EDC XXXX
ENGINE SPEED TCU XXXX
Connection: Function: 1.9.2 Sensor engine rpm

Signal value: XXXX = Active speed in rpm.
VDRF03.02GB
76
8 Control system 8.4.6.3 ENGINE, menu 3
PRESENT INPUT SIGNAL, ENGINE SPEED TCU
page
Description: Engine speed from transmission control unit (D793) to the

cab control unit (D790-1) via the CAN bus drivetrain. The actual value
for engine speed.
DIAG ENGINE
2(X)
ENGINE SPEED EDC XXXX
ENGINE SPEED TCU XXXX
Connection: Function: 2.2.5 Sensor engine rpm and oil temperature transmission
Signal value: XXXX = Active speed in rpm.
8.4.6.3
ENGINE, menu 3
PRESENT INPUT SIGNAL, PRESENT TORQUE
page
Description: Actual torque from engine control unit (D794). Percentage torque use of engines capacity.
DIAG ENGINE
3(X)
PRESENT TORQUE
XXX
PRESENT TORQUE
XXX
PRES TORQUE @ RPM XXX

Signal value: XXX = 0-100%
PRESENT INPUT SIGNAL, REQUIRED TORQUE
page
Description: Requested torque from cab control unit (D790-1) to engine control unit (D794).
DIAG ENGINE
3(X)
PRESENT TORQUE
XXX
PRESENT TORQUE
XXX

PRESENT INPUT SIGNAL, PRES TORQUE @ RPM
page
Description: Available torque at current engine speed.
VDRF03.02GB
DIAG ENGINE
3(X)
PRESENT TORQUE
XXX
PRESENT TORQUE
XXX
Function: 1.9 Control system, engine

8.4.6.4
77
ENGINE, menu 4
PRESENT INPUT SIGNAL, PREHEAT SWITCH
page
Description: Signal from ignition, preheating position. Only used on

machines with Volvo engines.
009282
DIAG ENGINE
4(X)
PREHEAT SWITCH
X
CRANK ENGINE SWITCH X
D+
X

Function: 1 Engine, 1.10.1 Preheating
Signal value:
1
No signal.
PRESENT INPUT SIGNAL, CRANK ENGINE SWITCH
page
Description: Signal from ignition, start position.

009282
DIAG ENGINE
4(X)
PREHEAT SWITCH
X
D+
X
Function: 1.1.1 Engine, 1.11 Start and stop

Signal value:
1
No signal.
PRESENT INPUT SIGNAL, D+
page
Description: Signal from alternator, indicates if alternator supplies current.

009282
DIAG ENGINE
4(X)
PREHEAT SWITCH
X
D+
X
Connection: from G660/D+ to digital in D797-R/K2:16

Function: 11.4.1 Alternator
Signal value:
1
No signal.
VDRF03.02GB
78
8.4.6.5
ENGINE, menu 5
PRESENT OUTPUT SIGNAL, PREHEAT
page
Description: Status for preheating of induction air.

Circuit diagram: Connection:
Volvo: software signals on CAN-bus drivetrain
000152
DIAG ENGINE
5(10)
PREHEAT
X
CRANK ENGINE
X
Cummins: controlled by engines control system.

Function: 1.10.1 Preheating
Signal value:
1
Output signal active.
No output signal.
PRESENT OUTPUT SIGNAL, CRANK ENGINE
page
Description: Status for Voltage feed starter motor.

Connection:
Volvo: software signals on CAN-bus drivetrain
000152
DIAG ENGINE
5(10)
PREHEAT
X
CRANK ENGINE
X
Cummins: digital out D797-R/K1:36 to K360/86

Function: 1.11 Start and stop
Signal value:
00
01

10
11

VDRF03.02GB
8.4.6.6
79
ENGINE, menu 6
PRESENT INPUT SIGNAL, OIL PRESSURE
page
Description: Engine oil pressure. CAN bus message from engine control unit (D794) to cab control unit (D790-1).
Circuit diagram: see supplier documentation, engine
006868
DIAG ENGINE
6(X)
OIL PRESSURE
XXX
BOOST PRESSURE
XXX
OIL LEVEL
XXX
Connection:
Volvo TWD1240VE: signal from "43 Sensor, oil temperature/pressure" to Control unit, engine (D794) "black connector" sleeve 14
Volvo TAD1250VE: signal from "28 Sensor, oil temperature and
oil pressure" to Control unit, engine (D794) "Connector B" sleeve
11
Cummins QSM11: signal from "oil pressure/temperature sensor"
to engine control unit (D794) "Sensor connector" sleeve 44
Function: 1.8.3 Sensor oil pressure engine
Signal Value: XXX = 10 corresponds to 100 kPa.
PRESENT INPUT SIGNAL, BOOST PRESSURE
page
Description: Charge air pressure. CAN bus message from engine control unit (D794) to cab control unit (D790-1).
Circuit diagram: See supplier documentation, engine
006868
DIAG ENGINE
6(X)
OIL PRESSURE
XXX
BOOST PRESSURE
XXX
OIL LEVEL
XXX
Connection:
Volvo TWD1240VE: signal from "36 Sensor, charge air pressure/
charge air temperature" to Control unit, engine (D794) "black connector" sleeve 2
Volvo TAD1250VE: signal from "23 Sensor, charge air pressure/
charge air temperature" to Control unit, engine (D794) "connector
A" sleeve 22
Cummins QSM11: signal from "Intake manifold (boost) pressure
sensor" to engine control unit (D794) "Sensor connector" sleeve
39
Function: 1.6.5 Sensor boost pressure
Signal Value: XXX = 10 corresponds to 100 kPa.
PRESENT INPUT SIGNAL, OIL LEVEL
page
Only for engine alternative Volvo TAD1250VE

006868
DIAG ENGINE
6(X)
OIL PRESSURE
XXX
BOOST PRESSURE
XXX
OIL LEVEL
XXX
Description: Engine oil level. CAN bus message from engine control
unit (D794) to cab control unit (D790-1).
Circuit diagram: See supplier documentation, engine
Connection: Volvo TAD1250VE: signal from "15 Sensor, oil level" to
Control unit, engine (D794) "connector A" sleeve 3
Function:
Signal value: XXX = 0-100 = 0-100% = Oil level in percent.
VDRF03.02GB
80
8.4.6.7
ENGINE, menu 7
PRESENT INPUT SIGNAL, OIL TEMP
page
Description: Engine oil temperature. CAN bus message from engine

control unit (D794) to cab control unit (D790-1).
009284
DIAG ENGINE
7(X)
OIL TEMP
XXX
COOLANT TEMP
XXX
INTAKE MAIN.TEMP XXX
Connection:
Volvo TWD1240VE: signal from "43 Sensor, oil temperature/pressure" to Control unit, engine (D794) "black connector" sleeve 1
Volvo TAD1250VE: signal from "28 Sensor, oil temperature and
oil pressure" to Control unit, engine (D794) "connector A" sleeve
31
Cummins QSM11: signal from "Oil pressure/temperature sensor"
sleeve 4 to Control unit, engine (D794) "Sensor connector" sleeve
42
Function: 1.8.7 Sensor oil temperature
Signal value: XXX = 200 equals 20 C.
PRESENT INPUT SIGNAL, COOLANT TEMP
page
Description: Coolant temperature. CAN bus message from engine

009284
DIAG ENGINE
7(X)
OIL TEMP
XXX
COOLANT TEMP
XXX
Connection:
Volvo TWD1240VE: signal from "35 Sensor, coolant temperature"
to Control unit, engine (D794) "black connector" sleeve 25
Volvo TAD1250VE: signal from "16 coolant temperature sensor"
to engine control unit (D794) "Connector B" sleeve 27
Cummins QSM11: signal from "Coolant temperature sensor" to
engine control unit (D794) "Sensor connector" sleeve 02
Function: 1.7.9 Sensor coolant temperature
PRESENT INPUT SIGNAL, INTAKE MAIN.TEMP
page
Description: Charge air temperature. CAN bus message from engine

009284
DIAG ENGINE
7(X)
OIL TEMP
XXX
COOLANT TEMP
XXX
Connection:
Volvo TWD1240VE: signal from "36 Sensor, charge air pressure/
charge air temperature." to Control unit, engine (D794) "black
connector" sleeve 2
Volvo TAD1250VE: signal from "23 charge air pressure/temperature sensor" to engine control unit (D794) "connector A" sleeve 47
Cummins QSM11: signal from "Intake manifold (boost) temperature sensor" to engine control unit (D794) "Sensor connector"
sleeve 38
Function: 1.6.6 Sensor charge-air temperature
VDRF03.02GB
8.4.6.8
81
ENGINE, menu 8
PRESENT EDC ERROR, NO. OF ACT ERROR
page
Description: Number of active error codes from Control unit, engine

(D794).
DIAG ENGINE
8(X)
PRESENT EDC ERROR
NR OF ACT ERROR
XX
SPN
XXXX
FMI
XX
Connection: Function: 1.9 Control system

Signal value: XX = number of active error codes.
PRESENT EDC ERROR, SPN
page
Description: SPN number for the first error code from engine control
unit (D794). SPN indicates the malfunction area, i.e. what component
or signal is defective. Error codes are shown with SPN/FMI in error
code menus.
009279
DIAG ENGINE
8(X)
PRESENT EDC ERROR
NR OF ACT ERROR
XX
SPN
XXXX
FMI
XX
Circuit diagram: Connection: Function: 8.3 Error codes

Signal value: XXXX = error code number. Use the error code list; see
section D Error codes.
PRESENT EDC ERROR, FMI
page
Description: FMI number for the first error code from the engine control
unit (D794). FMI indicates error type, e.g. short circuit or low value. Error codes are shown with SPN/FMI in error code menus.
DIAG ENGINE
8(X)
PRESENT EDC ERROR
NR OF ACT ERROR
XX
SPN
XXXX
FMI
XX
Connection: 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
page
Description: Current fuel consumption in litres/hour.
9(X)
Circuit diagram: -
XXX
Connection: 009280
DIAG ENGINE
FUEL CONSUMTION
MOMENTARILY l/h
Function: 1.2 Fuel system

Signal value: XXX = fuel consumption in l/h.
VDRF03.02GB
82
8 Control system 8.4.7 TRANSM
8.4.7
TRANSM
TRANSM, description
page
This group covers the transmission function.

009274
DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
8.4.7.1
TRANSM, menu 1
PRESENT INPUT SIGNAL, BRAKE PEDAL
page
Description: Not used.

000159
DIAG TRANSM.
1(15)
BRAKE PEDAL
X.XXV
DECLUTCH SWITCH
X
DECLUTCH PRESS SW. X
Connection: signal from B697/3 to analogue in on D790-1/K6:12

Function: Signal value: X.XXV = 0.00 - 5.00 V
PRESENT INPUT SIGNAL, DECLUTCH SWITCH
page
Description: Signal from declutch pedal.

Connection: signal from S220-1/2 to digital in D790-1/K6:14
000159
DIAG TRANSM.
1(15)
BRAKE PEDAL
X.XXV
DECLUTCH SWITCH
X
Function: 2.1.2 Declutch pedal

Signal value:
1
Input signal active. Declutch pedal pressed down.
No signal.
PRESENT INPUT SIGNAL, DECLUTCH PRESS SW.
page
Description: Signal from NO switch declutch (pressure switch).
VDRF03.02GB

Connection: signal from S220-2/2 to digital in D797-F/K1:41
000159
DIAG TRANSM.
1(15)
BRAKE PEDAL
X.XXV
DECLUTCH SWITCH
X
Function: 2.8.2 NO switch, declutch

Signal value:
1
No signal.
8 Control system 8.4.7.2 TRANSM, menu 2
8.4.7.2
83
TRANSM, menu 2
SWITCHES, FORWARD
page
Description: Signal from gear and multi-function lever (forward).
2(15)
X
X
X

Connection: from S162/F to digital in 790-2/K3:11
000160
DIAG TRANSM.
SWITCHES
FORWARD
REVERSE
SHIFT MODE
Function: 2 Transmission
Signal value:
1
Input signal active. Travel direction forward selected.
No signal.
SWITCHES, REVERSE
page
Description: Signal from gear and multi-function lever (reverse).
2(15)
X
X
X

Connection: from S162/R to digital in 790-2/K3:12
000160
DIAG TRANSM.
SWITCHES
FORWARD
REVERSE
SHIFT MODE
Signal value:
1
Input signal active. Travel direction reverse selected.
No signal.
SWITCHES, SHIFT MODE
page
Description: Signal from shifting program switch. Status on CAN bus

from KIT control unit (D790-2). The switches are integrated in the KIT
2(15)
X
X
X
DIAG TRANSM.
SWITCHES
FORWARD
REVERSE
SHIFT MODE
Connection: Function: 2 Transmission

Signal value:
1
Shifting program 1 selected.
Shifting program 2 selected.
Automatic shifting selected.
VDRF03.02GB
84
8.4.7.3
TRANSM, menu 3
PRESENT VALUE, FORWARD
page
Description: Status for forward direction of travel from transmission

control unit (D793). Indicates if forward drive is activated in the transmission.
3(15)
X
X
X
DIAG TRANSM.
PRESENT VALUE
FORWARD
REVERSE
GEAR
Connection: Function: 2.8 Control system, transmission

Signal value:
1
Output signal for travel direction forward active.
No output signal.
PRESENT VALUE, REVERSE
page
Description: Status for rearward direction of travel from transmission

control unit (D793). Indicates if rearward drive is activated in the transmission.
3(15)
X
X
X
DIAG TRANSM.
PRESENT VALUE
FORWARD
REVERSE
GEAR

Signal value:
1
Output signal for travel direction reverse active.
No output signal.
PRESENT VALUE, GEAR
page
Description: Current gear, status from transmission control unit

(D793). Shows which gear is activated in the transmission.
3(15)
X
X
X
DIAG TRANSM.
PRESENT VALUE
FORWARD
REVERSE
GEAR

Connection: Signal value: X = current gear.
8.4.7.4
TRANSM, menu 4
OPERATING STATE, AUT/MAN MODE
page
Description: Shows which shifting program is selected automatic or

manual.
4(15)
X
X
X
DIAG TRANSM.
OPERATING STATE
AUT/MAN MODE
WARNING
OPERATING MODE

Signal value:
VDRF03.02GB
Automatic.
Manual.
85
OPERATING STATE, WARNING
page
Description: Warning for serious malfunction in transmission from

transmission control unit (D793).
4(15)
X
X
X
DIAG TRANSM.
OPERATING STATE
AUT/MAN MODE
WARNING
OPERATING MODE

Signal value:
1
Active error.
No errors.
OPERATING STATE, OPERATING MODE
page
Description: Operating mode status for transmission control unit

(D793); also shown in control unit display.
4(15)
X
X
X
DIAG TRANSM.
OPERATING STATE
AUT/MAN MODE
WARNING
OPERATING MODE

Signal value:
0
Not used.
Manual or automatic shifting, standard mode shown during

operation.
Not used.
Not used.
Limp-home, reduced capacity due to malfunction in transmission.
Shut-down, serious transmission malfunction control unit

shuts down, likely that malfunction cannot be shown as CAN
bus.
Calibration of transmission in progress.
8.4.7.5
TRANSM, menu 5
OPERATING STATE, SHIFT IN PROGRESS
page
Description: Status for transmission function during operation, shifting

in progress. Active during shifting.
DIAG TRANSM.
5(15)
OPERATING STATE
SHIFT IN PROGRESS
X
FAULT
X
OLD FAULT
X

Signal value:
1
Shifting in progress.
No activity.
VDRF03.02GB
86
OPERATING STATE, FAULT
page
Description: Status for transmissions function during operation, active

error codes present.
Circuit diagram: Connection: -
000163
DIAG TRANSM.
5(15)
OPERATING STATE
SHIFT IN PROGRESS
X
FAULT
X
OLD FAULT
X

Signal value:
1
Active error code.
No error codes.
OPERATING STATE, OLD FAULT
page
Description: Status for transmissions function during operation, there

are inactive error codes that have not been acknowledged.
Circuit diagram: Connection: -
000163
DIAG TRANSM.
5(15)
OPERATING STATE
SHIFT IN PROGRESS
X
FAULT
X
OLD FAULT
X

Signal value:
1
There are inactive error codes that have not been acknowledged.
No unacknowledged error codes.
8.4.7.6
TRANSM, menu 6
DRUM SPEED (transmission alternative Dana)
page
Description: Signal from sensor rpm drum (position 1).
DIAG TRANSM.
DRUM SPEED
OUTPUT SPEED
ENGINE SPEED
TURBINE SPEED
1
6(15)
XXXXHz
XXXXHz
XXXXHz
XXXXHz
Circuit diagram: Circuit Dana TE 32000 group 2.0

Connection: signal from B752 till D793/B3 and D793/C3
Function: 2.3.7 Sensor rpm drum
Signal value: XXXXHz = frequency, indicates pulses from the sensor
in Hz (pulses /second). To convert to rpm, divide frequency by number
of teeth on drum gear.
000164
1. Sensor, drum rpm (B752)

2.Temperature switch, torque converter (S221)
3.Sensor, engine speed and transmission temperature (B758/766)
4.Sensor, turbine rpm transmission (B751)
5.Sensor rpm output shaft (B758)
VDRF03.02GB
87
OUTPUT SPEED (transmission alternative Dana)
page
DIAG TRANSM.
DRUM SPEED
OUTPUT SPEED
ENGINE SPEED
TURBINE SPEED
1
Description: Signal from sensor rpm output shaft (propeller shaft) (position 5).
6(15)
XXXXHz
XXXXHz
XXXXHz
XXXXHz

Connection: signal from B758 till D793/ D3 and D793/ E3
Function: 2.3.9 Sensor rpm output shaft
of teeth on output shafts gear.
000164

ENGINE SPEED (transmission alternative Dana)
page
Description: Rpm signal from sensor rpm engine speed (position 3).
DIAG TRANSM.
DRUM SPEED
OUTPUT SPEED
ENGINE SPEED
TURBINE SPEED
1
6(15)
XXXXHz
XXXXHz
XXXXHz
XXXXHz

Connection: signal from B7558/766 to D793/H3
Function: 2.2.5 Sensor engine rpm and oil temperature transmission
of teeth on input shafts gear.
000164

VDRF03.02GB
88
TURBINE SPEED (transmission alternative Dana)
page
Description: Signal from sensor rpm turbine transmission (position 4).
DIAG TRANSM.
DRUM SPEED
OUTPUT SPEED
ENGINE SPEED
TURBINE SPEED
1
6(15)
XXXXHz
XXXXHz
XXXXHz
XXXXHz

Connection: signal from B751 to D793/R2
Function: 2.3.6 Sensor rpm turbine
of teeth on turbines gear.
000164

ENGINE SPEED (transmission alternative Dana full flow)
page
Description: Rpm signal from sensor rpm engine speed (position 3).
DIAG TRANSM.
ENGINE SPEED
TURBINE SPEED
DRUM SPEED
OUTPUT SPEED
6(15)
XXXXrpm
XXXXrpm
XXXXrpm
XXXXrpm
Circuit diagram: Circuit Dana TE 32000FF group 2.0

Connection: signal from B7530 to D793/F3 and D793/K3
Signal value: XXXXrpm = rotation speed.
013149
5
4
3.Sensor, engine speed (B7530)
6. Sensor temperature (B7660)
VDRF03.02GB
89
TURBINE SPEED (transmission alternative Dana full flow)
page
Description: Signal from sensor rpm turbine transmission (position 4).
DIAG TRANSM.
ENGINE SPEED
TURBINE SPEED
DRUM SPEED
OUTPUT SPEED
6(15)
XXXXrpm
XXXXrpm
XXXXrpm
XXXXrpm

Connection: signal from B7510 to D793/G3 and D793/K3
Function: 2.3.6 Sensor rpm turbine
013149
5
4
DRUM SPEED (transmission alternative Dana full flow)
page
Description: Signal from sensor rpm drum (position 1).
DIAG TRANSM.
ENGINE SPEED
TURBINE SPEED
DRUM SPEED
OUTPUT SPEED
6(15)
XXXXrpm
XXXXrpm
XXXXrpm
XXXXrpm

Connection: signal from B7520 till D793/B3 and D793/C3
Function: 2.3.7 Sensor rpm drum
013149
5
4
VDRF03.02GB
90
OUTPUT SPEED (transmission alternative Dana full flow)
page
DIAG TRANSM.
ENGINE SPEED
TURBINE SPEED
DRUM SPEED
OUTPUT SPEED
1
Description: Signal from sensor rpm output shaft (propeller shaft) (position 5).
6(15)
XXXXrpm
XXXXrpm
XXXXrpm
XXXXrpm

Connection: signal from B7580 till D793/ D3 and D793/ E3
Function: 2.3.9 Sensor rpm output shaft
013149
5
4
8.4.7.7
TRANSM, menu 7
OUTPUT STATUS, RSP DRIVE (transmission alternative

Dana)
page
VDRF03.02GB
Description: Status high and low side for control of solenoid valve RSP
Drive.
000165
DIAG TRANSM.
7(15)
OUTPUT STATUS
RSP DRIVE
X X
2/4 VFS SELECTION
X
1/3 VFS SELECTION
X
Connection: signal from D793/K1 and D793/K2 to Y6066

11
Activated high and low side.
10
High side activated, low side no signal.
01
High side no signal, low side activated.
00
No signal.
91
OUTPUT STATUS, 2/4 VFS SELECTION (transmission

alternative Dana)
page
Description: Status of feed to solenoid valve VFS 2ND/4TH.

Connection: digital out from D793/D1 and D793/E1 to Y6069
000165
DIAG TRANSM.
7(15)
OUTPUT STATUS
RSP DRIVE
X X
2/4 VFS SELECTION
X
1/3 VFS SELECTION
X

Signal value:
1
Activated.
No signal.
OUTPUT STATUS, 1/3 VFS SELECTION (transmission

alternative Dana)
page
Description: Status of feed to solenoid valve VFS 1 ST/3 RD.

Connection: signal from D793/ H1 and D793/ J1 to Y6067
000165
DIAG TRANSM.
7(15)
OUTPUT STATUS
RSP DRIVE
X X
2/4 VFS SELECTION
X
1/3 VFS SELECTION
X

Signal value:
1
Activated.
No signal.
FWD SELECTION (transmission alternative Dana full flow)
page
Description: Status of the feed to solenoid valve FWD selection.
7(15)
X
X
X
X

Connection: signal from D793/K1 and D793/S3 to Y6066F
013178
DIAG TRANSM.
FWD SELECTION
REV SELECTION
2/4 SELECTION
1/3 SELECTION

1
Activated.
No signal.
REV SELECTION (transmission alternative Dana full flow)
page
Description: Status of the feed to solenoid valve FWD selection.
7(15)
X
X
X
X

Connection: signal from D793/E2 and D793/S3 to Y6066R
013178
DIAG TRANSM.
FWD SELECTION
REV SELECTION
2/4 SELECTION
1/3 SELECTION

Signal value:
1
Activated.
No signal.
VDRF03.02GB
92
2/4 SELECTION (transmission alternative Dana full flow)
page
Description: Status of feed to solenoid valve 2ND/4TH SELECTION.
7(15)
X
X
X
X

Connection: signal from D793/K2 and D793/R2 to Y6074
013178
DIAG TRANSM.
FWD SELECTION
REV SELECTION
2/4 SELECTION
1/3 SELECTION
Signal value:
1
Activated.
No signal.
1/3 SELECTION (transmission alternative Dana full flow)
page
Description: Status of feed to solenoid valve 1ST/3 RD SELECTION.
7(15)
X
X
X
X

Connection: signal from D793/F2 and D793/S3 to Y60675
013178
DIAG TRANSM.
FWD SELECTION
REV SELECTION
2/4 SELECTION
1/3 SELECTION
Signal value:
1
Activated.
No signal.
8.4.7.8
TRANSM, menu 8
FWD SUPPLY (transmission alternative Dana)
page
Description: Status for control current to clutch pack forward.
8(15)
X
X
X
X

Connection: signal from D793/B1 to Y630
000166
DIAG TRANSM.
FWD SUPPLY
REV SUPPLY
2/4 SUPPLY
1/3 SUPPLY
Function: 2.3.5 Valve block, transmission control, 2.8 Control system,

transmission
Signal value:
VDRF03.02GB
Activated.
No signal.
93
REV SUPPLY (transmission alternative Dana)
page
Description: Status for control current to clutch pack reverse.
8(15)
X
X
X
X

Connection: signal from D793/F1 to Y631
000166
DIAG TRANSM.
FWD SUPPLY
REV SUPPLY
2/4 SUPPLY
1/3 SUPPLY

transmission
Signal value:
1
Activated.
No signal.
2/4 SUPPLY (transmission alternative Dana)
page
Description: Status for control current to clutch pack 2/4.
8(15)
X
X
X
X

Connection: signal from D793/E2 to Y6074
000166
DIAG TRANSM.
FWD SUPPLY
REV SUPPLY
2/4 SUPPLY
1/3 SUPPLY

transmission
Signal value:
1
Activated.
No signal.
1/3 SUPPLY (transmission alternative Dana)
page
8(15)
X
X
X
X

000166
DIAG TRANSM.
FWD SUPPLY
REV SUPPLY
2/4 SUPPLY
1/3 SUPPLY

transmission
Signal value:
1
Activated.
No signal.
FWD/REV SUPPLY (transmission alternative Dana full

flow)
page
Description: Status for control current to clutch pack forward and reverse.
8(15)
X
X
X

013252
DIAG TRANSM.
SUPPLY
FWD/REV SUPPLY
2/4 SUPPLY
1/3 SUPPLY
Connection: digital out from D793/B1 and D793/C1 to Y6300

transmission
Signal value:
1
Activated.
No signal.
VDRF03.02GB
94
2/4 SUPPLY (transmission alternative Dana full flow)
page
8(15)
X
X
X

Connection: digital out from D793/F1 and D793/G1 to Y6069
013252
DIAG TRANSM.
SUPPLY
FWD/REV SUPPLY
2/4 SUPPLY
1/3 SUPPLY

transmission
Signal value:
1
Activated.
No signal.
1/3 SUPPLY (transmission alternative Dana full flow)
page
8(15)
X
X
X

Connection: digital out from D793/ D1 and D793/ E1 to Y6067
013252
DIAG TRANSM.
SUPPLY
FWD/REV SUPPLY
2/4 SUPPLY
1/3 SUPPLY

transmission
Signal value:
1
Activated.
No signal.
8.4.7.9
TRANSM, menu 9
FWD FEEDBACK (transmission alternative Dana)
page
9(X)
XXXXmA
XXXXmA
XXXXmA
XXXXmA
Description: Present control current to solenoid valve clutch pack forward.

006869
DIAG TRANSM.
FWD FEEDBACK
REV FEEDBACK
2/4 FEEDBACK
1/3 FEEDBACK
Connection: signal from D793/B1 to Y630

transmission
Signal value: XXXX = Measured value in mA.
REV FEEDBACK (transmission alternative Dana)
page
9(X)
XXXXmA
XXXXmA
XXXXmA
XXXXmA
Description: Present control current to solenoid valve clutch pack reverse

006869
DIAG TRANSM.
FWD FEEDBACK
REV FEEDBACK
2/4 FEEDBACK
1/3 FEEDBACK

transmission
VDRF03.02GB
95
2/4 FEEDBACK (transmission alternative Dana)
page
Description: Present control current to solenoid valve clutch pack 2/4.
9(X)
XXXXmA
XXXXmA
XXXXmA
XXXXmA

Connection: signal from D793/D1 to Y6069
006869
DIAG TRANSM.
FWD FEEDBACK
REV FEEDBACK
2/4 FEEDBACK
1/3 FEEDBACK

transmission
1/3 FEEDBACK (transmission alternative Dana)
page
9(X)
XXXXmA
XXXXmA
XXXXmA
XXXXmA

Connection: signal from D793/H1 to Y6067
006869
DIAG TRANSM.
FWD FEEDBACK
REV FEEDBACK
2/4 FEEDBACK
1/3 FEEDBACK

transmission
ANALOGUE OUTPUTS, FWD/REV FEEDBACK

(transmission alternative Dana full flow)
page
Description: Present control current to solenoid valve clutch pack forward and reverse.
9(X)
XXXXmA
XXXXmA
XXXXmA

013408
DIAG TRANSM.
ANALOG OUTPUTS
FWD/REV F.B
2/4 FEEDBACK
1/3 FEEDBACK
Connection: digital out from D793/B1 and D793/C1 to Y6300

transmission
ANALOGUE OUTPUTS, 2/4 FEEDBACK (transmission

page
9(X)
XXXXmA
XXXXmA
XXXXmA

Connection: digital out from D793/F1 and D793/G1 to Y6069
013408
DIAG TRANSM.
ANALOG OUTPUTS
FWD/REV F.B
2/4 FEEDBACK
1/3 FEEDBACK

transmission
ANALOGUE OUTPUTS, 1/3 FEEDBACK (transmission

page
9(X)
XXXXmA
XXXXmA
XXXXmA

Connection: digital out from D793/ D1 and D793/ E1 to Y6067
013408
DIAG TRANSM.
ANALOG OUTPUTS
FWD/REV F.B
2/4 FEEDBACK
1/3 FEEDBACK

transmission
VDRF03.02GB
96
8.4.7.10
TRANSM, menu 10
PRESENT SENSOR INPUT, PRESS FEEDBACK

page
10(X)
INPUT
XXXXmV
XXXXmV
XXXXmV
Description: Signal from sensor oil pressure in transmission. The

transmission uses a pressure-sensitive make-contact and two resistors in the cable harness to generate different voltage levels.
006870
DIAG TRANSM.
PRESENT SENSOR
PRESS FEEDBACK
TRANSM.TEMP
COOLER TEMP
Connection: signal from B6067 to D793/A2

Function: 2.6.2 Sensor oil pressure
Signal value:
0-1000 mV
Short-circuiting to ground.
1500-2500 mV
Oil pressure is correct.
2500-4000 mV
Oil pressure is low.
4500-8000 mV
Open circuit.
Over 8000 mV
Short-circuiting to voltage
PRESENT SENSOR INPUT, TRANS.TEMP (transmission

alternative Dana)
page
Description: Signal from sensor transmission oil temperature.
10(X)
INPUT
XXXXmV
XXXXmV
XXXXmV

Connection: signal from B758/766 to D793/H3
006870
DIAG TRANSM.
PRESENT SENSOR
PRESS FEEDBACK
TRANSM.TEMP
COOLER TEMP

Signal value: XXXX mV = signal voltage in mV (0-5000mV).
PRESENT SENSOR INPUT, COOLER TEMP (transmission

alternative Dana)
page
10(X)
INPUT
XXXXmV
XXXXmV
XXXXmV
Description: Signal from oil temperature sensor in radiator, transmission. The transmission uses a temperature-sensitive NO switch and
two resistors in the cable harness to generate different voltage levels.
006870
DIAG TRANSM.
PRESENT SENSOR
PRESS FEEDBACK
TRANSM.TEMP
COOLER TEMP
Connection: signal from S221 to D793/J3

Function: 2.7.4 Sensor oil temperature oil cooler
Signal value:
VDRF03.02GB
0 mV
Transmission oil has operating temperature.
2500 mV
Transmission oil temperature is low.
97
2/4 PRESSx10 (transmission alternative Dana full flow)
page
10(X)
XXXXBar
XXXXBar
XXXXmV
XXXXmV
Description: Signal from oil pressure sensor in transmission.

Connection: signal from B6069 to D793/S1
013410
DIAG TRANSM.
2/4 PRESSx10
1/3 PRESSx10
TRANSM.TEMP
CONV OUT TEMP

Signal value:
0-5 bar
8-15 bar
15-25 bar
Oil pressure is high.
Over 25 bar
Open circuit or short circuit to voltage.
1/3 PRESSx10 (transmission alternative Dana full flow)
page
10(X)
XXXXBar
XXXXBar
XXXXmV
XXXXmV
Description: Signal from oil pressure sensor in transmission.

Connection: signal from B6067 to D793/A2
013410
DIAG TRANSM.
2/4 PRESSx10
1/3 PRESSx10
TRANSM.TEMP
CONV OUT TEMP

Signal value:
0-5 bar
8-15 bar
15-25 bar
Oil pressure is high.
Over 25 bar
Open circuit or short circuit to voltage.
TRANSM.TEMP (transmission alternative Dana full flow)
page
10(X)
XXXXBar
XXXXBar
XXXXmV
XXXXmV
Description: Signal from sensor transmission oil temperature.

Connection: signal from B7660 to D793/H3
013410
DIAG TRANSM.
2/4 PRESSx10
1/3 PRESSx10
TRANSM.TEMP
CONV OUT TEMP

Signal value: XXXX mV = signal voltage in mV (0-5000mV).
CONV TEMP OUT (transmission alternative Dana full flow)
page
10(X)
XXXXBar
XXXXBar
XXXXmV
XXXXmV
Description: Signal from oil temperature sensor in radiator, transmission. The transmission uses a temperature-sensitive NO switch and
two resistors in the cable harness to generate different voltage levels.
013410
DIAG TRANSM.
2/4 PRESSx10
1/3 PRESSx10
TRANSM.TEMP
CONV OUT TEMP
Connection: signal from S2210 to D793/J3

Function: 2.7.4 Sensor oil temperature oil cooler
Signal value:
0 mV
Transmission oil has operating temperature.
2500 mV
Transmission oil temperature is low.
VDRF03.02GB
98
8.4.7.11
TRANSM, menu 11
AXLE RATIO (transmission alternative Dana)
page
Description: Drive axle gear ratio.
11(X)
XXXXX
XXXX
XXXX
DIAG TRANSM.
PRESENT VALUE
AXLE RATIO
RADIUS
SPEED LIMIT

Signal value: XXXXX = drive axles total gear ratio x 1024
RADIUS (transmission alternative Dana)
page
Description: Drive wheels radius
11(X)
XXXXX
XXXX
XXXX
DIAG TRANSM.
PRESENT VALUE
AXLE RATIO
RADIUS
SPEED LIMIT

Signal value: XXXX = Drive wheels radius in mm.
SPEED LIMIT (transmission alternative Dana)
page
Description: Speed limitation.
11(X)
XXXXX
XXXX
XXXX
DIAG TRANSM.
PRESENT VALUE
AXLE RATIO
RADIUS
SPEED LIMIT

Signal value: XXX = Speed limitation in km/h.
AXLE RATIOx1024 (transmission alternative Dana full

flow)
page
Description: Drive axle gear ratio.

DIAG TRANSM.
11(X)
PRESENT VALUE
AXLE RATIOx1024 XXXXX
RADIUS
XXXX
SPEED LIMIT
XXXX

Signal value: XXXXX = drive axles total gear ratio
RADIUS (transmission alternative Dana full flow)
page
Description: Drive wheels radius

DIAG TRANSM.
11(X)
PRESENT VALUE
RADIUS
XXXX
SPEED LIMIT
XXXX

Signal value: XXXX = Drive wheels radius in mm.
SPEED LIMIT (transmission alternative Dana full flow)
page
VDRF03.02GB
Description: Speed limitation.

DIAG TRANSM.
11(X)
PRESENT VALUE
RADIUS
XXXX
SPEED LIMIT
XXXX

Signal value: XXX = Speed limitation in km/h.
8.4.7.12
99
TRANSM, menu 12
NOT USED
page
This menu is not used.
DIAG TRANSM.
12(X)
006872
NOT USED
8.4.7.13
TRANSM, menu 13
ACT ERROR AREA
page
Description: Indicates malfunction area active error, first part of the error code. In case of several error codes, the most serious error code
is shown.
DIAG TRANSM.
13(15)
ACT ERROR AREA
XXX
TYPE
XXX
NUMBER OF OCCU. XXXXX
TIME AGO
XXXXX

Signal value: XXX = First part of error code; see section D Error codes.
TYPE
page
Description: Indicates type of active error.

DIAG TRANSM.
13(15)
ACT ERROR AREA
XXX
TYPE
XXX
TIME AGO
XXXXX

Signal value: XXX = Second part of error code.
NUMBER OF OCCU.
page
Description: Number of times active errors have occurred.

DIAG TRANSM.
13(15)
ACT ERROR AREA
XXX
TYPE
XXX
TIME AGO
XXXXX

Signal value: XXXXX = Number of times active errors have occurred.
TIME AGO
page
Description: When latest active error occurred.

DIAG TRANSM.
13(15)
ACT ERROR AREA
XXX
TYPE
XXX
TIME AGO
XXXXX

Signal value: XXXXX = Operating time in hours since latest error.
VDRF03.02GB
100
8.4.7.14
TRANSM, menu 14
CONVERTER STATUS (Nm), TORQUE IMPELLER
page
14(X)
(Nm)
XXXX
XXXX
Description: Torque transmitted by from engine to impeller in torque

converter. The torque absorbed by the transmission.
DIAG TRANSM.
CONVERTER STATUS
TORQUE IMPELLER
TORQUE TURBINE

Signal value: XXXX = Torque in Nm.
CONVERTER STATUS (Nm), TORQUE TURBINE
page
14(X)
(Nm)
XXXX
XXXX
Description: Current torque transmitted by torque converter to transmission.

DIAG TRANSM.
CONVERTER STATUS
TORQUE IMPELLER
TORQUE TURBINE

Signal value: XXXX = Torque in Nm.
VDRF03.02GB
8 Control system 8.4.8 BOOM
8.4.8
101
BOOM
BOOM, description
page
This group covers the boom functions.

009275
DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
8.4.8.1
BOOM, menu 1
PRESENT INPUT SIGNALS, BOOM UP/DOWN
page
Description: Signal from control lever (boom up/down).

000175
DIAG BOOM
1(8)
PRESENT INPUT SIGNALS
BOOM UP/DOWN
XX.XXV
BOOM IN/OUT
XX.XXV
Function: 7.1.1 Control lever

Signal value: XX.XXV = 0.50 - 4.50 V. 2.5 V in zero position.
PRESENT INPUT SIGNALS, BOOM IN/OUT
page
Description: Signal from control lever (boom in/out).

000175
DIAG BOOM
1(8)
BOOM UP/DOWN
XX.XXV
BOOM IN/OUT
XX.XXV
Function: 7.1.1 Control lever

Signal value: XX.XXV = 0.50 - 4.50 V. 2.5 V in zero position.
8.4.8.2
BOOM, menu 2
BLOCK VALVES, UP/DOWN
page
Description: Voltage feed to solenoid valve blocking, lower.

Circuit diagram: Circuit Boom up/down group 7.2
Connection:
LE: digital out from D797-F/K1:30 to H6002/1
012097
DIAG BOOM
2(8)
BLOCK VALVES
UP/DOWN
LE XY RI XY
IN
XY
RELIEVE PRESS. IN XY
RI: digital out from D797-F/K1:31 to H6001/1

Function: 7.2.7 Valve block lift cylinder
Signal value:
00
01

10
11

VDRF03.02GB
102
8 Control system 8.4.8.2 BOOM, menu 2
BLOCK VALVES, IN/OUT
page
Description: Voltage feed to solenoid valve blocking, boom in.

Circuit diagram: Circuit Boom in/out group 7.3
Connection: digital out from D797-R/K1:5 to B6050/1
012097
DIAG BOOM
2(8)
BLOCK VALVES
UP/DOWN
LE XY RI XY
IN
XY
Function: 7.3.7 Valve block extension cylinder

Signal value:
00
01

10
11

BLOCK VALVES, RELIEVE PRESS. IN
page
Description: Voltage feed to solenoid valve pump unloading.

012097
DIAG BOOM
2(8)
BLOCK VALVES
UP/DOWN
LE XY RI XY
IN
XY
Function: 7.3.9 Valve block pump unloading.

Signal value:
00
01

10
11

VDRF03.02GB
8.4.8.3
103
BOOM, menu 3
BOOM HIGH SPEED, UP
page
Description: Voltage feed to solenoid valve, regeneration boom up.

Connection:
LE: digital out from D797-F/K1:33 to H6052/1
000177
DIAG BOOM
3(8)
BOOM HIGH SPEED
UP
LE XY RI XY
OUT
XY
RE: digital out from D797-F/K1:32 to H6051/1

Function: 7.2.7 Valve block lift cylinder
Signal value:
00
01

10
11

BOOM HIGH SPEED, OUT
page
Description: Voltage feed to solenoid valve, regeneration, extension.

000177
DIAG BOOM
3(8)
BOOM HIGH SPEED
UP
LE XY RI XY
OUT
XY
Function: 7.3.7 Valve block extension cylinder

Signal value:
00
01

10
11

VDRF03.02GB
104
8.4.8.4
BOOM, menu 4
OUTPUT BOOM UP, REFERENCE
page
Description: Status for control current to control valve lift, lower and extension (solenoid valve lift).
4(8)
XY
XXX
XXX

000178
DIAG BOOM
OUTPUT BOOM UP
REFERENCE
REQUIRED VALUE
FEEDBACK
Connection: digital out from D797-F/K1:2 to Y6005/1

Function: 7.2.5 Control valve lift, lower and extension
Signal value:
00
01

10
11

OUTPUT BOOM UP, REQUIRED VALUE
page
Description: Reference value for control current to control valve lift,

lower and extension (solenoid valve lift).
4(8)
XY
XXX
XXX

000178
DIAG BOOM
OUTPUT BOOM UP
REFERENCE
REQUIRED VALUE
FEEDBACK
Connection: output signal reference value out from D797-F/K1:16 to

Y6005/2
Signal value: XXX = Current value: in mA for control of solenoid valve.
OUTPUT BOOM UP, FEEDBACK
page
Description: Present control current to control valve lift, lower and extension (solenoid valve lift).
4(8)
XY
XXX
XXX

000178
DIAG BOOM
OUTPUT BOOM UP
REFERENCE
REQUIRED VALUE
FEEDBACK
Connection: output signal actual value out from D797-F/K1:16 to

Y6005/2
Signal value: XXX = Measured current value in mA.
VDRF03.02GB
8.4.8.5
105
BOOM, menu 5
OUTPUT BOOM DOWN, REFERENCE
page
Description: Status for control current to control valve lift, lower and extension (solenoid valve lower).
5(8)
XY
XXX
XXX

000179
DIAG BOOM
OUTPUT BOOM DOWN
REFERENCE
REQUIRED VALUE
FEEDBACK

Signal value:
00
01

10
11

OUTPUT BOOM DOWN, REQUIRED VALUE
page

lower and extension (solenoid valve lower).
5(8)
XY
XXX
XXX

000179
DIAG BOOM
OUTPUT BOOM DOWN
REFERENCE
REQUIRED VALUE
FEEDBACK

Y6004/2
OUTPUT BOOM DOWN, FEEDBACK
page
Description: Present control current to control valve lift, lower and extension (solenoid valve lower).
5(8)
XY
XXX
XXX

000179
DIAG BOOM
OUTPUT BOOM DOWN
REFERENCE
REQUIRED VALUE
FEEDBACK

Y6004/2
VDRF03.02GB
106
8.4.8.6
BOOM, menu 6
OUTPUT BOOM IN, REFERENCE
page
Description: Status for control current to control valve lift, lower and extension (solenoid valve extension in).
6(8)
XY
XXX
XXX

000180
DIAG BOOM
OUTPUT BOOM IN
REFERENCE
REQUIRED VALUE
FEEDBACK

Signal value:
00
01

10
11

OUTPUT BOOM IN, REQUIRED VALUE
page

lower and extension (solenoid valve extension in).
6(8)
XY
XXX
XXX

000180
DIAG BOOM
OUTPUT BOOM IN
REFERENCE
REQUIRED VALUE
FEEDBACK

Y6007/2
OUTPUT BOOM IN, FEEDBACK
page
Description: Present value for control current to control valve lift, lower
and extension (solenoid valve extension in).
6(8)
XY
XXX
XXX

000180
DIAG BOOM
OUTPUT BOOM IN
REFERENCE
REQUIRED VALUE
FEEDBACK

Y6007/2
VDRF03.02GB
8.4.8.7
107
BOOM, menu 7
OUTPUT BOOM OUT, REFERENCE
page
Description: Status for control current to control valve lift, lower and extension (solenoid valve extension out).
7(8)
XY
XXX
XXX

000181
DIAG BOOM
OUTPUT BOOM OUT
REFERENCE
REQUIRED VALUE
FEEDBACK

Signal value:
00
01

10
11

OUTPUT BOOM OUT, REQUIRED VALUE
page

lower and extension (solenoid valve extension out).
7(8)
XY
XXX
XXX

000181
DIAG BOOM
OUTPUT BOOM OUT
REFERENCE
REQUIRED VALUE
FEEDBACK

Y6006/2
OUTPUT BOOM OUT, FEEDBACK
page
Description: Present control current to control valve lift, lower and extension (solenoid valve extension out).
7(8)
XY
XXX
XXX

000181
DIAG BOOM
OUTPUT BOOM OUT
REFERENCE
REQUIRED VALUE
FEEDBACK

Y6006/2
VDRF03.02GB
108
8.4.8.8
BOOM, menu 8
PRESENT INPUT SIGNAL BOOM LOW SPEED, UP/DOWN
page
Description: Signal from sensor boom angle, to activate damping during lifting and lowering.
000182
DIAG BOOM
8(8)
BOOM LOW SPEED
UP/DOWN
X
IN/OUT
X/X
Connection: signal in from B771 to analogue in D797-R/K1:21

Function: 7.2.11 Sensor, boom angle (position sensor)
Signal value:
1
No signal.
PRESENT INPUT SIGNAL BOOM LOW SPEED, IN/OUT
page
Description: Signal from sensor boom length to activate damping during extensions.
000182
DIAG BOOM
8(8)
BOOM LOW SPEED
UP/DOWN
X
IN/OUT
X/X
Circuit diagram: Circuit OP + Scale group 8.2 (Mechanical overload

system with analogue position sensor or Electrical overload system),
Circuit Boom in/out group 7.3 (Mechanical overload system)
Connection:
Mechanical overload system with analogue position sensor or
Electrical overload system:
Analogue signal in from B777/3 to analogue in D797-R/K1:22
Boom in: digital in from B769-3/C to digital in D797-R/K1:26
Boom out: digital in from B769-4/C to analogue in D797-R/K1:23
(software-generated signal from overload system)
Function: 7.3.11 Sensor, boom length
Signal value:
VDRF03.02GB
No signal.
8 Control system 8.4.9 ATTACH
8.4.9
109
ATTACH
ATTACH, description
page
This group covers attachment functions.

009276
DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
8.4.9.1
ATTACH, menu 1
PRESENT INPUT SIGNALS, ROT CW/CCW
page
Description: Signals from control lever for rotating the attachment

000184
DIAG ATTACHMENT 1(21)

ROT CW/CCW
XX.XXV
TILT IN/OUT
XX.XXV
Function: 7.6 Rotation

Signal value: XX.XXV = 0.50 - 4.50 V. 2.5 V in control lever zero position.
PRESENT INPUT SIGNALS, TILT IN/OUT
page
Description: Signals from control lever for tilting the attachment

000184

ROT CW/CCW
XX.XXV
TILT IN/OUT
XX.XXV

Function: 7.7 Tilt
Signal value: XX.XXV = 0.50 - 4.50 V. 2.5 V in control lever centre position.
8.4.9.2
ATTACH, menu 2
PRESENT INPUT SIGNALS, SIDE SHIFT
page
Description: Signals from control lever for side shift of attachment. If

the trigger button is depressed at the same time as side shift then
spreading is activated. Text in brackets describes spreading.
000185

SIDE SHIFT LE X RI X
PISTOL
X
30/35 STOP
X
Connection:
LE: from S815/14 to digital in D790-1/K7:14 (spreading in)
RI: from S815/16 to digital in D790-1/K7:13 (spreading out)
Function: 7.4 Side shift
Signal value:
1
No signal.
VDRF03.02GB
110
8 Control system 8.4.9.3 ATTACH, menu 3
PRESENT INPUT SIGNALS, PISTOL
page
Description: Signals from control lever for pistol trigger.

000185

PISTOL
X
30/35 STOP
X
Function: 7.5 Spreading, 7.10.2 Weight Indicator, 7.10.4 Synchronised lift

Signal value:
1
No signal.
PRESENT INPUT SIGNALS, 30/35 STOP
page
Description: Signal from switch for stop at 30/35.

Circuit diagram: Circuit Spreading Sensor group 7.5
000185

PISTOL
X
30/35 STOP
X

Function: 7.5 Spreading
Signal value:
1
No signal.
8.4.9.3
ATTACH, menu 3
PRESENT INPUT SIGNALS, LOCK TW
page
Description: Signal from switch lock twistlock.

Circuit diagram: Circuit Twistlock group 7.9
Connection: from S1003/7 and S1007/2 to digital in D790-1/K8:12
000186

LOCK TW
X
UNLOCK TW
X
BY-PASS HEIGHT
X

Signal value:
1
No signal.
PRESENT INPUT SIGNALS, UNLOCK TW
page
Description: Signal from control lever to unlock twistlock.
VDRF03.02GB

000186

LOCK TW
X
UNLOCK TW
X
BY-PASS HEIGHT
X

Signal value:
1
No signal.
111
PRESENT INPUT SIGNALS, BYPASS HEIGHT
page
Description: Signal from switch bypass of load centre limitation and

height limitation if the machine is equipped with these options.
000186

LOCK TW
X
UNLOCK TW
X
BY-PASS HEIGHT
X
Circuit diagram: Circuit Bypass group 8.2

Connection: from S1014/S1015/1 to digital in D790-1/K8:14
Function: 8.2.2 Bypass
Signal value:
1
No signal.
8.4.9.4
ATTACH, menu 4
PRESENT INPUT SIGNALS, TILT LOCKING
page
Description: Signal from control lever for tilt locking.

006874
DIAG ATTACHMENT
4(X)
TILT LOCKING
X
LEVELLING LOCKING
X
AUTO 20'-40'
X

Function: 7.7 Tilt
Signal value:
1
No signal.
PRESENT INPUT SIGNALS, LEVELLING LOCKING
page
Description: Signal from control lever for levelling lock.

006874
DIAG ATTACHMENT
4(X)
TILT LOCKING
X
LEVELLING LOCKING
X
AUTO 20'-40'
X

Function: 7.8 Levelling
Signal value:
1
No signal.
VDRF03.02GB
112
PRESENT INPUT SIGNALS, AUTO 20'-40'
page
Description: Signal from switch automatic spreading 20'-40'.

Circuit diagram: Circuit Extra equipment group 9.1
006874
DIAG ATTACHMENT
4(X)
TILT LOCKING
X
LEVELLING LOCKING
X
AUTO 20'-40'
X
Connection: from S199/-2 to digital in D790-1/K8:11

Signal value:
1
No signal.
8.4.9.5
ATTACH, menu 5
PRESENT INPUT SIGNALS, LOW SPEED 20/40
page
Description: Signal from position sensor spreading for end position

damping 20/40. On machines with 30 stop the sensor also produces
a signal to control the stopping point for the 30 position.
000188

LOW SPEED 20/40
X
30/35 STOP
X
EXTENSION 60CM
X
Connection: from inductive sensor B769/C to digital in D791-1/K1:12

Function: 7.5.10 Position sensor spreading
Signal value:
1
No signal.
PRESENT INPUT SIGNALS, 30/35 STOP

LOW SPEED 20/40
X
30/35 STOP
X
EXTENSION 60CM
X
000188
page
Description: Signal from position sensor spreading for stop at 30/35.

The sensor produces a signal for damping at the 30 position and for
stop at the 20 and 40 position.
Connection: from inductive sensor B777-3/C to digital in D791-1/K1:20
Function: 7.5.10 Position sensor spreading
Signal value:
VDRF03.02GB
No signal.
113
PRESENT INPUT SIGNALS, EXTENSION 60CM (model year

-2008)
page
Description: Signal from position sensor extension 60 cm, for fixed

scale.
000188

LOW SPEED 20/40
X
30/35 STOP
X
EXTENSION 60CM
X

Connection: from inductive sensor B7224/C to digital in D791-1/K1:21
Function: 7.10.2 Weight indicator
Signal value:
1
No signal.
8.4.9.6
ATTACH, menu 6
PRESENT INPUT SIGNALS, ALIGNMENT, FRONT
page
Description: Signals from sensors alignment right front and left front.
Connection:
LE: signal from B7202L/C to analogue in (used as digital)
D791-1/K1:13
000202

ALIGNMENT
LE
RI
FRONT
X
X
REAR
X
X
RI: signal from B7202R/C to digital in D791-1/K1:40

Function: 7.9.1.8 Alignment sensor
Signal value:
1
No signal.
PRESENT INPUT SIGNALS, ALIGNMENT, REAR
page
Description: Signals from sensors alignment right rear and left rear.
Connection:
D791-1/K1:27
000202

ALIGNMENT
LE
RI
FRONT
X
X
REAR
X
X

Function: 7.9.1.8 Alignment sensor
Signal value:
1
No signal.
VDRF03.02GB
114
8.4.9.7
ATTACH, menu 7
PRESENT INPUT SIGNAL, LOCKED TW
page
Description: Signals from sensors locked twistlock right and left.

Connection:
D791-1/K1:23
001633

LE
RI
LOCKED TW
X
X
UNLOCKED TW
X
X
RI: signal from B7205R/C to analogue in (used as digital)

D791-1/K1:24
Function: 7.9.1.9 Sensor twistlock
Signal value:
1
No signal.
PRESENT OUTPUT SIGNAL, UNLOCKED TW
page
Description: Signals from sensors open twistlock right and left.

Connection:
D791-1/K1:22
001633

LE
RI
LOCKED TW
X
X
UNLOCKED TW
X
X
RI: signal from B7204R/C to analogue in (used as digital)

D791-1/K1:41
Function: 7.9.1.9 Sensor twistlock
Signal value:
VDRF03.02GB
Output signal active.
No signal.
8.4.9.8
115
ATTACH, menu 8
PRESENT OUTPUT SIGNAL, SIDE SHIFT LEFT
page
Description: Voltage feed to control valve attachment, side shift left.

Connection: digital out from D791-1/K1:31 to Y6020/1
000189

SIDE SHIFT LEFT
XY
SIDE SHIFT RIGHT
XY
Function: 7.4.3 Control valve attachment

Signal value:
00
01

10
11

PRESENT OUTPUT SIGNAL, SIDE SHIFT RIGHT
page
Description: Voltage feed to control valve attachment, side shift right.

000189

SIDE SHIFT LEFT
XY
SIDE SHIFT RIGHT
XY

Signal value:
00
01

10
11

VDRF03.02GB
116
8.4.9.9
ATTACH, menu 9
PRESENT OUTPUT SIGNAL, LOCK TW
page
Description: Voltage feed to attachment control valve, lock twistlock.

000190

LOCK TW
XY
UNLOCK TW
XY
Function: 7.9.1.3 Attachment control valve

Signal value:
00
01

10
11

PRESENT OUTPUT SIGNAL, UNLOCK TW
page
Description: Voltage feed to control valve attachment, open twistlock.

000190

LOCK TW
XY
UNLOCK TW
XY
Function: 7.9.1.3 Attachment control valve

Signal value:
00
01

10
11

VDRF03.02GB
8.4.9.10
117
ATTACH, menu 10
PRESENT OUTPUT SIGNAL, IND. LOCKED TW
page
Description: Voltage feed indicator light locked twistlock.

Connection: digital out from D791-1/K1:39 to H563/1
000191

IND. LOCKED TW
XY
IND. UNLOCKED TW
XY
IND. ALIGNMENT
XY

Signal value:
00
01

10
11

PRESENT OUTPUT SIGNAL, IND. UNLOCKED TW
page
Description: Voltage feed indicator light open twistlock.

000191

IND. LOCKED TW
XY
IND. UNLOCKED TW
XY
IND. ALIGNMENT
XY

Signal value:
00
01

10
11

VDRF03.02GB
118
PRESENT OUTPUT SIGNAL, ALIGNMENT
page
Description: Voltage feed indicator light alignment.

000191

IND. LOCKED TW
XY
IND. UNLOCKED TW
XY
IND. ALIGNMENT
XY

Signal value:
00
01

10
11

8.4.9.11
ATTACH, menu 11
OUTPUT ROTATION C.W., REFERENCE
page
Description: Status control current to control valve attachment for rotation clockwise.
000192

OUTPUT ROTATION C.W.
REFERENCE
XY
RQUIRED VALUE
XXX
FEEDBACK
XXX
Connection: digital out from D791-1/K1:2 to solenoid valve Y6008/1

Signal value:
00
01

10
11

VDRF03.02GB
119
OUTPUT ROTATION C.W., REQUIRED VALUE
page
Description: Reference value for control current to control valve attachment for rotation clockwise.
000192

REFERENCE
XY
RQUIRED VALUE
XXX
FEEDBACK
XXX
Connection: output signal reference value out from D791-1/K1:16 to

Y6008/2
OUTPUT ROTATION C.W., FEEDBACK
page
Description: Present control current to control valve attachment for rotation clockwise.
000192

REFERENCE
XY
RQUIRED VALUE
XXX
FEEDBACK
XXX
Connection: output signal, actual value out from D791-1/K1:16 to

Y6008/2
8.4.9.12
ATTACH, menu 12
OUTPUT ROTATION C.C.W., REFERENCE
page
Description: Status control current to control valve attachment for rotation anticlockwise.
000193

OUTPUT ROTATION C.C.W.
REFERENCE
XY
REQUIRED VALUE
XXX
FEEDBACK
XXX
Connection: digital out from D791-1/K1:3 to solenoid valve Y6009/1

Signal value:
00
01

10
11

OUTPUT ROTATION C.C.W., REQUIRED VALUE
page
Description: Reference value for control current to control valve attachment for rotation anticlockwise.
000193

REFERENCE
XY
REQUIRED VALUE
XXX
FEEDBACK
XXX

Y6009/2
VDRF03.02GB
120
OUTPUT ROTATION C.C.W., FEEDBACK
page
Description: Present control current to control valve attachment for rotation clockwise.
000193

REFERENCE
XY
REQUIRED VALUE
XXX
FEEDBACK
XXX

Y6009/2
8.4.9.13
ATTACH, menu 13
OUTPUT SPREADER OUT, REFERENCE
page
Description: Status control current to control valve attachment for

spreader out.
000194

OUTPUT SPREADER OUT
REFERENCE
XY
REQUIRED VALUE
XXX
FEEDBACK
XXX

Signal value:
00
01

10
11

OUTPUT SPREADER OUT, REQUIRED VALUE
page
Description: Reference value for control current to control valve attachment for output signal, spreading out.
000194

OUTPUT SPREADER OUT
REFERENCE
XY
REQUIRED VALUE
XXX
FEEDBACK
XXX

Y6018/2
OUTPUT SPREADER OUT, FEEDBACK
page
Description: Present control current to control valve attachment for

spreader out.
000194

OUTPUT SPREADER OUT
REFERENCE
XY
REQUIRED VALUE
XXX
FEEDBACK
XXX

Y6018/2
VDRF03.02GB
8.4.9.14
121
ATTACH, menu 14
OUTPUT SPREADER IN, REFERENCE
page
Description: Status control current to control valve attachment for

spreader in.
000195

OUTPUT SPREADER IN
REFERENCE
XY
RQUIRED VALUE
XXX
FEEDBACK
XXX

Signal value:
00
01

10
11

OUTPUT SPREADER IN, REQUIRED VALUE
page
Description: Reference value for control current to control valve attachment for spreading in.
000195

OUTPUT SPREADER IN
REFERENCE
XY
RQUIRED VALUE
XXX
FEEDBACK
XXX
Connection: output signal, reference value out from D791-1/K1:19 to

Y6019/2
OUTPUT SPREADER IN, FEEDBACK
page

spreader in.
000195

OUTPUT SPREADER IN
REFERENCE
XY
RQUIRED VALUE
XXX
FEEDBACK
XXX

Y6019/2
VDRF03.02GB
122
8.4.9.15
ATTACH, menu 15
PRESENT OUTPUT SIGNAL, TILT LOCKING 1
page
Description: Voltage feed to lock valve tilt.

Circuit diagram: Circuit Tilt locking group 7.7
006875
DIAG ATTACHMENT 15(X)

TILT LOCKING 1
XY
TILT LOCKING 2
XY
BUZZER AUTO 20-40 XY
Connection: digital out from D791-1/K1:7 to Y6012-1/1

Function: 7.7.4 Lock valve tilt
Signal value:
00
01

10
11

PRESENT OUTPUT SIGNAL, TILT LOCKING 2
page
Description: Voltage feed to lock valve tilt.

Circuit diagram: Circuit Tilt locking group 7.7
006875

TILT LOCKING 1
XY
TILT LOCKING 2
XY
Connection: digital out from D791-1/K1:9 to Y6012-2/1

Function: 7.7.4 Lock valve tilt
Signal value:
00
01

10
11

VDRF03.02GB
123
PRESENT OUTPUT SIGNAL, BUZZER AUTO 20-40
page
Description: Voltage feed to buzzer automatic spreading 20-40.

Circuit diagram: Circuit Spreading Auto group 7.5
006875

TILT LOCKING 1
XY
TILT LOCKING 2
XY

Signal value:
00
01

10
11

8.4.9.16
ATTACH, menu 16
OUTPUT TILT OUT, REFERENCE
page
Description: Status control current to control valve attachment for tilt

out.
000197

OUTPUT TILT OUT
REFERENCE
XY
REQUIRED VALUE
XXX
FEEDBACK
XXX
Circuit diagram: Circuit Tilt + Levelling group 7.7

Connection:
Top lift attachment: digital out from D791-2/K1:4 to Y6010/1
Combi attachment: digital out from D791-4/K1:2 to Y6010
Signal value:
00
01

10
11

VDRF03.02GB
124
OUTPUT TILT OUT, REQUIRED VALUE
page
Description: Reference value for control current to control valve attachment for tilt out.
000197

OUTPUT TILT OUT
REFERENCE
XY
REQUIRED VALUE
XXX
FEEDBACK
XXX

Connection:
Top lift attachment: output signal reference value out from D7912/K1:18 to Y6010/2
Combi attachment: output signal reference value out from D7914/K1:16 to Y6010/2
OUTPUT TILT OUT, FEEDBACK
page
Description: Present control current to control valve attachment for tilt

out.
000197

OUTPUT TILT OUT
REFERENCE
XY
REQUIRED VALUE
XXX
FEEDBACK
XXX

Connection:
Top lift attachment: output signal actual value out from D791-2/
K1:18 to Y6010/2
Combi attachment: output signal actual value out from D791-4/
K1:16 to Y6010/2
VDRF03.02GB
8.4.9.17
125
ATTACH, menu 17
OUTPUT TILT IN, REFERENCE
page
Description: Status control current to control valve attachment for tilt

in.
000198

OUTPUT TILT IN
REFERENCE
XY
REQUIRED VALUE
XXX
FEEDBACK
XXX

Connection:
Combi attachment: digital out from D791-4/K1:3 to Y6011/1
Signal value:
00
01

10
11

OUTPUT TILT IN, REQUIRED VALUE
page
Description: Reference value for control current to control valve attachment for tilt in.
000198

OUTPUT TILT IN
REFERENCE
XY
REQUIRED VALUE
XXX
FEEDBACK
XXX

Connection:
VDRF03.02GB
126
OUTPUT TILT IN, FEEDBACK
page
Description: Present control current to control valve attachment for tilt

in.
000198

OUTPUT TILT IN
REFERENCE
XY
REQUIRED VALUE
XXX
FEEDBACK
XXX

Connection:
K1:19 to Y6011/2
K1:17 to Y6011/2
8.4.9.18
ATTACH, menu 18
PRESENT OUTPUT SIGNAL, LOCK LEVELLING 1
page
Description: Voltage feed to lock valve levelling.

000199

LOCK LEVELLING 1
XY
LOCK LEVELLING 2
XY
Connection:
Top lift attachment: digital out from D791-2/K1:30 to Y6034-1/1
Combi attachment: digital out from D791-3/K1:15 to Y6034-1/1
and Y6034-2/1
Function: 7.8.6 Valve block, levelling cylinders
Signal value:
00
01

10
11

VDRF03.02GB
127
PRESENT OUTPUT SIGNAL, LOCK LEVELLING 2
page
Description: Voltage feed to lock valve levelling.

Connection: Circuit Tilt + Levelling group 7.7
000199

LOCK LEVELLING 1
XY
LOCK LEVELLING 2
XY
Top lift attachment: digital out from D791-2/K1:31 to Y6034-2/1

Combi attachment: digital out from D791-3/K1:15 to Y6034-1/1
and Y6034-2/1
Function: 7.8.6 Valve block, levelling cylinders
Signal value:
00
01

10
11

8.4.9.19
ATTACH, menu 19
OUTPUT LEVELLING RI, REFERENCE
page
Description: Status control current to control valve attachment for levelling right.
000200

OUTPUT LEVELLING RI
REFERENCE
XY
RQUIRED VALUE
XXX
FEEDBACK
XXX

Connection:
Signal value:
00
01

10
11

VDRF03.02GB
128
OUTPUT LEVELLING RI, REQUIRED VALUE
page
Description: Reference value for control current to control valve attachment for levelling right.
000200

OUTPUT LEVELLING RI
REFERENCE
XY
RQUIRED VALUE
XXX
FEEDBACK
XXX

Connection:
OUTPUT LEVELLING RI, FEEDBACK
page

levelling right.
000200

OUTPUT LEVELLING RI
REFERENCE
XY
RQUIRED VALUE
XXX
FEEDBACK
XXX

Connection:
K1:16 to Y6035/2
K1:16 to Y6035/2
VDRF03.02GB
8.4.9.20
129
ATTACH, menu 20
OUTPUT LEVELLING LE, REFERENCE
page
Description: Status control current to control valve attachment for levelling left.
006876

OUTPUT LEVELLING LE
REFERENCE
XY
REQUIRED VALUE
XXX
FEEDBACK
XXX

Connection:
Signal value:
00
01

10
11

OUTPUT LEVELLING LE, REQUIRED VALUE
page
Description: Reference value for control current to control valve attachment for levelling left.
006876

OUTPUT LEVELLING LE
REFERENCE
XY
REQUIRED VALUE
XXX
FEEDBACK
XXX

Connection:
VDRF03.02GB
130
OUTPUT LEVELLING LE, FEEDBACK
page

levelling left.
006876

OUTPUT LEVELLING LE
REFERENCE
XY
REQUIRED VALUE
XXX
FEEDBACK
XXX

Connection:
K1:17 to Y6036/2
K1:17 to Y6036/2
8.4.9.21
ATTACH, menu 21
ROTATION STOP, SWITCH
page
Description: Signal from rotation stop switch.

006877

ROTATION STOP
SWITCH
X
SENSOR STOP
X
Connection: signal from S1014/1015/3 to digital in D790-1/K8:14

Function: 7.6 Rotation
Signal value:
1
No signal.
ROTATION STOP, SENSOR STOP
page
Description: Signal from sensor rotation stop, with rotation 25 .

006877

ROTATION STOP
SWITCH
X
SENSOR STOP
X
Connection: signal from B7225/C to digital in D791-1/K1:11

Function: 7.6.10 Sensor, rotation stop
Signal value:
VDRF03.02GB
No signal.
8.4.9.22
131
ATTACH, menu 22
PRESENT INPUT SIGNAL, LENGTH TO CONTAINER
page
Description: Current distance from attachment to container.

Circuit diagram: Circuit diagram sensor ultrasonic
006878

LENGTH TO
CONTAINER (cm)
XXXX
DAMP DOWN
X
Connection: signal from B769/4 to analogue in D791-1/K1:21

Function: 7.2 lifting/lowering
Signal value: XXXX = distance to container in cm.
PRESENT INPUT SIGNAL, DAMP DOWN
page
Description: Status damping lower boom.

Circuit diagram:
006878

LENGTH TO
CONTAINER (cm)
XXXX
DAMP DOWN
X
Connection: Function: 7.2 Lifting/lowering

Signal value:
1
Damping active.
No damping.
VDRF03.02GB
132
8 Control system 8.4.10 OP
8.4.10
OP
OP, description
page
This group covers the overload system functions.

009277
DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
8.4.10.1
OP, menu 1
PRESENT INPUT SIGNAL, STEERING AXLE (model year 2008)
page
Description: Signal from sensor steering axle load right and left (mechanical overload system). It is sufficient that a sensor produces a signal to activate an overload warning.
008203
DIAG OP
1(X)
STEERING AXLE
X X
BOOM ANGLE
X
EXTENSION
X
Connection: signal from B7221R/C to digital in D797-R/K1:12 and

B7221L/C digital I D797-R/K1:11
Function: 8.2.1.1 Sensor, steering axle load
Signal value:
11
Input signal active left and right.
10
No signal left, input signal active right.
01
Input signal active left, no signal right.
00
No signal right and left.
PRESENT INPUT SIGNAL, BOOM ANGLE (model year 2008)
page
Description: Status for boom angle to overload system indicates when

the boom angle is over 35 .
008203
DIAG OP
1(X)
STEERING AXLE
X X
BOOM ANGLE
X
EXTENSION
X

Connection: signal from B771/3 to analogue in D797-R/K1:21
Function: 8.2.1.2 Sensor, boom angle
Signal value:
VDRF03.02GB
Input signal active. Boom angle over 35 .
No signal. Boom angle under 35 .
8 Control system 8.4.10.2 OP, menu 2
133
PRESENT INPUT SIGNAL, EXTENSION (model year -2008)
DIAG OP
1(X)
STEERING AXLE
X X
BOOM ANGLE
X
EXTENSION
X
008203
page
Description: Signal from sensor boom length (position sensor boom

length 1.5 m). On machines with mechanical overload system with analogue position sensors or electrical overload system the menu is
used to show the status for boom extension to the overload system.
Connection: signal from B777/C to analogue in (used as digital) D797R/K1:22
Function: 8.2.1.3 Sensor, boom length
Signal value:
1
Input signal active. Boom extension over 1.5 m.
No signal. Boom extension under 1.5 m.
8.4.10.2
OP, menu 2
PRESENT INPUT SIGNAL, BYPASS
page
Description: Signal from bypass switch.
DIAG OP
2(5)
000206
BY-PASS
Function: 7.1.3 Bypass switch

Signal value:
1
Input signal active. Signal is only active for max. 60 seconds.
No signal.
VDRF03.02GB
134
8.4.10.3
OP, menu 3
PRESENT INPUT SIGNAL LIFT CYL LE RI, C-
page
DIAG OP
3(5)
LIFT CYL LE
RI
CX.XXV X.XXV
C+
X.XXV X.XXV
Description: Signal from hydraulic pressure sensor, lift cylinder (C- rod
side). See also PRESSURE LIFTING CYL, C- page 71 (for pressure
information).
Connection:
LE: signal from B768-L2/3 to analogue in D797-F/K1:22
RI: signal from B768-R2/3 to analogue in D797-F/K1:24
000207
Signal value: X.XXV = 0.50-4.50 V = Hydraulic oil pressure, 0.50 V

corresponds to 0 MPa, 4.50 V corresponds to 25 MPa.
1. Pressure C2.Pressure C+
PRESENT INPUT SIGNAL LIFT CYL LE RI, C+
page
DIAG OP
3(5)
LIFT CYL LE
RI
CX.XXV X.XXV
C+
X.XXV X.XXV
Description: Signal from hydraulic pressure sensor, lift cylinder (C+

piston side). See also PRESSURE LIFTING CYL, C+ page 72 for
pressure.
Connection:
LE: signal from B768-L1 to analogue in D797-F/K1:21
RI: signal from B768-R1 to analogue in D797-F/K1:23
Signal value: X.XXV = 0.50-4.50 V = Hydraulic oil pressure, 0.50 V
corresponds to 0 MPa, 4.50 V corresponds to 25 MPa.
000207
1. Pressure C2.Pressure C+
VDRF03.02GB
8.4.10.4
135
OP, menu 4
PRESENT INPUT SIGNAL, BOOM ANGLE
page
(Standard model year 2009-)

Description: Signal from sensor boom angle.
000208
DIAG OP
4(5)
BOOM ANGLE
X.XXV
BOOM EXTENSION X.XXV

Function: 7.2.11 Sensor, boom angle
Signal value: X.XXV = 0.50 - 4.50 V
PRESENT INPUT SIGNAL, BOOM EXTENSION
page
(Standard model year 2009-)

Description: Signal from sensor boom length (analogue sensor).
000208
DIAG OP
4(5)
BOOM ANGLE
X.XXV
BOOM EXTENSION X.XXV

Function: 7.3.11 Sensor, boom length
8.4.10.5
OP, menu 5
ALLOWED LOAD
page
Description: Permitted load at the current load centre.

DIAG OP
5(X)
ALLOWED LOAD XXXXXkg
PRESENT LOAD XXXXXkg
LOAD STR.AXLE XXXXXkg
LOAD-CENTER
XX.XXm

Signal value: XXXXkg = Weight in kg.
PRESENT LOAD
page
Description: Calculated load.

DIAG OP
5(X)
LOAD-CENTER
XX.XXm

LOAD STR.AXLE
page
Description: Estimated load on the steering axle.

DIAG OP
5(X)
LOAD-CENTER
XX.XXm

VDRF03.02GB
136
LOAD-CENTRE
page
Description: Horizontal distance between centre drive axle and load

centre.
DIAG OP
5(X)
LOAD-CENTER
XX.XXm
Connection: Function: 8.2.1 Overload system, 8.2.3 Load centre limitation

Signal value: XX.XXm = distance in metres
8.4.10.6
OP, menu 6
BOOM ANGLE
page
Description: Current boom angle.
6(X)
XXX
XXX
XXX
XXX
DIAG OP
BOOM ANGLE
EXTENSION
BOOM HEIGHT
BOOM HEIGHT-NOSE

Signal value: XXX = boom angle in .
BOOM EXTENSION
page
Description: Current boom extension.
6(X)
XXX
XXX
XXX
XXX
DIAG OP
BOOM ANGLE
EXTENSION
BOOM HEIGHT
BOOM HEIGHT-NOSE

Signal value: XXX = boom extension in cm.
BOOM HEIGHT
page
6(X)
XXX
XXX
XXX
XXX
Description: Status for boom height at the top edge of the boom, the
machines total height.
DIAG OP
BOOM ANGLE
EXTENSION
BOOM HEIGHT
BOOM HEIGHT-NOSE
Connection: Function: 8.2.4 Height limitation

Signal value: XXX = height above ground in cm.
BOOM HEIGHT-NOSE
page
6(X)
XXX
XXX
XXX
XXX
Description: Status for current height of the attachments fixing point in

the boom, suspension. The height is used to calculate the loads centre of gravity as a part of the overload system.
DIAG OP
BOOM ANGLE
EXTENSION
BOOM HEIGHT
BOOM HEIGHT-NOSE
Connection: Function: 8.2.1 Overload system

Signal value: XXX = height above ground in cm.
VDRF03.02GB
8 Control system 8.4.11 EXTRA
8.4.11
137
EXTRA
EXTRA, description
page
This menu consists of optional functions:

009278
DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
Bottom lift-attachment, COMBI
Sliding cab, SLIDING-CAB
Support jacks, SUPPORT-JACKS
Lever steering or mini-wheel, EL-STEERING
Confirm selection in main menu with function key for Enter.
8.4.11.1
COMBI
COMBI, menu 1
page
This menu handles the function of the bottom lift-attachment.

000211
DIAGNOSIS EXTRA
COMBI SLIDING-CAB
SUPPORT-JACKS
EL-STEERING
SWITCHES, FRONT LEG UP/DOWN

Description: Signal from switch lowering front jacks (bottom lift).
DIAG COMBI
1(17)
SWITCHES
FRONT LEG UP/DOWN X/Y
REAR LEG UP/DOWN X/Y
CLAMP IN/OUT
X/Y

Connection:
Up: signal from S1006/1 to digital in D790-1/K9:3
Down: signal from S1006/7 to digital in D790-1/K9:4
Function: 7.9.2 Lifting jacks
Signal value:
1/0
Input signal active, jack up
0/1
Input signal active, jack down
0/0
No signal.
000212
1. Knee
2.Jack
3.Clamping plate
VDRF03.02GB
138
8 Control system 8.4.11.1 COMBI
SWITCHES, REAR LEG UP/DOWN

Description: Signal from switch lowering rear jacks (bottom lift).
DIAG COMBI
1(17)
SWITCHES
CLAMP IN/OUT
X/Y

Connection:
Up: signal from S1007/1 to digital in D790-1/K9:5
Down: signal from S1007/7 to digital in D790-1/K9:10
Signal value:
1/0
0/1
0/0
No signal.
000212
1. Knee
2.Jack
3.Clamping plate
SWITCHES, CLAMP IN/OUT

Description: Signal from switch clamp/release jacks (bottom lift).
DIAG COMBI
1(17)
SWITCHES
CLAMP IN/OUT
X/Y

Connection:
Together: signal from S1008/1 to analogue in (used as digital)
D790-1/K9:8
Apart: signal from S1008/7 to analogue in (used as digital) D7901/K9:9
Signal value:
1/0
0/1
0/0
No signal.
000212
1. Knee
2.Jack
3.Clamping plate
VDRF03.02GB
139
COMBI, menu 2
page
PRESENT INPUT SIGNAL CLAMPING SENSORS, FRONT

LEGS
Description: Signal from sensor clamping position front (jack against
load).
DIAG COMBI
2(17)
CLAMPING SENSORS
FRONT LEGS LE X RI X
REAR LEGS LE X RI X

Connection:
LE: signal from B7215L/C to digital in D791-3/K1:36
Function: 7.9.2.15 Sensor clamping position
Signal value:
1
No signal.
000214
1. Sensor clamping position
PRESENT INPUT SIGNAL CLAMPING SENSORS, REAR

LEGS
Description: Signal from sensor clamping position rear (jack against
load).
DIAG COMBI
2(17)
CLAMPING SENSORS
REAR LEGS LE X RI X

Connection:
Function: 7.9.2.15 Sensor clamping position
Signal value:
1
No signal.
000214
1. Sensor clamping position
VDRF03.02GB
140
COMBI, menu 3
page
PRESENT INPUT SIGNAL ALIGNMENT SENSORS, FRONT

LEGS
Description: Signal from sensor alignment front (load secured).
DIAG COMBI
3(17)
ALIGNMENT SENSORS
REAR LEGS LE X RI X

Connection:
Function: 7.9.2.14 Sensor, alignment
Signal value:
1
No signal.
000216
1. Alignment sensor
PRESENT INPUT SIGNAL ALIGNMENT SENSORS, REAR

LEGS
Description: Signal from sensor alignment rear (load secured).
DIAG COMBI
3(17)
ALIGNMENT SENSORS
REAR LEGS LE X RI X

Connection:
Function: 7.9.2.14 Sensor, alignment
Signal value:
1
No signal.
000216
1. Alignment sensor
VDRF03.02GB
141
COMBI, menu 4
page
PRESENT INPUT SIGNAL END POS SENSORS FRONT,

KNEE
Description: Signal from sensor knee front.
Connection:
000217
DIAG COMBI
4(17)
END POS SENSORS FRONT
KNEE
LE X RI X
LEG
LE X RI X

Function: 7.9.2.10 Sensor knee
Signal value:
1
Input signal active. In motion.
No signal.
PRESENT INPUT SIGNAL END POS SENSORS FRONT,

LEG
Description: Signal from sensor lifting jacks front.
Connection:
000217
DIAG COMBI
4(17)
END POS SENSORS FRONT
KNEE
LE X RI X
LEG
LE X RI X

Function: 7.9.2.13 Sensor, lifting jacks
Signal value:
1
No signal.
COMBI, menu 5
page
PRESENT INPUT SIGNAL END POS SENSORS REAR,

KNEE
Description: Signal from sensor knee rear.
Connection:
000218
DIAG COMBI
5(17)
END POS SENSORS REAR
KNEE
LE X RI X
LEG
LE X RI X

Function: 7.9.2.10 Sensor knee
Signal value:
1
No signal.
VDRF03.02GB
142
PRESENT INPUT SIGNAL END POS SENSORS REAR, LEG

Description: Signal from sensor lifting jacks rear
Connection:
000218
DIAG COMBI
5(17)
END POS SENSORS REAR
KNEE
LE X RI X
LEG
LE X RI X

Function: 7.9.2.13 Sensor, lifting jacks
Signal value:
1
No signal.
COMBI, menu 6
page
PRESENT INPUT SIGNAL LEGS IN DRIVE, POSITION

Description: Signal from sensor operating position.
Connection:
000219
DIAG COMBI
6(17)
LEGS IN DRIVE
POSITION
LE X RI X

Function: 7.9.2.9 Sensor operating position
Signal value:
VDRF03.02GB
No signal.
143
COMBI, menu 7
page
INDICATION LAMPS ALIGNMENT, FRONT

Description: Voltage feed to indicator light alignment front.
Connection:
LE: digital out from D791-3/K1:29 to H566L/1
000220
DIAG COMBI
7(17)
INDICATION LAMPS
ALIGNMENT
FRONT
LE XY RI XY
REAR
LE XY RI XY
RI: digital out from D791-3/K1:10 to H566R/1

Signal value:
00
01

10
11

INDICATION LAMPS ALIGNMENT, REAR

Description: Status for voltage feed to indicator light alignment rear.
Connection:
LE: digital out from D791-3/K1:39 to H567L/1
000220
DIAG COMBI
7(17)
INDICATION LAMPS
ALIGNMENT
FRONT
LE XY RI XY
REAR
LE XY RI XY
RI: digital out from D791-3/K1:25 to H567R/1

Signal value:
00
01

10
11

VDRF03.02GB
144
COMBI, menu 8
page
INDICATION LAMPS CLAMP, FRONT

Description: Status for voltage feed to indicator light clamping position
front.
000221
DIAG COMBI
8(17)
INDICATION LAMPS
CLAMP
FRONT
XY
REAR
XY

Signal value:
00
01

10
11

INDICATION LAMPS CLAMP, REAR

Description: Status for voltage feed to indicator light clamping position
rear.
000221
DIAG COMBI
8(17)
INDICATION LAMPS
CLAMP
FRONT
XY
REAR
XY

Signal value:
00
01

10
11

VDRF03.02GB
145
COMBI, menu 9
page
INDICATION LAMPS, FRONT LEGS UP

Description: Status for voltage feed to indicator light front jacks raised.
DIAG COMBI
9(17)
INDICATION LAMPS
XY
XY
000222
FRONT LEGS UP
FRONT LEGS DOWN

Signal value:
00
01

10
11

INDICATION LAMPS, FRONT LEGS DOWN

Description: Status for voltage feed to indicator light front jacks lowered.
DIAG COMBI
9(17)
INDICATION LAMPS
XY
XY
000222
FRONT LEGS UP
FRONT LEGS DOWN

Signal value:
00
01

10
11

VDRF03.02GB
146
COMBI, menu 10
page
PRESENT OUTPUT SIGNAL FRONT LEGS DOWN, KNEE

Description: Status for voltage feed to control valve lifting jacks, solenoid valve front knee out.
000223
DIAG COMBI
10(17)
FRONT LEGS DOWN
KNEE
LE XY RI XY
LEGS
LE XY RI XY
Connection:
LE: digital out from D791-3/K1:5 to Y6056L/1
RI: digital out from D791-4/K1:5 to Y6056R/1
Function: 7.9.2.3 Control valve lifting jacks
Signal value:
00
01

10
11

PRESENT OUTPUT SIGNAL FRONT LEGS DOWN, LEGS

Description: Status for voltage feed to control valve lifting jacks, solenoid valve front jacks down.
000223
DIAG COMBI
10(17)
FRONT LEGS DOWN
KNEE
LE XY RI XY
LEGS
LE XY RI XY
Connection:
Signal value:
00
01

10
11

VDRF03.02GB
147
COMBI, menu 11
page
PRESENT OUTPUT SIGNAL FRONT LEGS UP, KNEE

Description: Status for voltage feed to control valve lifting jacks, solenoid valve front knee in.
000224
DIAG COMBI
11(17)
FRONT LEGS UP
KNEE
LE XY RI XY
LEGS
LE XY RI XY
Connection:
Signal value:
00
01

10
11

PRESENT OUTPUT SIGNAL FRONT LEGS UP, LEGS

Description: Status for voltage feed to control valve lifting jacks, solenoid valve front jacks up.
000224
DIAG COMBI
11(17)
FRONT LEGS UP
KNEE
LE XY RI XY
LEGS
LE XY RI XY
Connection:
Signal value:
00
01

10
11

VDRF03.02GB
148
COMBI, menu 12
page
PRESENT OUTPUT SIGNAL REAR LEGS DOWN, KNEE

Description: Status for voltage feed to control valve lifting jacks, solenoid valve rear knee out.
000225
DIAG COMBI
12(17)
REAR LEGS DOWN
KNEE
LE XY RI XY
LEGS
LE XY RI XY
Connection:
Function: 7.9.2.3 Solenoid valve lifting jacks
Signal value:
00
01

10
11

PRESENT OUTPUT SIGNAL REAR LEGS DOWN, LEGS

Description: Status for voltage feed to control valve lifting jacks, solenoid valve rear jacks down.
000225
DIAG COMBI
12(17)
REAR LEGS DOWN
KNEE
LE XY RI XY
LEGS
LE XY RI XY
Connection:
Signal value:
00
01

10
11

VDRF03.02GB
149
COMBI, menu 13
page
PRESENT OUTPUT SIGNAL REAR LEGS UP, KNEE

Description: Status for voltage feed to control valve lifting jacks, solenoid valve rear knee in.
000226
DIAG COMBI
13(17)
REAR LEGS UP
KNEE
LE XY RI XY
LEGS
LE XY RI XY
Connection:
Signal value:
00
01

10
11

PRESENT OUTPUT SIGNAL REAR LEGS UP, LEGS

Description: Status for voltage feed to control valve lifting jacks, solenoid valve rear jacks up.
000226
DIAG COMBI
13(17)
REAR LEGS UP
KNEE
LE XY RI XY
LEGS
LE XY RI XY
Connection:
Signal value:
00
01

10
11

VDRF03.02GB
150
COMBI, menu 14
page
SEQUENCE MODE, FRONT

Description: Current sequence mode for lowering the front jacks.
FRONT
REAR
14(17)
LE
X
X
RI
X
X

Connection: 000227
DIAG COMBI
SEQUENCE MODE

Signal value:
0
Sequence error
Jack up (0), knee in (0).
Jack up (0), knee moving (1).
Jack up (0), knee out (0).
Jack moving (1), knee out (0).
Jack down (0), knee out (0). No signal.
SEQUENCE MODE, REAR

Description: Current sequence mode for lowering the rear jacks.
FRONT
REAR
VDRF03.02GB
14(17)
LE
X
X
RI
X
X

Connection: 000227
DIAG COMBI
SEQUENCE MODE

Signal value:
0
Sequence error
Jack up (0), knee in (0).
Jack up (0), knee moving (1).
Jack up (0), knee out (0).
Jack moving (1), knee out (0).
Jack down (0), knee out (0). No signal.
151
COMBI, menu 15
page
PRESENT OUTPUT SIGNAL CLAMP, OUT

Description: Status for voltage feed to control valve lifting jacks, solenoid valve clamp release.
006881
DIAG COMBI
15(X)
CLAMP
IN
LE XY RI XY
OUT
LE XY RI XY
Connection:
Signal value:
00
01

10
11

PRESENT OUTPUT SIGNAL CLAMP, IN

Description: Status for voltage feed to control valve lifting jacks, solenoid valve clamp.
006881
DIAG COMBI
15(X)
CLAMP
IN
LE XY RI XY
OUT
LE XY RI XY
Connection:
Signal value:
00
01

10
11

VDRF03.02GB
152
COMBI, menu 16
page
PRESENT OUTPUT SIGNAL DRIVE POSITION
DIAG COMBI
16(17)
DRIVE POSITION
RI XY
000229
LE XY
Description: Status for voltage feed to solenoid valve operating position.

Connection:
LE: digital out from D791-3/K1:42 to Y6053L
RI: digital out from D797-4/K1:42 to Y6053R
Function: 7.9.2.5 Valve block operating position
Signal value:
00
01

10
11

VDRF03.02GB
153
COMBI, menu 17
page
FORCE CONTROL (+/-), VALVE
"VALVE"
000230
DIAG COMBI
17(17)
FORCE CONTROL (+/-)
Description: Forced operation of the solenoid valves that control the

lifting jacks. Select solenoid valve with the +/- keys and activate the
valve with the Enter key.
0: no valve selected
1: Y6056L (knee out left front)
2: Y6057L (knee in left front)
3: Y6013L (jack down left front)
4: Y6060L (jack up left front)
5: Y6056R (knee out right front)
6: Y6057R (knee in right front)
7: Y6013R (jack down right front)
8: Y6060R (jack up right front)
9: Y6058L (knee out left rear)
10: Y6059L (knee in left rear)
11: Y6014K (jack down left rear)
12: Y6061L (jack up left rear)
13: Y6058R (knee out right rear)
14: Y6059R (knee in right rear)
15: Y6014R (jack down right rear)
16: Y6061R (jack up right rear)
17: Y6054L (clamp left)
18: Y6055L (clamp release left)
19: Y6054R (clamp right)
20: Y6055R (clamp release right)
Connection: Function: 7.9.2.3 Control valve lifting jacks
Signal value: -
VDRF03.02GB
154
8 Control system 8.4.11.2 SLIDING-CAB
8.4.11.2
SLIDING-CAB
SLIDING-CAB, menu 1
page
This group handles functions for hydraulic sliding cab and hydraulic
vertically adjustable cab. The menu texts are created for hydraulic sliding cab.
DIAGNOSIS EXTRA
COMBI SLIDING-CAB
SUPPORT-JACKS
EL-STEERING
000231
SWITCHES, FORWARD
Description: Signal from switch hydraulic sliding cab (forward) or
switch hydraulic vertically adjustable cab (up).
1(4)
X
X
X
Circuit diagram: Circuit Sliding/Vertically adjustable Cab group 9.10

000215
DIAG SLID-CAB
SWITCHES
FORWARD
REVERSE
OPENED DOORS

Function: 9.10.4 Sliding cab, 9.10.5 Vertically adjustable cab
Signal value:
1
No signal.
SWITCHES, REVERSE
Description: Signal from switch hydraulic sliding cab (backward) or
switch hydraulic vertically adjustable cab (down).
1(4)
X
X
X

000215
DIAG SLID-CAB
SWITCHES
FORWARD
REVERSE
OPENED DOORS

Function: 9.10.4 Sliding cab, 9.10.5 Vertically adjustable cab
Signal value:
1
No signal.
SWITCHES, OPENED DOORS

Description: Signal from door contacts, provided that the doors are
closed.
1(4)
X
X
X

000215
DIAG SLID-CAB
SWITCHES
FORWARD
REVERSE
OPENED DOORS
Connection: from S266-LE/2 or S266-RI/2 to digital in D790-1/K11:3

Signal value:
VDRF03.02GB
Input signal active. Door open.
No signal. Doors closed.
155
SLIDING-CAB, menu 2
page
PRESENT INPUT SIGNAL, LOW SPEED

Description: Signal from sensor damping end position, sliding cab or
vertically adjustable cab.
000232
DIAG SLID-CAB
2(4)
LOW SPEED
X
CAB DOWN
(LIFT) X
Connection: from B769-2/3 to digital in D790-1/K10:6

Function: 9.10.4.8 Sensor damping end position, 9.10.5.9 Sensor
damping end position
Signal value:
1
No signal.
PRESENT INPUT SIGNAL, CAB SPEED (LIFT)

Description: Signal from sensor lowered cab (vertically adjustable
cab).
000232
DIAG SLID-CAB
2(4)
LOW SPEED
X
CAB DOWN
(LIFT) X
Connection: from B777-2/3 to analogue in (used as digital) D797-O/

K1:21
Function: 9.10.5.8 Sensor lowered cab
Signal value:
1
No signal.
SLIDING-CAB, menu 3
page
OUTPUT FORWARD, REFERENCE

Description: Status for control current to control valve option, solenoid
valve sliding cab forward.
3(4)
XY
XXX
XXX

000233
DIAG SLID-CAB
OUTPUT FORWARD
REFERENCE
REQUIRED VALUE
FEEDBACK
Connection: digital out from D797-O/K1:2 to B6016/1

Function: 9.10.4.4 Control valve option frame
Signal value:
00
01

10
11

VDRF03.02GB
156
OUTPUT FORWARD, REQUIRED VALUE

Description: Reference value for control current to control valve option, solenoid valve sliding cab forward.
3(4)
XY
XXX
XXX

000233
DIAG SLID-CAB
OUTPUT FORWARD
REFERENCE
REQUIRED VALUE
FEEDBACK
Connection: output signal reference value out from D797-O/K1:16 to

Y6016/2
OUTPUT FORWARD, FEEDBACK

Description: Present control current to control valve option, solenoid
valve sliding cab forward.
3(4)
XY
XXX
XXX

000233
DIAG SLID-CAB
OUTPUT FORWARD
REFERENCE
REQUIRED VALUE
FEEDBACK
Connection: output signal actual value out from D797-O/K1:16 to

Y6016/2
Signal value: XXX = Measured value in mA.
SLIDING-CAB, menu 4
page
OUTPUT REVERSE, REFERENCE

Description: Status for control current to control valve option, solenoid
valve sliding cab backward.
4(4)
XY
XXX
XXX

000234
DIAG SLID-CAB
OUTPUT REVERSE
REFERENCE
REQUIRED VALUE
FEEDBACK

Signal value:
00
01

10
11

VDRF03.02GB
157
OUTPUT REVERSE, REQUIRED VALUE

Description: Reference value for control current to control valve option, solenoid valve sliding cab backward.
4(4)
XY
XXX
XXX

000234
DIAG SLID-CAB
OUTPUT REVERSE
REFERENCE
REQUIRED VALUE
FEEDBACK

Y6017/2
OUTPUT REVERSE, FEEDBACK

Description: Present control current to control valve option, solenoid
valve sliding cab backward.
4(4)
XY
XXX
XXX

000234
DIAG SLID-CAB
OUTPUT REVERSE
REFERENCE
REQUIRED VALUE
FEEDBACK
Connection: output signal actual value out from D797-O/K1:17 to

Y6017/2
Signal value: XXX = Measured value in mA.
VDRF03.02GB
158
8 Control system 8.4.11.3 SUPPORT-JACKS
8.4.11.3
SUPPORT-JACKS
SUPPORT-JACKS, menu 1
page
This group covers the support jacks functions.
DIAGNOSIS EXTRA
COMBI SLIDING-CAB
SUPPORT-JACKS
EL-STEERING
000235
SWITCHES, UP
Description: Signal from switch support jacks (up).
1(4)
X
X
Circuit diagram: Circuit Hyd support jacks group 7.10

000213
DIAG S-JACKS
SWITCHES
UP
DOWN
Function: 7.10.1 Support jacks

Signal value:
1
No signal.
SWITCHES, DOWN
Description: Signal from switch support jacks (down).
1(4)
X
X

000213
DIAG S-JACKS
SWITCHES
UP
DOWN

Signal value:
1
No signal.
page
PRESENT INPUT SIGNALS, UP

Description: Signal from sensor support jacks up.
DIAG S-JACKS
2(4)

Connection:
LE X
LE X
RI X
RI X
LE: from B7222L/A, to digital in D797-O/K1:13
000236
UP
DOWN
RI: from B7222R/A, to digital in D797-O/K1:27

Function: 7.10.1.5 Sensor support jacks up
Signal value:
VDRF03.02GB
No signal.
159
PRESENT INPUT SIGNALS, DOWN

Description: Signal from sensor support jacks down.
DIAG S-JACKS
2(4)
LE X
LE X
RI X
RI X
000236
Connection:
UP
DOWN
LE: from B7223L/A, to digital in D797-O/K1:20
RI: from B7223R/A, to digital in D797-O/K1:41
Function: 7.10.1.6 Sensor support jacks down

Signal value:
1
No signal.
page
OUTPUT VALVE S-J UP

Description: Voltage feed to control valve option frame, solenoid valve
support jacks up.
3(4)
XY
XY

000237
DIAG S-JACKS
OUTPUT VALVE
S-J UP
S-J DOWN

Signal value:
00
01

10
11

VDRF03.02GB
160
OUTPUT VALVE S-J DOWN

Description: Voltage feed to control valve option frame, solenoid valve
support jacks down.
3(4)
XY
XY

000237
DIAG S-JACKS
OUTPUT VALVE
S-J UP
S-J DOWN

Signal value:
00
01

10
11

page
INDICATION LAMP, DOWN
DOWN
Description: The status of voltage feed to indicator light support jacks

down.
4(4)
XY
000238
DIAG S-JACKS
INDICATOR LAMP

Signal value:
00
01

10
11

VDRF03.02GB
8 Control system 8.4.11.4 EL-STEERING
8.4.11.4
161
EL-STEERING
EL-STEERING, menu 1
page
This group handles functions for lever steering/mini-wheel steering.
DIAGNOSIS EXTRA
COMBI SLIDING-CAB
SUPPORT-JACKS
EL-STEERING
000239
PRESENT INPUT SIGNAL, SIGNAL 1

Description: Signal from mini-wheel (signal 1) or steering lever.
Circuit diagram: Circuit Steering lever/mini wheel group 5.2, Circuit
Steering lever/mini wheel and Combi att. group 5.2
001972
DIAG STEERING
1(5)
SIGNAL 1
X.XXV
SIGNAL 2
X.XXV
Connection:
Top lift attachment: signal from R825/H1 to digital in D790-1/K9:8
Combi attachment: signal from R825/H1 to digital in D790-3/
K1:21
Function: 5.2 Power assisted system
PRESENT INPUT SIGNAL, SIGNAL 2

Description: Signal from mini-wheel (signal 2). (Only applies to miniwheel)
001972
DIAG STEERING
1(5)
SIGNAL 1
X.XXV
SIGNAL 2
X.XXV
Connection:
Top lift attachment: signal from R825/H2 to digital in D790-1/K9:9
Combi attachment: signal from R825/H2 to digital in D790-3/
K1:22
EL-STEERING, menu 2
page
SWITCHES, ON/OFF
Description: Signal from switch mini-wheel/steering lever.
2(5)
X
X
X

000240
DIAG STEERING
SWITCHES
ON/OFF
FORWARD
REVERSE
Connection:
Top lift attachment: signal from S113/1 to digital in D790-1/K9:5
Combi attachment: signal from S113/1 to digital in D790-3/K1:27
Signal value:
1
No signal.
VDRF03.02GB
162
SWITCHES, FORWARD
Description: Signal from mini-wheel or steering lever (travel direction
selector forward).
2(5)
X
X
X

000240
DIAG STEERING
SWITCHES
ON/OFF
FORWARD
REVERSE
Connection:
Top lift attachment: signal from S160-2/1 to digital in D790-1/K9:4
Combi attachment: signal from S160-2/1 to digital in D790-3/
K1:20
Signal value:
1
No signal.
SWITCHES, REVERSE
Description: Signal from mini-wheel or steering lever (travel direction
selector reverse).
2(5)
X
X
X

000240
DIAG STEERING
SWITCHES
ON/OFF
FORWARD
REVERSE
Connection:
Top lift attachment: signal from S160-2/7 to digital in D790-1/K9:3
K1:13
Signal value:
VDRF03.02GB
No signal.
163
EL-STEERING, menu 3
page
PRESENT INPUT SIGNAL, HORN

Description: Signal from mini-wheel or steering lever (audible signal).
006882
DIAG S-JACKS
3(X)
HORN
X
STEER.WHEEL CUT OFF X
Connection:
Top lift attachment: signal from S149-2/1 to digital in D790-1/
K9:10
K1:41
Signal value:
1
No signal.
PRESENT INPUT SIGNAL, STEER.WHEEL CUT OFF

Description: Signal from sensor steering angle.
006882
DIAG S-JACKS
3(X)
HORN
X
STEER.WHEEL CUT OFF X
Connection: from B720/2 to digital in D790-2/K8:2

Function: 5.2.12 Sensor steering angle
Signal value:
1
No signal.
VDRF03.02GB
164
EL-STEERING, menu 4
page
OUTPUT STEERING LEFT, REFERENCE

Description: Status for control current to control valve option frame,
solenoid valve steering left.
000242
DIAG STEERING
4(5)
OUTPUT STEERING LEFT
REFERENCE
XY
REQUIRED VALUE
XXX
FEEDBACK
XXX

Y636L/1
Function: 5.2.10 Control valve option frame
Signal value:
00
01

10
11

OUTPUT STEERING LEFT, REQUIRED VALUE

Description: Reference value for control current to control valve option
frame, solenoid valve steering left.
000242
DIAG STEERING
4(5)
REFERENCE
XY
REQUIRED VALUE
XXX
FEEDBACK
XXX

Y636L/2
OUTPUT STEERING LEFT, FEEDBACK

Description: Present control current to control valve option frame, solenoid valve steering left.
000242
DIAG STEERING
4(5)
REFERENCE
XY
REQUIRED VALUE
XXX
FEEDBACK
XXX
Connection: output signal, reference value out from D797-0/K1:18 to

Y636L/2
VDRF03.02GB
165
EL-STEERING, menu 5
page
OUTPUT STEERING RIGHT, REFERENCE

Description: Status for control current to control valve option frame,
solenoid valve steering left.
000243
DIAG STEERING
5(5)
OUTPUT STEERING RIGHT
REFERENCE
XY
REQUIRED VALUE
XXX
FEEDBACK
XXX

Y636R/1
Signal value:
00
01

10
11

OUTPUT STEERING RIGHT, REQUIRED VALUE

Description: Reference value for control current to control valve option
frame, solenoid valve steering left.
000243
DIAG STEERING
5(5)
REFERENCE
XY
REQUIRED VALUE
XXX
FEEDBACK
XXX

Y636R/2
OUTPUT STEERING RIGHT, FEEDBACK

Description: Present control current to control valve option frame, solenoid valve steering left.
000243
DIAG STEERING
5(5)
REFERENCE
XY
REQUIRED VALUE
XXX
FEEDBACK
XXX

Y636R/2
VDRF03.02GB
166
8 Control system 8.4.13 RMI
8.4.13
RMI
RMI, description
page
This group covers RMI (Remote Machine Interface) function.

007442
DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA RMI
8.4.13.1
RMI, menu 1
MIU SW VER
page
DIAG RMI
1(3)
MIU SW VER XXXX.XXXX
MIU TIME
XXXX.XX.XX
Description: Software version in RMI interface.

007439
Circuit diagram: Connection: Function: 11.6.5 RMI (Remote Machine Interface)

Signal value: xxxx.xxxx = software number.
MIU TIME
page
DIAG RMI
1(3)
MIU SW VER XXXX.XXXX
MIU TIME
XXXX.XX.XX
Description: Date setting in RMI interface.

007439
Circuit diagram: Connection: Function: 11.6.5 RMI (Remote Machine Interface)

Signal value: xxxx.xx.xx = Date in format YYYY.MM.DD.
8.4.13.2
RMI, menu 2
SIGNAL QUALITY, GSM
page
Description: Signal strength of GSM signal through receiver in the RMI

interface.
007440
DIAG RMI
2(3)
SIGNAL QUALITY
GSM XXX
GPRS XXX
WLAN XXX
RADIO XXX
SMS XXX:UNS.DATA XXX
Circuit diagram: Circuit RMI group 8.2

Connection: Function: 11.6.5 RMI (Remote Machine Interface)
Signal value: XXX = 0-100 = Signal strength, 0-100%.
VDRF03.02GB
8 Control system 8.4.13.2 RMI, menu 2
167
SIGNAL QUALITY, GPRS
page
Description: Signal strength of GPRS signal through receiver in the

RMI interface.
007440
DIAG RMI
2(3)
SIGNAL QUALITY
GSM XXX
GPRS XXX
WLAN XXX
RADIO XXX

SIGNAL QUALITY, WLAN
page
Description: Signal strength of WLAN signal through receiver in the

RMI interface.
SIGNAL QUALITY, RADIO
page
Description: Signal strength of RADIO signal through receiver in the

RMI interface.
007440
DIAG RMI
2(3)
SIGNAL QUALITY
GSM XXX
GPRS XXX
WLAN XXX
RADIO XXX

SIGNAL QUALITY, SMS
page
Description: Signal strength of SMS signal through receiver in the RMI

interface.
007440
DIAG RMI
2(3)
SIGNAL QUALITY
GSM XXX
GPRS XXX
WLAN XXX
RADIO XXX

VDRF03.02GB
168
8 Control system 8.4.13.3 RMI, menu 3
SIGNAL QUALITY, UNS.DATA
page
Description: Amount of unsent data in line in transmitter part in the RMI

interface.
007440
DIAG RMI
2(3)
SIGNAL QUALITY
GSM XXX
GPRS XXX
WLAN XXX
RADIO XXX

Signal value: XXX = 0-100 = Data amount in percent of transmitter
buffer, 0-100%.
8.4.13.3
RMI, menu 3
ERROR
page
Description: Internal error code for the RMI interface

007441
DIAG RMI
3(3)
ERROR
XX.XX.XX.XX
ERR.VALID XX.XX.XX.XX
ACT.ERR. XX.XX.XX.XX
Connection:Function: 11.6.5 RMI (Remote Machine Interface)

Signal value: XX.XX.XX.XX = Error code
ERR.VALID
page

007441
DIAG RMI
3(3)
ERROR
XX.XX.XX.XX
Connection:Function: 11.6.5 RMI (Remote Machine Interface)

ACT.ERR
page

007441
DIAG RMI
3(3)
ERROR
XX.XX.XX.XX

VDRF03.02GB
8 Control system 8.5 Setup
8.5
169
Setup
Setup, general
page
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 done 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 change of control units, and in certain cases, service or
change of components. Calibration is performed so that certain functions shall function properly and show correct values.
8.5.1
Initiation
Initiation, description
page
9(10)
XXXmA
XXXmA
000058
INIT STEERING
START CURRENT
STEERING LEFT
STORED VALUE
PRESENT VALUE
D ANGER
Example of initiation menu, start current for lift function.

1.Menu group
2.Menu number (in brackets, total number of menus)
3.Values
4.Actual variable
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.
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 construction and use a common terminology explained here:
PRESENT
Displays the stored value when the menu is opened. Adjust the value
with the plus and minus keys. Save the set value with the Enter key.
Go to the next menu with the arrow keys. Go back with the R-key.
STORED
States the stored value for the current variable.
VDRF03.02GB
170
8 Control system 8.5.1 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, this controls how slowly a function can be operated. On functions with analogue control activation (variable), 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 triggered. 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 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.
Overview initiations
Function
Menu
1 Engine, speed limitation (limitation of engine speed
INIT DRIVE-TRAIN, menu 9 page 194
1 Engine, automatic shut-down on idling
INIT DRIVE-TRAIN, menu 11 page

194
2 Transmission, starting gear
2 Transmission, speed limit shifting forward - reverse
2 Transmission, engine speed limit shifting forward - reverse
2 Transmission, engine speed limit shifting neutral - gear
2 Transmission, engine speed limit kickdown to 1st
2 Transmission, speed limit declutch
2 Transmission, speed limitation (gear lock-out)

194
2 Transmission, automatic engine speed reduction for shift forward - reverse

195
5.2 Power assisted system (product option joystick control or mini-wheel), lever response
VDRF03.02GB
INIT STEERING, menu 1 page 186
171
Function
Menu
5.2 Power assisted system (product option joystick control or mini-wheel), speed
dependent

5.2 Power assisted system (product option joystick control or mini-wheel), steering
angle right
5.2 Power assisted system (product option joystick control or mini-wheel), steering
angle left
7.2 Lifting/lowering, boom up
INIT BOOM, menu 1 page 173

7.2 Lifting/lowering, boom down
Note: The current value is for unladen machines. When loaded, the current value is
controlled by the limited lowering speed.
7.2 Lifting/lowering, lift speed during operation
7.2 Lifting/lowering, damping at container (top lift)
INIT ATTACH, menu 15 page 182
7.2 Lifting/lowering, damping at container (bottom lift)
7.3 Extension, boom out

7.3 Extension, boom in
Note: The current value is for unladen machines. When loaded, the current value is
controlled by the limited lowering speed.
7.5 Spreading out

7.5 Spreading in

7.6 Rotation, clockwise

7.6 Rotation, anticlockwise

7.7 Tilt

7.8 Levelling

8.2.3 Load centre limitation
VDRF03.02GB
172
Function
Menu
8.2.4 Height limitation
9.10.4 Sliding cab, forward
INIT SLID-CAB, menu 1 page 183
9.10.5 Vertically adjustable cab, up

9.10.4 Sliding cab, backward
9.10.5 Vertically adjustable cab, down

Initiate hydraulic function, work instruction
page
To select a hydraulic function to initiate, proceed as follows:

All hydraulic functions are initiated the same way.
1 Navigate to the service menu.
000056
2 Press Enter.
3 Enter the code for initiation.

000060
1 23
4 5
The code determines which service menu is activated (Diagnostic test, Initiation or Calibration).
4 Select group by scrolling with the arrow keys (1 and 2) and confirm with Enter.
000057
INITIATION
BOOM ATTACHMENT
SLIDING-CAB STEERING
TIMES RETURN
NOTE
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 menus with the arrow keys (1 and 2).
5 Change the current value with the plus and minus keys.
INITIATION BOOM
1(8)
START CURRENT
LIFT
STORED VALUE
XXXmA
PRESENT VALUE
XXXmA
VDRF03.02GB
Current values can only be adjusted within specific limits.

6 Use the function key for Enter to store the desired current value
setting, "STORED".
000061
INITIATION BOOM
2(8)
END CURRENT
LIFT
STORED VALUE
XXXmA
PRESENT VALUE
XXXmA
NOTE
8 Control system 8.5.1.1 BOOM
8.5.1.1
173
BOOM
INIT BOOM
page
This function menu group handles initiation of the boom functions lift,
lower and extension.
BOOM ATTACHMENT
DRIVE-TRAIN
000651
INITIATION
D ANGER
The settings affect the functions lift, lower, and extension. Adjustment can impair functionality. If in doubt,
contact Cargotec Service.
NOTE
INIT BOOM, menu 1
page
START CURRENT, LIFT
1(11)
XXXmA
XXXmA
Description: Start current for activation of solenoid valve, lift (Y6005).
005042
INIT BOOM
START CURRENT
LIFT
STORED VALUE
PRESENT VALUE
PRESENT VALUE: Indicates the current value for the start current.
Adjust the value with the plus and minus keys. Save the set value with
the Enter key. Go to the next menu with the arrow keys. Exit initiation
with the R-key.
STORED VALUE: indicates stored value for start current.
Component: Solenoid valve, lift (Y6005)
Signal value: XXXmA = 0 - 999 mA
INIT BOOM, menu 2
page
END CURRENT, LIFT
2(11)
XXXmA
XXXmA
Description: Control current at full lever actuation for the activation of

the solenoid valve for lift (Y6005).
005043
INIT BOOM
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. Save the set value with the Enter key. Go to the next menu with the arrow keys. Exit initiation with the
R-key.
STORED VALUE indicates stored value for max. current.
Component: Solenoid valve, lift (Y6005)
VDRF03.02GB
174
INIT BOOM, menu 3
page
START CURRENT, LOWER
3(11)
XXXmA
XXXmA
Description: Start current for activation of solenoid valve, lower

(Y6004).
005044
INIT BOOM
START CURRENT
LOWER
STORED VALUE
PRESENT VALUE
with the R-key.
STORED VALUE indicates stored value for start current.
Component: Solenoid valve, lower (Y6004)
INIT BOOM, menu 4
page
END CURRENT, LOWER
4(11)
XXXmA
XXXmA

the solenoid valve for lower (Y6004).
005045
INIT BOOM
END CURRENT
LOWER
STORED VALUE
PRESENT VALUE
R-key.
Component: Solenoid valve, lower (Y6004)
INIT BOOM, menu 5
page
START CURRENT, BOOM OUT
5(11)
XXXmA
XXXmA
Description: Start current for activation of solenoid valve, boom out

(Y6006).
005046
INIT BOOM
START CURRENT
BOOM OUT
STORED VALUE
PRESENT VALUE
with the R-key.
Component: solenoid valve boom out (Y6006)
VDRF03.02GB
175
INIT BOOM, menu 6
page
END CURRENT, BOOM OUT
6(11)
XXXmA
XXXmA

the solenoid valve for boom out (Y6006).
005047
INIT BOOM
END CURRENT
BOOM OUT
STORED VALUE
PRESENT VALUE
R-key.
Component: solenoid valve boom out (Y6006)
INIT BOOM, menu 7
page
START CURRENT, BOOM IN
7(11)
XXXmA
XXXmA
Description: Start current for activation of solenoid valve, boom in

(Y6007).
005048
INIT BOOM
START CURRENT
BOOM IN
STORED VALUE
PRESENT VALUE
with the R-key.
Component: solenoid valve boom in (Y6007)
INIT BOOM, menu 8
page
END CURRENT, BOOM IN
8(11)
XXXmA
XXXmA

the solenoid valve for boom in (Y6007).
005049
INIT BOOM
END CURRENT
BOOM IN
STORED VALUE
PRESENT VALUE
R-key.
Component: solenoid valve boom in (Y6007)
VDRF03.02GB
176
INIT BOOM, menu 9
page
OUTPUT LIFT AT F/R

Description: Lift speed with gear engaged, as a percentage of max. lift
speed.
004930
INIT BOOM
9(11)
OUTPUT LIFT AT F/R
(PROC)
STORED VALUE
XXX
PRESENT VALUE
XXX
PRESENT VALUE: Indicates the current value for the lift speed. Adjust the value with the plus and minus keys. Save the set value with
with the R-key.
STORED VALUE: indicates stored value for lift speed.
Function: 7.2 Lifting/lowering
Component: Signal Value: XXX = lift speed as a percentage of max. value.
INIT BOOM, menu 10
page
OPTION LC-LIMIT
STORED VALUE
PRESENT VALUE
10(11)
XX.XX
XX.XX
004931
INIT BOOM
OPTION LC-LIMIT
Description: Limit value for load centre limitation in metres. Distance

from the drive axles centre.
NOTE
On machines with vertically adjustable cab, a load centre less
than the cabs frontmost point cannot be selected.
PRESENT VALUE: Indicates the current value for load centre. Adjust
R-key.
STORED VALUE indicates stored value for load centre.
Function: 8.2.3 Load centre limitation
Component: Signal Value: XX.XX = load centre limitation in metres.
INIT BOOM, menu 11
page
OPTION HEIGHT-LIMIT
STORED VALUE
PRESENT VALUE
XX.XX
XX.XX
004932
INIT BOOM
11(11)
OPTION HEIGHT-LIMIT
Description: Limit value for height limitation in metres. Distance to the
booms highest point.
PRESENT VALUE: Indicates the current value for height limitation.
with the R-key.
STORED VALUE indicates stored value for height limitation.
Function: 8.2.4 Height limitation
Component: Signal Value: XX.XX = height limitation in metres.
VDRF03.02GB
8 Control system 8.5.1.2 ATTACHMENT
8.5.1.2
177
ATTACHMENT
INIT ATTACH
page
This function handles initiation of the attachment functions rotation,

controllable tilt and controllable levelling.
BOOM ATTACHMENT
DRIVE-TRAIN
001157
INITIATION
D ANGER
The settings affect the functions rotation, controllable
tilt and controllable levelling. Adjustments can impair
functionality. Contact Cargotec Service in the event of
uncertainty.
NOTE
INIT ATTACH, menu 1
page
START CURRENT, ROTATION CW
1(14)
XXXmA
XXXmA
Description: Start current for activation of solenoid valve, rotation

clockwise (Y6008).
005091
INIT ATTACH
START CURRENT
ROTATION CW
STORED VALUE
PRESENT VALUE
with the R-key.
Component: Solenoid valve rotation clockwise (Y6008)
INIT ATTACH, menu 2
page
END CURRENT, ROTATION CW
2(14)
XXXmA
XXXmA

the solenoid valve for rotation anticlockwise (Y6009).
005092
INIT ATTACH
END CURRENT
ROTATION CW
STORED VALUE
PRESENT VALUE
R-key.
Component: Solenoid valve anticlockwise (Y6009)
VDRF03.02GB
178
INIT ATTACH, menu 3
page
START CURRENT, ROTATION CCW
3(14)
XXXmA
XXXmA
Description: Start current for activation of solenoid valve, rotation anticlockwise (Y6009).
005093
INIT ATTACH
START CURRENT
ROTATION CCW
STORED VALUE
PRESENT VALUE
with the R-key.
Component: Solenoid valve rotation anticlockwise (Y6009)
INIT ATTACH, menu 4
page
END CURRENT, ROTATION CCW
4(14)
XXXmA
XXXmA

the solenoid valve for rotation anticlockwise (Y6009).
005094
INIT ATTACH
END CURRENT
ROTATION CCW
STORED VALUE
PRESENT VALUE
R-key.
Component: Solenoid valve anticlockwise (Y6009)
INIT ATTACH, menu 5
page
START CURRENT, TILT
5(14)
XXXmA
XXXmA
Description: Start current for activation of solenoid valve for rotation tilt
in (Y6010) and solenoid valve for tilt out (Y6011).
005095
INIT ATTACH
START CURRENT
TILT
STORED VALUE
PRESENT VALUE
with the R-key.
Component: Solenoid valve rotation tilt in (Y6010), Solenoid valve tilt
out (Y6011)
VDRF03.02GB
179
INIT ATTACH, menu 6
page
END CURRENT, TILT
6(14)
XXXmA
XXXmA
005096
INIT ATTACH
END CURRENT
TILT
STORED VALUE
PRESENT VALUE
Description: Control current at full lever actuation for activation of solenoid valve for rotation tilt in (Y6010), and solenoid valve for tilt out
(Y6011).
R-key.
Component: Solenoid valve rotation tilt in (Y6010), Solenoid valve tilt
out (Y6011)
INIT ATTACH, menu 7
page
START CURRENT, LEVELLING
7(14)
XXXmA
XXXmA
Description: Start current of activation of solenoid valve for levelling

right (Y6035) and solenoid valve for levelling left (Y6036).
005097
INIT ATTACH
START CURRENT
LEVELING
STORED VALUE
PRESENT VALUE
with the R-key.
Component: Solenoid valve for levelling right (Y6035), Solenoid valve
for levelling left (Y6036)
INIT ATTACH, menu 8
page
END CURRENT, LEVELLING
8(14)
XXXmA
XXXmA
005098
INIT ATTACH
END CURRENT
LEVELING
STORED VALUE
PRESENT VALUE
Description: Control current at full lever actuation of activation of solenoid valve for levelling right (Y6035) and solenoid valve for levelling
left (Y6036).
R-key.
Component: Solenoid valve for levelling right (Y6035), Solenoid valve
for levelling left (Y6036)
VDRF03.02GB
180
INIT ATTACH, menu 9
page
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 (Y6018).
R-key.
I [mA]
1
2
t [s]
005517
Component: Solenoid valve for spreading out (6018)

Signal value: XXXmA = 0 - 999 mA.
1. Max. current (END CURRENT)

2. Damping (PROC DAMPING)
3. Start current (START CURRENT)
INIT ATTACH, menu 10
page
END CURRENT, SPREADER OUT 20'-40'
INIT ATTACH
10(X)
END CURRENT
STORED VALUE
XXXmA
PRESENT VALUE
XXXmA
Description: Control current at full lever actuation for activation of solenoid valve for spreading out (Y6018).
R-key.
I [mA]
1
2
t [s]
005518
Component: Solenoid valve for spreading out (Y6018)


page
DAMP (PROC), SPREADING, OUT 20'-40'
INIT ATTACH
11(X)
DAMP (PROC)
STORED VALUE
XX
PRESENT VALUE
XX
Description: Control current to solenoid valve for spreading out

(Y6018) during damping, when damping is approaching 40.
R-key.
I [mA]
1
STORED VALUE: indicates stored value in percent.
2
t [s]
VDRF03.02GB
005519
Component: Solenoid valve for spreading out (Y6018)

Signal value: XXX = 0 - 100%. 100% means no damping i.e. max. current. 0% means full damping i.e. start current
181
page
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 (Y6019).
R-key.
I [mA]
1
2
3
t [s]
005520

Component: Solenoid valve for spreading in (6019)
Signal value: XXXmA = 0 - 999 mA.

page
END CURRENT, SPREADER IN 40'-20'
INIT ATTACH
13(X)
END CURRENT
STORED VALUE
XXXmA
PRESENT VALUE
XXXmA
Description: Control current at full lever actuation for activation of solenoid valve for spreading in (Y6019).
R-key.
I [mA]
1
2
3
t [s]
005521

Component: Solenoid valve for spreading in (Y6019)

page
DAMP (PROC), SPREADING, IN 40'-20'
INIT ATTACH
14(X)
DAMP (PROC)
STORED VALUE
XX
PRESENT VALUE
XX
Description: Control current to solenoid valve for spreading in (Y6019)

during damping, when damping is approaching 20.
R-key.
I [mA]
1
STORED VALUE: indicates stored value in percent.
2
t [s]
005522
Component: Solenoid valve for spreading in (Y6019)

Signal value: XXX = 0 - 100%. 100% means no damping i.e. max. current. 0% means full damping i.e. start current
VDRF03.02GB
182
page
OPT DAMP BOOM DOWN, TOP LIFT (cm)

006756
INIT ATTACH
15(X)
OPT DAMP BOOM DOWN
TOP LIFT (cm)
STORED VALUE
XXXX
PRESENT VALUE
XXXX
Description: Distance setting for activation of damping of lowering

speed for top lift, the distance between the attachment and the container.
PRESENT VALUE: Indicates the current value for the distance. Adjust
R-key.
STORED VALUE: indicates stored value for the distance.
Function:
Component:
Signal value: XXXX = distance in cm.
page
006842
OPT DAMP DOWN, BOTTOM LIFT (cm)
INIT ATTACH
16(X)
OPT DAMP BOOM DOWN
BOTTOM LIFT (cm)
STORED VALUE
XXXX
PRESENT VALUE
XXXX
Description: Distance setting for activation of damping of lowering

speed for bottom lift, the distance between the attachment and the
trailer.
PRESENT VALUE: Indicates the current value for the distance. Adjust
R-key.
STORED VALUE: indicates stored value for the distance.
Function:
Component:
Signal value: XXXX = distance in cm
VDRF03.02GB
8.5.1.3
183
SLIDING-CAB
INIT SLIDING-CAB
page
This function handles the initiation of hydraulic sliding cab or cab hydraulic cab lift.
INITIATION
The sliding cab is smooth started by means of the control current to

the solenoid valves being increased from a low start value to a max.
level. When the cab reaches an end position the speed is dampened
by means of the control current being reduced.
001645
BOOM ATTACHMENT
DRIVE-TRAIN
D ANGER
The settings affect the function of the hydraulic sliding cab, vertically adjustable cab and tiltable cab. Adjustments can impair functionality. Contact Cargotec
Service in the event of uncertainty.
NOTE
INIT SLID-CAB, menu 1
page
START CURRENT, FORWARD
INIT SLID-CAB
START CURRENT
FORWARD
STORED VALUE
PRESENT VALUE
1(6)
Description: Start current to solenoid valve sliding cab forward

(Y6016) at activation of sliding cab. The control current controls the
start speed for sliding cab forward.
XXXmA
XXXmA
with the R-key.
3
t [s]
001698
I [mA]

Component: Solenoid valve sliding cab forward (Y6016)
VDRF03.02GB
184
page
END CURRENT, FORWARD
INIT SLID-CAB
END CURRENT
FORWARD
STORED VALUE
PRESENT VALUE
2(6)
Description: Control current to solenoid valve for sliding cab forward

(Y6016) after full ramp time at activation of switch for cab sliding. This
current controls maximum speed cab sliding speed forward.
XXXmA
XXXmA
R-key.
3
t [s]
001787
I [mA]


page
PROC DAMPING, FORWARD
INIT SLID-CAB
PROC DAMPING
FORWARD
STORED VALUE
PRESENT VALUE
3(6)
Description: Percentage damping of control current to solenoid valve

for sliding cab forward (Y6016) when the cab is at the end position for
forward.
XXXmA
XXXmA
PRESENT VALUE: Indicates the current value for damping. Adjust the
value with the plus and minus keys. Save the set value with the Enter
key. Go to the next menu with the arrow keys. Exit initiation with the Rkey.
3
t [s]
001850
I [mA]


Signal value: XXX = 0 - 100%. 100% means no damping, i.e. max. current. 0% means full damping, i.e., start current.
page
START CURRENT, REVERSE
INIT SLID-CAB
START CURRENT
REVERSE
STORED VALUE
PRESENT VALUE
4(6)
Description: Start current to solenoid valve sliding cab backward

(Y6016) at activation of sliding cab. The control current controls the
start speed for sliding cab backward.
XXXmA
XXXmA
with the R-key.
3
t [s]
VDRF03.02GB
003001
I [mA]

Component: Solenoid valve sliding cab backward (Y6017)
185
page
END CURRENT, REVERSE
INIT SLID-CAB
END CURRENT
REVERSE
STORED VALUE
PRESENT VALUE
5(6)
Description: Control current to solenoid valve for sliding cab backward

(Y6017) after full ramp time at activation of switch for cab sliding. This
current controls maximum speed cab sliding speed backward.
XXXmA
XXXmA
R-key.
3
t [s]
003022
I [mA]


page
PROC DAMPING, REVERSE
INIT SLID-CAB
PROC DAMPING
REVERSE
STORED VALUE
PRESENT VALUE
6(6)
Description: Percentage damping of control current to solenoid valve

for sliding cab backward (Y6017) when the cab is at the end position
for backward.
XXXmA
XXXmA
PRESENT VALUE: Indicates the current value for damping. Adjust the
value with the plus and minus keys. Save the set value with the Enter
key. Go to the next menu with the arrow keys. Exit initiation with the Rkey.
3
t [s]
003093
I [mA]

Signal value: XXX = 0 - 100%. 100% means no damping, i.e. max. current. 0% means full damping, i.e., start current.
VDRF03.02GB
186
8 Control system 8.5.1.4 STEERING
8.5.1.4
STEERING
INIT STEERING
page
This function covers initiation of lever steering or mini-wheel.
INITIATION
D ANGER
002954
BOOM ATTACHMENT
DRIVE-TRAIN
The settings affect the functions joystick control or

mini-wheel. Adjustment can impair functionality. If in
doubt, contact Cargotec Service.
NOTE
INIT STEERING, menu 1
page
CHARACTER OF THE STEERING LEVER
INIT STEERING
1(10)
CHARACTER OF THE
STEERING LEVER, 0-31
STORED VALUE
XX
PRESENT VALUE
XX
U [V]
Description: Indicates the responsiveness of the steering lever in accordance with 32 predefined curves (0-31) 0 means that linear wheel
angle is uniform in relation to lever angle during the whole lever movement. 31 means that the wheel angle is small at the beginning of the
lever movement and large at the end.
PRESENT VALUE: Indicates the current curve. Change the curve with
the plus and minus keys. Save the set curve with the Enter key. Go to
the next menu with the arrow keys. Exit initiation with the R-key.
31
U = Output signal to solenoid valve

X = Lever movement
VDRF03.02GB
003130
STORED VALUE: indicates saved curve.

Function: 5.2 Power assisted system (product option joystick control
or mini-wheel)
Component: Signal value: XX = 0-31.
187
page
BREAK POINT BP1
INIT STEERING
BRAKE POINT BP1
(kph)
STORED VALUE
PRESENT VALUE
2(10)
Description: Speed for break point 1. Break points are used to adapt
the steering angle to the machines speed. This enables both sensitive
steering at low speeds and stable steering at higher speeds.
XX.X
XX.X
PRESENT VALUE: indicates present speed setting for break point 1.

Change speed with plus or minus keys. Save set speed with the Enterkey. Go to the next menu with arrow keys. Exit initiation with the R-key.
I [mA]
100%
STORED VALUE: indicates saved speed for break point 1.
% BP2
% BP3
V [kph]
BP1
BP2
BP3
003131

or mini-wheel)
I [mA] = control current to solenoid valve

V [kph] = machine speed in km/h
BP1 = speed setting for break point 1
%BP2 = percent of control current to solenoid valve at
BP2
BP3
Component: Signal value: XX.X = speed for BP1 in km/h.
page
BREAK POINT BP2
INIT STEERING
BRAKE POINT BP2
(kph)
STORED VALUE
PRESENT VALUE
3(10)
XX.X
XX.X

Change speed with plus or minus keys. Save set speed with the Enterkey. Go to the next menu with arrow keys. Exit initiation with the R-key.
I [mA]
100%
% BP2
% BP3
V [kph]
BP1
BP2
BP3
003132

or mini-wheel)

BP2
BP3
VDRF03.02GB
188
page
BREAK POINT BP3
INIT STEERING
BRAKE POINT BP3
(kph)
STORED VALUE
PRESENT VALUE
4(10)
XX.X
XX.X

Change speed with plus or minus keys. Save set speed with the Enter
key. Go to the next menu with arrow keys. Exit initiation with the R-key.
I [mA]
100%
% BP2
% BP3
V [kph]
BP1
BP2
BP3
003133

or mini-wheel)

BP2
BP3
page
PROC REDUCTION, AT PB2
INIT STEERING
PROC REDUCTION
AT BP2
STORED VALUE
PRESENT VALUE
5(10)
Description: Percentage reduction of control current to solenoid valve

for steering right (Y636R) and solenoid valve for steering left (Y636L)
at BP2.
XXX
XXX
PRESENT VALUE: Indicates the current value for the reduction. Adjust the value with the plus and minus keys. Save the set value with
with the R-key.
I [mA]
100%
% BP2
% BP3
V [kph]
BP1
BP2
BP3
003134
STORED VALUE: indicates stored value for the reduction.

BP2
BP3
VDRF03.02GB

or mini-wheel)
Component: Signal value: XXX = 0 - 100%. 100% means no damping, i.e. max. current. 0% means full damping, i.e., start current.
189
page
PROC REDUCTION, AT PB3
INIT STEERING
PROC REDUCTION
AT BP3
STORED VALUE
PRESENT VALUE
6(10)
Description: Percentage reduction of control current to solenoid valve

for steering right (Y636R) and solenoid valve for steering left (Y636L)
at BP3.
XXX
XXX
PRESENT VALUE: Indicates the current value for the reduction. Adjust the value with the plus and minus keys. Save the set value with
with the R-key.
I [mA]
100%
% BP2
% BP3
V [kph]
BP1
BP2
BP3
003135
STORED VALUE: indicates stored value for the reduction.

BP2
BP3

or mini-wheel)
Component: Signal value: XXX = 0 - 100%. 100% means no damping, i.e. max. current. 0% means full damping, i.e., start current.
page
START CURRENT, STEERING RIGHT
7(10)
XXXmA
XXXmA
Description: Start current to the solenoid valve for steering right

(Y636R).
003136
INIT STEERING
START CURRENT
STEERING RIGHT
STORED VALUE
PRESENT VALUE
with the R key.
Function: 5.2.10 Control valve, lever steering/mini wheel
Component: Solenoid valve for steering right (Y636R)
page
END CURRENT, STEERING RIGHT
8(10)
XXXmA
XXXmA
Description: Control current to the solenoid valve for steering right

(Y636R) at lever end position.
003137
INIT STEERING
END CURRENT
STEERING RIGHT
STORED VALUE
PRESENT VALUE
R key.
Component: Solenoid valve for steering right (Y636R)
VDRF03.02GB
190
page
START CURRENT, STEERING LEFT
9(10)
XXXmA
XXXmA
Description: Start current to the solenoid valve for steering left

(Y636L).
003138
INIT STEERING
START CURRENT
STEERING LEFT
STORED VALUE
PRESENT VALUE
with the R-key.
Component: Solenoid valve for steering left (Y636L)
page
END CURRENT, STEERING LEFT
10(10)
XXXmA
XXXmA
Description: Control current to the solenoid valve for steering left

(Y636L) at lever end position.
006704
INIT STEERING
END CURRENT
STEERING LEFT
STORED VALUE
PRESENT VALUE
R-key.
Component: Solenoid valve for steering left (Y636L)
VDRF03.02GB
8 Control system 8.5.1.5 DRIVETRAIN
8.5.1.5
191
DRIVETRAIN
INIT DRIVE-TRAIN
page
This function handles initialisation of the transmission.
INITIATION
NOTE
003140
BOOM ATTACHMENT
DRIVE-TRAIN

The machine must be stationary with applied parking brake to enable access to the menus.
After changes have been made, the ignition must be turned off
and on for the changes to be saved and start to apply.
INIT DRIVE-TRAIN, menu 1
page
START IN 2ND
1(6)
XXX
XXX
Description: Setting to get transmission to start in 2nd gear instead of

in 1st. Kick-down to 1st takes place as needed.
003151
INIT DRIVE-TRN
START IN 2:ND
0=NO 1=YES
STORED VALUE
PRESENT VALUE
PRESENT VALUE: Indicates the current setting. Change the value

Go to the next menu with the arrow keys. Exit initiation with the R-key.
STORED VALUE: indicates saved setting.
Component: Signal value: XXX = 1= yes, XXX = 0 = no
page
VEHICLE SPEED F-R
INIT DRIVE-TRN
2(12)
VEHICLE SPEED F-R
XXX
XXX
005051
STORED VALUE
PRESENT VALUE
Description: Setting of highest permitted speed for shifting between

forward and reverse.
Component: Signal value: XXX = speed in km/h
VDRF03.02GB
192
page
ENGINE SPEED F-R
3(12)
STORED VALUE
PRESENT VALUE
XXX
XXX
Description: Setting of highest permitted engine speed for shifting between forward and reverse.
005052
INIT DRIVE-TRN
ENGINE SPEED F-R
NOTE
If the rpm is set lower than the engines idle rpm, shifting will not
be allowed.
Component: Signal value: XXX = engine speed (rpm)
page
ENGINE SPEED N-DIR
INIT DRIVE-TRN
4(12)
ENGINE SPEED N-DIR
XXX
XXX
005053
STORED VALUE
PRESENT VALUE
Description: Setting of highest permitted engine speed for shifting from

neutral position to gear.
NOTE
This setting takes priority over the setting in INIT DRIVE-TRAIN,
menu 3 page 192. If the engine speed is set lower in this menu
that in menu 3, this engine speed will also apply to switching direction of travel. This occurs because the transmission must shift
into neutral when changing direction of travel.
Component: Signal value: XXX = engine speed (rpm)
VDRF03.02GB
193
page
ENGINE SPEED, KICKDOWN 1ST
5(12)
XXX
XXX
Description: Setting of the lowest engine rpm when conditions for kickdown to 1st gear are to be checked.
005054
INIT DRIVE-TRN
ENGINE SPEED
KICK DOWN 1:ST
STORED VALUE
PRESENT VALUE
NOTE
If the rpm is set too low, kick-down may take place before the machine has used the engagement on the selected gear.
If the rpm is set too high, kick-down takes place slowly or not at
all.
Component: Signal value: XXX = speed (km/h)
page
VEHICLE SPEED, DECLUTCH
6(12)
XXX
XXX
Description: Setting of highest permitted speed for disengaging the

transmission.
005055
INIT DRIVE-TRN
VEHICLE SPEED
DECLUTCH
STORED VALUE
PRESENT VALUE

page

Not used.
page

Not used.
VDRF03.02GB
194
page
OPTION SPEED LIMIT
Description: Setting of speed limitation.

004935
INIT DRIVE-TRN
9(12)
OPTION SPEED LIMIT
(KM/H)
STORED VALUE
XXX
PRESENT VALUE
XXX

page
004936
OPTION HIGHEST GEAR AT SPEED LIMIT
INIT DRIVE-TRN
10(12)
OPTION HIGHETS GEAR
AT SPEED LIMIT
STORED VALUE
XXX
PRESENT VALUE
XXX
Description: Setting of highest permissible gear (speed limitation

through blocked gears).
Component: Signal value: XXX = gear
page
OPTION ENGINE SHUT DOWN
Description: Setting of idle time prior to automatic engine shutdown

004937
INIT DRIVE-TRN
11(12)
OPTION ENGINE SHUT
DOWN AT IDLE (sec)
STORED VALUE
XXX
PRESENT VALUE
XXX

Function: 1 Engine
Component: Signal value: XXX = time in seconds before engine shutdown.
VDRF03.02GB
195
page
004938
F-R WITHOUT ENGINE SPEED REDUCTION
INIT DRIVE-TRN
12(12)
F-R WITHOUT ENGINE
SPEED REDUCTION
STORED VALUE
XXX
PRESENT VALUE
XXX
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 192). If no value is set in menu 3, engine
speed goes to idle speed.
Component: Signal value:
X = 1, activated
X = 0, deactivated
VDRF03.02GB
196
8 Control system 8.5.2 Calibration
8.5.2
Calibration
Calibration, description
page
Certain functions require calibration in order to operate correctly. The

control system has integrated calibrations for these functions.
SCALE
This menu handles calibration of sensors to weight indication.
SCALE STEERING
DRIVE-TRAIN RETURN
000062
CALIBRATION
There are two variants of weight indicator, fixed or dynamic scale, see
section 7 Load handling , group 7.10.2 Weight indicator. The current
option on the machine is programmed and does not need selection,
see:
Weight indicator, calibration (product alternative fixed scale) (only

model year -2008) page 198
Weight indicator, calibration (product alternative dynamic scale) page
200
EL-STEERING
This menu handles calibration of the steering lever for lever steering,
see:
SCALE STEERING
DRIVE-TRAIN RETURN
Lever steering, calibration page 202

000074
CALIBRATION
NOTE
Calibration does not need to be performed in one process but
each step can be performed separately, independently of other
steps.
DRIVETRAIN
This function handles calibrations for engine and transmission. The
menu loop contains two different calibrations which are not connected
to each other, see:
CALIBRATION
Accelerator pedal, calibration page 203

000078
SCALE STEERING
DRIVE-TRAIN RETURN
Section 2 Transmission, group 2.8 Control system transmission
NOTE
steps.
VDRF03.02GB
8 Control system 8.5.2 Calibration
197
Calibration menu, explanation

The figure shows an example of a menu, here for calibrating the boom
extension inner position. The table indicates what a description contains (which follows in the next section):
CALIBR SCALE
3(7)
BOOM FULLY RETRACTED
STORED VALUE
PRESENT VALUE
X.XXV
X.XXV
000063
1. Menu group
2.Sequence number (the total number of sequences is
indicated in brackets)
3.Signal value
4.STORED indicates stored value, PRESENT indicates current value of the signal to be calibrated
5. Heading of menu figure
Designation: Example
Description
Variable (position 4): BOOM

FULLY RETRACTED
Name of the affected input signal/control signal.
Description: Setting sensor

boom length (R777) for boom extension in the innermost position.
A short description of what is

calibrated and the meaning of
the variables.
CALIBR VALUE: Indicates

stored signal value from boom
length (R777) for boom extension in the innermost position.
PRESENT VALUE: Indicates the
current signal value from sensor
boom length (R777).
Function: 7.3.11 Sensor, boom
length
Name of current function.
Component: Sensor, boom angle (R777)
Indicates the component

whose signal is the basis for
calibration.
Calibration, work instructions
page
Calibration consists of a number of menus (the number of menus depends on the function). All menus are similar in construction and therefore the descriptions are similar.
To select a function to calibrate, proceed as follows:
1 Navigate to the service menu.
000056
2 Press Enter.
3 State code for calibration.

000060
1 23
4 5
4 Select group by scrolling with the arrow keys (1 and 2) and confirm with Enter.
000062
CALIBRATION
SCALE STEERING
DRIVE-TRAIN RETURN
NOTE
Each calibration consists of a sequence of a number of menus.

The first menu for the selected calibration appears in the display.
Select the next menu with key 1 and 2 (arrow function).
VDRF03.02GB
198
8 Control system 8.5.2.1 Calibrate SCALE
8.5.2.1
Calibrate SCALE
Weight indicator, calibration (product alternative fixed

scale) (only model year -2008)
page
NOTE
It is very important for accuracy that all steps are performed in the
given order.
1 Park the machine on level ground without load and centre the attachment.
000056
2 Navigate to the service menu and press ENTER.

000060
1 23
4 5
NOTE
4 Scroll to SCALE with the arrow keys and press ENTER.
CALIBRATION
000062
SCALE STEERING
DRIVE-TRAIN RETURN
Every calibration consists of a sequence of menus. Scroll between the menus with the arrow keys.
5 Lower the boom to the lowest position (0).
CALIBR SCALE
1(X)
MINIMUM BOOM ANGLE
X.XXV
X.XXV
006798
CALIBR VALUE
PRESENT VALUE
6 CALIBR SCALE, menu 1 save the setting with ENTER.
7 Lift the boom to its highest angle.
CALIBR SCALE
2(x)
MAXIMUM BOOM ANGLE
X.XXV
X.XXV
006799
CALIBR VALUE
PRESENT VALUE
8 Scroll to CALIBR SCALE, menu 2 and save the setting with ENTER.
9 Scroll to CALIBR SCALE, menu 8.

10 Move the boom into measuring position, see section 7 Load handling, group 7.10.2 Weight indicator.
006805
CALIBR SCALE
8(X)
BOOM IN MEAS. POS X X
WITHOUT LOAD
LE XX.XV
RI XX.XV
STORED SUM
XX.XV
"BOOM IN MEAS. POS" should show " '1' '1' ", this indicates that
measuring position has been achieved for " 'Extension' 'Lift' ".
11 Wait approximately five seconds to stabilise the pressure.
VDRF03.02GB
199
12 Save the setting with ENTER.
NOTE
New values can only be saved when the boom is in the
measuring position.
Negative values indicate shifted contacts on the pressure
sensors.
Large variations between the right and left indicate errors in
sensor signals.
14 Lifting a known reference load and move the boom into measuring position.
006806
CALIBR SCALE
9(X)
BOOM IN MEAS. POS X X
WITH LOAD
XX.XT
LE XX.XV
RI XX.XV
STORED SUM
XX.XV
"BOOM IN MEAS. POS" should show " '1' '1' ", this indicates that
measuring position has been achieved for " 'Extension' 'Lift' ".
16 Enter the weight of the reference load with the + and - keys. Save
the setting with ENTER.
NOTE
New values can only be saved when the boom is in the
measuring position.
I M P OR TA NT
Check that the correct weight for the reference load is
shown in the menu before the setting is saved. Incorrectly input weight means that the scale indicates incorrectly.
Checking calibration
LOAD
10(X)
XX.XT
18 Lift a reference weight and check that the control system calculates the correct weight of the load that the machine is lifting,
LOAD.
006806
CALIBR SCALE
PRESS BUTTON
The weight shown in tonnes to one decimal place.

If the weight is not correct, repeat steps 13-16.
19 Operate the machine without a load, stop the machine and check
that LOAD = 00.0 0.5 tonnes.
NOTE
Check when stationary. (Operating generates dynamic forces.)
20 Back out of calibration with the R-key.
VDRF03.02GB
200
Weight indicator, calibration (product alternative dynamic

scale)
page
NOTE
It is very important for accuracy that all steps are performed in the
given order.
1 Warm the hydraulic oil to operating temperature, min. 40 C.
2 Park the machine on level ground without load and centre the attachment.
000056
3 Navigate to the service menu and press ENTER.

000060
1 23
4 5
NOTE
5 Scroll to SCALE with the arrow keys and press ENTER.
CALIBRATION
000062
SCALE STEERING
DRIVE-TRAIN RETURN
Every calibration consists of a sequence of menus. Scroll between the menus with the arrow keys.
NOTE
Some options, such as height limitation and load centre limitation, mean that bypass must be used to reach the booms
end positions.
6 CALIBR SCALE, menu 1.
CALIBR SCALE
1(X)
MINIMUM BOOM ANGLE
7 Lower the boom to the lowest position (0).
X.XXV
X.XXV
011329
8 Save the setting with ENTER
STORED VALUE
PRESENT VALUE
CALIBR SCALE
2(x)
MAXIMUM BOOM ANGLE
10 Lift the boom to its highest angle.
X.XXV
X.XXV
011330
STORED VALUE
PRESENT VALUE
CALIBR SCALE
3(X)
BOOM FULLY RETRACTED
13 Retract the boom completely.
VDRF03.02GB
X.XXV
X.XXV
011331
STORED VALUE
PRESENT VALUE
201
CALIBR SCALE
4(X)
BOOM FULLY EXTENDED
16 Extend the boom completely.
X.XXV
X.XXV
011332
STORED VALUE
PRESENT VALUE

19 Retract the boom completely.
20 Lower the boom and inch towards the end until 2-4 cm remains
on the lift cylinders.
011333
CALIBR SCALE
5(X)
LOAD SENSOR BOOM
RETRACTED
LE
RI
STORED
XXXX XXXX
PRESENT
XXXX XXXX

24 Extend the boom completely.
26 Check that "LOAD SENSOR BOOM" is set to 0 t. If not, adjust
with the minus key to 0 t and save the setting with ENTER.
010454
CALIBR SCALE
6(X)
LOAD SENSOR BOOM
0t
EXTENDED
LE
RI
CALIBR
XXXX XXXX
PRESENT
XXXX XXXX
I M P OR TA NT
Check that the correct weight is shown in the menu
before the setting is saved. Incorrectly input weight
means that the scale indicates incorrectly.
Checking calibration
28 Lift a reference load and check that the control system calculates
the correct weight of the load that the machine is lifting.
PRESENT LOAD = Reference load 500 kg. Weight is given in
kg.
If the weight is not correct, repeat the calibration.
29 Operate the machine without a load, stop the machine and check
that PRESENT LOAD = 00000 500 kg.
Check in various ranges, as illustrated. The boom must not reach
the end positions during checking.
NOTE
010455
7(X)
XXXXXKg
XXXXXKg
XXXXXKg
XXX.XXm
006804
CALIBR SCALE
ALLOWED LOAD
PRESENT LOAD
LOAD STR.AXLE
LOAD-CENTER
Check when stationary. (Operating generates dynamic forces.)

30 Back out of calibration with the R-key. When the code menu appears, press Enter.
VDRF03.02GB
202
8 Control system 8.5.2.2 Calibrate STEERING
8.5.2.2
Calibrate STEERING
Lever steering, calibration
page
NOTE
steps.
1 Start key in operating position.
CALIBR STEERING, menu 1

2 Go into the calibration menus and select CALIBR STEERING,
menu 1, see Calibration, work instructions page 197
STEERING LEVER CENTRE POSITION
000075
CALIBR STEERING
1(3)
STEERING LEVER CENTER
POSITION
CALIBR VALUE
X.XXV
PRESENT VALUE
X.XXV
Description: Setting the centre position of the lever steering control (R825).
PRESENT VALUE: indicates current signal value from lever
steering control (R825).
STORED VALUE: indicates stored signal value from lever steering control (R825).
Component: Lever steering control (R825)
Function: 5.1.3 Joystick
3 Move steering lever to required centre position.
4 Store the position with function key for Enter.

5 Select CALIBR STEERING, menu 2.
STEERING LEVER LEFT POSITION
000076
CALIBR STEERING
2(3)
STEERING LEVER LEFT
POSITION
CALIBR VALUE
X.XXV
PRESENT VALUE
X.XXV
Description: Setting of position for max. angle left on lever steering control (R825).
6 Move steering lever to required position for max. angle left.
VDRF03.02GB
8 Control system 8.5.2.3 Calibrate DRIVETRAIN
203

8 STEERING LEVER RIGHT POSITION
Description: Setting for position for max. angle right on lever
000077
CALIBR STEERING
3(3)
STEERING LEVER RIGHT
POSITION
CALIBR VALUE
X.XXV
PRESENT VALUE
X.XXV

9 Move steering lever to required position for max. angle right.
8.5.2.3
Calibrate DRIVETRAIN
Accelerator pedal, calibration
page
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 197
ACCELERATOR, RELEASE THE PEDAL
000079
CALIBR DRIVE-TRN 1(4)

ACCELERATOR,
RELEASE THE PEDAL
CALIBR VALUE
X.XXV
PRESENT VALUE
X.XXV
Description: setting accelerators pedal zero position.

CALIBR VALUE: Indicates current calibrated control value from
Accelerator pedal (R690).
PRESENT VALUE: Indicates present signal value from Accelerator pedal (R690).
Function: 1.1.2 Accelerator pedal
Component: Accelerator pedal (R690).
3 Release the accelerator pedal.
DRIVE-TRAIN, menu 2
5 ACCELERATOR, THE PEDAL TO FLOOR
Description: Setting of full-throttle position of Accelerator pedal
(R690).
000080

ACCELERATOR,
THE PEDAL TO FLOOR
CALIBR VALUE
X.XXV
PRESENT VALUE
X.XXV
CALIBR VALUE: Indicates current calibrated control value from

Accelerator pedal (R690).
PRESENT VALUE: Indicates present signal value from Accelerator pedal (R690).
Function: 1.1.2 Accelerator pedal
Component: Accelerator pedal (R690).
6 Depress the accelerator pedal fully and keep it down until the position is stored.
VDRF03.02GB
204
Transmission, calibration
page
D ANGER
Do not leave the machine during calibration. The machine may start to move.
1 Park the machine on level ground, engage neutral position and

apply the parking brake. Run the engine at idling speed.
000056
2 To select the function to calibrate, first navigate to the service

menu. Then press Enter.

000060
1 23
4 5
The code determines which service menu shall be activated

(Diagnostics, Initiation or Calibration).
4 Select group by scrolling with the arrow keys (1 and 2) and confirm DRIVE-TRAIN with Enter.
SCALE STEERING
DRIVE-TRAIN RETURN
000062
CALIBRATION
5 Scroll with the arrow keys (1 and 2) and select DRIVE-TRAIN,

menu 4.
4(4)
X
XXX
XXX
6 Check that the oil temperature is at least 61 C.

000082
CALIBR DRIVE-TRN
GEARBOX WARM UP
MODE
ACTUAL TEMP
TARGET TEMP
NOTE
If the oil temperature is too low then go to DRIVE-TRAIN, menu 4.

A. Apply the footbrake so that the machine is stationary.
B. Select travel direction forward and apply full throttle for 20
seconds.
C. Engage neutral position, apply full throttle for 10 seconds
and then run the engine at idling speed.
D. Repeat steps B and C until the oil is hot.
The engine speed may be reduced towards the end of heating as
the oil from the gearbox is too hot. If this occurs, maintain neutral
position and maintain an engine speed of 1200 rpm for 20 seconds.
When the temperature is correct, MODE changes from 0 to 1.
VDRF03.02GB
205
7 Select DRIVE-TRAIN, menu 3.

GEARBOX TUNING
Description: Calibration of transmission couplings.
000081

CLUTCH TUNING
PHASE
X
SUB-PH X
CLUTCH X
STATUS X
ACTION X
XXXXrpm
PHASE:
Indicates current phase in the calibration.

0. Pre-filling of clutch
1. Calibration of clutch
4. Calibration complete
5. Calibration incorrect
6. Calibration paused
CLUTCH:
Indicates which clutch shall be calibrated.

F. Clutch forward
R. Clutch reverse
1. Clutch gear 1
2. Clutch gear 2
3. Clutch gear 3
4. Clutch gear 4
ACTION:
Indicates action from mechanics (in the event of a

fault)
0. No action (normal condition if no malfunction).
1. Increase throttle application.
2. Reduce throttle application.
3. Select neutral position.
4. Select travel direction forward.
5. Stop the vehicle (depress the brake if the machine
starts to move).
6. Heat the transmission, see step 4.
7. No action; the engine is controlled via Control unit,
transmission.
8. Keep the accelerator pedal in its current position.
9. Check error codes.
10. Apply the parking brake.
SUB-PH:
Internal value for sub-phase 1 or 0.
STATUS:
Calibration status.
0. Calibration not in progress.
3. Calibration in progress
8 Check that the gear selector is in neutral position.

9 Start calibration by pressing Enter.
VDRF03.02GB
206
10 Calibration starts (takes approx. 15 minutes) and engine speed is

raised to approx. 770 rpm.
The transmission will activate different gears during calibration.
NOTE
If the machine starts to move during calibration, use the footbrake to keep the machine stationary.
I M P OR TA NT
Calibration can be interrupted at any time by selecting
travel direction reverse.
11 When the engine speed decreases to idling and PHASE = 4 then

calibration is complete.
12 Switch off the ignition to store the values.
VDRF03.02GB
Table of Contents 9 Frame, body, cab and accessories

mm mm mm mm mm mm
9
Frame, body, cab and accessories............................................................... 5
9.1
9.1.1
Gear selector and multi-function lever ................................................. 12
9.1.22
Switch, direction indicators .................................................................. 13
9.2
Safety and emergency equipment ............................................................ 14
9.2.1
Safety switch ........................................................................................ 14
9.2.2
Seat belt ............................................................................................... 14
9.2.3
Fire extinguisher .................................................................................. 14
9.2.4
Buzzer .................................................................................................. 14
9.3
Seat .......................................................................................................... 15
9.3.1
Seat cushion ........................................................................................ 19
9.3.2
Back cushion ....................................................................................... 19
9.3.3
Electric heater ...................................................................................... 20
9.3.4
Shock absorbers .................................................................................. 21
9.3.5
Air suspension ..................................................................................... 21
9.3.6
Mechanical seat adjustment ................................................................ 22
9.3.7
Passenger seat .................................................................................... 22
9.3.8
Armrest ................................................................................................ 22
9.3.9
Sensor operator in seat ....................................................................... 23
9.4
Heating, ventilation and air conditioning ................................................... 24
9.4.1
Fresh air filter ....................................................................................... 32
9.4.2
Fresh air and recirculation damper ...................................................... 33
9.4.3
Cab fan ................................................................................................ 36
9.4.4
Heat exchanger heat ........................................................................... 39
9.4.5
Water valve .......................................................................................... 42
9.4.6
Engine temperature sensor ................................................................. 43
9.4.7
Compressor ......................................................................................... 43
9.4.8
Condenser ........................................................................................... 46
9.4.9
Moisture filter ....................................................................................... 48
9.4.10
Pressure switch ................................................................................... 48
9.4.11
Expansion valve ................................................................................... 49
9.4.12
Sensor temperature refrigerant ............................................................ 51
9.4.13
Heat exchanger cooling ....................................................................... 52
9.4.14
Air distributor ........................................................................................ 53
9.4.15
Air vents ............................................................................................... 54
9.4.16
Sensor temperature outlet fan ............................................................. 55
9.4.17
Sensor cab temperature ...................................................................... 56
9.4.18
Sensor outdoor temperature ................................................................ 57
9.5
Wiper/washer system ............................................................................... 58
9.5.1
Wiper front ........................................................................................... 58
9.5.2
Wiper roof ............................................................................................ 58
9.5.3
Wiper rear ............................................................................................ 58
9.5.4
Washer motor and reservoir ................................................................ 58
9.5.5
Wiper motor, front ................................................................................ 59
VDRF03.02GB
9.5.6
9.5.7
9.6
9.6.1
9.6.2
9.6.3
9.6.4
9.6.5
9.6.6
9.6.7
9.6.8
9.6.9
9.6.10
9.6.11
9.6.12
9.7
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
9.9.6
9.9.7
9.10
9.10.1
9.10.2
9.10.3
9.10.4
9.10.5
9.11
9.11.1
9.11.2
9.11.3
9.11.4
9.11.5
9.11.6
9.11.7
9.11.8
9.12
9.13
VDRF03.02GB
Wiper motor, roof .................................................................................. 60

Wiper motor, rear ................................................................................. 61
Lighting system ......................................................................................... 63
Headlights ............................................................................................ 68
Running light ........................................................................................ 68
Tail light ................................................................................................ 68
Brake light ............................................................................................ 69
Reversing light ...................................................................................... 69
Driving direction indicator ..................................................................... 69
Flashing hazard lights .......................................................................... 70
Revolving beacon ................................................................................. 70
Working lights, cab ............................................................................... 70
Working lights, boom ............................................................................ 71
Work lights, attachment ........................................................................ 72
Interior lighting ...................................................................................... 72
Signalling system ...................................................................................... 73
Horn ...................................................................................................... 76
Flashing hazard lights .......................................................................... 76
Revolving beacon ................................................................................. 76
Warning parking brake ......................................................................... 76
Reverse alarm ...................................................................................... 76
Entertainment and communication ........................................................... 77
Glass/windows/mirrors .............................................................................. 78
Windscreen .......................................................................................... 79
Side window ......................................................................................... 81
Roof window ......................................................................................... 84
Rear window ......................................................................................... 85
Rearview mirror .................................................................................... 85
Reversing camera ................................................................................ 85
Monitor, reversing camera .................................................................... 86
Cab structure and suspension .................................................................. 87
Cab frame ............................................................................................. 87
Doors .................................................................................................... 88
Cab undercarriage ................................................................................ 88
Sliding cab ............................................................................................ 90
Vertically adjustable cab ..................................................................... 101
Cab interior ............................................................................................. 113
Instrument and control panels ............................................................ 113
Interior details, plastic ......................................................................... 114
Interior details, textile ......................................................................... 114
Floor covering ..................................................................................... 114
Insulation ............................................................................................ 114
Sun blinds ........................................................................................... 115
Terminal console ................................................................................ 115
Writing desk ........................................................................................ 115
Frame ...................................................................................................... 116
Body ........................................................................................................ 117
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
Wings .................................................................................................
Hood engine compartment ................................................................
Footstep and rail ................................................................................
Counterweights ..................................................................................
Central lubrication ..................................................................................
Pump unit ...........................................................................................
Distribution block ...............................................................................
Lines ..................................................................................................
Paint/coatings .........................................................................................
117
117
118
118
119
121
122
122
123
VDRF03.02GB
VDRF03.02GB
9 Frame, body, cab and

accessories
mm mm mm mm mm mm
9.1
Controls and instruments, overview
page
Overview
11
10
15
13
12
6
004852
12
14
1 Left-hand instrument panel

2 Gear and multi-function lever (S162)
3 Steering wheel panel
4 Steering wheel
5 Switch direction indicators (S161)
6 Panel for load handling functions
7 Switch control switch (S250)
8 Switch parking brake (S107)
9 Control lever (S815)
10 Drivers seat
11 Accelerator pedal (B690)
12 Brake pedal
13 Clutch-release pedal (S220-1)
14 Electrical distribution box with fuses
15 Hour meter (P708)
A Steering lever or mini-wheel
VDRF03.02GB
9 Frame, body, cab and accessories 9.1 Controls and instruments
Left-hand instrument panel

16 Switch fan (S118)
17 Switch temperature (S139)
18 Switch air distribution (S117)
24..28
29 30 31
20 Switch working lights attachment (S105-2)
19..23
21 Switch working lights boom (S105-3)
16
Left-hand instrument panel
013031
18
17
19 Switch work lights cab roof (S105-1)
22 Switch rotating beacon (S110)

23 Switch hazard lights (S109)
24 Switch headlights (S100)
25 Switch seat heater (S143)
26 Switch rearview mirror defroster (S199-4)
27 Spare
28 Switch, pause heater (S199-1)
29 Spare
30 Spare
31 Socket 24 VDC (E804)
VDRF03.02GB
32
33
35
34
Steering wheel panel
36
32 Warning lamp, low battery charge

33 Warning lamp, low brake pressure
34 Indicator, active error codes
35 Warning lamp, bypass of hydraulic functions
37..41
36 Indicator light for activated steering with lever or mini-wheel
49
37 Warning lamp, high coolant temperature
42..46
38 Warning lamp, low oil pressure in engine
47 48
39 Indicator lamp, preheating

40 Warning lamp, low engine coolant level
41 Warning lamp, high transmission fluid temperature
50
51
52
42 Warning lamp, low fuel level
53
43 Warning lamp, high hydraulic oil temperature

44 Indicator light high beam
45 Indicator light direction indicator
46 Indicator lamp, parking brake
47 Indicator light locked twistlocks
48 Indicator light alignment
63
62
61
60
59 58 57
54
49 Indicator light unlocked twistlocks
55
50 Panel, warning and indicator lamps
56
51 Display, control system

000399
64
Steering wheel panel for warning and indicator lamps
52 Indicator, control system

53 Ignition switch (S150)
54 Switch, defroster
55 Switch, windscreen wiper at roof, interval
56 Switch, windscreen wiper at roof, continuous
57 Switch interior lighting
58 Switch, rear window wiper, interval
59 Switch, rear window wiper, continuous
60 Function keys, control system
61 Travel direction indicator, Forward Neutral Reverse
62 Switch, shifting program A, automatic shifting
63 Switch, shifting program 1, locked to first gear
64 Switch, shifting program 2, locked to second gear
VDRF03.02GB
Panel for load handling functions

65 Switch for lowering front jacks (S1006)
65 66 67 68
66 Switch for lowering rear jacks (S1007)

67 Switch for bypassing rotation stop (S1014)
Switch for bypassing height limit (S1015)
69..72
Switch for bypassing LC-limitation (load centre) (S1015)

68 Switch, automatic cab tilt (S199-5)
73
75
Panel for load handling functions
69 Switch, lock twistlocks (S1003)
76
70 Switches clamp/loosen clamping position, jacks (S1008)

013032
74
Switch overheight jacks (S1031)

71 Switch, stop at 30' or 35' (S1004)
72 Switch hydraulic sliding cab (S177)
Switch hydraulic vertically adjustable cab (S177)
Switch hydraulically tiltable cab (S177)
73 Indicator light support jacks down (H517)
74 Switch support jacks (S1013)
75 Switch for automatic spreading 20'-40' (S1012)
76 Bypass switch (S1005)
VDRF03.02GB
Operating menus, overview
12
11
13
1.
2.
3.
4.
5.
6.
7.
8.
14
Operating menu engine and transmission

Operating menu dynamic scale
Operating menu engine
Operating menu, transmission and hydraulics
Operating menu electrical system
Operating menu, container counter
Operating menu service interval
Operating menu statistics
15
9.
10.
11.
12.
13.
14.
15.
16.
16
005080
10
Operating menu, printer

Operating menu control of dynamic scale
Operating menu service
Operating menu heating and air conditioning
Operating menu statistics, operating hours
Operating menu statistics, fuel consumption
Operating menu statistics, driving distance
Operating menu, statistics, lift statistics
VDRF03.02GB
10
Event menus overview
14
13
12
11
10
1.
Event menu start interlock
9.
2.
Event menu overload forward
10.
3.
Event menu overload on steering axle
11.
4.
5.
6.
7.
8.
Event menu overload on steering axle

Event menu, top lift alignment
Event menu bottom lift alignment
Event menu, twistlocks
12.
13.
14.
15.
Event menu, height limitation

Event menu fixed scale
Event menu open door
Event menu rotation stop
Event menu tilt lock
Event menu levelling lock
Event menu automatic spreading 20'-40'
Event menu support jacks
VDRF03.02GB
006734
15
page
11
Switch, replacement
NOTE
The instructions apply to switches in general.
2 Remove the dashboard panel.
3 Detach the connector from the switch.

4 Remove the switch from the instrument panel. Use a screwdriver
to bend in the tabs.
5 Replace the switch.
VDRF03.02GB
12
9 Frame, body, cab and accessories 9.1.1 Gear selector and multi-function lever
9.1.1
Gear selector and multi-function

lever
page
2
3
The following functions are handled by the gear and multi-function

lever (position 2).
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.

The signal can be checked from the diagnostic menu,
see section 8 Control system , group 8.4.3.1 CAB,
menu 1.
Rotation
Windscreen wiper front.

0 No wiping front windscreen. If wiper rear or roof
are active, these run at slow interval wiping.
1 Slow interval wiping windscreen, controls slow interval wiping for roof window and rear window.
2 Fast interval wiping front windscreen, controls fast
interval wiping for roof window and rear window.
3 Continuous wiping front windscreen. If wiper rear
or roof are active, these run at fast interval wiping.
menu 2.
Light signal
Downward
High beams (on/off)

With headlights on: Gear and multi-function lever is
used to switch between high and low beams.
With headlights off: Gear and multi-function lever is
used to flash with the headlights.
000339
Upward
The signal can be checked with the diagnostic menu,

see section 8 Control system , group 8.4.2.6 LIGHTS,
menu 6.
Inward,
button
VDRF03.02GB
Horn (position A).

menu 5.
9 Frame, body, cab and accessories 9.1.22 Switch, direction indicators
page
13
Gear and multi-function lever, replacement

1 Separate the dashboard panel.
6 attaching bolts and 2 bolts to the steering wheel shaft.
Remove the steering wheel, see Dashboard panel, replacement
page 113.
2 Undo the attaching bolts (2 x hexagonal socket bolts).
3 Unplug the connector from the KIT control unit (D790-2).
4 Fit a new lever and refit the dashboard panel.
9.1.22
page
Switch, direction indicators
Switch, direction indicators, replacement

2 Remove the steering wheel and open the steering wheel panel.
3 Detach the direction indicator wiring harness.

4 Press together the clips on the direction indicator and detach it
from the steering wheel panel.
5 Replace the direction indicator, fitting it in the reverse order.
VDRF03.02GB
14
9 Frame, body, cab and accessories 9.2 Safety and emergency equipment
9.2
9.2.1
page
Safety and emergency

equipment
Safety switch
Emergency stop, description

See section 11 Common electrics, group 11.5.1.4 Emergency stop
switch voltage.
9.2.2
page
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
page
Fire extinguisher
Fire extinguisher, description
The fire extinguisher is located at the entry on the left frame beam. Usage instructions are found on the fire extinguisher.
9.2.4
page
Buzzer
Seat buzzer, description

See Sensor operator in seat, description page 23.
VDRF03.02GB
9 Frame, body, cab and accessories 9.3 Seat
9.3
15
Seat
Seat, general
page
There are three versions of operators seat:
Seat, description (product alternative standard seat) page 15

Seat, description (product alternative BE-GE 9120) page 16
Seat, description (product alternative Isringhausen 6800)
page 17
As an option, the machine can be equipped with a fold-down passenger seat to the left of the operator.
Seat, description (product alternative standard

seat)
page
The seats function is to give the operator a good sitting position and
contribute to a good work environment. The cabs seat has several adjustment possibilities and meets high comfort standards.
The seat has the following equipment:
mechanical adjustment
right armrest
seat belt (option until model year 2007)
left armrest
seat heating
head restraint
6
7
006825
Controls, standard seat

1. Lumbar support adjustment
2. Right armrest adjustment
3. Left armrest adjustment
4. Backrest rake adjustment
5. Springing adjustment
6. Seat cushion angle adjustment
7. Seat height adjustment
8. Front/rear adjustment
VDRF03.02GB
16
Seat, description (product alternative BE-GE

9120)
page
BE-GE 9120 is the same as the standard seat, but is equipped with air
suspension. Air suspension automatically adjusts seat height and
springing to the operators weight. Air suspension is supplied by a special compressor installed on the underside of the cab.
2
3
The seat has the following equipment:
6
7
Controls BE-GE 9120

2. Right armrest adjustment
006826
mechanical adjustment
air suspension (with external compressor)
right armrest
seat belt (option until model year 2007)
left armrest
seat heating
head restraint
3. Left armrest adjustment

4. Backrest rake adjustment
5. Springing adjustment
6. Seat cushion angle adjustment
7. Seat height adjustment
VDRF03.02GB
17
Seat, description (product alternative

Isringhausen 6800)
page
The Isringhausen 6800 seat has the following equipment:
11
head restraint
armrest
air suspension (with external compressor)
air-adjusted lumbar support
seat belt
seat heating
34
8 2
567
004691
10
Controls, Isringhausen 6800

2. Seat cushion adjustment
3. Seat height lowering
4. Seat cushion angle
5. Seat height raising
6. Backrest rake
7. Damping adjustment
8. Seat heating
9. Level damping OFF/ON
11. Armrest
VDRF03.02GB
18
page
Seat, changing
2 Slide back the seat to its rear position, remove the front attaching
bolts.
3 Slide the seat to its front position, remove the rear attaching bolts.
4 Disconnect the seats connectors from the machines cabling.
5 Remove the seat.
VDRF03.02GB
9 Frame, body, cab and accessories 9.3.1 Seat cushion
9.3.1
19
Seat cushion
Seat cushion, description
page
The function of the seat cushion is to provide comfort to the operator.

The seat cushion houses the operators seat frame and a breaker for
the buzzer. There may also be a heating coil (
).
For location, see Seat, general page 15.
Seat cushion, changing (product alternative BE-GE)
page

2 Loosen the rubber bellows by removing the plastic clips (position
1).
3 Unhook the upholsterys rails (position 2) from the seat frame (position 3) and remove the upholstery.
4 Remove the padding (position 4).
4
If the seat is equipped with seat heater.
Unplug the connector for the heating coil before the padding is removed.
NOTE
The seats heating coil is glued to the padding. Be careful if
the padding is to be replaced but the heating coil is to be reused, or if only the coil is to be replaced.
5 Assemble in reverse order.
006276
1. Plastic clip, rubber bellows

2. Upholstery
3. Seat frame
4. Padding
5. Heat coil
9.3.2
page
Back cushion
Back cushion, description

The function of the back cushion is to provide comfort to the operator.
The back cushion houses the operators seat frame. There may also
be a heating coil (
).
For location, see Seat, general page 15.
VDRF03.02GB
20
9 Frame, body, cab and accessories 9.3.3 Electric heater
Back cushion, changing (product alternative BE-GE)
page

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, changing (product alternative BE-GE) page 19.
3 Remove the backrest by first removing the attaching bolts

(position1) on the right and left side of the seat and then remove
the attaching bolts for the seatbelt (position 2) on the right and left
side of the seat.
If the seat is equipped with 3-point seatbelt.

Remove the belt guide (position 3) by removing the cover and the
attaching bolt (position 4).
If the seat is equipped with armrest (position 5).

Remove the armrest by removing the attaching bolts (position 6).
6 Place the backrest on the seat and install the attaching bolts (position 1), do not tighten. Then install the attaching bolts for the
seatbelt (position 2).
Tighten the attaching bolts for the seatbelt (position 2) with torque
42 Nm , then tighten the attaching bolts (position 1) with torque
33 Nm.
1
1. Attaching bolt, backrest
2. Attaching bolt, seat belt
3. Cover, belt guide
4. Attaching bolt, belt guide
5. Armrest
6. Attaching bolt, armrest
006278
If the seat is equipped with 3-point seatbelt or armrest.

Cut holes in the upholstery for seatbelt and armrest on the new
backrest before armrest or seatbelt is installed.
9.3.3
page
Electric heater
Electric heater, description
The heating coils function is to warm the back and seat cushions in
the operators seat. The heating coil is located under the upholstery on
the seat.
The heating coil (E803) is supplied voltage upon warm-up of the cab
control unit (D790-1) by the seat heating relay (K383). The signal can
be checked with the diagnostic menu, see section 8 Control system ,
group 8.4.3.8 CAB, menu 8.
page
Heating coil, changing (product alternative BE-GE)

See Seat cushion, changing (product alternative BE-GE) page 19.
VDRF03.02GB
9 Frame, body, cab and accessories 9.3.4 Shock absorbers
9.3.4
21
Shock absorbers
Shock absorbers, description
page
Shock absorbers are integrated in the suspension unit in the seats

bracket and are self-adjusting, that is, they adjust themselves according to the operators body weight.
Shock absorber, changing (product alternative BEGE)
page
2 Remove the operators seat from the bracket and lift it out of the
machine. See Seat, changing page 18.
3 Remove the seat cushion; see Seat cushion, changing (product
alternative BE-GE) page 19.
4 Remove the back cushion; see Back cushion, changing (product

alternative BE-GE) page 20.
006277
5 Remove the shock absorbers attaching bolts (position 2 and 3).

6 Replace shock absorber (position 1).
7 Assemble in reverse order.
1. Shock absorbers
2. Attaching bolt
3. Attaching bolt
9.3.5
Air suspension
Air suspension, description
page
The air-suspended operators seat consists of a seat with rubber bellows and compressor. Air suspension is self-adjusting, that is, adjust
automatically to the operators body weight. The compressor provides
air for the suspension unit.
9.3.5.1
Compressor, air suspension
Compressed air-suspended seat, description
page
BE-GE 9120:
001621
The compressor is part of the air-suspended operators seat and is located inside the seats suspension unit.
Isringhausen 6800:
Compressed air-suspended seat

The compressor is an external part for the air-suspended operators
seat that is installed on the cab floors underside.
VDRF03.02GB
22
9 Frame, body, cab and accessories 9.3.6 Mechanical seat adjustment
9.3.6
Mechanical seat adjustment
Mechanical seat adjustment, description
page
Seat adjustment is all mechanical and is adapted by the operator with

different controls to obtain a good sitting position.
See:
Seat, description (product alternative standard seat) page 15
Seat, description (product alternative BE-GE 9120) page 16
Seat, description (product alternative Isringhausen 6800) page 17
9.3.7
Passenger seat
Passenger seat, description
page
001627
The passenger seat is collapsible (vertically) and is located on the lefthand side of the operators seat.
Passenger seat with bracket
9.3.8
page
Armrest
Armrests, description
The arm rest is fixed to the backrest and is individually adjustable vertically (around the attachment point). Depending on options there is
also an arm rest for the left-hand side:
VDRF03.02GB
Mini-wheel
Joystick control
9 Frame, body, cab and accessories 9.3.9 Sensor operator in seat
9.3.9
23
Sensor operator in seat
Sensor operator in seat, description
page
Sensor, operator in seat (S230) senses if the drivers seat suspension

is depressed which indicates for the control and monitoring system
that the operator is sitting in the drivers seat. This is used to give to
the control system the facility to indicate with the buzzer for operator
in seat (H853) if the operator leaves the machine without applying the
parking brake.
008220
From and including model year 2009 - the signal from the sensor for
operator in seat (S230) is also used to put 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
switch for bypass, select the travel direction and drive the machine to
the workshop. The speed is limited to 10 km/h.
Seat, view from underneath

1. Sensor, operator in seat (S230)
2. Buzzer (H853)
D ANGER
Bypassing the safety systems results in a risk of tipping. Use at your own risk.
The operator-in-seat sensor (S230) is supplied voltage by and sends

a voltage signal to Control unit, cab (ECU 790-1). The signal can be
checked with the diagnostic menu, see section 8 Control system ,
group 8.4.3.6 CAB, menu 6.
VDRF03.02GB
24
9 Frame, body, cab and accessories 9.4 Heating, ventilation and air conditioning
9.4
Heating, ventilation and air

conditioning
Heating, ventilation and air conditioning,

description
page
The heating system controls heating and ventilation of the cab. The
cab can also be equipped with a climate control system (
The temperature in the cab is thermostat-controlled by the cab control

unit (D790-1). The cab temperature is regulated to the set temperature. The temperature can be set between 16 and 28 C. The unit is
operated with controls on the instrument panel.
2
4
D
Heating system (EHC)
The heating system (EHC) handles heating and ventilation. (The heating system cannot provide cooling.)
E
3
).
The heating system uses heat from the engines cooling system via a
heating coil to heat ambient air. The fan forces the ambient air through
the heating coil on through ducts in the cab interior. It is then directed
to the windscreen (defroster) or the feet.
Climate control system (ECC)
The climate control system (ECC) is responsible for heating, ventilation, cooling and drying. The air is heated in the same way as for the
heating system (EHC).
1
000762
Principle illustration, climate control system

1. Fluid reservoir/filter dryer with integrated pressure
switch
2. Heating element 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
VDRF03.02GB
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.
The function of the climate control system 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)
25

page
D1
26
D3 3
25
4
6
D15
D5
D9
C
C
D2
D4
D23
D6
7
D790-1
15 D15
D797-R
D21
16
M
5
D795
D790-2
D794
12
22
14
M
M
D10
Pa
D17
D14
13
D13
19
18
20 C
23
C
21
24
17
D9
M
10
C
11
006416
Pos
Explanation
Signal description
Reference
The temperature switch (S139) sends a

(D790-1).
Raise: U = 2.02.5 V
Controls and instruments, overview page 5
Unaffected: U = 0-0.5 V
Lower: U = 4.5-5.0 V

system , group 8.4.4.5 CLIMATE, menu 5
The fan switch (S118) sends a voltage

signal to the cab control unit (D790-1).
Raise: U = 2.02.5 V
Unaffected: U = 0-0.5 V
Lower: U = 4.5-5.0 V

The air distribution switch (S117) sends

(D790-1).
Scroll up: U = 2.02.5 V
Unaffected: U = 0 V

The cab temperature sensor (B775-1)

sends the cab control unit (D790-1) a
voltage signal proportional to the temperature.
R = 10 k at 25 C
Scroll down: U = 4.5-5.0V
Sensor, cab temperature, description page

56
VDRF03.02GB
26
Pos
Explanation
Signal description
Reference
The blower fan temperature sensor

(B775-2) sends the cab control unit
(D790-1) a voltage signal proportional to
temperature.
R = 10 k at 25 C
Sensor, temperature outlet fan, description

page 55
The ambient temperature sensor (B774)

sends the cab control unit (D790-1) a
voltage signal proportional to temperature.
R = 10 k at 25 C
The cab control unit (D790-1) regulates

temperature and air distribution with signals from sensors and controls.

The engine produces heat when running. It is cooled with the cooling system. The heat from the cooling system is
used to heat the cab air.
The cab control unit (D790-1) controls

the water valve (Y673), which directs
hot water to heat exchanger heating.
U = 0.54.5 V
Water valve, description page 42



and 8.4.4.4 CLIMATE, menu 4
The water valves opening (%) is sent

back to the cab control unit (D790-1).
This gives information for controlling the
water valves position.
10
Sensor, ambient temperature, description

page 57
Section 1 Engine
The engine temperature sensor sends

the engine control unit (D794) a voltage
signal proportional to engine temperature.
11
Heat exchanger heat adds heat to the

cab air. Heat is transferred from the engines cooling system to the cab air.
Heat exchanger heat, description page 39
12

engine temperature in the cooling system on the CAN bus.

13

the recirculation actuator motor (M612)
which sets the fresh air or recirculation
damper in the required position.
Fresh air filter or recirculation damper, description page 33

the fan motor (M657), which increases
airflow in the cab.
14
VDRF03.02GB
D10: Diagnostic menu, see section 8 Control system , group 8.4.4.2 CLIMATE,
menu 2
D13: Diagnostic menu, see section 8 Control system , group 8.4.4.6 CLIMATE, menu
6
Cab fan, description page 36

6
27
Pos
Explanation
Signal description
Reference
15

the actuator motor (Y672), which sets
the air distributor to the required position.
U = 0.54.5 V
Air distributor, description page 53

menu 8 and 8.4.4.4 CLIMATE, menu 4
The air distributors position is sent back

to the cab control unit (D790-1). This
gives information for controlling the air
distributors position.
16
The rear frame control unit (D797-R)

controls AC compressor engagement.

17
The rear frame control unit (D797-R)

supplies voltage to the compressors solenoid valve (645).
U = 24 V
Compressor air conditioning, description

(engine alternative Volvo) page 43
18
The compressor draws gaseous refrigerant from the evaporator, compresses

it, and forces it on to the condenser.
Compressor air conditioning, description

(engine alternative Volvo) page 43
19
The condenser cools the refrigerant.

The gaseous refrigerant condenses to
liquid form and is pumped on in the circuit.
Condenser, description page 46
20
The moisture filter absorbs any moisture

from the cooling circuit. The fluid reservoir stores the refrigerant.
Moisture filter, description page 48
21
The pressure switch (S246) sends a signal to the rear frame control unit
(D797-R) if the pressure in the system
becomes abnormally high or low.
U = 24 V
Pressure switch, description page 48
22
The expansion valve adjusts the amount

of refrigerant that is let in to the evaporator. If the temperature in the evaporators outlet pipe increases, the
evaporator valve increases flow of refrigerant so that heat dissipation in the
evaporator increases.
Expansion valve, description page 49
23
The refrigerant circuit temperature sensor sends the cab control unit (D790-1)
a voltage signal proportional to temperature.
R = 10 k at 25 C
Sensor temperature refrigerant, description

page 51
6
menu 3
2.
VDRF03.02GB
28
Pos
Explanation
Signal description
Reference
24
Heat exchanger cooling dissipates heat

from the cab air. Heat is transferred from
the air to the refrigerant and transforms
the refrigerant to a gaseous state.
Evaporator, description page 52
25
The defroster switch on the KIT control

unit (D790-2) activates the defroster
program of the climate control system
for six minutes.

26

heating and ventilation settings in the
display.


checking
page
000056
2 Navigate to the service menu and press Enter.
3 Enter code for diagnosis. Code is obtained from Cargotec Support.
1 23
4 5
000060
NOTE
DIAG CLIMATE
1(8)
REQUIRED TEMP
XXX
PRESENT TEMP
XXX
4 Select CLIMATE.
000131
Menu 1
5 Check of desired temperature, inside temperature sensor and

water valve.
000132
DIAGNOSIS
CLIMATE HYD ENGINE
TRANSM BOOM ATTACH
OP EXTRA HIST
The code decides which service menu is to be activated

(Diagnostic test, Initiation, Calibration, or Service indication).
REQUIRED TEMP: 160 (16.0 C) for max. cooling and 280

(28.0 C) for max. heating. The setting is changed with the temperature switch.
PRESENT TEMP shows the temperature inside the cab. This is
measured by Sensor cab temperature (located down to the right
on the instrument panel, behind the rubber bushing). Blowing
through the hole should increase the value.
WATER VALVE FEEDB. should show 0 (closed) when the requested temperature is 160 and 100 (open) when the requested
temperature is 280. The water valve is located under the cab.
VDRF03.02GB
29
Menu 2
CLIMATE
COIL
COOLANT
AMBIENT
DE-ICE
2(8)
XXX
XXX
XXX
XXX
6 Check of Sensor temperature outlet fan (B775-2), engine temperature, Sensor outdoor temperature (B774), 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).
000133
DIAG
TEMP
TEMP
TEMP
TEMP
TEMP COOLANT: engine temperature sent on the CAN-bus.

TEMP AMBIENT: outdoor temperature measured by Sensor outdoor temperature (B774).
TEMP DE-ICE: cooling circuits temperature measured by Sensor temperature refrigerant (B775-1). If the compressor is activated the value will be low. However, if heat has been selected and
the compressor is deactivated, the value will almost be equal to
TEMP COIL.
Menu 3
7
(Only machines with ECC)

Checks that refrigerant circuit is filled.
PRESSURE SWITCH: 0 = not filled 1 = filled.
006865
DIAG CLIMATE
3(X)
PRESSURE SWITCH
X
OPT DOOR SWITCH
X
The sensor is located on the dryer filter which is fitted right rear in
the frame.
Menu 4
8 Checks Water valve (Y673) and Air distributor (Y642).
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 temperature setting from min. to max.
000135
DIAG CLIMATE
4(8)
WATER 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 windscreen. 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 unit.
Menu 5
9 Checks 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.
000136
DIAG CLIMATE
5(8)
REQ. DRAUGHT
XX.XXV
REQ. DRAUGHT: home position U = 0 V; against windscreen 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.
VDRF03.02GB
30
Menu 6
10 Checks cab fan (M657), fresh air and recirculation damper
(M612) and compressors electromagnetic clutch (M645)
FAN SPEED: increase and decrease fan speed, value should increase from 0 to 255 in steps.
000137
DIAG CLIMATE
6(8)
FAN SPEED
XXX
RECIRKULATION
XY
COMPRESSOR
XY
RECIRCULATION: press in the bypass switch (S1005) (on the

panel for load handling functions). When checking, the display
should show "11". Check that the damper really moves as it
should by removing the fresh air filter at the front of the climate
control system casing and feeling with your hand.
(Only machines with ECC)
COMPRESSOR: lower temperature setting to max. cooling, after
approx. 45 seconds the compressor will be activated and the display should show "11".
NOTE
Compressor activation can only be tested when the engine
is running and the system is filled.
Menu 7
11 Checks direction selector for Water valve (Y673).
DIAG CLIMATE
7(8)
OUTPUT WATER VALVE
CLOCKWISE
XY XY
CLOCKWISE: When temperature is increased and the water

valve opens shows "CLOCKWISE 11 11" and "COUNTERCLOCKWISE 00 11".
COUNTER-CLOCKWISE: When temperature is lowered and the
water valve closes shows "CLOCKWISE 00 11" and "COUNTERCLOCKWISE 11 11".
24V
NOTE
The ones are only showed for a moment when the water
valve changes position, zeros are shown when the valve is
not changing position. The water valve does not open if engine temperature is low, or if outdoor temperature is high.
0V
VDRF03.02GB
000138
31
Menu 8
12 Checks direction selector for air distributor.
DIAG CLIMATE
8(8)
CLOCKWISE
XY XY
CLOCKWISE: when the air is directed against the windscreen

and the air distributor changes position shows "CLOCKWISE 00
11" and "COUNTER-CLOCKWISE 11 11".
COUNTER-CLOCKWISE: when the air is directed against the
feet and the air distributor changes position shows "CLOCKWISE
11 11" and "COUNTER-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 is not changing position.
0V
000139
Pause heater, description
page
An extra electrically operated water pump pumps the coolant through

the heater unit when the engine is stopped. The cabin fan forces air
into the cab. The pause heater is automatically switched off when the
temperature in the cab is six degrees below the value set on the climate control system. The pause heater is activated with the pause
heater switch when the ignition is on.
2
004909
Pause heating is an option for the heating unit, which uses residual
heat in the engine's cooling system to keep the cab warm.
1. Switch, pause heater (S0_OPT-1)

2. Control unit cab (D790-1)
3. Circulation pump, pause heater (M667)
VDRF03.02GB
32
9 Frame, body, cab and accessories 9.4.1 Fresh air filter
9.4.1
Fresh air filter
Fresh air filter, description
page
The fresh air filter is located under a cover in the external unit for fresh
air intake into the cab - in front of the cab fan. A finer filter can be used
(
), but the maximum airflow may be affected.
003208
2
1
Fresh air intake, cab
VDRF03.02GB
1.
Fresh air filter
2.
Fresh air and recirculation damper
9 Frame, body, cab and accessories 9.4.2 Fresh air and recirculation damper
9.4.2
33
Fresh air filter or recirculation damper, description
page
The damper is controlled electrically and controls the air between fully
open for fresh air to recirculation of air. The damper is located in the
external unit for fresh air intake into the cab.
Control system , group 8.4.4.6 CLIMATE, menu 6.
003208
2
1
1.
Fresh air filter
2.
VDRF03.02GB
34
page
Motor, fresh air filter or recirculation damper,

replacement
2 Remove the wiper arms.
3 Remove the nuts which hold the wiper motor in the protective
plate.
4 Remove the protective plate.
5 Remove the fresh air filter.
VDRF03.02GB
35
6 Remove the bolts which secure the arm and motor in the plate.
7 Detach the connector from the motor.
8 Replace the motor.
9 Fit in the reverse order. Tighten the wiper arm to 16-20 Nm.
VDRF03.02GB
36
9 Frame, body, cab and accessories 9.4.3 Cab fan
9.4.3
Cab fan
Cab fan, description
page
The cab fan is located in the external unit for fresh air intake into the
cab. The fan consists of two single fans that are driven by a motor.
Control system , group 8.4.4.6 CLIMATE, menu 6.
003209

1. Cab fan
page
Cab fan, replacement

VDRF03.02GB
37
3 Remove the bolts which secure the wiper motor in the protective
plate.
5 Detach the washer hose from the protective plate.
VDRF03.02GB
38
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.
VDRF03.02GB
9 Frame, body, cab and accessories 9.4.4 Heat exchanger heat
9.4.4
39
Heat exchanger heat
Heat exchanger heat, description
page
The heat from the engines coolant is transmitted to the cab via the
heat exchanger. The heat exchanger is located behind the fan in the
external unit for fresh air intake into the cab.
1, 2
003210

1. Heat exchanger heat
2. Heat exchanger cooling
3. Refrigerant expansion valve and temperature
sensor
VDRF03.02GB
40
page
Heat exchanger, cooling/heating, replacement
WARN IN G
Personal injury, environmental damage.
Read the safety instructions for refrigerant, see section B Safety.

2 Drain the AC system of R134a refrigerant.
I M P OR TA NT
Working on the air conditioning requires special authorisation.
3 Detach the AC system hoses and the coolant hoses.

5 Remove the nuts which hold the wiper motor in the protective
plate.
VDRF03.02GB
41
Remove the plate frame.
10 Remove the cab fan.
11 Remove the heat exchanger cover plate.
VDRF03.02GB
42
9 Frame, body, cab and accessories 9.4.5 Water valve
12 Detach all fluid inlets and outlets from the heat exchanger.
13 Lift out the heat exchanger carefully.
14 Replace the heat exchanger.
16 Check for leaks and refill the AC-system with refrigerant R134a,
with the intended equipment.
For volume, see section F Technical data.
I M P OR TA NT
9.4.5
Water valve
Water valve, description
page
The water valve controls the climate control systems capacity for
heating from 0 (closed valve) to 100% (open valve). The water valve
is electrically controlled.
002229
The signal can be checked from the diagnostic menu, see 8 Control
system , group 8.4.4.1 CLIMATE, menu 1 , 8.4.4.4 CLIMATE, menu 4
and 8.4.4.7 CLIMATE, menu 7.
Water valve position under cab floor (from below)
VDRF03.02GB
9 Frame, body, cab and accessories 9.4.6 Engine temperature sensor
43
Water valve, replacement
page

2 Detach the connector from the water valve.
3 Stop the flow of fluid to and from the water valve using hose
pinch-off pliers.
4 Detach the coolant hoses from the water valve.
5 Remove the water valve from the cab floor.
6 Replace the water valve.
8 Check coolant level.
1. Water valve
2. Steering valve
9.4.6
Engine temperature sensor
Sensor, engine temperature, description
page
The coolant temperature sensor sits on the engine and detects engine
coolant temperature. See supplier documentation, engine.
8 Control system , group 8.4.4.2 CLIMATE, menu 2.
For location, see section 1 Engine.
9.4.7
Compressor
Compressor air conditioning, description (engine

alternative Volvo)
page
The compressor drives the climate control system 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 highpressure gas to the condenser.
The compressor is driven by V-belts directly by the machines engine.
Activation and deactivation of the compressor is handled by an electromagnetic clutch, which is controlled by a thermostat.
001242
VDRF03.02GB
44
page
9 Frame, body, cab and accessories 9.4.7 Compressor
Compressor, replacement (engine alternative Volvo)
WARN IN G

I M P OR TA NT
3 Detach the coolant hoses from the compressor.

4 Loosen the belt tensioner so that the compressor belt is released.
5 Remove the bolts which secure the compressor.
1. Alternator, belt tensioner
2. Compressor
6 Replace the compressor.

I M P OR TA NT
VDRF03.02GB
9 Frame, body, cab and accessories 9.4.7 Compressor
45
Compressor air conditioning, description (engine

alternative Cummins QSM11)
page
The compressor drives the climate control system 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 highpressure gas to the condenser.
The compressor is driven by V-belts directly by the machines engine.

Activation and deactivation of the compressor is handled by an electromagnetic clutch, which is controlled by a thermostat.
005000
1. Compressor air conditioning

2. Turnbuckle
Compressor, replacement (engine alternative

Cummins QSM11)
page
WARN IN G
2
005000
1. Compressor air conditioning

2. Turnbuckle
I M P OR TA NT
3 Detach the coolant hoses from the compressor.

4 Loosen the turnbuckle so that the compressor belt is released.
5 Remove the bolts which secure the compressor.
6 Replace the compressor.
VDRF03.02GB
46
9 Frame, body, cab and accessories 9.4.8 Condenser
I M P OR TA NT
9.4.8
Condenser
Condenser, description
page
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.
002228
The temperature of the refrigerant in the condenser varies from approx. 50 C to 70 C and the pressure varies between 12 and 14 bar
depending on ambient temperature and airflow through the condenser. When the refrigerant has been condensed to liquid, it is directed on
to the fluid reservoir/filter dryer.
VDRF03.02GB
9 Frame, body, cab and accessories 9.4.8 Condenser
page
47
Condenser, replacement
WARN IN G

1. Radiator
2. Condenser
I M P OR TA NT
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.
I M P OR TA NT
VDRF03.02GB
48
9 Frame, body, cab and accessories 9.4.9 Moisture filter
9.4.9
Moisture filter
Moisture filter, description
page
The moisture filter collects the liquid refrigerant, binds moisture and filters impurities. The reservoir functions as an expansion tank in the
cooling circuit.
002227
When the refrigerant has passed through the dryer in the bottom of the
fluid reservoir, it rises through a standpipe. Through a sight glass, it is
possible to check that flow is without bubbles and that the system is
adequately filled with refrigerant.
1. Fluid reservoir, moisture filter

2. Pressure switch
9.4.10
Pressure switch
Pressure switch, description
page
The pressure switch cuts off the current to the compressors electromagnetic clutch if the pressure in the cooling circuit becomes abnormally high or low.
002227
1. Fluid reservoir, moisture filter

2. Pressure switch
VDRF03.02GB
9 Frame, body, cab and accessories 9.4.11 Expansion valve
49
Pressure switch, replacement
page
WARN IN G
1

2 Drain the machine of refrigerant, R134a.
I M P OR TA NT
002227
1. Fluid reservoir, moisture filter.

2. Pressure switch.
3 Disconnect the connector from the pressure switch.

4 Unscrew the pressure switch from its mounting.
5 Replace the pressure switch.
I M P OR TA NT
9.4.11
page
Expansion valve
Expansion valve, description
The expansion valve is the part in the circuit that separates the highpressure 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 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.
VDRF03.02GB
50
page
9 Frame, body, cab and accessories 9.4.11 Expansion valve
Expansion valve, replacement
WARN IN G

2 Drain the AC system of refrigerant.
I M P OR TA NT
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 40.
6 Replace the expansion valve.
I M P OR TA NT
VDRF03.02GB
9 Frame, body, cab and accessories 9.4.12 Sensor temperature refrigerant
9.4.12
51
Sensor temperature refrigerant
Sensor temperature refrigerant, description
page
Refrigerant temperature sensor (position 2) detects the refrigerant

temperature in the heat exchanger cooling. This is used to control the
air conditioning.
002226
1. Sensor cab temperature

2. Sensor temperature refrigerant
3. Sensor temperature outlet fan
page
Sensor, refrigerant temperature, replacement
WARN IN G
NOTE
Requires special authorisation.
2 Drain the AC system of refrigerant.
I M P OR TA NT
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
40.
6 Replace the temperature sensor.
VDRF03.02GB
52
9 Frame, body, cab and accessories 9.4.13 Heat exchanger cooling
I M P OR TA NT
9.4.13
Heat exchanger cooling
Evaporator, description
page
The heat exchanger for cooling consists of pipes and cooling fins. The
cab air is cooled as it passes through the cooling heat exchanger. The
heat exchanger is located behind the fan in the external unit for fresh
air intake into the cab.
1, 2
003210

1. Heat exchanger heat
2. Heat exchanger cooling
3. Refrigerant expansion valve and temperature
sensor
VDRF03.02GB
9 Frame, body, cab and accessories 9.4.14 Air distributor
53
Heat exchanger cooling, replacement
page
See Heat exchanger, cooling/heating, replacement page 40.
9.4.14
Air distributor
Air distributor, description
page
The air distributor controls the air between defroster and floor and is
located behind the panel inside the cab. The damper is controlled electrically by the control system.
002230
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.
page
Air distributor, replacement

3 Remove the steering wheel shaft cover.
4 Detach the steering wheel shaft and angle it back against the operators seat.
5 Remove the lower cover in front of the pedal bracket.
6 Detach the air hoses from the air distributor and detach the
connector.
1. Instrument panel
2. Steering column adjustment
3. Lower protective cover
7 Remove the air distributor from its mounting.
8 Replace the air distributor, fitting it in the reverse order.
Air distributor
VDRF03.02GB
54
9 Frame, body, cab and accessories 9.4.15 Air vents
9.4.15
Air vents
Air vents, description
page
There are a number of fixed air vents in the cabs 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 panels outside corners.
001839
There is an air inlet towards the cabs lower part (floor).
page
Defroster nozzles, replacement

2 Remove the air damper manually.
3 Remove the bolts which hold the other part of the defroster nozzle in the dashboard.
VDRF03.02GB
9 Frame, body, cab and accessories 9.4.16 Sensor temperature outlet fan
55
4 Detach the air hose from the defroster nozzle.

5 Replace the defroster nozzle.
9.4.16
Sensor temperature outlet fan
Sensor, temperature outlet fan, description
page
The outlet fan temperature sensor (position 3) detects the temperature

of the air that blows out in the defroster nozzles. The air conditioning
is controlled by signals from the following sensors:
Sensor cab temperature
2.
3.
002226
page
1.
Outlet fan temperature sensor, replacement

3 Remove the lower protective cover in front of the steering wheel
shaft.
4 Detach the steering wheel shaft and angle it back against the operators seat.
1. Instrument panel
2. Steering column adjustment
3. Lower protective cover
VDRF03.02GB
56
9 Frame, body, cab and accessories 9.4.17 Sensor cab temperature
5 Detach the temperature sensor from the air distributor.

Air distributor including temperature sensor.
9.4.17
Sensor, cab temperature, description
page
The cab temperature sensor (position 1) detects the temperature of

the air in the cab.
002226
1. Sensor cab temperature

2. Sensor temperature refrigerant
3. Sensor temperature outlet fan
page
Cab temperature sensor, replacement

VDRF03.02GB
9 Frame, body, cab and accessories 9.4.18 Sensor outdoor temperature
57
3 Detach the hose from the temperature sensor.

4 Detach the connector from the temperature sensor.
5 Remove the temperature sensor.
9.4.18
page
Sensor outdoor temperature
Sensor, ambient temperature, description

The ambient temperature sensor detects the temperature of the air
outside the cab.

page
Ambient temperature sensor, replacement

2 Detach the connector from the temperature sensor.
3 Remove the temperature sensor from its mounting in the cab.
VDRF03.02GB
58
9 Frame, body, cab and accessories 9.5 Wiper/washer system
9.5
9.5.1
Wiper/washer system
Wiper front
Wiper, front, description
page
The front wiper is the parallel wiper type, i.e. the wiper blade is moved
in a constant vertical manner over the windscreen.
9.5.2
Wiper roof
Wiper, roof, description
page
Wiper roof are of the type sector wiper. Wiping angle is approx. 180
degrees.
9.5.3
Wiper rear
Wiper, rear, description
page
The rear wiper is a sector wiper type. The wiping angle is approx.
180 degrees.
9.5.4
Washer motor and reservoir
Washer motor and reservoir, description
page
Washer motors are located on the washer fluid reservoir. There are
non-return valves on the lines from the reservoir to the washer nozzles, preventing the washer fluid from draining back in the line between washings. This minimises the time from activation of switch
washing and washer fluid spraying on the windscreen.
The washer nozzles are mounted on the wiper arms.
004924
8 Control system , group 8.4.3.1 CAB, menu 1.
VDRF03.02GB
9 Frame, body, cab and accessories 9.5.5 Wiper motor, front
59
Washer motor and container, replacement
page

2 Remove the protection over the washer fluid reservoir.
3 Drain the washer fluid from the container.
4 Remove the washer motors from the fluid reservoir.
5 Remove the bolts which secure the fluid container in the cab wall.
003619
6 Change the washer fluid reservoir. Change the washer motor, if

needed.
Washer fluid reservoir without protective plate.

A. Washer fluid reservoir
B. Washer motors
9.5.5
page
Wiper motor, front
Wiper motor, front, description

The wiper motor drives the front windscreen wiper. The wiper arm is
mounted on the motor. The motor produces the movement of the
wiper.
page
Front wiper motor, replacement

3 Remove the nuts which hold the motor in the protective plate.
VDRF03.02GB
60
9 Frame, body, cab and accessories 9.5.6 Wiper motor, roof
6 Remove the nuts which hold the motor in the cab.

7 Detach the connector from the wiper motor.
8 Replace the motor.
9 Fit in the reverse order. Tighten the wiper arms to 16-20 Nm.
9.5.6
page
Wiper motor, roof
Wiper motor, roof, description

The wiper motor drives the roof windows wiper. The wiper arm is
wiper.
page
Wiper motor (roof), replacement

2 Remove the plastic cover.
3 Detach the washer hose and the connector to the wiper motor.
VDRF03.02GB
9 Frame, body, cab and accessories 9.5.7 Wiper motor, rear
61
4 Undo the lock nut securing the wiper arm and disconnect the
washer fluid hose.
5 Remove and replace the wiper motor.
9.5.7
page
Wiper motor, rear
Wiper motor, rear, description

The wiper motor drives the rear window wiper. The wiper arm is
wiper.
page
Rear wiper motor, replacement

2 Remove the panels behind the operators seat.
3 Remove the screws holding the motors plastic cover.
4 Detach the connector from the motor.

5 Raise the plastic cover and remove the nut securing the wiper
arm. Disconnect the washer hose.
VDRF03.02GB
62
9 Frame, body, cab and accessories 9.5.7 Wiper motor, rear
6 Remove the screws securing the motor and the lock nut on the
motor.
7 Replace the wiper motor.
8 Fit in the reverse order. Tighten the wiper arms to 16-20 Nm.
VDRF03.02GB
9 Frame, body, cab and accessories 9.6 Lighting system
9.6
63
Lighting system
Lighting system, function description
page
The lights are shut off automatically after 5 minutes idling in order to
prevent discharge of the batteries. Extra working lights are shut off after 2 minutes. Lighting is 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
D4
D1
D3
D2
D5
8
9
10
14
6
D6
D16
15
D17
17
D10
D13
D27
D790-1
7, 12
26
D797-R
D31
18 D18
D29
D30
32 D28
D22 D23
Pa
24
D21
D20
27 28 29 30 31
D790-2
11
19
D797-F
33
D791-1
D34
34
20 21 22 23
25
D35
35
007417
D32
D8
13
16 M
D9
Pos
Explanation
Signal description
Reference
The switch for cab working lights (S105-1)

sends a voltage signal to the cab control unit
(D790-1).
Switch in ON position: U
= 24 V

Control system group 8.4.2.1 LIGHTS,
menu 1
The switch for attachment work lights (S105-2)

(D790-1).
= 24 V

menu 2
The switch for boom working lights (S105-3)

(D790-1).
= 24 V

menu 3
The headlights switch (S100) sends a voltage

signal to the cab control unit (D790-1).
= 24 V

menu 4
The revolving beacon switch (S110) sends a

voltage signal to the cab control unit (D790-1).
= 24 V

LIGHTS, menu 9
VDRF03.02GB
64
Interior lighting cab, description page

72
The door NC switch (S226-LE & S226-RI)

(D790-1).
Door open: U = 24 V

"switch on lights" message on the CAN bus.

error code.

The multi-function lever (S162) sends a voltage signal to the KIT control unit (D790-2).
Lever in high beam position: US162/56a = 24 V
Gear and multi-function lever, description page 12

Control system group 8.4.2.12
LIGHTS, menu 12

menu 6
9

menu 7
The direction indicator lever (S161) sends a

voltage signal to the KIT control unit (D790-2).
Left: US161/6 = 24 V
10
The interior lighting switch of the KIT control

unit (D790-2) sends a voltage signal to the KIT

error code.

LIGHTS, menu 12
11

"switch on lights" message on the CAN bus.

error code.

12
The cab control unit (D790-1) supplies voltage

to the lights in and around the cab.

error code.

13
The cab working lights (E404-1L & E404-1R)

are switched on when the cab working lights
are activated.
Light on: U = 24 V
Working lights, cab, description page

70
Relay extra working lights boom (K304) is activated when the boom working lights are activated and supplies voltage to the extra working
lights boom (E404-5L & E404-5R).
UK304/30 = 24 V
14
Right: US161/1 = 24 V

menu 1
Working lights, boom, lights page 71
UK304/85 = 0 V
Working lights boom
switched on:
UK304/86 = 24 V
UK304/87 = 24 V
Working lights boom
switched off:
UK304/86 = 0 V
UK304/87 = 0 V
15
Extra working lights boom (E404-5L & E4045R) are switched on when boom working lights
are activated.
VDRF03.02GB
Light on: U = 24 V
16
17
18
Rotating beacon (H428) is lit when rotating

work light is activated.
Light on: U = 24 V
Interior lighting comes on when a door is

opened or if activated when the switch on the
KIT control unit (D790-2).
Light on: U = 24 V
NO switch, brake lights (S216) sends a voltage

signal to Control unit, frame front (D797-F).
Brake pressure over 0.2

MPa: U = 24 V
65
Revolving beacon, description page 70

menu 9
Interior lighting cab, description page

72
LIGHTS, menu 12
Section 4 Brakes, group 4.3.8 NO
(normally open) switch, brake lights
LIGHTS, menu 10
19
Control unit frame front (D797-F) supplies

power to the front lights on the machine.

error code.

20
The front direction indicators (H422 & H423)

come on when they or the warning lights are
activated.
Light on: U = 24 V
Driving direction indicator, description

page 69
The front running lights (H416-1 & H417-1)

come on together with the headlights.
Light on: U = 24 V
Headlights low beams (E400L & E400R) are lit

when headlights are activated.
Light on: U = 24 V
Headlights high beam (E402L & E402R) are lit

when high beam is activated.
Light on: U = 24 V
24
Extra working lights front (E404-7L & E4047R) are switched on at the same time as high
beam.
Light on: U = 24 V
25
Extra working lights front (E404-8L & E4048R) are switched on at the same time as high
beam.
Light on: U = 24 V
26
Control unit frame rear (D797-R) supplies power to the rear lights on the machine.

error code.
21
22
23

menu 8
Running lights, description page 68

menu 5
Headlights, description page 68

menu 6
Headlights, description page 68

menu 6

VDRF03.02GB
66
27
Tail light, description page 68
Tail lights (H412L & H412R) red are lit when

headlights are activated.
Light on: U = 24 V
Brake lights (H411L & H411R) are lit when the

brake is activated.
Light on: U = 24 V
The rear direction indicators (H426 & H427)

come on when they or the warning lights are
activated.
Light on: U = 24 V
The rear running lights (H416-2 & H417-2) are

switched on when the headlights are activated.
Light on: U = 24 V
The white reversing lights (E405L & E405R)

come on when reverse gear is selected.
Light on: U = 24 V
Working lights boom (E404-3L & E404-3R) are

switched on when boom working lights are activated.
Light on: U = 24 V
33
The attachment control unit (D791-1) supplies

voltage to the attachments lights.

error code.

34
Working lights attachment (E406-L & E406R)

are switched on when the attachments working lights are activated.
Light on: U = 24 V
Attachment work lights, description

page 72
Extra working lights attachment (E404-4L &

E404-4R) are switched on when the attachments working lights are activated.
Light on: U = 24 V
28
29
30
31
32
35
VDRF03.02GB

menu 5
Brake light, description page 69

LIGHTS, menu 11

page 69
menu 8
Running lights, description page 68

menu 5
Reversing light, description page 69

LIGHTS, menu 11

menu 3

menu 2

page 72
menu 2
67
Lighting system, component positions
page
The purpose of lighting is to increase safety during operation and load

handling. The machine has the following lights:
NOTE
20
1.
17
18, 19
Rotating beacon (H428)
16
15
14
13, 12, 11
10
006426
21, 22, 23, 24
13. Headlights, low beam (E400L & E400R)

Headlights, high beam (E402L & E402R)
2.
Interior lighting
3.
15. Control unit, frame front (D797-F)
4.
16. Switch, see section 9 Frame, body, cab and accessories,

5.
Cab working lights (E404-1L & E404-1R)
17. Door NC (normally closed) switch (S226-LE & S226-RI)
6.
Extra working lights boom (E404-5L & E404-5R)
7.
Working lights boom (E404-3L & E404-3R)
19.
8.
Attachment control unit (D791-1)
20. Control unit, frame rear (D797-R)
9.
Working lights attachment (E406-L & E406R)
21. Rear running lights (H416-2 & H417-2)
Relay extra working lights boom (K304)
Extra working lights attachment (E404-4L & E404-4R)
10. Extra working lights front (E404-7L, E404-8L, E404-7R & 22. Reversing lights (E405L & E405R), white
E404-8R)
11. Direction indicators front (H422 & H423)
23. Tail lights (H421L & H412R), red

Brake lights (H411L & H411R)
12. Front running lights (H416-1 & H417-1)
24. Direction indicators rear (H426 & H427)
VDRF03.02GB
68
9 Frame, body, cab and accessories 9.6.1 Headlights
9.6.1
page
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 machines position.
Headlights have high beam and low beam (for meeting other traffic).
Switch between low and high beam with the gear and multi-function lever. The signal goes to the cab control unit (D790-1).
The low and high beam signals can be checked from the diagnostic
menu, section 8 Control system , group 8.4.2.6 LIGHTS, menu 6.
9.6.2
page
Running light
Running lights, description

The running lights are located on the right and left-hand sides of the
machine to provide surrounding traffic and the environment an indication of the machines position and direction of travel.
The running lights are controlled by selecting with the headlight switch.
The signal travels to the cab control unit (D790-1).
The lights and their signal can be checked from the diagnostic menu,
section 8 Control system , group 8.4.2.5 LIGHTS, menu 5.
As an option the machine can be equipped with running lights of the

LED type. These are replaced as a complete unit.
9.6.3
page
Tail light
Tail light, description

Tail lights are located in the rear of the machine to provide surrounding
traffic and the environment an indication of the machines position, and
a limited enhancement of the view for the operator in darkness.
The tail lights are controlled by selecting with the headlight switch. The
signal travels to the cab control unit (D790-1).
As an option the machine can be equipped with combined direction indicators rear and brake lights of the LED type. These are replaced as
a complete unit.
VDRF03.02GB
9 Frame, body, cab and accessories 9.6.4 Brake light
9.6.4
page
69
Brake light
Brake light, description

The brake lights are located in 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
NC switch). The signal travels to the front frame control unit (D797-F),
which supplies power to the brake lights.
a complete unit.
9.6.5
page
Reversing light
Reversing light, description

The reversing lights are located in the rear of the machine to provide
surrounding traffic and the environment an indication that the machine
is travelling backwards. In addition, this provides the operator enhanced view when operating in darkness.
Reversing lights are controlled by the selected travel direction with the
gear selector and multi-function lever (S162) that sends a voltage signal to the KIT control unit (D790-2).
The reversing lights are supplied voltage by Control unit, frame rear
(D797-R).
9.6.6
page
Driving direction indicator

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 selecting with the switch for
direction indicators (S161) that sends a voltage signal to the KIT control unit (D790-2).
The direction indicators are supplied voltage by Control unit, frame
front (D797-F) and Control unit, frame rear (D797-R).
a complete unit.
VDRF03.02GB
70
9 Frame, body, cab and accessories 9.6.7 Flashing hazard lights
9.6.7
page
Flashing hazard lights
Hazard lights, description

Hazard lights (hazard) are used to warn the surroundings, hazard
lights activate all direction indicators at the same time.
The flashing hazard lights are controlled by selecting with the switch
for flashing hazard lights. The signal travels to the control unit
(D790-2).
Control system , group 8.4.2.8 LIGHTS, menu 8.
Machines for the North American market are equipped with flashing
brake lights front and rear during operation.
9.6.8
page
Revolving beacon
Revolving beacon, description

A rotating beacon is located at a high level on the machines boom
(rear section). 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 rotating beacon is controlled by selecting with the rotating beacon
switch. The signal travels to the cab control unit (D790-1).
9.6.9
page
Working lights, cab
Working lights, cab, description

Work lights on the cab provide visibility when handling a load in darkness.
The work lights are controlled by selecting with the switch for cab roof
work lights. The signal travels to the cab control unit (D790-1) which in
turn supplies power to the work lights.
VDRF03.02GB
9 Frame, body, cab and accessories 9.6.10 Working lights, boom
page
71
Work lights, changing (product alternative Xenon

lights)
D ANGER
Xenon lights are activated with high voltage. Always
turn off the main electric power before working on xenon lights.
Handle the headlights 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
page
Working lights, boom
Working lights, boom, lights

Working lights on the boom provide increased visibility when handling
a load in darkness.
The working lights are controlled by selecting with the switch for boom
working lights. The signal travels to the cab control unit (D790-1).
The lifting boom can be equipped with two extra working lights (
page
).

lights)
See Work lights, changing (product alternative Xenon lights) page 71.
VDRF03.02GB
72
9 Frame, body, cab and accessories 9.6.11 Work lights, attachment
9.6.11
page
Work lights, attachment

Work lights on the attachment provide enhanced view when load handling in darkness.
The work lights are controlled by selecting with the attachment work
light switch. The signal travels to the cab control unit (D790-1).
The attachment can be equipped with two extra working lights (
page
).

lights)
See Work lights, changing (product alternative Xenon lights) page 71.
9.6.12
page
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 illumination in all switches, function keys and rotary controls. This is so that the driver will be able to read their functions and settings in darkness. Brightness is controlled by the plus and
minus keys.
VDRF03.02GB
9 Frame, body, cab and accessories 9.7 Signalling system
9.7
73
Signalling system
Signalling system, function description
page
NOTE
3
D2
D3
D1
18
16
D6
17
D18
D5
D19
D14
14
15 M
19
D790-1 4
8
D797-R
D15
D9
D790-2
D797-F
D10
10
D11
11
D13
D791-1
12
13
20
D795
D22
21
22
007418
Pos
Description
Signal description
Reference
The revolving beacon switch

(S110) sends a voltage signal to
Switch in ON position: U =
24 V

system group 8.4.2.9 LIGHTS, menu 9
The switch for warning lights (hazard) (S109) sends a voltage signal
24 V

The parking brake switch (S107)

sends a voltage signal to the cab
24 V

system group 8.4.5.4 HYD, menu 4

transmits activation messages on
the CAN bus


Cab control unit
The multi-function lever (S162)

sends a voltage signal to the KIT
Signal button pressed in:

US162/H = 24 V

page 12
The direction indicator lever (S161)

sends a voltage signal to the KIT
Left: US161/6 = 24 V

Right: US161/1 = 24 V

VDRF03.02GB
74
Pos
Description
Signal description
Reference
The KIT control unit (D790-2) transmits activation messages on the

CAN bus.



supplies power to the rear lights
and buzzer on the machine.


The rear direction indicators (H426

& H427) come on when the warning
lights are activated.
Light on: U = 24 V
Driving direction indicator, description page

69
The reversing lights (E405L &

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 engaged: U =

24 V
Reverse alarm, description page 76
12

supplies power to the front lights on
the machine.


13
The front direction indicators (H422

& H423) come on when they are
activated.
Light on: U = 24 V
Driving direction indicator, description page

69
Horn (H850) sounds when the horn

is activated.
Horn active: U = 24 V
Rotating beacon (H428) is lit when

hazard lights are activated.
Light on: U = 24 V
Relay loud horn (K3016) is activated when horn is activated.
UK3016/30 = 24 V
10
11
14
15
16

Reversing light, description page 69



Horn, description page 76

Revolving beacon, description page 76

S15: Diagnostic menu, see section 8 Control
system , group 8.4.2.9 LIGHTS, menu 9
UK3016/85 = 0 V
Horn activated:
UK3016/86 = 24 V
UK3016/87 = 24 V
17
Loud horn (H850-1) sounds when

the horn is activated.
Horn active: U = 24 V
18
The operator-in-seat NO switch

the cab control unit (D790-1) when
there is a load on the operators
seat.
Operator in seat: U = 24 V
Sensor operator in seat, description page 23
VDRF03.02GB

system group 8.4.3.6 CAB, menu 6
75
Pos
Description
Signal description
Reference
19
In the event of warnings, the cab

buzzer (H853) is supplied voltage
by the KIT control unit (D790-2) to
draw the operators attention to the
warning message.


20
In the event of warnings, the KID

control unit (D795) activates the
warning light to draw the operators
attention to the warning message.
A clicking sound is audible

when then termination resistor is activated.

21
The attachment control unit (D7911) supplies voltage to the automatic

spreading buzzer during automatic
spreading.


22
The automatic spreading buzzer

(H9003) is activated when automatic spreading 20'-40' is
activated.
Section 7 Load handling group 7.5.13 Buzzer, automatic spreading 20-40

system , group 8.4.9.15 ATTACH, menu 15
Signalling system, component position
page
16, 17
15
12
13, 14
11
10
006427
10.
Switch, see section 9 Frame, body, cab and accessories, group 9.1 Controls and instruments
Buzzer cab (H853)
11.
Horn (H850)
4.
12.
Make-contact operator in seat (S230)
5.
13.
1.
Rotating beacon (H428)
2.
3.
6.
14.
Automatic spreading buzzer (H9003)
Relay loud horn (K3016)
7.
Direction indicators front (H422 & H423)
15.
8.
16.
Direction indicators rear (H426 & H427)
17.
Back-up alarm (H965)
9.
Loud horn (H850-1)
VDRF03.02GB
76
9 Frame, body, cab and accessories 9.7.1 Horn
9.7.1
Horn
Horn, description
page
The horn is electromagnetic. Air horn can be selected (
).
001247
The horn is activated from the gear and multi-function lever. The horn
can also be activated with the switch for open twistlocks on the control
lever, when the attachment does not have contact with a container.
The horn is located under the cab (the compressed air horn is located
in the rear edge of the cab roof).
Control system , group 8.4.3.5 CAB, menu 5..
As an option the machine can be equipped so that the twistlocks
button on the control lever controls the horn when there is no contact.
9.7.2
page
Hazard lights, description

See Hazard lights, description page 70.
9.7.3
page
Revolving beacon
Revolving beacon, description

See Revolving beacon, description page 70.
9.7.4
page
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 operators seat (see Sensor operator in seat, description page 23) indicates to the control system if the operator leaves the
seat.
The buzzer is located in the steering wheel panel.
Control system , group 8.4.3.6 CAB, menu 6..
9.7.5
page
Reverse alarm
Reverse alarm, description

When reverse is selected, a warning sound and the back-up lights are
activated. This is to give others in traffic an indication that the machine
is reversing. Indication to bystanders to take caution.
Control system , group 8.4.2.11 LIGHTS, menu 11.
VDRF03.02GB
9 Frame, body, cab and accessories 9.8 Entertainment and communication
9.8
page
77
Entertainment and
communication
Entertainment and communication, general

The machine is prepped with a connector for customer accessories,
see section 11 Common electrics, group 11.5.2.1 Electronic box, cab.
page
Entertainment and communication, repair

Repairs should be left to authorised personnel.
VDRF03.02GB
78
9 Frame, body, cab and accessories 9.9 Glass/windows/mirrors
9.9
Glass/windows/mirrors
Glass/windows/mirrors, description
page
The windows are designed to both enclose the cab and provide the operator with a good view.
The windows on the Spirit Delta cab are made of tinted hardened
glass, except the roof window which is made of polycarbonate plastic.
As an option, the cab can be equipped with windows of laminated

glass.
001512
The rearview mirrors are of the convex mirror type. There is an interior
rearview mirror on all machines.
A. Side windows
B. Windscreen (front window)
C. Roof window
D. Rear window
E. Windscreen (front side window)
page
Silicone adhesive, handling advice

The window panes are secured with key 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, twocomponent silicone adhesive that can withstand temperatures between -50 C and +200 C. The hardening properties
of the adhesive are extremely dependent on the ambient
temperature. An increase of 10 C cuts hardening time in
half.
Silicone adhesive 923854.0100 is mixed at a ratio of 1:10 in
a static mixer. Change mixer after every interruption that
lasts more than 5 minutes. The short setting time means that
work has to be planned carefully to avoid undesired hardening.
Fixing time:
10-20 minutes at 20 C
approx. 5 minutes at 60 C
Hardening time:
approx. 24 hours at 20 C
approx. 1 hour at 60 C
Full strength is obtained after 7 days.
VDRF03.02GB
9 Frame, body, cab and accessories 9.9.1 Windscreen
In warm climates, it is advantageous to cool the container to

increase hardening time. The silicone adhesive should not
be used at temperatures above +75 C.
In cold climates, the hardening time can be shortened by

covering the joints so that cooling is prevented. The window
pane can be warmed with defroster or cab heater.
The recommended storage temperature is between -30 C

and +20 C. Storage in a refrigerator or a colder environment
is recommended.
9.9.1
page
79
Windscreen
Windscreen, description
The windscreen consists of the front window and side windows. The
windscreen is attached to the cab with a key strip and is glued to the
roof window with silicone adhesive. Front and side windows are joined
with silicone adhesive to give good allround visibility from the operators station.
For location, see Glass/windows/mirrors, description page 78.
page
Windscreen, replacement
NOTE
Read the handling advice for silicone adhesive before starting
work. See Silicone adhesive, handling advice page 78.
2 Remove the key strip.
3 Remove the broken window pane and check that no glass or other particles remain in the window panes 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 panes lower front
edge.
If the roof window is to be changed, then all bolts must be
removed before the silicone adhesive is cut away.
C AUTION
Figure 1: Removing key strip
Acetone may not come into contact with a roof window made of polycarbonate plastic. Acetone has a
chemical effect on the polycarbonate plastic which
reduces the roof windows strength.
4 Clean all surfaces thoroughly. Remove old remains of silicone

with a razor blade or similar.
VDRF03.02GB
80
9 Frame, body, cab and accessories 9.9.1 Windscreen
5 Fit masking tape on the inside and outside of the window panes
by the surfaces that are to be glued.
6 When the windscreen or a side window is to be changed, then the

window panes must be adjusted so that the upper edge on the
side window has the same height as the top edge of the roof (see
figure 2) and so that the distance between windscreen and side
window is as shown in figure 3.
Use spacers against the roof member to ensure that the distances are obtained.
006268
1,0
1
1,0
006269
Figure 2: Adjusting side window - cab roof

1. Side window
2. Rubber strip
3. Cab frame/door opening
Figure 3: Adjusting side window - windscreen

1. Masking tape
7 Install the key strip around the whole window pane.
8 Apply silicone adhesive 923854.0100 around the window panes.
Make the new joint wider than the old one to create a good seam.
The silicone should be applied from the outside of the joints, to
give a full and smooth joint.
NOTE
There must be silicone between the window panes, to avoid
contact between the window panes.
VDRF03.02GB
9 Frame, body, cab and accessories 9.9.2 Side window
81
9 Remove excess silicone adhesive from the outer vertical corners

with a tool made of cardboard as shown in figure 4. Smooth out
the joints on the inside with a finger, wet with water or soapy
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).
006272
12 Lay the roof window into place and check that there is a uniform
distance of one or several millimetres along the window panes
edges and by the protection over the frames sides. Then tighten
the corner bolts for the window pane.
Figure 4: Tool template for silicone joint, scale 1:1
13 Apply silicone adhesive 923854.0100 by the edges and smooth

out the joints with a finger, wet with water or soapy water.
I M P OR TA NT
Mark the window panes with "New adhesive. Do not
touch.".
14 Remove the masking tape immediately after applying adhesive to

avoid edge formation. Hardening time is dependent on ambient
temperature, plan the change so that downtime is minimised.
9.9.2
page
Side window
Side window, description

The side windows are secured in the cab and doors with key strips.
For further details, see Glass/windows/mirrors, description page 78.
page
Side window, replacement
NOTE
The method describes a general procedure.
VDRF03.02GB
82
2 Use special tools to detach the wedge strip.
3 Remove the wedge strip which runs around the whole window.
4 Carefully remove any glass remains from the rubber strip.
5 Fit the new window, securing it at the bottom edge.
VDRF03.02GB
83
6 Spray soap solution on the window and rubber strip to facilitate

fitting.
7 Thread the rubber strip around the whole window; use special
tools.
8 Secure the wedge strip with a special tool.

9 Pull the wedge strip around the whole window.
VDRF03.02GB
84
9 Frame, body, cab and accessories 9.9.3 Roof window
10 Cut off the wedge strip approx. 2 cm too long.

11 Fit the other end of the wedge strip edge to edge.
12 Adjust the wedge strip so that the correct fit is obtained.
9.9.3
page
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 is elastic.
Safety is maintained within a temperature interval of 120 C to -45 C
(becomes brittle at -110 C, glass conversion temperature 145 C).
The roof window has a patented surface layer that increases its resistance to wear, UV light and chemicals.
The roof window is joined with the windscreen. Joints between the window panes and between roof window and cab are sealed with silicone
adhesive. Lay a new seal of silicone adhesive when replacing.
For location, see Glass/windows/mirrors, description page 78.
WARN IN G
The strength of the roof window may be significantly
reduced in case of exposure to substances containing: aromatic hydrocarbons, ketones, esters and
chlorinated hydrocarbons.
Check the roof windows surface at regular intervals,
and only clean with washer fluid or mild cleaning
agents. Rinse with lukewarm water. Replace the roof
window if it is damaged, cracked, or scratched!
page
Roof window, replacement

See Windscreen, replacement page 79 for the general procedure.
The roof window is combined with the windscreen. The joint is sealed
with silicone. Add a new silicone seal when replacing.
VDRF03.02GB
9 Frame, body, cab and accessories 9.9.4 Rear window
9.9.4
85
Rear window
Rear window, description
page
The rear window is attached to the cab with a key strip.

On machines with hydraulic sliding cab or hydraulic vertically adjustable cab, the rear window can be opened to provide an emergency
exit.
For further details, see Glass/windows/mirrors, description page 78.
Rear window, replacement
page
See Side window, replacement page 81 for the general procedure.
9.9.5
Rearview mirror
Rearview mirror, description
page
001510
The cab has a rearview mirror (position A) located in the cab as well
as rearview mirrors (position B) on left and right front wing. The function of the rearview mirror is to give the operator vision around the machine.
A. Rearview mirror
B. External mirror
As an option the machine can be equipped with electrically controlled

and heated exterior rearview mirrors.
9.9.6
Reversing camera
Reversing camera, description
page
The reversing camera is located at the rear edge of the horizontal

counterbalance weight, furthest back on the machine. It is designed to
provide improved vision when reversing. The reversing camera is watertight and has a microphone and infrared lighting for night vision. In
addition, the camera is equipped with automatic heating which is activated at ambient temperatures below +10 C.
1
1
3
1. IR diodes
2. Camera
3. Microphone
007425
The reversing camera sends colour images and audio to the monitor
in the cab; see Monitor, reversing camera, description page 86.
As an option the machine can be equipped with an extra camera at the

front of the machine for improved vision in front of the machine.
Switching between the display of the image from the front and rear
cameras is controlled with a button on the monitor.
VDRF03.02GB
86
9 Frame, body, cab and accessories 9.9.7 Monitor, reversing camera
9.9.7
Monitor, reversing camera
Monitor, reversing camera, description
page
The monitor shows picture and sound from the back-up camera. The
picture is shown in colour and light intensity is automatically adjusted
according to light conditions in the cab. The monitor can handle signals from two different cameras.
CA.SE
MENU
The monitor is mounted on a hinged bracket to the left in front of the

door in the cab.
VOL
3
BRI
007416
1. Selection of camera
2. Menu
3. Brightness
4. Volume setting
5. Switching ON/OFF
VDRF03.02GB
9 Frame, body, cab and accessories 9.10 Cab structure and suspension
9.10
87
Cab structure and

suspension
Cab structure and suspension, description
page
The cab is mounted in a cab undercarriage via strong rubber insulators

located on the underside of the cab. This minimises vibrations from the
frame to the cab. There is an insulator at four points - one at each corner. Each insulator mounting has one rubber bushing and one bolt.
3
4
003206
Cab Spirit Delta

1. Cab frame
2. Door
3. Cab suspension
4. Cab undercarriage
9.10.1
Cab frame
Cab frame, description
page
002210
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!
Cab Spirit Delta
VDRF03.02GB
88
9 Frame, body, cab and accessories 9.10.2 Doors
9.10.2
page
Doors
Doors, description
The cab has two doors - the left is the operators door and the right is
the emergency exit. The door has:
rail
handle
key lock
openable window (passenger door
Switches in the doors locks sense if the door is open. The switch is
used to light the interior lighting and warn of an open door.
8 Control system , group 8.4.2.12 LIGHTS, menu 12 or 8.4.11.2
SLIDING CAB, menu 1.
9.10.3
page
Cab undercarriage
Cab substructure, description

The cab is mounted on a cab undercarriage via strong rubber insulators located on the underside of the cab. This is to minimise vibrations
from the frame to the cab.
The cab undercarriage is fitted on the machines chassis (frame) via a
mounting. The chassis mounting depends on whether the machine is
equipped with:
manual sliding cab
hydraulic sliding cab
hydraulic vertically adjustable cab
hydraulically tiltable cab.
9.10.3.1
page
Cab undercarriage, sliding cab
Cab undercarriage, sliding cab, description

mounting. The mounting to the chassis consists of four ball bearing
metal rollers which run in rails above the machines frame.
VDRF03.02GB
9 Frame, body, cab and accessories 9.10.3.2 Cab undercarriage, vertically adjustable cab
9.10.3.2
89
Cab undercarriage, vertically

adjustable cab
Cab undercarriage, vertically adjustable cab, description
page
3
mounting. The mounting runs in a lift mast which is secured in the machines chassis behind the right-hand front wing which means that the
cab is positioned above the right-hand drive wheel.
The lift mast consists of outer mast, inner mast lift cylinder and chains.
The inner mast runs in the outer mast on ball bearing rollers.
001873
1. Hydraulic cylinder, vertically adjustable cab

2. Mast, vertically adjustable cab
3. Cab undercarriage, vertically adjustable cab
4. Safety lock
VDRF03.02GB
90
9 Frame, body, cab and accessories 9.10.4 Sliding cab
9.10.4
Sliding cab
Manual sliding cab, description
page
Manual sliding cab means that the cab can be moved forward to facilitate access for service and maintenance in the engine compartment.
The cab is pushed for and aft by hand. Two cable chains on each side
ensure that hoses and electric cabling to and from the cab are not
damaged when the cab is moved. The cab is secured in the rear position during operation with two lock handles at the rear edge of the cab.
D ANGER
The cab may start to move.
Fatal danger!
A. Position, lock handle

B. Lock pin
VDRF03.02GB
000270
The cab is heavy and the machine must absolutely

not be moved without first securing the cab. Secure
the cab with both lock handles before operating the
machine.
WARN IN G
It is important to that the lock handles are intact! They
should be checked regularly. However, it is not included as part of the service schedule for preventive
maintenance!
91
Hydraulic sliding cab, function description
page
Condition
Reference
value
Reference
Doors
Closed
Doors, description page 88.
D1
D2
1
D790-1
3, 13
D12
4,14
D797-O
5
D4
P1
12
LS
11, 17
TP
B
T1
10, 16
006901
6, 9, 15
Pos
Explanation
Signal description
Reference
Switch (S177) sliding cab sends a voltage

U = 24 V
Contact closed door, sends signal to control unit cab when door is closed.
U = 24 V
The cab control unit (D790-1) sends cab

forward or cab backward on the CAN bus.
Checked by control
system, error shown
with error code.

Cab control unit
Control unit frame option (D797-O) supplies voltage to servo valve sliding cab forward or servo valve sliding cab backward
on control valve option frame.
I = 435650 mA

Control unit, frame option

system , group 8.4.11.2 SLIDING CAB,
menu 1
Doors, description page 88

system , group 8.4.11.2 SLIDING CAB,
menu 1

system , group 8.4.11.2 SLIDING CAB, menu
3 and 4
VDRF03.02GB
92
Pos
Explanation
Signal description
Reference
Servo valve sliding cab forward or servo

valve sliding cab backward pressurises
the sliding cab slide in control valve, option frame.
Control valve, option frame, description page

93
Control valve, option frame sends control

signal to shuttle valve option.

93
The shuttle valve sends the strongest control signal to main pumps if several functions are activated at the same time.
Shuttle valve, frame option, description page

97
The main pumps pump oil from the tank.
Pressure plate "Max.

pressure hydraulic oil
pumps" on left frame
member.

Control valve, option frame pressurises

valve block sliding cab.

93
10
Valve block sliding cab pressurises hydraulic motor for sliding cab.
Valve block, manual sliding cab, description

page 97
11
Hydraulic motor, sliding cab pulls the cab

forward or backward.
Hydraulic motor, sliding cab, description page

97
12
Sensor end position (B769-2) sends a

(D790-1) when cab is close to the end position.
U = 24 V
Sensor, end position damping, description

page 100
13

"dampen sliding cab" on the CAN bus.
Checked by control
system, error shown
with error code.

Cab control unit
14
Control unit, frame option (D797-O) reduces control current to servo valve, sliding cab forward or servo valve, sliding cab
backward in control valve, option frame.

Control valve, option frame reduces the

hydraulic pressure to valve block sliding
cab.
16
Valve block sliding cab lets pressure

through to hydraulic motor sliding cab.

page 97
17
Hydraulic motor sliding cab reduces the

speed of sliding cab.
Hydraulic motor, sliding cab, description page

97
15

3 and 4

system , group 8.4.11.2 SLIDING CAB, menu 2

3 and 4

93
3 and 4
Hydraulic diagram, sliding cab

Hydraulic diagram, sliding cab + support jacks
VDRF03.02GB
9 Frame, body, cab and accessories 9.10.4.1 Cab cradle
9.10.4.1
page
93
Cab cradle
Cab cradle, description

The cab is secured on a cradle which runs on wheels in rails on the
frame. See Cab substructure, description page 88.
9.10.4.2
page
Hydraulic oil pump
Hydraulic oil pump, description
The hydraulic sliding cab is pressurised from hydraulic oil pump 1 and
2, see section 10 Common hydraulics , group 10.4.2 Axial piston pump
9.10.4.3
page
The hydraulic sliding cab is controlled by a separate section in control

valve, option frame.
pressure and reducing valves convert electrical 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 flow limits so that several functions can be activated simultaneously.
The control valve is located at the front of the engine compartment and
is controlled by Control unit, frame option (D797-O). Control valve, option frame is made up of several sections, each section controls one
function. The following functions are controlled by control valve, option
frame:
Support jacks
Sliding cab / Vertically adjustable cab
Cab tilt
VDRF03.02GB
94
9 Frame, body, cab and accessories 9.10.4.3 Control valve, option frame
Valve slide, sliding cab
1
6
The valve slide controls direction and speed of sliding cab by controlling hydraulic motor pressure, sliding cab.
The valve slide is controlled by servo valve forward and servo valve
backward.
Servo valve sliding cab forward
Servo valve sliding cab forward controls servo pressure to valve slide
sliding cab so that this controls oil pressure to hydraulic motor sliding
cab forward.
Servo valve sliding cab forward regulates electrically with the solenoid
valve sliding cab forward (Y6016), which is activated by Control unit,
000624
Control system , group 8.4.11.2 SLIDING CAB, menu 3.
1. Load signal (LS)

3. Tank return (T1)
4. Connection hydraulic motor (B)
5. Tank return (TP)
6. Connection hydraulic motor (A)
Servo valve sliding cab backward

Servo valve sliding cab backward controls servo pressure to valve
slide steering so that this controls oil pressure to hydraulic motor sliding cab forward.
Servo valve sliding cab backward regulates electrically with the solenoid valve sliding cab backward (Y6017), which is activated by Control
unit, frame option (D797-O).
VDRF03.02GB
95
page
NOTE
Safety.
Safety.
NOTE
6

NOTE
000624
1. Load signal (LS)

3. Tank return (T1)
4. Connection hydraulic motor (B)
5. Tank return (TP)
6. Connection hydraulic motor (A)
NOTE
up.
8 Fit the valve.
marking.
with the marking.
NOTE
VDRF03.02GB
96
NOTE
C AUTION
010475

C AUTION
product damage.
C AUTION
VDRF03.02GB
9 Frame, body, cab and accessories 9.10.4.4 Shuttle valve, frame option
9.10.4.4
97
Shuttle valve, frame option
Shuttle valve, frame option, description
page
See section 10 Common hydraulics, group 10.5.3 Shuttle valve.
9.10.4.5
Valve block, manual sliding cab
page
Valve block sliding cab is fitted on hydraulic motor sliding cab and prevents the motor rotating when sliding cab is not activated.
9.10.4.6
Hydraulic motor, sliding cab
Hydraulic motor, sliding cab, description
page
001862
The hydraulic motor is located furthest forward on the right-hand side

of the cab chain. The hydraulic motor pulls the chain which in turn pulls
the cab forward and backward.
1. Sensor, damping (rear edge of cab on left-hand

side)
2. Indicator plate, damping
3. Chain, sliding cab
4. Hydraulic motor, sliding cab
5. Control valve, sliding cab
VDRF03.02GB
98
9 Frame, body, cab and accessories 9.10.4.6 Hydraulic motor, sliding cab
Hydraulic motor, sliding cab, replacement
page
NOTE
Safety.
2 Depressurise the hydraulic systems, See section B Safety.
3 Remove the protective cover.
4 Slacken the chain, loosen the chain tensioner and the adjusting
screw.
5 Detach the chain from its mounting.
6 Detach the hydraulic hoses from the motor.
7 Remove the ring gear.
8 Remove the hydraulic motor from its mounting.
1. Protective cover
2. Hydraulic motor
3. Chain tensioner
9 Replace the hydraulic motor.
NOTE
C AUTION
010475

VDRF03.02GB
9 Frame, body, cab and accessories 9.10.4.7 Chain, sliding cab
99
C AUTION
9.10.4.7
Chain, sliding cab
Chain, sliding cab, description
page
001862
The chain pulls the cab forward and backward and is secured in the
front and rear edges on the cab undercarriage. The chain tension is
adjusted by moving the hydraulic motor for sliding cab.
1. Sensor, damping (rear edge of cab on left-hand

side)
3. Chain, sliding cab
4. Hydraulic motor, sliding cab
5. Control valve, sliding cab
page
Chain and chain wheel, sliding cab, replacement

2 Slacken the chain, loosen the chain tensioner and the adjusting
screw.
3 Detach the chain at the front edge.
4 Detach the chain at the rear edge.
5 Replace the chain.
7 Adjust the chain with the adjusting screw.
8 Tighten the chain tensioner.
VDRF03.02GB
100
9 Frame, body, cab and accessories 9.10.4.8 Sensor, end position damping
9.10.4.8
page
Sensor, end position damping
Sensor end position damping indicates when the cab is near the end
position and is used to activate end position damping.
8 Control system , group 8.4.11.2 SLIDING CAB, menu 2.
page

VDRF03.02GB
9 Frame, body, cab and accessories 9.10.5 Vertically adjustable cab
9.10.5
101
Vertically adjustable cab
Vertically adjustable cab, function description
page
Condition
Reference value
Reference
Doors
Closed.
Doors, description page 88.
If the door is open with lifted cab, the lift and lower functions for the boom are limited.
D1
D2
1
D790-1
4, 14, 17
D797-O
D17
D4
5
D15
3, 16, 22
10
18
11, 20
P1
LS
15
D13
12, 21
13
TP
T3
T1
6, 9, 19
013033
Pos
Explanation
Signal description
Reference
Switch vertically adjustable cab

Control unit, cab (D790-1).
U = 24 V
Contact closed door, sends a signal

to the cab control unit (D790-1)
when door is closed.
U = 24 V
The cab control unit (D790-1) sends

cab up or cab down on the CAN
bus.
D1: Diagnostic menu, see section 8 Control system , group 8.4.11.2 SLIDING CAB, menu 1
Doors, description page 88

D2: Diagnostic menu, see section 8 Control system , group 8.4.11.2 SLIDING CAB, menu 1
Cab control unit
VDRF03.02GB
102
9 Frame, body, cab and accessories 9.10.5 Vertically adjustable cab
Pos
Explanation
Signal description
Reference
Control unit, frame option (D797-O)

supplies voltage to servo valve
raise cab (Y6016) or servo lower
valve cab (Y6017) on control valve,
option frame.
I = 435650 mA

Servo valve, raise cab (Y6016) or

servo valve, lower cab (Y6017)
pressurises the sliding cab slide in
control valve, option frame.
Control valve, option frame sends a

control signal to shuttle valve option.

104
The shuttle valve sends the strongest control signal to main pumps if
several functions are activated at
the same time.
Shuttle valve, frame option, description page 97
The main pumps pump oil from the

tank.

frame beam.

Control valve, option frame pressurises the accumulator and the load
control valve.

104
10
The accumulator stores pressure.
Accumulator, vertically adjustable cab, description page 105
11
The load control valve lets the pressure through to hydraulic cylinder
for vertically adjustable cab.
Load control valve, description page 105
D4: Diagnostic menu, see section 8 Control system , group 8.4.11.2 SLIDING CAB, menu 3 and
4

104
D4: Diagnostic menu, see section 8 Control system , group 8.4.11.2 SLIDING CAB, menu 3 and
4
When lowering, the load control

valve changes position and restricts
flow from hydraulic cylinder for vertically adjustable cab.
12
Hydraulic cylinder for vertically adjustable cab lifts or lowers the cab.
Hydraulic cylinder, vertically adjustable cab, description page 106
13
Sensor lowered cab (B777-2) stops

sending a voltage signal to Control
unit, frame option (D797-O) when
the cab leaves the lowest position.
U = 24 V
Sensor, lowered cab, description page 110
14

sends "cab up" on the CAN bus.

15
Sensor end position damping

(B769-2) sends a voltage signal to
the cab control unit (D790-1) when
cab is close to the end position.
U = 24 V
Sensor, end position damping, description page

111
VDRF03.02GB


9 Frame, body, cab and accessories 9.10.5.1 Hydraulic oil pump
103
Pos
Explanation
Signal description
Reference
16
The cab control unit (D790-1) transmits "cab lift" on the CAN bus.

Cab control unit
17

reduces the control current to servo
valve raise cab (Y6016) or servo
lower valve cab (Y6017) in control
valve, option frame.

Servo valve, raise cab (Y6016) or

servo valve, lower cab (Y6017) controls the pressure to the sliding cab
slide in control valve, option frame.
19
Control valve, option frame reduces

hydraulic pressure to valve block

104
20
Valve block lift cylinder for vertically

adjustable cab lets pressure
through to hydraulic cylinder for vertically adjustable cab.
Load control valve, description page 105
21
Hydraulic cylinder for vertically adjustable cab reduces the speed of

raising or lowering the cab.
Hydraulic cylinder, vertically adjustable cab, description page 106
22
When the cab is lifted the cab control unit (D790-1) activates speed
limitation.
Maximum speed: 5 km/h.

Cab control unit
18

and 4

104
and 4
Hydraulic diagram, cab lift and support jacks
9.10.5.1
page
Hydraulic oil pump
Hydraulic oil pump, description

The hydraulic sliding cab is pressurised from hydraulic oil pump 1 and
2, see section 10 Common hydraulics , group 10.4.2 Axial piston pump
VDRF03.02GB
104
9.10.5.2
page
1
6
The vertically adjustable cab is controlled by a separate section in control valve, option frame, for details see Control valve, option frame, description page 93.
Valve slide raise/lower cab

The valve slide controls the direction and speed of raising and lowering the cab by controlling the hydraulic pressure for hydraulic cylinder,
The valve slide is controlled by servo valve raise cab and servo valve
lower cab.
Servo valve raise cab
000624
Servo valve raise cab controls servo pressure to valve slide raise/lower cab so that this controls oil pressure to hydraulic cylinder, vertically
adjustable cab, for raising the cab.
1. Load signal (LS)

3. Tank return (T1)
4. Connection, hydraulic cylinder (B)
5. Tank return (TP)
6. Connection, hydraulic cylinder (A)
Servo valve raise cab regulates electrically with the solenoid valve
raise cab (Y6016), which is activated by Control unit, frame option
(D797-O).
Servo valve lower cab

Servo valve lower cab controls servo pressure to valve slide raise/lower cab so that this drains hydraulic cylinder, vertically adjustable cab,
for lowering the cab.
Servo valve lower cab regulates electrically with the solenoid valve
raise cab (Y6017), which is activated by Control unit, frame option
(D797-O).
Servo valve lower cab can be checked from the diagnostic menu, see
section 8 Control system , group 8.4.11.2 SLIDING CAB, menu 4.
page
See Control valve, option frame, replacement page 95.
9.10.5.3
page
Shuttle valve, frame option
Shuttle valve, frame option, description
VDRF03.02GB
9 Frame, body, cab and accessories 9.10.5.4 Accumulator, vertically adjustable cab
9.10.5.4
105
Accumulator, vertically adjustable cab
Accumulator, vertically adjustable cab, description
page
The accumulator stores pressure so that the cab does not lower if the
engine stops and the machine becomes depressurised.
9.10.5.5
Load control valve
Load control valve, description
page
The load control valve reduces the speed when lowering the cab.
000621
When the pressure is released behind the valve, the valve slide changes position and restricts the channel through the valve.
VDRF03.02GB
106
9 Frame, body, cab and accessories 9.10.5.6 Hydraulic cylinder, vertically adjustable cab
9.10.5.6
Hydraulic cylinder, vertically

adjustable cab
Hydraulic cylinder, vertically adjustable cab, description
page
3
The hydraulic cylinder lifts the inner mast and thus the cab.
001873

4. Safety lock
Hydraulic cylinder, vertically adjustable cab, replacement
page
NOTE
Safety.
1 Raise the cab so high to secure its position with both lock lugs
(position A).
Lower the cab so that it rests on the safety brackets.
C AUTION
Risk of fatal danger under raised cab.
A
001977
Secure the cab with the lock lugs (position A) on both

sides of the cab frame.
A. Lock lug

Safety.
4 Mark up and detach the hydraulic hoses from the extension
cylinder.
NOTE
VDRF03.02GB
107
5 Release the upper cylinder mounting (position 1) from the moving

part of the cab frame.
1
2
008206
1. Upper mounting hydraulic cylinder

2. Retaining bracket hydraulic cylinder
6 Remove the load control valve and compress the hydraulic
cylinder.
NOTE
7 Attach hoisting equipment to the hydraulic cylinder.
8 Remove the hydraulic cylinders retaining brackets from the fixed
part of the cab frame.
9 Tilt and lift the hydraulic cylinder out upwards.
10 Transfer parts to the new hydraulic cylinder.
11 Fit the hydraulic cylinder in the reverse order.
000621
Load control valve
VDRF03.02GB
108
NOTE
C AUTION
010475

C AUTION
page

VDRF03.02GB
9 Frame, body, cab and accessories 9.10.5.7 Mast, vertically adjustable cab
9.10.5.7
109
Mast, vertically adjustable cab
Mast, vertically adjustable cab, description
page
3
The mast holds the cab secure and enables raising and lowering.
001873

4. Safety lock
VDRF03.02GB
110
9 Frame, body, cab and accessories 9.10.5.8 Sensor, lowered cab
9.10.5.8
Sensor, lowered cab
Sensor, lowered cab, description
page
000618
The sensor indicates when the cab is completely lowered. When the
cab is raised, the machines speed is reduced and the transmission is
blocked in second gear.
1. Sensor, end position damping

2. Sensor, end position lowered cab
page

VDRF03.02GB
9 Frame, body, cab and accessories 9.10.5.9 Sensor, end position damping
9.10.5.9
111
Sensor, end position damping
page
8 Control system , group 8.4.11.2 SLIDING CAB, menu 2.
000618
Sensor damping end position indicates when the cab is close to end
position. This is used to activate end-position damping. When the cab
is raised, the machines speed is reduced and the transmission is
blocked in second gear.
1. Sensor, end position damping

2. Sensor, end position lowered cab
page

VDRF03.02GB
112
9 Frame, body, cab and accessories 9.10.5.10 Emergency lowering valve
9.10.5.10
Emergency lowering valve
Emergency lowering valve, description
page
The emergency lowering valve (position A) opens a connection between the hydraulic cylinders piston side and tank, and makes it possible to lower the cab if the machine becomes depressurised or deenergised.
001978
A. Location, emergency lowering valve
9.10.5.11
Safety lock, vertically adjustable cab
Safety lock, vertically adjustable cab, description
page
On the mast are two lock lugs which are used to secure the cab in the
raised position during maintenance work with raised cab.
001977
A. Lock lug
VDRF03.02GB
9 Frame, body, cab and accessories 9.11 Cab interior
9.11
9.11.1
page
113
Cab interior
Instrument and control panels
Dashboard panel, description

The dashboard panel is secured to the steering column and contains
warning and indicator lamps, display (KID), function keys (KIT) and
switches.
page
Left-hand dashboard panel, description

Left instrument panel is located in the left corner of the cab. It contains
rotary controls, switches, and ventilation.
page
Panel for load handling functions, description

The panel is mounted on the drivers seat. The panel includes switches for load handling functions and safety switches to interrupt ongoing
load handling functions. The control lever is located next to the panel.
page
Dashboard panel, replacement

2 Remove the steering wheel centre cover.
3 Remove the nut and the steering wheel.
4 Remove the bolts on the underside of the dashboard panel.
VDRF03.02GB
114
9 Frame, body, cab and accessories 9.11.2 Interior details, plastic
5 Remove the bolts on the top of the dashboard panel.
6 Unplug the connector from the multi-function levers, ignition

switch, KIT control unit (D790-2) and KID control unit (D795).
7 Transfer the components to the new steering wheel cover.
9.11.2
page
Interior details, plastic
Interior plastic components, description

The interior of the cab consists of recyclable material.
9.11.3
page
Interior details, textile
Interior textile components, description

The interior of the cab consists of recyclable material.
9.11.4
page
Floor covering
Floor covering, description

The floor covering is a wear-resistant and recyclable material.
9.11.5
page
Insulation
Insulation, description
The cab insulation consists of recyclable material.
VDRF03.02GB
9 Frame, body, cab and accessories 9.11.6 Sun blinds
9.11.6
115
Sun blinds
Sun blinds, description
page
Sun blinds can be chosen for the front window (windscreen) and the
roof window.
1.
Sun visor, front window: Can be raised and lowered using a cord
on the right-hand side. Stops in selected position.
2.
Sun visor, roof window: Extends forward to fasten in two hooks in

the front edge of the window.
9.11.7
Terminal console
Terminal console, description
page
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
page
008228
The writing table with reading light is located on a flexible attachment

to the right in front of the door in the cab. That is where work orders,
etc. can be fastened.
VDRF03.02GB
116
9 Frame, body, cab and accessories 9.12 Frame
9.12
Frame
Frame, description
page
The frame is a modular construction and consists of front section, rear

section and a beam pair. This construction provides advantages in
terms of rigidity and strength.
There are mounting points in the frame for engine, transmission, drive
axle, steering axle, fuel and hydraulic tanks, cab, boom 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 a view rearwards as
possible.
The front wings are bolted into the frame (which has advantages when
delivering the machine).
4
6
2
1
VDRF03.02GB
001511
1.
Frames front part with drive axle mounting
2.
Cab mounting (4 points)
3.
Steering axle mounting
4.
Frames rear part with counterweights
5.
Boom mounting
6.
Engine compartment with mountings for engine and transmission
7.
Beam pair
8.
Mounting for front wing
9 Frame, body, cab and accessories 9.13 Body
9.13
117
Body
Body, description
page
The bodys components comprise:
3
1
002213
1.
Wings
2.
Hood engine compartment
3.
Counterweight
9.13.1
page
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 Counterweight, description page 118) acts as a mudguard for the rear
wheels.
The wings can be equipped with extra mudguards when the machines
work environment requires such (
9.13.2
page
).
Hood engine compartment, description

The machines engine compartment is protected by tread plates which
function as an engine hood. The tread plates are divided into five sections and are secured with retaining bolts. The tread plates are designed to be walked on and are ribbed to provide sure footing.
VDRF03.02GB
118
9 Frame, body, cab and accessories 9.13.3 Footstep and rail
9.13.3
page
Footstep and rail
Steps and rails, description

The cab has steps and handrails for easy access.
Railing is also available on the front wings (
9.13.4
page
).
Counterweights
Counterweight, description
The machine has counterweights to balance the machines lift capacity and 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 places:
Under the steering axle
Furthest back on the machine there are vertical counterweights

secured in the rear edge of the frame; the outer has a towing eye.
Between the outer counterweight and the frame, there are smaller
counterweights whose dimensions and quantity are adapted to
balance the machines lifting capacity.
Upper horizontal counterweight.

Under the horizontal counterweight, there are smaller counterweights whose dimensions and quantity are adapted to balance
the machines lifting capacity.
D ANGER
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.
VDRF03.02GB
9 Frame, body, cab and accessories 9.14 Central lubrication
9.14
119
Central lubrication
Central lubrication, checking
page
1 Check that no grease has been forced out through the safety
valve (position 2).
If grease has been forced out through the safety valve it means
that there is a stop in the system. Determine which line is clogged
by feeling the connections at the distribution blocks. A clogged
hose remains pressurised and the connection becomes hard.
NOTE
If several distribution blocks are connected in series, a
clogged line will be pressurised all the way to the first 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 blocks.
To operate the pump, loosen the cover and press in the switch for
manual operation (position 5).
Overview - central lubrication pump unit and distribution block. Example illustration.
1. Lubricant nipple, lubricating grease filler orifice
2. Safety valve
3. Lubricant nipple, manual system lubrication
4. Indicator pin
5. Switch, manual operation
If the indicator pin does 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 (position 3).
4 Fill grease in the pump unit through the filler nipple, see section
F Technical data.
VDRF03.02GB
120
9 Frame, body, cab and accessories 9.14 Central lubrication
Central lubrication, adjusting lubrication times
page
The central lubrications pause and run-time must be set after replacement, the setting is unique to each machine, depending on the machines equipment. At replacement, the new pump unit should be set
in the same way as the old one.
If the machine is not lubricated correctly, pause and run-time can be
adjusted. Primarily, run-time should be adjusted so that all lubrication
points on the machine are greased every time. If large amounts of
grease are pressed out at all lubrication points, pause-time can be
increased.
NOTE
Adjust only one step each time. Small adjustments make a big
difference.
Test or extra greasing

Central lubrication can be operated manually by holding in the button
for manual operation (position 3) for 2 seconds. This starts an extra lubrication cycle.
Pause-time
Example illustration
1. Pause time setting (red)
2. Run time setting (blue)
3. Manual pump operation
Pause-time is the length of the interval between greasings. The interval is adjusted in whole hours between 1 and 15 hours. Pause-time is
adjusted with the red handle (position 1).
Switch position
Pause-time [hours]
10
11
12
13
14
15
Run-time
Run-time is how long the pump is activated every time. Run-time can
be adjusted between 2 and 30 minutes. Pause-time is adjusted with
the blue handle (position 2).
Switch position
Run-time [minutes]
10
12
14
16
18
20
22
24
26
28
30
VDRF03.02GB
9 Frame, body, cab and accessories 9.14.1 Pump unit
9.14.1
121
Pump unit
Pump unit, description
page
The pump unit consists of containers with stirrer, pump housing with
built-in motor, timer, pump element, filler nipple, and safety valve.
The central lubrication works with lubrication cycles (pause and running time as well as read-in time). In the pump there is a circuit board
with a timer with which one can set the pump motors run and pause
time.
When the central lubrication works, it greases the lubrication points
one at a time in series. If a stop should occur in a lubrication point, the
pressure will increase and the safety valve will release grease and
also the following lubrication points will not be greased.
NOTE
The safety valve will press out grease if a grease point cannot be
greased. If a grease point is not greased, none of the following
grease points will be greased Therefore, it is very important to
check the safety valve.
Example illustration, central lubrication components
1. Pump unit
2. Safety valve
3. Distribution block
VDRF03.02GB
122
9 Frame, body, cab and accessories 9.14.2 Distribution block
9.14.2
Distribution block
Distribution block, description
page
The distribution blocks distribute grease from the pump unit to grease
points or on to other distribution blocks. The number of distribution
blocks can vary depending on how may (and which) grease points
have been selected.
The distribution blocks consist of pistons that meter out grease to each
grease point. The pistons are driven by the grease and do not have
springs and gaskets. It is the grease that drives the pistons inside the
distributor. The shape of the pistons and channels in the distribution
block enable the pistons to move in a predetermined way. Each piston
must have completed its motion before the next piston can move. The
pistons are dependent on each other. It is technically impossible to
skip any connected grease point. If a grease point cannot be greased,
the whole system is blocked and grease is pressed out through the
safety valve.
Example illustration, central lubrication components

1. Pump unit
2. Safety valve
3. Distribution block
The systems first distribution block (i.e. the block closest to the pump)
has an indicator pin. If the pin moves forward and backward (in time
with the piston movements), this indicates that grease is pumped
through the system. If a distribution block is unable to supply grease
to any of its lubrication points, the pin stops and accordingly the entire
system.
If there is clogging in the system, that line will be pressurised, from the
pump to the stop, through all the distribution blocks on the way. This
makes it easy to find a block in the system. By feeling the distribution
blocks connections and feeling which connection is stiff, the blockage
can be traced. Keep in mind that several distribution blocks may be
connected in series.
9.14.3
page
Lines
Lines, description
Central lubrication works under very high pressure, only use lines that
meet the following specifications.
Main hose
VDRF03.02GB
Diameter
8.4 mm
Explosion pressure
min. 60.0 MPa
9 Frame, body, cab and accessories 9.15 Paint/coatings
9.15
page
123
Paint/coatings
Paint/coatings, description
The machine is painted with an alkyd-based mono-component paint
that is applied with a brush or a sprayer. For paint codes (RAL), see
machine card.
Check the machine frequently for stone chips, dents and paint scratches, rectify 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
Touching up, the surfaces to be touched up must be thoroughly
cleaned.
Please contact Cargotec for information about other surface treatment
and material colours.
VDRF03.02GB
124
VDRF03.02GB
9 Frame, body, cab and accessories 9.15 Paint/coatings
Table of Contents 10 Common hydraulics

mm mm mm mm mm mm
10 Common hydraulics....................................................................................... 3
10.2
Safety valves .............................................................................................. 3
10.2.1
Accumulator drain valve ........................................................................ 3
10.2.2
Attachment relief valve .......................................................................... 4
10.2.3
Pipes and hoses .................................................................................... 4
10.3
Tanks and accumulators ............................................................................ 5
10.3.1
Tank ....................................................................................................... 5
10.3.2
Pipes and hoses .................................................................................... 5
10.4
Pumps ........................................................................................................ 6
10.4.1
Gear pump with fixed displacement ....................................................... 6
10.4.2
Axial piston pump with variable displacement ..................................... 12
10.4.3
Pipes and hoses .................................................................................. 30
10.5
Hoses, pipes and valves .......................................................................... 31
10.5.1
Pipes and hoses .................................................................................. 31
10.5.2
Priority valve ........................................................................................ 32
10.5.3
Shuttle valve ........................................................................................ 32
10.5.4
Collection block, filtered returns ........................................................... 34
10.5.5
Collection block, unfiltered returns ....................................................... 34
10.6
Temperature control, cleaning and hydraulic oil ....................................... 35
10.6.1
Tank heater .......................................................................................... 36
10.6.2
Hydraulic oil cooler .............................................................................. 37
10.6.3
Cooling fan ........................................................................................... 38
10.6.4
Sensor hydraulic oil temperature ......................................................... 39
10.6.5
Radiator bypass valve ......................................................................... 40
10.6.6
Breather filter hydraulic oil tank ........................................................... 42
10.6.7
Oil filter ................................................................................................. 43
10.6.8
Hydraulic oil ......................................................................................... 47
10.6.9
Hydraulic oil fine-filter .......................................................................... 47
10.6.10
Pipes and hoses .................................................................................. 48
10.7
Auxiliaries ................................................................................................. 49
10.7.1
Hydraulic cylinders ............................................................................... 49
VDRF03.02GB
VDRF03.02GB
mm mm mm mm mm mm
10.2
10.2.1
Safety valves
Accumulator drain valve
Accumulator drain valve, description
page
000434
The accumulator drain valve is located on the accumulator charging

valve. See section 4 Brakes , group 4.3.3 Accumulator charging valve.
VDRF03.02GB
10 Common hydraulics 10.2.2 Attachment relief valve
10.2.2
Attachment relief valve
page
002269
The relief valve is located on the lift cylinder beam. See section 7 Load
handling, group 7.4.8 Attachment relief valve.
10.2.3
page
Pipes and hoses
Pipes and hoses, general

See Pipes and hoses, general page 31.
VDRF03.02GB
10 Common hydraulics 10.3 Tanks and accumulators
10.3
10.3.1
Tanks and accumulators

Tank
Tank, description
page
The hydraulic oil tank forms part of the side panel on the right-hand
side of the machine. The oil filters for the working hydraulics are fitted
inside the tank. These are accessible through hatches on top of the
tank.
Hydraulic oil is filled directly into the tank through the filler caps on the
filter manhole covers. For oil capacity and grade, see section F Technical data. The entire filter unit can be removed to facilitate access for
cleaning. There is a drain plug at the bottom of the tank.
The tank has filtered venting which allows changes in the tank volume
due to usage and temperature variations.
The oil level is checked on the level glass on the tanks side when all
hydraulic cylinders are in the bottom position.
001457
1. Hydraulic oil filler plug

2. Cover for hydraulic oil filter
3. Sight glass, hydraulic oil
4. Breather filter hydraulic oil tank
5. Drain plugs, hydraulic oil
10.3.2
page
Pipes and hoses

VDRF03.02GB
10 Common hydraulics 10.4 Pumps
10.4
10.4.1
Pumps
Gear pump with fixed displacement
Gear pump with fixed displacement, description
page
There are two gear pumps with fixed displacement. One (position 1)
supplies the brake system with pressure, see section 4 Brakes , group
4.3.1 Brake oil pump. The other gear pump (position 2) circulates hydraulic oil for working hydraulics through the cooler and filter.
The gear pump pumps oil using two gear wheels that rotate opposite
each other. One is driven by the pumps input shaft and the other rotates freely. The gear pumps flow is directly dependent on the speed
of the input shaft.
The cooling pump is fitted on the right main pump and is driven by the
main pump shaft from the transmissions power take-off. Pump speed
is directly dependent on engine speed. Pump flow increases and engine speed increases.
000006
The illustration shows hydraulic oil pump alternative

Rexroth
1. Brake fluid pump
2. Pump cooling and filtration
page
Gear pump, replacement (hydraulic oil pump

NOTE
Safety.
Safety.
3 Mark up and release the hydraulic hoses from the gear pump.
VDRF03.02GB
10 Common hydraulics 10.4.1 Gear pump with fixed displacement
4 Remove the gear pump.

Remove the attaching bolts, pull the pump out backwards and lift
it away.
5 Transfer the connection adapters to the new gear pump.
6 Remove the spacer ring from the gear pump or axial piston pump.
Clean the O rings contact surfaces on the spacer ring.
7 Check the O-rings and replace as needed. Install the O-rings on
the gear pump, see section F Technical data.
NOTE
Only use silicone on the side facing the gear pump.
8 Fit the spacer ring on the axial piston pump.
VDRF03.02GB
9 Brush sealing silicone on the gear pumps sealing face against

10 Fit the gear pump on the axial piston pump.
Fit the pump and check that the gear grips the shaft and that the
spacer ring is directly against the gear pump. Fit the pumps retaining bolts.
11 Connect the hydraulic hoses to the gear pump.
NOTE
C AUTION
010475

VDRF03.02GB

15 Check that the hose connections and seal between gear pump
and axial piston pump are airtight.
16 Check the oil level in the brake or hydraulic system, depending
on which pump ahs been changed, fill if necessary.
C AUTION
NOTE
and filters as well.
17 If the brake fluid pump is replaced:
Check the brake pressure; see section 4 Brakes, group 4.3.1
Brake fluid pump.
page
Gear pump with fixed displacement, replacement

(hydraulic oil pump alternative Sauer-Danfoss)
NOTE
Safety.
2 Depressurise the brake and hydraulic systems, see Workshop
Manual section B Safety.
NOTE
VDRF03.02GB
10
it away.
pump.
6 Brush sealing silicone on the brake pumps sealing surface, see

Workshop Manual section F Technical data.
Position the pump and check that the pumps splines engage in
the shaft in the main pump.
NOTE
VDRF03.02GB
11
9 Close the drain valve and tighten the lock ring on the accumulator
charging valve.
C AUTION
010475

13 If the brake fluid pump is replaced:
Check the brake pressure; see section 4 Brakes, group 4.3.1
Brake fluid pump.
14 Check the oil level in the brake or hydraulic system, depending
on which pump ahs been changed, fill if necessary.
C AUTION
NOTE
and filters as well.
VDRF03.02GB
12
10 Common hydraulics 10.4.2 Axial piston pump with variable displacement
10.4.2
Axial piston pump with variable

displacement
Axial piston pump with variable displacement,

description (hydraulic oil pump alternative Rexroth)
page
The hydraulic oil pumps are of the type variable axial piston pump, and
are controlled by load signals depending on the flow demand from
each function.
The hydraulic oil pumps are assembled in pairs with an inlet section
for the suction line. The inlet section leads oil to and from the pumps.
At the inlet section is a connection block containing test outlets for
checking pump pressure. On the connection block are non-return
valves that prevent the oil being pumped around between the pumps
instead of out into the hydraulic system.
10
One of the left-hand pumps connection blocks also contains a branching unit to the attachment hydraulics with a separate non-return valve.
9
8
000528
Hydraulic oil pump unit

1. Adjusting screw standby pressure front pump
2. Adjusting screw max. pressure front pump
3. Test outlet pump pressure rear pump
4. Connection pressure side rear pump
5. Connection pressure side front pump
6. Test outlet pump pressure front pump
7. Left hydraulic oil pump unit
8. Right hydraulic oil pump unit
9. Adjusting screw max. pressure rear pump
10. Adjusting screw standby pressure rear pump
VDRF03.02GB
13

description (hydraulic oil pump alternative SauerDanfoss)
page
The hydraulic oil pumps are of the type variable axial piston pump, and
are controlled by load signals depending on the flow demand from
each function.
5
6
The left hydraulic oil pump (pump 2, position 2) supplies the control
valve for lift and extension and also supplies the attachments control
valve. At boom in pump 2 is disconnected.
The right hydraulic oil pump (pump 1, position 1) supplies the control
system as well as the control valve for lift and extension. The priority
valve ensures that there is always pressure to the control system, the
residual flow is led to the control valve for lift and extension.
On the pumps pressure side is a connection block. On the connection

block are non-return valves that prevent the oil being pumped around
between the pumps instead of out into the hydraulic system.
On the right pumps connection block is a branching unit to the attachment hydraulics with a separate non-return valve. On the connection
block there is also a test outlet for checking pump pressure.
011055
On the left pumps connection block is a branching unit to pressure reduction. On this branching unit there is also a test outlet for this pump.
Hydraulic oil pump unit

1. Right hydraulic oil pump
2. Left hydraulic oil pump
3. Adjusting screw standby pressure pump
4. Adjusting screw max. pressure pump
5. Spacer block pressure side pump
6. Test outlet pump pressure left pump
7. Test outlet pump pressure right pump
VDRF03.02GB
14

function description (hydraulic oil pump alternative
Rexroth)
page
D790-1
1
D797-R 7, 16
P
12
P
P1
D16
LS
LS
P
2, 13
EF
CF
15
LS
C14
C3
C10
No 1
C15
5, 9
No 2
11
6, 10
No 3
3, 14
No 4
3, 14
006417
4, 17
C6
Pos
Explanation
Signal description
Reference
The lift and extension control valve sends a

load signal when a function is activated.
See pressure plate Servo

pressure lift and extension on left frame
member.
Section 7 Load handling, group 7.2 Lifting/lowering
Control signal goes to the shuttle valve that

sends the load signal on to hydraulic oil
pumps No. 3 and No 4.

member.
Shuttle valve, description (hydraulic oil

Hydraulic oil pumps No. 3 and No. 4 increase the flow.
See pressure plate Max.

pumps on left frame
member.
Axial piston pump with variable displacement, description (hydraulic oil pump alternative Rexroth) page 12
Solenoid valve, unloading main pump

(Y6062) leads load signal on to hydraulic oil
pump No. 1 and the shuttle valve
(position 5).

member.
Section 7 Load handling, group 7.3.9

Valve block pump unloading
The shuttle valve sends load signal on to

hydraulic oil pump No. 2.

member.

VDRF03.02GB
15
Pos
Explanation
Signal description
Reference

pumps on left frame
member.
If any attachment function is activated the

Control unit frame rear (D797-R) activates
Solenoid valve top hydraulics (Y6003).
U = 24 V

Solenoid valve top hydraulics (Y6003) controls an unloaded constant pressure to hydraulic oil pump No. 2, this functions as a
load signal.

Valve block top lift hydraulics


10
Hydraulic oil pump No. 2 increases the

flow.

pumps on left frame
member.
11
When Solenoid valve top hydraulics

(Y6003) is not activated, the unloaded
pressure is directed to tank.

Valve block top lift hydraulics
12
The steering valve sends a load signal

when the steering wheel is turned.
Section 5 Steering, group 5.2.3 Steering

valve
13

hydraulic oil pumps No. 3 and 4.

14
See pressure plate Steering pressure, on left

frame member.
15
The priority valve controls the pressure

from the pumps to the steering valve.

frame member.
Section 5 Steering, group 5.2.2 Priority

valve
16
For boom in Control unit frame rear

(D797-R) activates Solenoid valve pump
unloading (Y6062).
U = 24 V

Solenoid valve pump unloading (Y6062)

leads the pressure from the control valve to
the tank.
17
Diagnostic menu, see section 8 Control

system , group 8.4.5.6 HYD, menu 6.
Diagnostic menu, see section 8 Control

system , group 8.4.8.2 BOOM, menu 2

Valve block pump unloading
VDRF03.02GB
16

function description (hydraulic oil pump alternative
Sauer-Danfoss)
page
D790-1
12
D797-R
P
7, 16
D7
P
LS
D7
LS
P1
2, 13
EF
CF
15
LS
P
5, 9
C15
C6
8, 11, 18
C6
3, 14
6, 10
No 2
No 1
011051
4, 17
Pos
Explanation
Signal description
Reference
The lift and extension control valve

sends a load signal when a function is
activated.

pressure lift and extension on left frame member.
Section 7 Load handling, group 7.2 Lifting/

lowering
Control signal goes to the shuttle valve

that sends the load signal on to hydraulic oil pump No. 2.

Shuttle valve, description (hydraulic oil pump

alternative Rexroth) page 32

flow.

pumps on left frame
member.
Axial piston pump with variable displacement, description (hydraulic oil pump alternative Sauer-Danfoss) page 13
Solenoid valve, unloading main pump

(Y6062) leads load signal on to hydraulic oil pump No. 1 and the shuttle valve
(position 5).

Section 7 Load handling, group 7.3.9 Valve

block pump unloading



VDRF03.02GB
17
Pos
Explanation
Signal description
Reference

flow.

pumps on left frame
member.
If any attachment function is activated

the Control unit frame rear (D797-R) activates Solenoid valve top hydraulics
(Y6003).
U = 24 V

Solenoid valve top hydraulics (Y6003)

controls an unloaded constant pressure
to hydraulic oil pump No. 1, this functions as a load signal.

block top lift hydraulics


10

flow.

pumps on left frame
member.
11


block top lift hydraulics
12
The steering valve sends a load signal

when the steering wheel is turned.
Section 5 Steering, group 5.2.3 Steering

valve
13


14

flow.

frame member.
15
The priority valve controls the pressure

from the pumps to the steering valve.

frame member.
Section 5 Steering, group 5.2.2 Priority

valve
16
For boom in Control unit frame rear

(D797-R) activates Solenoid valve
pump unloading (Y6062).
U = 24 V

17
Solenoid valve pump unloading (Y6062)

leads the pressure from the control
valve to Solenoid valve (Y6003).

18


Diagnostic menu, see section 8 Control system , group 8.4.5.6 HYD, menu 6.
Diagnostic menu, see section 8 Control system , group 8.4.8.2 BOOM, menu 2
VDRF03.02GB
18
Hydraulic oil pump, checking (hydraulic oil pump

page
NOTE
Safety.
1 Operate and warm up the machine so that the hydraulic oil reaches operating temperature, approx. 50 C.
2 Stop the engine
3 Connect a pressure gauge to measuring outlet on hydraulic oil
pump 1.
5 Check the standby pressure for one pump at a time in the following order:
Hydraulic oil pump 1: 1.8 MPa
The settings apply to standard machine, certain machines can

have higher standby pressure. For correct standby pressure, see
pressure plate. However, the difference in pressure between the
different pumps must always be maintained.
6 Increase engine speed to approx. 1100 rpm and run extension
function against end-position (overflow).
Run out the boom to max and continue to request max. extension
with the control lever. This will cause the overflow of the extension function.
7 Check the max. pressure on hydraulic oil pump 1, the pressure
should match the value on the pressure plate.
MPa
All pumps should give the same pressure. The order between the
pumps is of no importance.
8 Stop the engine
MPa
9 Transfer the pressure gauge to the next pump and repeat steps
38 on all four pumps.
MPa
MPa
MPa
MPa
MPa
MPa
MPa
920643.0024
VDRF03.02GB
001028
MPa
19
Axial piston pump, checking (hydraulic oil pump

page
NOTE
Read the safety instructions for oil before working, see Workshop
Manual section B Safety.
1 Operate and warm up the machine so that the hydraulic oil reaches operating temperature, approx. 50 C.
2 Stop the engine
3 Connect a pressure gauge to measuring outlet on hydraulic oil
pump 1.
5 Check the standby pressure for one pump at a time in the following order:
The settings apply to standard machine, certain machines can
have higher standby pressure. For correct standby pressure, see
pressure plate. However, the difference in pressure between the
different pumps must always be maintained.

6 Increase engine speed to approx. 1100 rpm and run extension

function against end-position (overflow).
Run out the boom to max and continue to request max. extension
with the control lever. This will cause the overflow of the extension function.
7 Check the max. pressure on hydraulic oil pump 1, the pressure
should match the value on the pressure plate.
MPa
Both pumps should give the same pressure. The order between
the pumps is of no importance.
MPa
8 Stop the engine

9 Transfer the pressure gauge to pump 2 and repeat steps 38.
MPa
MPa
MPa
MPa
MPa
MPa
MPa
MPa
MPa
A49195.0400
VDRF03.02GB
20
page

replacement (hydraulic oil pump alternative Rexroth)
NOTE
Safety.
1 Park the machine with the cab in the rearmost position and the
boom fully raised, and half extended.
C AUTION
Make sure that the oil level in the hydraulic oil tank is
below the mouth of the axial piston pumps suction
hose.
If there is not enough room to lift the boom, the hydraulic oil tank
must be drained; see Hydraulic oil, changing page 47.
2 Disconnect the main power supply.
B Safety.
4 Release the brake fluid pump or cooling pump from the hydraulic
oil pump depending on the pump to be replaced.
5 Suspend the gear pump.
6 Use a plastic bag or similar to protect the connection to the gear
pump.
7 Mark up and detach the hydraulic hoses from the axial piston
pump.
NOTE
contamination.
VDRF03.02GB
21
8 Attach lifting equipment to the axial piston pump.

9 Remove the axial piston pump.
Remove the attaching bolts and lift the pump away.
10 Clean the flange on the gearbox, removing all silicone remnants.
C AUTION
Be careful and make sure that no gasket remains fall
down into the gearbox.
Gasket remains may fall into the gearbox and cause
product damage.
11 Transfer the connection adapters to the new axial piston pump.
NOTE
12 Apply sealing silicone on the axial piston pump flange where it
mates with the gearbox, see section F Technical data.
13 Install the axial piston pump.
Position the axial piston pump so that the pump shaft engages
the gearbox transmission. Install the attaching bolts.
14 Connect the suction hose to the axial piston pump.
15 Fill the pump with oil through the connections on the top.
VDRF03.02GB
22
16 Connect the hydraulic hoses to the axial piston pump in accordance with the marking.
NOTE
17 If the spacer ring is still on the axial piston pump. Remove the
spacer ring between the gear pump and axial piston pump.
If the spacer ring remains in place on the gear pump, go to step
20.
Clean the O rings contact surfaces on the spacer ring.
18 Check the O-rings and replace as needed. Install the O-rings on
the gear pump, see section F Technical data.
NOTE
Only use silicone on one side, the side facing the brake
pump.
19 Fit the spacer ring on the axial piston pump.
VDRF03.02GB
23
20 Brush sealing silicone on the gear pumps sealing face against

The illustration shows a separate pump.

21 Fit the gear pump in place.
Fit the gear pump on the axial piston pump and install the attaching bolts. Be careful so that the O-ring on the spacer ring is located correctly and that the gear pumps shaft engages the axial
piston pumps output shaft.
22 Vent the axial piston pump, see Axial piston pump with variable
displacement, bleeding (hydraulic oil pump alternative Rexroth)
page 29.
C AUTION
Vent the axial piston pump before starting the engine.
The oil in the axial piston pump may cavitate and
cause product damage.
VDRF03.02GB
24
C AUTION
010475

27 Check the pump pressures, see Hydraulic oil pump, checking
(hydraulic oil pump alternative Rexroth) page 18.
28 Check the hydraulic oil level with the lift cylinders completely
down and the extension cylinder completely in. The oil level
should be at the top of the level glass. Top up if necessary, for
grade see section F Technical data.
NOTE
and filter in the hydraulic system as well.
C AUTION
VDRF03.02GB
page
25

replacement (hydraulic oil pump alternative SauerDanfoss)
NOTE
Safety.
1 Park the machine with the cab in the rearmost position and the
boom fully raised, and half extended.
C AUTION
Make sure that the oil level in the hydraulic oil tank is
below the mouth of the axial piston pumps suction
hose.
If there is not enough room to lift the boom, the hydraulic oil tank
must be drained; see Hydraulic oil, changing page 47.
2 Disconnect the main power supply.
Safety.
4 Release the brake fluid pump or cooling pump from the hydraulic
oil pump depending on the pump to be replaced.
5 Suspend the gear pump.
6 Use a plastic bag or similar to protect the connection to the gear
pump.
Axial piston pump 2 (left)

Axial piston pump 1 (right)
7 Mark up and detach the hydraulic hoses from the axial piston
pump.
VDRF03.02GB
26
NOTE
contamination.
8 Attach lifting equipment to the axial piston pump.
9 Remove the axial piston pump.
Remove the attaching bolts and lift the pump away.
10 Clean the flange on the gearbox, removing all silicone remnants.
C AUTION
Be careful and make sure that no gasket remains fall
down into the gearbox.
Gasket remains may fall into the gearbox and cause
product damage.
11 Transfer the connection adapters to the new axial piston pump.
NOTE
12 Apply sealing silicone on the axial piston pump flange where it
mates with the gearbox, see section F Technical data.
13 Install the axial piston pump.
Position the axial piston pump so that the pump shaft engages
the gearbox transmission. Install the attaching bolts.
14 Connect the suction hose to the axial piston pump.

VDRF03.02GB
15 Fill the pump with oil through the connections on the top.
27
Axial piston pump 2 (Left)

16 Connect the hydraulic hoses to the axial piston pump in accordance with the marking.
NOTE
17 Brush sealing silicone on the gear pumps sealing surface; see
The illustration shows a separate pump.

18 Fit the gear pump in place.
Fit the gear pump on the axial piston pump and install the attaching bolts. Be careful so that the gear pumps shaft engages the
axial piston pumps output shaft.
19 Vent the axial piston pump, see Axial piston pump with variable
displacement, bleeding (hydraulic oil pump alternative SauerDanfoss) page 29.
C AUTION
The illustration shows the gear pump pre-assembled
on hydraulic oil pump 1
Vent the axial piston pump before starting the engine.

The oil in the axial piston pump may cavitate and
cause product damage.
VDRF03.02GB
28

C AUTION
010475

24 Check the pump pressures, see Axial piston pump, checking (hydraulic oil pump alternative Sauer-Danfoss) page 19.
NOTE
and filter in the hydraulic system as well.
C AUTION
VDRF03.02GB
page
29

bleeding (hydraulic oil pump alternative Rexroth)
NOTE
Safety.
1 Remove the hydraulic oil tanks breather filter.
2 Connect compressed air at max. pressure max. 10 kPa to the hydraulic oil tanks connection for breather filter.
3 Loosen the hoses to the hydraulic systems feed from the axial
piston pump one at a time and let oil flow out. Tighten the connections when oil free of air flows out.
4 Remove the compressed air from the tank and fit the breather filter.
6 Let the engine idle for at least one minute. Check that all connections seal tightly.
7 Lower the boom and raise it again very slowly so that the pump
operates under minimum load while air pockets are eliminated.
8 Stop the engine
9 Wash the engine compartment.
page

bleeding (hydraulic oil pump alternative SauerDanfoss)
NOTE
Safety.
1 Remove the hydraulic oil tanks breather filter.
2 Connect compressed air at max. pressure max. 10 kPa to the hydraulic oil tanks connection for breather filter.
VDRF03.02GB
30
10 Common hydraulics 10.4.3 Pipes and hoses

3 Loosen the hoses to the hydraulic systems feed from the axial
piston pump (1 or 2) one at a time and let oil flow out. Tighten the
connections when oil free of air flows out.
4 Remove the compressed air from the tank and fit the breather filter.
6 Let the engine idle for at least one minute. Check that all connections seal tightly.
7 Lower the boom and raise it again very slowly so that the pump
operates under minimum load while air pockets are eliminated.
8 Stop the engine
9 Wash the engine compartment.
10.4.3
page
Pipes and hoses

VDRF03.02GB
10 Common hydraulics 10.5 Hoses, pipes and valves
10.5
31
Hoses, pipes and valves
10.5.1
Pipes and hoses
page
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 may not be twisted. (A twist of 7% reduces service life

by 90%.)
3.
Minimise the number of bends by using correct couplings.
4.
Avoid sharp bends.
5.
Keep the hoses clean internally. Leave the plugs in place as long
as possible when installing.
6.
Check the position of the O-rings and tighten to the correct torque,
NOTE
Straight coupling requires a counterhold wrench to prevent
damage to the O-ring.
7.
The O-rings must not be oiled when fitted.
Hose length
C/L
Hose length is measured on a laid-out hose between the sealing surfaces. On angled connections, measure from the sealing surface's
centre line [C/L] according to the figure.
Cleanliness
The function and service life of hydraulic components depend to a
great extent on how clean the hydraulic oil is. Therefore, it is very important to prevent dirt from entering the brake and hydraulic system.
001015
Some simple advice to keep the hydraulic system clean.
C/L line for measuring hose length
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 reuse oil that has been drained from the machine.
If possible, filter the oil before pouring it into the machine. Oil barrels often contain impurities.
When filling hydraulic oil, fill through the caps at the hydraulic oil
filters in the tank so that the oil is filtered.
VDRF03.02GB
32
10 Common hydraulics 10.5.2 Priority valve
10.5.2
Priority valve
Priority valve, description
page
See section 5 Steering, group 5.2.2 Priority valve.
10.5.3
Shuttle valve

page
A shuttle valve chooses between two pressure signals and sends on

the strongest. The shuttle valves are used to sends load signals to the
hydraulic oil pumps. This means that the pumps are controlled by the
function that demands the highest pressure, if several functions are
activated at the same time.
Depending on options, there are two to four shuttle valves. The shuttle
valves are fitted on a bracket for oil filling between the engine and
transmission.
2
3
The shuttle valves choose between the following control signals:

1.
Chooses between the pressure signal from the control valve for
lift, lower and extension and the pressure signal from valve block
top lift hydraulics. The shuttle valve sends the pressure signal on
to hydraulic oil pump 4. See Axial piston pump with variable displacement, description (hydraulic oil pump alternative Rexroth)
page 12.
2.
lift, lower and extension and the pressure signal from the steering
valve. The shuttle valve sends the pressure signal on to control
hydraulic oil pump 2. See Axial piston pump with variable displacement, description (hydraulic oil pump alternative Rexroth)
page 12.
002203
1. Shuttle valve attachment

2. Shuttle valve control
3.
Chooses between the pressure signal from shuttle valve steering
(position 2) and the pressure signal from the control valve option
frame. The shuttle valve sends the pressure signal on to hydraulic
oil pumps 3 and 4. See Axial piston pump with variable displacement, description (hydraulic oil pump alternative Rexroth) page
12.
3. Shuttle valve for mini-wheel or joystick control

4. Shuttle valve option frame
This shuttle valve is fitted if the machine is equipped with joystick

control or mini-wheel.
4.
Chooses between the pressure signal from shuttle valve attachment(position 1) and the pressure signal from the control valve
option frame. The shuttle valve sends the pressure signal on to
hydraulic oil pump 2. See Axial piston pump with variable displacement, description (hydraulic oil pump alternative Rexroth)
page 12.
This shuttle valve is fitted if the machine is equipped with support
jacks, hydraulic sliding cab or vertically adjustable cab.
VDRF03.02GB
10 Common hydraulics 10.5.3 Shuttle valve
33

page
A shuttle valve chooses between two pressure signals and sends on

the strongest. The shuttle valves are used to sends load signals to the
hydraulic oil pumps. This means that the pumps are controlled by the
function that demands the highest pressure, if several functions are
activated at the same time.
Depending on options, there are two to four shuttle valves. The shuttle
valves are fitted on a bracket for oil filling between the engine and
transmission.
2
3
The shuttle valves choose between the following pressure signals:

1.
lift, lower and extension and the pressure signal from valve block
top lift hydraulics. The shuttle valve sends the pressure signal on
to main pump 1. See Axial piston pump with variable displacement, description (hydraulic oil pump alternative Sauer-Danfoss)
page 13.
2.
lift, lower and extension and the pressure signal from the steering
valve. The shuttle valve sends the pressure signal on to control
hydraulic oil pump 2. See Axial piston pump with variable displacement, description (hydraulic oil pump alternative Sauer-Danfoss) page 13.
002203
1. Shuttle valve attachment

2. Shuttle valve control
3.
Chooses between the pressure signal from control valve option
frame and the pressure signal from the shuttle valve option frame
(position 4). The shuttle valve sends the pressure signal on to hydraulic oil pump 2. See Axial piston pump with variable displacement, description (hydraulic oil pump alternative Sauer-Danfoss)
page 13.
3. Shuttle valve for mini-wheel or joystick control

This shuttle valve is fitted if the machine is equipped with joystick

control or mini-wheel.
4.
Chooses between the pressure signal from shuttle valve attachment (position 1) and the pressure signal from the control valve
option frame. The shuttle valve sends the pressure signal on to
hydraulic oil pump 1. See Axial piston pump with variable displacement, description (hydraulic oil pump alternative Sauer-Danfoss) page 13.
This shuttle valve is fitted if the machine is equipped with support
jacks, hydraulic sliding cab or vertically adjustable cab.
VDRF03.02GB
34
10 Common hydraulics 10.5.4 Collection block, filtered returns
10.5.4
Collection block, filtered returns
Collection block, filtered returns, description
page
The block collects several return lines from different components and
leads these on back to the tank through the tank filters.
003205
The block is fitted on top of the lifting beam in front of the transmission.
1. Collection block, unfiltered returns

2. Collection block, filtered returns
10.5.5
Collection block, unfiltered returns
Collection block, unfiltered return lines, description
page
The block collects several return lines from different valves and leads
these directly back to the tank.
The drain lines are very sensitive to back-pressure, if pressure builds

up in the drain lines the valves will not work properly.
003205
The block is fitted to the side of the lifting beam in front of the transmission.
1. Collection block, unfiltered returns

2. Collection block, filtered returns
VDRF03.02GB
10 Common hydraulics 10.6 Temperature control, cleaning and hydraulic oil
10.6
35
Temperature control,
cleaning and hydraulic oil
Temperature control, cleaning and hydraulic oil,

page
The oil of the hydraulic system is cooled and cleaned through circulation by a separate pump through the radiator and filters. The radiator
has a temperature-regulated electric fan that prevents overheating.
Temperature control consists of a hydraulic oil tank, hydraulic oil

pump, hydraulic oil cooler, cooling fan, hydraulic oil filter, fine filter, hydraulic oil temperature sensor and bypass valve.
D795
D3
D797-R
D4
The hydraulic oil pump pumps oil (from the tank) which is cooled in the
hydraulic oil cooler and cleaned by the oil filters in the tank. 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 leads the hydraulic oil past the cooler directly to the
tank if the resistance through the cooler and filters is too high. The
temperature sensor controls fan activation and temperature display.
5
2
8
7
007414
C 3
Pos
Description
Signal value
Reference
The hydraulic oil pump pumps oil from

Gear pump with fixed displacement, description page 6
The hydraulic oil cooler cools the oil.
Hydraulic oil cooler, description page 37
The hydraulic oil temperature sensor

(B776) sends Control unit frame rear
(D797-R) a voltage signal proportional to
the hydraulic oil temperature.
U = 0.5-4.5 V
Sensor hydraulic oil temperature, description page 39
Control unit frame rear (D797-R) transmits temperature on the CAN bus and
supplies power to the cooling fan as necessary.
Hydraulic fan active:

U = 24 V
The cooling fan (M668) increases air flow

through the radiator.
Cooling fan, description page 38
The hydraulic oil filters clean the hydraulic oil.
Hydraulic oil filter, description page 43
Some of the oil is pumped through the

hydraulic oil fine-filter for deep cleaning.
Fine filter hydraulic oil, description page 47
If resistance through the oil cooler and

hydraulic oil filter becomes too great, the
cooler bypass valve opens and directs
the oil to the tank.
Cooler bypass valve, description page 40

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36
10 Common hydraulics 10.6.1 Tank heater
Pos
Description
Signal value
Reference
The KID control unit (D795) shows hydraulic oil temperature in the display.

error code.

10.6.1
Tank heater
Tank heater, safety
page
C AUTION
The tank heater is connected to high voltage. Connection and reconnection of the tank heater may only be
performed by personnel authorised for work with high
voltage.
Tank heater, description
page
The tank can be equipped with a heater. The tank heater is designed
for cold climates.
000430
The tank heater runs off high current. Heater output is adapted through
different connections and adaptation to different operating voltages 110, 230 or 400 V AC. Higher voltage generates higher heater output.
The heater is mounted in a hole in the connection cover at the bottom
of the short side of the tank.
VDRF03.02GB
The tank heater can be equipped with a programmable thermostat

which maintains the temperature at an even level. The thermostat is
fitted directly onto the heating element and can be adjusted with a
knob on the junction box. Recommended temperature setting is 2030 C.
10 Common hydraulics 10.6.2 Hydraulic oil cooler
10.6.2
37
Hydraulic oil cooler
Hydraulic oil cooler, description
page
001013
The working hydraulics use a through-flow cooler with electric cooling

fan (the same type of cooler as used for the brake system). The oil is
cooled when it passes the cooler, which is fitted inside the side panel
on the right-hand side behind the hydraulic oil tank.
page
Hydraulic oil cooler, change
NOTE
Safety.
2 Drain the oil from the hydraulic oil tank; see Hydraulic oil, changing page 47.
VDRF03.02GB
38
10 Common hydraulics 10.6.3 Cooling fan
3 Mark up and disconnect hydraulic hoses from the cooler. Let the
oil in the cooler drain into the collection container.
NOTE
contamination.
4 Disconnect the cabling from the cooling fan.
5 Remove the attaching bolts and lift away the cooler.
6 Transfer the cooling fan to the new cooler.
7 Install the cooler.
8 Connect the cabling to the cooling fan.
9 Connect the hydraulic hoses to the cooler.
1. Cooling fan
2. Connector
3. Radiator
NOTE
C AUTION
10.6.3
Cooling fan
Cooling fan, description
page
The electric cooling fan is forcing. The cooling fan is located at the rear
of the cooler. The fan draws air from the machines outside through the
cooler. Openings in the side cover allows air to pass through the
cooler.
The radiator is supplied voltage by Control unit frame rear (D797-R)
upon activation when the engine is running. The cooling fan is activated when oil temperature is 65 C in the hydraulic oil tank and is deactivated when oil temperature is 55 C.
001014
The signal can be checked from the diagnostic menu, see tab 8 Control system , group 8.4.5.1 HYD, menu 1.7
VDRF03.02GB
10 Common hydraulics 10.6.4 Sensor hydraulic oil temperature
10.6.4
39
Sensor hydraulic oil temperature
Sensor hydraulic oil temperature, description
page
The hydraulic oil temperature sensor (B776) detects the temperature

of the hydraulic oil. The sensor is located on the hydraulic oil tanks
rear short end.
The sensor detects the oil temperature in the tank, determining 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.
001092
The hydraulic oil temperature sensor (B776) is supplied voltage by,

and sends a voltage signal proportional to the oil temperature to, Control unit frame rear (D797-R).
Control system, group 8.4.5.1 HYD, menu 1.
Hydraulic oil temperature sensor, change
page
NOTE
Safety.
3 Disconnect the cabling from sensor hydraulic oil temperature
(B776).
4 Change sensor hydraulic oil temperature (B776).
NOTE
008222
5 Connect the cabling to the sensor.
Sensor hydraulic oil temperature (B776)
VDRF03.02GB
40
10 Common hydraulics 10.6.5 Radiator bypass valve
C AUTION
7 Use the display, go to the diagnostic menu, see section 8 Control
system, group 8.4.5.1 HYD, menu 1.
1(6)
XXX
XY
TEMP indicates hydraulic oil temperature in C. Check that correct temperature is shown.
000141
DIAG HYD
HYDRAULIC OIL
TEMP
FAN
Diagnostic menu Hyd, menu 1
10.6.5
Radiator bypass valve
Cooler bypass valve, description
page
007426
The bypass valve protects the cooler from overpressure. The valve
opens a passage past the cooler directly to the tank if resistance in the
cooler becomes too high.
VDRF03.02GB
10 Common hydraulics 10.6.5 Radiator bypass valve
41
Cooler bypass valve, replacement
page
NOTE
Safety.
I M P OR TA NT
Ensure cleanliness around the filter and filling point
when working on the hydraulic tank.
Dirt particles may cause machine damage.
1 Machine in service position, section B Safety.
4 Disconnect the bypass valve from the tank.
NOTE
007426
Note how the bypass valve faces; the valve is marked with
an arrow.
5 Install the new bypass valve, turning the valve to face the same
way as the old one. Use Loctite when fitting the bypass valve.
Bypass valve
C AUTION
VDRF03.02GB
42
10 Common hydraulics 10.6.6 Breather filter hydraulic oil tank
10.6.6
Breather filter hydraulic oil tank
Breather filter hydraulic oil tank, description
page
001454
A breather filter of insert type is mounted on the hydraulic oil tank to

protect the tank from impurities. On top of the filter housing is an indicator that shows when the filter is clogged and should be changed.
VDRF03.02GB
10 Common hydraulics 10.6.7 Oil filter
10.6.7
43
Oil filter
Hydraulic oil filter, description
page
001455
The oil in the hydraulic system is cleaned by two return filters located
inside the hydraulic oil tank. The oil is pumped through the cooler and
back through the filters by the cooling pump. Some of the return oil
from the load handling functions also passes through the filters.
Hydraulic oil filter, description (high-pressure filter)
page
003602
As an option the machine can be equipped with two additional highpressure filters that are fitted directly after the axial piston pumps. The
filters are placed in front of the transmission under the lifting beam.
The filters are used in conjunction with the hydraulic oil filters in the
tank.
VDRF03.02GB
44
page
Hydraulic oil filter, replacement
NOTE
Safety.
I M P OR TA NT

2 Remove the cover plates (position 1) over the hydraulic oil filters.
3 Lift up the filter unit and place it in the receptacle. Let the hydraulic oil drain.
4 Separate the filter unit and remove the filter insert. Handle the filter insert as environmentally hazardous waste. Note the position
of the parts.
1. Oil filter cover

2. Hydraulic oil filler orifice
5 Clean the filter holders parts. Be especially thorough with the
magnetic rod.
6 Fit the new filters and assemble the filter units.
7 Install the filter units and the covers. Tighten the screws
crosswise.
Magnetic rod
VDRF03.02GB
45
C AUTION
Hydraulic oil filter (high-pressure filter), replacement
page
NOTE
Safety.
I M P OR TA NT
2 Depressurise the hydraulic and brake systems; see section B
Safety.
3 Remove the drain plugs in the bottom of the filters.
Let the oil run out. Wait a moment since it runs out slowly.
4 Remove the filter holders.
NOTE
The filter holders are heavy, loosen them carefully.
5 Clean the filter holders.
6 Remove the filter inserts.
NOTE
003602
Note the location of the O-rings.
High-pressure filter, under machine
7 Fit the O-rings on the filter inserts and filter holders. Lubricate the
O-rings with hydraulic oil.
8 Fit the new filter inserts on the filter mounting.
9 Fit the filter holder and drain plug.
VDRF03.02GB
46
NOTE
C AUTION
010475

13 Check that the filter holders are not leaking.
C AUTION
VDRF03.02GB
10 Common hydraulics 10.6.8 Hydraulic oil
10.6.8
page
47
Hydraulic oil
Hydraulic oil, changing
NOTE
Safety.
I M P OR TA NT
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 tanks drain plug and drain the
last of the hydraulic oil.
4 Fit the drain plug when the oil has drained.
1. Oil filter cover
NOTE
Make sure that the seal washer is installed 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
44 and Hydraulic oil filter (high-pressure filter), replacement page
45.
6 Fill new hydraulic oil through the filler holes on the filters covers.
This results in filtering of the oil that is filled and protects the hydraulic system from impurities.
Fill oil until the oil level is in the middle of the level glass. For volume and grade, see section F Technical data.
10.6.9
page
Hydraulic oil fine-filter
Fine filter hydraulic oil, description

The fine filter is located on the frame member in the engine compartment. The filter is connected to hydraulic oil pump cooling and filtration. The filter is connected in parallel to the hydraulic oil filters in the
hydraulic oil tank.
Oil is pumped from the hydraulic oil tank through the fine filter and then
back to the hydraulic oil tank.
The fine filter cleans a smaller amount of oil but with a higher degree
of filtration when the machine is running.
VDRF03.02GB
48
page
10 Common hydraulics 10.6.10 Pipes and hoses
Hydraulic oil fine filter, replacement
NOTE
Safety.
I M P OR TA NT
Make sure that the area around the filter is clean when
working.
2 Remove the cover.
3 Lift up the filter insert and place it in the receptacle. Let the hydraulic oil drain.
4 Fit the new filter insert and refit the cover over the fine filter.
C AUTION
10.6.10
page
Pipes and hoses

VDRF03.02GB
10 Common hydraulics 10.7 Auxiliaries
10.7
10.7.1
page
49
Auxiliaries
Hydraulic cylinders

Fault tracing, leakage
C AUTION
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 end welds
At sleeve coupling welds
Between cylinder barrel and cylinder head

This could be due to a defective O-ring or damaged O-ring
sealing surfaces. Both faults can be rectified with the cylinder
in situ.
Between cylinder head an piston rod

This could be due to a damaged piston rod or damaged or
worn piston rod seal.
1. Piston rod
2. Scraper
3. Cylinder head
4. Piston rod seal
5. O-ring with thrust ring
6. Cylinder barrel
7. Sleeve coupling
8. Welded cylinder end face
9. Piston
10. Piston seal, double-acting
11. Example of weld
3 Check for internal leakage. Pressurise the cylinder and check

whether the piston sinks back.
This could be due to a worn piston seal.
Dismantling of cylinders
C AUTION
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.
VDRF03.02GB
50
10 Common hydraulics 10.7.1 Hydraulic cylinders
3 If the cylinder is opened - observe the strictest cleanliness!
Inspection of surfaces
1 Inspect the sealing surfaces. Always bearing mind the function of
the seals and the type of sealing surfaces they have. See the 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 be the direct cause of leakage.
all sliding surfaces (dynamic surfaces), e.g. cylinder barrel

and piston rod. These are always the hardest to seal.
C AUTION
When fitting the cylinder head:
Get it absolutely straight. This is best done by hand.
Under no circumstances hit it with any mallet. If the
cylinder head is fitted crooked, the sealing lip of the
piston rod seal could be damaged, making an improper seal. This applies to all types of piston rod seals.
VDRF03.02GB
51
Function and removal of the seals

Piston rod seal
The piston rod seal is the seal that sits in the groove in the cylinder
head and seals against the piston rod. This seal is greatly subject 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:
001497
5
1. Hydraulic pressure
2. Seal lip pressed out toward piston rod
3. Seal lip pressed inward toward cylinder head
4. Sealing surface, piston rod
5. Sealing surface, cylinder head
6. Screwdriver
Pre-stressed V-ring seal with thrust ring
Compressible seal
The simple V seal has a V-shaped section with two lips that seal in
opposite directions. The hydraulic pressure works in the V-shape,
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.
3
4
001498
Single V-ring seal
The pretensioned V seal also has an O-ring in the seals V-shaped

space. The O-ring creates a strong seal at low hydraulic pressure
since the O-ring already presses the sealing lips out toward the sealing
surfaces when unloaded. It is just as sensitive to damage as the V
seal. Examine in the same manner. To remove, use a screwdriver to
prise the seal outward and bend it up (see illustration). It is extremely
important that the screwdriver is always inserted in the V shape so that
it cannot touch and thereby damage a sealing surface. A mark from a
screwdriver on a sealing surface can have a devastating effect and
cause major leakage.
5
6. Screwdriver
7. O-ring
VDRF03.02GB
52
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
001499
5
6. Screwdriver
Thrust ring and O-ring

The thrust ring and O-ring combination is used for sealing between two
fixed surfaces, such as between cylinder barrel and cylinder head.
The purpose of the thrust ring is to lend rigidity to the O-ring so that it
is not deformed. The O-ring is pressed against the thrust ring and the
sealing surface by the hydraulic pressure in the cylinder.
When the cylinder head is mounted in the barrel: Take extreme care
not to damage the O-ring.
001506
2. O-ring
3. Thrust ring
VDRF03.02GB
53
Scraper
D+10
1
The purpose of the scraper is to scrape the piston rod clean and prevent impurities from entering the cylinder barrel.
The scraper is fitted with a special fitting tool, which has a greater outer
diameter than the scraper so that the press force against the scraper
ceases right when the scraper is pressed into position. If the scraper
were to be pressed in further, the metal capsule will be deformed (see
lower illustration), which would impair the function of the scraper.
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
D
5
001496
1. Correct assembly tool

2. Scraper, correctly fitted
3. Cylinder head
4. Clearance between scraper and bottom of cylinder
head cavity
5. Incorrect assembly tool
6. Deformed scraper
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
C AUTION
No tool must be applied from the inside. This could
give rise to burrs on the cylinder head which could in
turn damage the piston rod. Burrs may also damage
the piston rod seal when fitting the piston.
001551
1. Screwdriver
2. Scraper
3. Cylinder head
VDRF03.02GB
54
On the single-acting V-ring seal it is always the long side that seals
against the fixed surface and the short side that seals against the moving surface.
To remove, use a screwdriver to prise the seal outward and bend it up

(see illustration). It is extremely important that the screwdriver is always inserted in the V shape so that it cannot touch and thereby damage a sealing surface. A mark from a screwdriver on a sealing surface
can have a devastating effect and cause major leakage.
002370
5
2. Seal pressed out toward cylinder barrel
3. Seal pressed in toward piston
4. Sealing surface, cylinder barrel
5. Sealing surface. piston
6. Screwdriver
The seal must always be fitted as an assembly together with the thrust
ring.
Always assemble by hand. No tools should be used as they could easily damage the surface of the piston.
For easier assembly the seal can be heated in hot water to make it
soft.
002950
Lubricate with hydraulic oil.
Double-acting piston seal
The double-acting seal functions with pressure from both sides, e.g. in
a steering cylinder.
2
1. Variable sealing surface to cylinder barrel
2. Fixed sealing surface with piston
3. Guide ring
4. Thrust ring
5. Piston crown
6. Cylinder barrel
VDRF03.02GB
002951
All of the interior surface of the cylinder barrel is a sealing surface and
it is therefore extremely important that it is completely free from
damage.
Exercise care 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 thrust rings.
2 Move the seal over to one side of the sealing groove.
3 Press it up so that there is a gap between seal and piston.
55
4 Without damaging the surface of the piston - cut off the seal with
a knife.
5 Carefully examine the seal to find any damage that can cause
leakage. This will be easier if you bend the seal sharply bit by bit
and feel over the sealing surface with a fingernail.
Assembly:
1 All double-acting piston seals are of similar design: a middle sealing body. then thrust rings and farthest out guide rings.
2 First fit the sealing body, then the thrust rings and finally the guide
rings - all must be done by hand without tools to avoid damage.
Repairing the piston rod surface
A small impact mark on a piston rod may be sufficient to cause leakage. The chromium plating on the piston rod has a thickness of 20-50
micrometres and can be treated to make good minor damage. This
may be a satisfactory alternative to costly disassembly.
1 Locate the damage using your fingertips and fingernails.

2 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.
002952
5 It is important to treat small impact marks before disassembly and

assembly to avoid damaging the cylinder head.
1. Piston rod
2. Chromium plating
3. Impact mark
4. Highly-polished hammer
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
VDRF03.02GB
56
Dismantling steering cylinders

It can prove extremely difficult to extract the piston rod from the cylinder barrel on steering cylinders because the O-ring in the cylinder
head fastens in the retaining ring groove in the cylinder barrel. It is
therefore best to remove the O-ring before trying to withdraw the 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
the like into the shape of a hook. Use this to snag the O-ring.
5 Pull the O-ring up slightly and hold it with a pair of needle-nose
pliers.
6 Continue to pull the O-ring out through the hole.
7 Hold the O-ring steady and cut it with a knife.
8 Rotate the piston rod while pulling the O-ring out through the
hole.
9 Remove the retaining ring from the cylinder barrel.
002953
10 Carefully extract the piston rod from the cylinder barrel.
VDRF03.02GB
11 Common electrics
11 Common electrics
Table of Contents 11 Common electrics

mm mm mm mm mm mm
11 Common electrics .......................................................................................... 3

11.2
Electric protection ....................................................................................... 3
11.2.1
Battery disconnector .............................................................................. 3
11.2.2
Fuses ..................................................................................................... 3
11.2.3
Safety switch .......................................................................................... 3
11.3
Batteries ..................................................................................................... 4
11.3.1
Start battery ........................................................................................... 4
11.4
Alternator .................................................................................................... 6
11.4.1
Alternator ............................................................................................... 6
11.5
Distribution of electricity ............................................................................. 7
11.5.1
Power supply ......................................................................................... 7
11.5.2
Electronic box ...................................................................................... 16
11.5.3
Control units ......................................................................................... 18
11.5.5
Cables .................................................................................................. 33
11.6
Communication ........................................................................................ 43
11.6.1
CAN-bus .............................................................................................. 43
11.6.2
Redundant CAN bus ............................................................................ 45
11.6.3
CAN bus drivetrain ............................................................................... 48
11.6.4
Communication between PC and machine .......................................... 49
11.6.5
RMI (Remote Machine Interface) ......................................................... 50
11.6.6
Kalmar CAN Customer Gateway ......................................................... 51
VDRF03.02GB
VDRF03.02GB
11 Common electrics
11 Common electrics
11 Common electrics
mm mm mm mm mm mm
11.2
Electric protection
11.2.1
Battery disconnector
Battery disconnector, description
page
The positive terminals of the batteries connected in series are connected to the machines electrical system via the battery disconnect
switch. The battery disconnector cuts off all power from the batteries
to the machines electrical system.
I M P OR TA NT
Never turn off the voltage with the battery disconnect
switch when the engine is running. This could damage the alternator.
000268
The battery disconnect switch must not be used for

emergency stop!
A. Position of battery disconnect switch
11.2.2
page
Fuses
Fuses, replacement
When checking and replacing the main fuse:
1.
Switch off the main current (battery disconnect switch).
2.
Remove the plastic cover.
3.
Check that fuses are intact. Replace if necessary.

The fuses are 25 A.
When checking and replacing the fuse:

1.
Switch off the main current (battery disconnect switch).
2.
Remove the cover of the electronic box.
3.
Check and, if necessary, replace fuses.

The fuse chart provides information about each fuse.
11.2.3
page
Safety switch
Emergency stop, description

See Emergency stop switch voltage (15E), function description page
11.
VDRF03.02GB
11 Common electrics 11.3 Batteries
11.3
11.3.1
Batteries
Start battery
Start battery, description
page
The machines 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 Volvo) page 6.
WARN IN G
Battery electrolyte contains corrosive sulphuric acid
000269
Risk of corrosive injuries, health hazard!

Immediately remove electrolyte from the skin. Wash
with soap and copious amounts of water. If electrolyte
gets in the eyes, rinse with copious amounts of water
and seek medical help immediately.
WARN IN G
Risk of explosion!
013022
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
disconnect switch.
Alternative location for batteries
WARN IN G
Risk of explosion if the battery short circuits (also
causes loss of capacity).
Fire hazard, personal injury!
The battery's terminals may not be connected to each
other or commonly to ground (frame).
VDRF03.02GB
11 Common electrics 11.3.1 Start battery
Starter battery, replacement
page

2 Disconnect the cables from the battery terminals, starting with the
negative (minus) cable.
3 Replace the batteries.
4 Connect the cables to the battery terminals. Connect the negative cable last of all.
NOTE
000269
Take great care when reconnecting the cables to prevent

short circuiting.
VDRF03.02GB
11 Common electrics 11.4 Alternator
11.4
Alternator
11.4.1
Alternator
Alternator, description (engine alternative Volvo)
page
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.
001905
The signal can be checked from the diagnostic menu, section 8 Control system , section 8.4.6.4 ENGINE, menu 4.
The illustration shows engine alternative Volvo

TWD1240VE
Alternator, description (engine alternative Cummins

QSM11)
page
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.
007444
The signal can be checked from the diagnostic menu, section 8 Control system , section 8.4.6.4 ENGINE, menu 4.
page
Alternator, replacement
VDRF03.02GB
11 Common electrics 11.5 Distribution of electricity
11.5
Distribution of electricity
11.5.1
Power supply
11.5.1.2
Redundant voltage feed of control

units
Redundant voltage feed for control units, description of

operation
D1
D3
D2
D8
D11
D4
D7
D9
D795
11
D790-1
5, 6
D797-R
8
D797-F
7
D797-O
9
D790-2
10
D791-1
12
D791-2
13
D791-3
14
D791-4
D12
D13
D10
D793
D794
D14
007420
page
Pos
Explanation
Signal description
Reference
The NC switch, operators door (S 266-LE)

or the NC switch, passenger door (S 266RI) 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 cab control

unit (D790-2) sends a voltage signal to the
The switch for warning lights (S109) sends

(D790-1).
U = 24 V
When the ignition (S150) is turned to position I, it sends a voltage signal to the cab
U = 24 V
The cab control unit (D790-1) activates a

hold circuit, which activates the control
units control logic.
D1: Diagnostic menu, see section 8 Control system,

group 8.4.2.12 LIGHTS, menu 12 or 8.4.11.2 SLIDING CAB, menu 1
9.6.12 Interior lighting
group 8.4.2.12 LIGHTS, menu 12
9.6.7 Warning lights
9.1 Controls and instruments
D4: Diagnostics menu, see section 8 Control system, group 8.4.1.4 CAN/POWER, menu 4
Cab control unit, description page 19
VDRF03.02GB
11 Common electrics 11.5.1.2 Redundant voltage feed of control units
Pos
Explanation
Signal description
Reference
The cab control unit (D790-1) activates a

redundant voltage feed to other control
units.
UK11:7 = 24 V
The cab control unit (D790-1) has 4 outputs

for redundant voltage feed while other control units have two inputs for redundant voltage feed. In case of a malfunction of one
voltage feed the control unit is supplied by
the other feed.
7
The cab control unit (D790-1) supplies voltage to the control logic of the other control
units via the redundant voltage feed.
10
11
12
13
UK11:8 = 24 V
UK11:9 = 24 V
UK11:10 = 24 V
UK2:7 = 24 V
Control unit, frame front, description page 20
UK2:8 = 24 V
UK2:7 = 24 V
Control unit, frame rear, description page 21
UK2:8 = 24 V
UK2:7 = 24 V
Control unit, frame option, description page 22
UK2:8 = 24 V
UK2:7 = 24 V
Attachment control unit, description page 23
UK2:8 = 24 V
D10: Diagnostics menu, see section 8 Control system , group 8.4.1.16 CAN/POWER, menu 16
UK2:7 = 24 V
KID control unit, description page 31
UK2:8 = 24 V
UK2:7 = 24 V
Attachment control unit, option, description page 24
UK2:8 = 24 V
UK2:7 = 24 V
Control unit, attachment left jack pair, description

page 25
UK2:8 = 24 V
14
UK2:7 = 24 V
UK2:8 = 24 V
Control unit, attachment right jack pair, description

page 26
VDRF03.02GB
11 Common electrics 11.5.1.3 Ignition voltage (15)
11.5.1.3
Ignition voltage (15)
Ignition voltage (15), description of operation
page
Condition
Reference value
Reference
In position 1
Battery disconnector, description page 3
Redundant voltage feed
Activated
Redundant voltage feed for control units, description of operation page 7
Redundant CAN bus
Communication established
Redundant CAN bus, description page 45
+
D4
1
D1
2
D2
D3
6
4, 5
D8
D795
D790-1
2, 8
D9
D10
D11
D797-R
9
D797-F
10
D797-O
11
D12
D793
12
7
D791-1
D791-2
D791-3
D791-4
D794
007421
D790-2
Pos
Explanation
Signal
description
Reference
Warning light comes on and sends a

(D790-1).
U = 24 V

9.6.7 Warning lights
When the start key is turned to position I, it sends a voltage signal to the
U = 24 V
The cab control unit (D790-1) supplies voltage to ignition voltage relay
K315-1 in the frame electronic box
and ignition voltage relay K315-2.
U = 24 V
Ignition voltage relay K315-1 supplies

voltage to fuse holder in the cab electronic box and in the frame electronic
box.
U = 24 V
D1: Diagnostic menu, see section 8 Control system ,

9.1 Controls and instruments
D2: Diagnostics menu, see section 8 Control system,
group 8.4.1.4 CAN/POWER, menu 4

-
VDRF03.02GB
10
11 Common electrics 11.5.1.3 Ignition voltage (15)
Pos
Explanation
Signal
description
Reference
The fuses feed voltage to control

units, relays, solenoid valves and other electronic components.
U = 24 V
Ignition voltage relay K315-2 supplies

voltage to the engine control unit
(D794).
U = 24 V
Control unit, engine, description (engine alternative

Volvo TWD1240VE) page 28
Drivetrains CAN-bus establishes

communication.
Checked by control
system, error
shown with error
code.
Drivetrain CAN bus, description page 48
Ignition voltage to the cab control unit

(D790-1).
UK1:2 = 24 V
UK1:3 = 24 V

UK1:4 = 24 V
9
10
Ignition voltage to Control unit, frame

rear (D797-R).
UK2:1 = 24 V
UK2:9 = 24 V


front (D797-F).
UK2:1 = 24 V
UK2:9 = 24 V
UK2:10 = 24 V
11
12

option (D797-O).
UK2:10 = 24 V
Ignition voltage to the transmission

UA1 = 24 V
VDRF03.02GB

Transmission control unit, description page 27

11 Common electrics 11.5.1.4 Emergency stop switch voltage
11.5.1.4
11
Emergency stop switch voltage
Emergency stop switch voltage (15E), function description
page
Condition
Reference
value
Reference
Activated
Ignition voltage
Activated
Ignition voltage (15), description of operation page 9
Safety switch
Not activated
3, 4
D4
D5
+
D2
D7
D790-1
1, 2, 5
D797-R
D797-F
7
D797-O
8
12
D791-1
11
D791-2
10
D791-3
9
D791-4
D790-2
D12
D11
D10
D9
D793
D794
007422
D795
D8
Pos
Explanation
Signal description
Reference
Ignition voltage is activated by the cab


error code.
Ignition voltage (15), description of operation page 9
The cab control unit (D790-1) supplies

voltage to the emergency stop switch voltage relay (K3009-1) in the frame electronic box.
UK3009-1/86 = 24 V
The emergency stop switch voltage relay

(K3009-1) supplies voltage to the emergency stop switch voltage relay (K3009-2)
in the frame electrical distribution box.
UK3009-2/87 = 24 V
D2: Diagnostics menu, see section 8 Control system , group 8.4.1.5 CAN/POWER,
menu 5
Electronic box frame, description page 17

menu 5
VDRF03.02GB
12
Pos
Explanation
Signal description
Reference

(K3009-1) also sends a voltage signal to
the cab control unit (D790-1), which verifies that emergency stop switch voltage
relay K3009-1 is active but emergency
stop switch voltage relay K3009-2 is
inactive.
UK3009-1/87 = 24 V
UK3009-2/87 = 0 V
menu 5
The cab control unit (D790-1) activates

the emergency stop switch voltage relay
(K3009-2) in the electronic box.
UK3009-2/86 = 24 V

K3009-2 supplies voltage to emergency
stop switch circuit.
UK3009-2/87 = 24 V
This verifies that the operation breaker is

working.
5
VDRF03.02GB
menu 5
13
Pos
Explanation
Signal description
Reference
The control units are supplied with emergency stop switch voltage as long as
emergency stop switch is not pressed in.
Emergency stop switch

in home position: UK2:6
Control unit, frame front, description page

20
= 24 V
menu 8

Control unit, frame option, description page

22
= 24 V
menu 12

Control unit, attachment right jack pair, description page 26
= 24 V
menu 19
10
The control units on the attachment are

only supplied emergency stop switch voltage, 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) and emergency stop
switch voltage relay (K3009-2). 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.

= 24 V
Control unit, attachment left jack pair, description page 25
= 24 V
menu 18

= 24 V
11

Attachment control unit, option, description

page 24
= 24 V
menu 17

= 24 V
12

Attachment control unit, description page

23
= 24 V
menu 16

= 24 V
= 24 V
= 24 V
VDRF03.02GB
14
11 Common electrics 11.5.1.5 Voltage converter
Emergency stop switch, checking
page
1 Start the machine and active any load handling function.

2 Activate lift.
3 Press in the emergency stop switch and check that the lifting
movement stops.
000039
4 Reset the emergency stop switch (turn in the arrows direction)

and check that the lift function works again.
Safety switch
11.5.1.5
page
Voltage converter
Voltage converter, description
The voltage converter is located under a protective casing to the left

behind the operators seat.
The voltage converter converts 24 Volt to 12 Volt. 12 V voltage is available for accessories by means of a connector X067 in the cabs electronic box. (Contains both 15, 30-voltage, ground and 12V.)
VDRF03.02GB
11 Common electrics 11.5.1.5 Voltage converter
15
Voltage converter, replacement
page

2 Remove the covers behind the drivers seat.
3 Detach the electrical cables from the converter.
4 Remove the voltage converter.
The voltage converter is located behind the operators

seat.
VDRF03.02GB
16
11 Common electrics 11.5.2 Electronic box
11.5.2
Electronic box
11.5.2.1
Electronic box cab
Electronic box cab, description
page
The electronic box is mounted on the rear wall of the cab, on the left.
Located there are:
Circuit fuses
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
Connector customer accessory. Output voltage 24 V, max. 10 A.

Connector 2-pin Universal mate-n-lock. For part number see
Spare parts catalogue.
NOTE
This connector is not on the machine if the machine is

equipped with voltage converter.
008230

2. Outlet for control unit programming
3. Outlet for drivetrain CAN bus
4. Fuse holder
5. Voltage converter
6. Customer accessory connector 24V / 10A
VDRF03.02GB
11 Common electrics 11.5.2.2 Electronic box frame
11.5.2.2
17
Electronic box frame
Electronic box frame, description
page
The electrical distribution box is mounted on the side of the machine.

Also located there are:
5
4
F5
6
3
9
D7
8-3
8-2
F5
8-1
F5
F5
K1
K3
68
X1
Circuit fuses
Socket for programming transmission control unit (D793)
Main fuses
Power relays for voltage feed to the machines functions.
K4
K2
004923
1. Circuit fuses
2. Socket for programming transmission control unit
(D793)
3. Power relay (K315-1)
4. Main fuses
5. Transmission control unit (D793)
6. Main fuse
7. Relay (K315-2)
VDRF03.02GB
18
11 Common electrics 11.5.3 Control units
11.5.3
Control units
Control units, position
page
15
13
1.
2.
3.
4.
5.
6.
7.
8.
9.
12
11

10
10.
11.
12.
13.
.
Frame option control unit (D797-O)


Engine control unit (D794)
Control unit cab, option (D790-3)
Only on machines with both the combi attachment and
mini-wheel or combi attachment and joystick control
14.
Attachment control unit, option (D791-2)

Control unit, attachment left jack pair (D791-3)
15.
Control unit CAN gateway RMI (D795-2)

Control unit, Kalmar CAN customer gateway (D795-2)
Control unit, attachment right jack pair (D791-4)
VDRF03.02GB
010503
14
11 Common electrics 11.5.3.1 Control unit cab
11.5.3.1
19
Control unit cab
Cab control unit, description
page
The cab control unit (D790-1) is the central control unit of the control
system. The cab control unit (D790-1) sends activation signals to other
units and controls and monitors their functions. It administrates work
in the control unit network. The control unit controls the redundant voltage feed and handles communication via a redundant CAN bus and
gateway for the drivetrain CAN bus. The cab control unit (D790-1) also
processes all input signals from cab controls and transmits these signals on the CAN bus.
3
2
5 6
000041
1. Connection terminals - fan, work 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
The cab control unit has four indicator lights that indicate the control
units function (see illustration).
Light 1
Green light on when there is battery voltage to the unit.

The light is physically controlled by voltage feed to the
control unit.
Light 2
Flashes green when the redundant voltage feed to the

control units and redundant CAN bus communication
are active. No power in the system.
Shines with a steady green when power electronics
and 15-voltage are supplied voltage.
Light 3
Long single flash yellow during communication with the

control unit display (D795). This is a basic condition of
fault tracing.
Short single flash yellow during communication with
the engine control unit (D794) and transmission control
unit (D793).
Double flash yellow (short and long flash) during communication with the display and engine or transmission.
Light 4
page
Red light on at active error.
Control unit cab, replacement

2 Remove the cover from the electronic box.
3 Unplug the cab control unit (D790-1) connectors.
4 Change control unit.
5 Check that the new control unit matches the machines forklift
number (Z-number).
6 Calibrate the new control unit; see section 8 Control system,
group 8.5.2.3 Calibrate DRIVETRAIN.
7 Set the fresh air damper at fully closed and fully open, wait a few
seconds in each position so that the damper has time to go to the
end position.
VDRF03.02GB
20
11 Common electrics 11.5.3.2 Control unit, frame front
11.5.3.2
1
2
3
Control unit, frame front (D797-F) processes input data from sensors
and sends control signals to relays and solenoid valves in the machines front half.
The control unit has four indicator lights that indicate the control units
function (see illustration).
Light 1

control unit.
Light 2
Flashes green when one or more of the following is

missing: redundant voltage feed left, redundant voltage feed right or 15-voltage.
000043

2. Light 2, redundant voltage feed and power supply
5. Control signals (inputs and outputs)
6. Power supply (redundant voltage feed for control
units, redundant CAN bus) and input data
Shines green when redundant voltage feed left, redundant voltage feed right and 15-voltage are supplied
voltage.
Light 3
Single yellow flash during communication with display

(KID) or cab control unit (D790-1).
Double yellow flash during communication with display
and cab control unit (D790-1).
Light 4
page
Control unit, frame front, description
page
Control unit, frame front, replacement

2 Detach the cables from the control unit, frame front (D797-F).
number (Z-number).
group 8.5.2.1 Calibrate SCALE (pressure sensor).
6 Verify lowering speed, see section 7 Load handling, group 7.2
Lifting/lowering. In the event of deviations contact Cargotec.
D ANGER
VDRF03.02GB
11 Common electrics 11.5.3.3 Control unit, frame rear
11.5.3.3
Control unit, frame rear, description
page
1
2
3
Control unit, frame rear (D797-R) processes input data from sensors
and sends control signals to relays and solenoid valves for functions
in the machines rear half.
Light 1

control unit.
Light 2

000043

voltage.
Light 3

Light 4
page
21
Control unit, frame rear, replacement

2 Detach the cables from the control unit, frame rear (D797-R).
number (Z-number).
group 8.5.2.1 Calibrate SCALE (length sensor, angle sensor).
VDRF03.02GB
22
11 Common electrics 11.5.3.4 Frame option control unit
11.5.3.4
Frame option control unit
Control unit, frame option, description
page
1
2
3
000043

Control unit, frame option (D797-O) is a unit that processes input data
from sensors and sends control signals to relays and solenoid valves
for the optional functions in the machines front half.
Light 1

control unit.
Light 2

voltage.
Light 3

Light 4
page
Control unit, frame option, replacement

2 Disconnect the cable harness from the control unit.
number (Z-number).
5 The control unit is not calibrated.
VDRF03.02GB
11 Common electrics 11.5.3.5 Control unit, attachment
11.5.3.5
Attachment control unit, description
page
1
2
3
The attachment control unit (D791) processes input data from sensors
and sends control signals to relays and solenoid valves for functions
for the top lift attachment.
Light 1

control unit.
Light 2

000043

voltage.
Light 3

Light 4
page
23
Attachment control unit, replacement

number (Z-number).
VDRF03.02GB
24
11 Common electrics 11.5.3.6 Attachment control unit, option
11.5.3.6
Attachment control unit, option
page
1
2
3
000043

The attachment control unit, option (D791-2) processes input data

for optional functions on the top lift attachment.
Light 1

control unit.
Light 2

voltage.
Light 3

Light 4
page
Attachment control unit, option, replacement

number (Z-number).
VDRF03.02GB
11 Common electrics 11.5.3.7 Control unit, attachment left jack pair
11.5.3.7
25
Control unit, attachment left jack pair, description
page
1
2
3
000043

Control unit, attachment left jack pair (D791-3) processes input data
to control the left jack pair on the attachment with lifting jacks. See section 7 Load handling , group 7.9.2 Twistlock and lifting jacks.
Light 1

control unit.
Light 2

voltage.
Light 3

Light 4
Control unit, attachment left jack pair, replacement
page

number (Z-number).
FRONT
REAR
6 Start the machine and drive to a free space. Operate the folding
sequence for lifting jacks up and down. Use the diagnostic menu
Combi, menu 14 and check that the lifting jacks go through all the
sequence modes from 1-5.
14(17)
LE
X
X
RI
X
X
000227
DIAG COMBI
SEQUENCE MODE
Diagnostic menu Combi, menu 14
VDRF03.02GB
26
11 Common electrics 11.5.3.8 Control unit, attachment right jack pair
11.5.3.8
Control unit, attachment right jack pair, description
page
1
2
3
000043

Control unit, attachment right jack pair (D791-4) processes input data
to control the right jack pair on the attachment with lifting jacks. See
section 7 Load handling , group 7.9.2 Twistlock and lifting jacks.
Light 1

control unit.
Light 2

voltage.
Light 3

Light 4
Control unit, attachment right jack pair, replacement
page

number (Z-number).
FRONT
REAR
6 Start the machine and drive to a free space. Operate the folding
sequence for lifting jacks up and down. Use the diagnostic menu
Combi, menu 14 and check that the lifting jacks go through all the
sequence modes from 1-5.
14(17)
LE
X
X
RI
X
X
000227
DIAG COMBI
SEQUENCE MODE
Diagnostic menu Combi, menu 14
VDRF03.02GB
11 Common electrics 11.5.3.9 Control unit transmission
11.5.3.9
27
Transmission control unit, description
page
The transmission control unit TCU (D793) is part of drivetrain control

and handles the transmissions function, selection of gear at load and
engine speed, etc.
The transmission control unit TCU (D793) is connected via separate

CAN bus communication to the engine, which is connected to the cab
control unit (D790-1). The cab control unit (D790-1) sends drivetrain
information on to other units.
E
F
000045
The control unit has two function keys and three status lights (see
illustration).
1. Display
2. Status lights
3. Function keys
Function button M
Select display group.
Function button S
Select display group mode.
Status light D
Yellow light indicates test mode.
Status light E
Yellow light indicates fault in unit.
Status light F
Red light during reset.
Control units can show information in the display in three display

groups with various status information. The M and S function keys are
used to navigate in the display and select display group and status information.
The following status information can be shown in the display:
Display group I
GPOS - shows transmissions direction of rotation
VSPD - shows speed in km/h
dist - shows distance driven in km or miles
Display group II
CPOS - shows gear position
Tspd - shows measured turbine speed in km/h or mph
Espd - shows measured engine speed in rpm
Ospd - shows measured speed out from the transmission in rpm
Srat - shows the turbine speed ratio (Tspd)/engine speed (Espd)
TQ I - shows measured torque (Nm) of transmission in
Ttmp - shows measured temperature in the oil sump (Celsius or

Fahrenheit)
Ctmp - shows measured temperature in the converter (Celsius or

Fahrenheit)
Display group III
Err - shows error codes (current and history)
VDRF03.02GB
28
11 Common electrics 11.5.3.10 Control unit, engine
Transmission control unit, replacement
page

2 Disconnect the cable harness from the TCU control unit.
number (Z-number).
group 8.5.2.3 Calibrate DRIVETRAIN and section 2 Transmission, group 2.8 Control system, transmission.
11.5.3.10
Control unit, engine, description (engine alternative Volvo

TWD1240VE)
page
The engine control unit (D794) is part of drivetrain control and handles
engine function, fuel injection, etc.
The engine control unit (D794) is connected via separate CAN bus
communication to the transmission, which is connected to the cab
3
1. Connector 1 (black)
2. Connector 2 (red)
3. Cooling duct for control unit (fuel)
007427
The control unit is located on the engine has no function keys or display. All functions are controlled via the CAN bus and an external control system.
The control unit monitors the following values to optimise engine
performance.
engine rpm
camshafts position
boost pressure
charge-air temperature
coolant temperature
oil pressure
oil temperature
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.
VDRF03.02GB
11 Common electrics 11.5.3.10 Control unit, engine
29
Control unit, engine, description (engine alternative Volvo

TAD1250VE)
page
007424

1. Cooling duct for control unit (fuel)
2. Connector A (black)
3. Connector B (grey)
The control unit monitors the following values to optimise engine
performance.
engine rpm
camshafts position
boost pressure
coolant temperature
oil pressure
oil temperature
oil level
crankcase pressure
water in fuel
fuel pressure
coolant level
VDRF03.02GB
30
11 Common electrics 11.5.3.11 Control unit KIT
Control unit, engine, description (engine alternative

Cummins)
page
007423
The control unit monitors the following values to optimise engine performance.
1. Connector OEM
2. Connector, Actuator
3. Connector, Sensor
engine rpm
boost pressure
coolant temperature
oil pressure
oil temperature
coolant level
water in fuel
air pressure
Engine control unit, replacement
page
11.5.3.11
Control unit KIT
KIT control unit, description
page
The KIT control unit (D790-2) handles functions for the gear selector
and multi-function lever, the direction indicator switch and start key positions II and III. It also handles the key panel (B) for the control system
and its panel for warning and indicator lights (A).
The KIT control unit (D790-2) has several individual function keys and
indicator lights (see illustration).
000049
See the operators manual for detailed information on warning and indicator lights and function keys.
1. Panel for warning and indicator lights

2. Panel for keys
VDRF03.02GB
11 Common electrics 11.5.3.12 Control unit KID
31
Control unit KIT, replacement
page

3 Detach KIT from the steering wheel panel.
4 Detach the connector sockets.
5 Remove the warning panel for warning and indicator lights.
7 KIT is not calibrated.
11.5.3.12
Control unit KID
KID control unit, description
page
The KID control unit (D795) displays to the operator information sent
by the control unit, such as speed, in the form of messages, status, error indications, etc.
There is an indicator light to the right of the display that is activated

with a red light when there is a serious malfunction in the control system. The error code and information are shown on the display.
000051
See the operators manual for detailed information on the display.
1. LCD display
2. Series of diodes that serve as an indicator light for
major error.
page
Control unit KID, replacement

3 Detach the connector from KID.
4 Detach KID from the steering wheel panel.
6 KID is not calibrated.
VDRF03.02GB
32
11 Common electrics 11.5.3.13 Control unit cab, option
11.5.3.13
Control unit cab, option
Control unit cab, option, description
page
1
2
3
000043

Control unit, cab option (D790-3) is only available on machines with

both combi attachment and joystick control or combi attachment and
mini-wheel. The control unit handles the signals to and from the joystick or mini-wheel and sends the information further on the CAN bus.
Light 1

control unit.
Light 2

Shines green when redundant voltage feed left and
right and 15-voltage are supplied voltage.
Light 3
Single yellow flash during communication with either

KID control unit (D795) or cab control unit (D790-1).
Double yellow flash during communication with both
KID control unit (D795) and cab control unit (D790-1).
Light 4
page
Control unit cab, option, replacement

number (Z-number).
VDRF03.02GB
11 Common electrics 11.5.5 Cables
11.5.5
33
Cables
Connectors, overview
page
The list includes all connectors on the machine with a brief description
of their locations and to which functions the signals in them are related.
Connector
Location
Function
X001
Power supply and earth connection Control unit cab (D790-1)
X002
Windscreen wipers
Cooling fan
Actuator motor, recirculation
X004
Air conditioning system
X005
Switch option
Switch warning light (Hazard)
Extra sensors
Accelerator pedal
X006
Instrument lighting dimmer

Switch work lights
Switch option
Seat heater
Accelerator pedal
Brake pedal
X007
Control lever
Indicator light support jacks down
X008
Control lever
Switch, bypass
Switch, parking brake
Switch sliding cab
Switch support jacks
Switch 30-35 stop
Switch option
Switch twistlocks
X009
Combi attachment
Overheight
Lever steering or mini-wheel
X009A
Extension X009A
VDRF03.02GB
34
Connector
Location
Function
X010
Sensor, end position cab

Water valve
Seat heating
Relay, work lighting
Hour counter
Relay, Compressor
Power supply relays K315-1, K3009-1, K3009-2 and K315-2
Windscreen washing
Windscreen wiper, roof
X011
Ignition
Lighting, control unit KID (D795)
Switches, cab doors
Buzzer
Interior lighting
Power supply, Control unit cab (D790-1)
Horn
NC switch, seat
Feedback relay K3009-1
Seat heating
X012
Windscreen wiper, rear

X013
CAN-bus
RS232
X015
CAN-bus
Power supply and earth connection, Control unit KIT (D790-2)
X016
Ignition switch
X017
Control, windscreen wipers

Control, gear
Control, main and dipped beams
X018

X018A
Extension X018
X020
CAN-bus
RS232 Printer
Power supply and earth connection, Control unit KID (D795)
X021
VDRF03.02GB
35
Connector
Location
Function
X022
Power supply and earth connection Control unit cab, option (D790-3)
CAN bus, Control unit, cab option (D790-3)
X033
Control, fan
Control, temperature
Control, air distribution
X034
Heater fan
Water valve
X035
Valve, air distribution

Sensor, air temperature
X036

Sensor, air temperature
X038
Instrument panel, cab
Accelerator pedal
Clutch-release pedal
X039
Electronic box cab
Hour counter
Relay, Compressor, seat with air suspension
Switch, cab door
Fan motor, heating
Water valve, ECC
X048
Electronic box cab
Termination resistor
X049
Electronic box cab
CAN-bus
X050
Electronic box cab
D-sub
RS232 Control unit cab (D790-1)
X051
Electronic box cab
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
Working lights
X055
Electronic box cab

Current, CD player
Current, COM radio
VDRF03.02GB
36
Connector
Location
Function
X056
Electronic box cab

Working lights, cab
X057
Electronic box cab
Windscreen wiper, rear

Power supply, reversing camera
X058
Electronic box cab
Motor, windscreen washers

Engine heater start inhibitor
X059
Electronic box cab
CAN-bus,
Power supply, Control unit cab, option (D790-3)
X060
Electronic box cab
CAN-bus
Interior lighting
X060A
Extension X060
CAN-bus
Interior lighting
X061
Electronic box cab
Earth connection, Control unit KID (D795)

Power supply, Control unit KIT (D790-2)
Windscreen wiper front
Actuator, recirculation
X061A
Extension X061
Earth connection, Control unit KID (D795)

Power supply, Control unit KIT (D790-2)
X062
Electronic box cab
Horn
Map lighting
Cigarette lighter 12V
X063
Electronic box cab
Seat heater
Compressed-air damped seat
X064
Electronic box cab
Sensor, end position cab
X071-1
Electronic box cab
Power supply, cab
X071-2
Electronic box cab
Earth connection, cab
X072
To Right Behind Seat
Power outlet
X073
Right side of instrument panel
Cigarette socket 12V
X080
Switch work lights

Switch, main beams
Switch, warning lights
Switch, seat heater
Switch, option
VDRF03.02GB
Connector
Location
Function
X081
Switch, option
37

Extra sensors
Hour counter
X082
NC switch, cab door left side
X168
Power supply, boom and attachment
X200
Boom mounting
CAN-bus
Redundant power supply, control units
X201
Earth connection and power supply, Control unit transmission (D793)
X202
Boom mounting
Sensor, boom length

Sensor, boom angle
Sensor, damping boom out
Sensor, damping boom in
Sensor, damping boom up
Sensor, damping boom down
Earth connection and power supply, boom sensor
Solenoid valve regeneration extension
Solenoid valve blocking extension
X203
Termination resistor
X205
CAN-bus
X206
Boom mounting
Revolving beacon boom

X210
Between engine and transmission
Power supply and earth connection, Control unit engine (D794)

CAN bus, Control unit engine (D794)
X211
42-pin connector to Control unit, frame front (D797-F)
X212
Power supply and earth connection, Control unit, frame front (D797-F)
CAN bus, Control unit, frame front (D797-F)
Temperature brake fluid
Safety switch
X221
42-pin connector to Control unit, frame rear (D797-R)
VDRF03.02GB
38
Connector
Location
Function
X222
Power supply and earth connection, Control unit, frame rear (D797-R)
CAN bus, Control unit, frame rear (D797-R)
Temperature hydraulic oil
Fuel gauge
Safety switch
D+ alternator
X231
42-pin connector to Control unit, frame option (D797-O)
X232
Power supply and earth connection, Control unit, frame option (D797-O)
CAN bus, Control unit, frame option (D797-O)
Safety switch
X233
Sensor support jacks

Solenoid valve support jacks up and down
X235
Solenoid valve steering left and right (joystick control or mini-wheel)
X246
AC compressor
Power supply sensor pressure refrigerant
X251
Control unit transmission (D793),

electronic box frame
30-pin connector for Transmission control unit (D793)
X252
Control unit transmission (D793),

electronic box frame
18-pin connector for Transmission control unit (D793)
X253
Transmission
Solenoid valves, transmission

Pressure sensor, transmission
X254
Power supply and earth connection Control unit transmission (D793)
X259
Transmission
Temperature sensor, transmission oil for radiator
X260
CAN bus, Control unit transmission (D793)
X261
RS232 Control unit transmission (D793)
X264
Solenoid valve brake transmission
X265
Cab
Reversing camera
X270
Lamp bracket left frame
Main and dipped beams

Side marker lights
X271
Lamp bracket front
Main and dipped beams

Side marker lights
VDRF03.02GB
Connector
Location
Function
X272
Lamp bracket left rear
Reversing light
39
Tail light
Brake light
Side marker lights
X273
Lamp bracket right rear
Reversing light
Tail light
Brake light
Side marker lights
X278
Between engine and transmission
Electromagnetic clutch compressor

Solenoid valve, engagement of hydraulics for top lift
Sensor pressure refrigerant
Solenoid valve deactivation of hydraulics
X279
Engine
Power supply and earth connection, Control unit engine (D794)

CAN-bus Drivetrain
X282
Cable connected to printer
RS232 Printer
X301
Boom mounting
Fuse holder power supply and earth connection to boom and attachment
X400
Boom nose
Fuse holder power supply and earth connection to boom and attachment
X401
Boom nose
CAN bus control units on boom nose and attachment

Redundant power supply control units on boom nose and attachment
X403A
Attachment, right side
Sensor, abutment right side

Sensor, twistlocks right side
X403B
Attachment, right side
Sensor, abutment right side

Sensor, twistlocks right side
X404
Attachment left side
Sensor, abutment left side

Sensor, twistlocks left side
X405
Boom nose
Indicator light locked twistlocks

Indicator light unlocked twistlocks
Indicator light alignment
X406
Attachment centre section
Extra working lights combi attachment
X408
Boom nose
Indicator light overheight jacks raised
X411
42-pin connector for attachment control unit (D791-1)
VDRF03.02GB
40
Connector
Location
Function
X412
Power supply and earth connection, attachment control unit (D791-1)

CAN bus, Control unit attachment (D791-1)
Safety switch
X414
Boom nose
CAN bus and power supply control unit attachment right jack pair
(D791-4)
X415
Boom nose
Combi attachment
X416
Rotation stop
X421

(D791-2)
42-pin connector for Control unit, attachment option (D791-2)
X422

(D791-2)
Power supply and earth connection, Control unit, attachment option

(D791-2)
CAN bus attachment option control unit (D791-2)
Safety switch
X428
Boom
Revolving beacon
X431
Control unit, attachment left jack

pair (D791-3)
42-pin connector for Control unit, attachment left jack pair (D791-3)
X432

pair (D791-3)
Power supply and earth connection, Control unit, attachment left jack pair
(D791-3)
CAN bus, Control unit, attachment left jack pair (D791-3)
Safety switch
X433
X434

pair (D791-3)
Levelling
Combi attachment, left side front
Sensor, clamping position left front jack
Indicator lights, alignment combi attachment
Sensor, alignment left front jack

X435
Combi attachment, left side rear
Sensor, clamping position left rear jack

Sensor, alignment left rear jack
X441
Control unit, attachment right jack

pair (D791-4)
42-pin connector for Control unit, attachment right jack pair (D791-4)
X442

pair (D791-4)
Power supply and earth connection, Control unit, attachment right jack
pair (D791-4)
CAN bus, Control unit, attachment right jack pair (D791-4)
Safety switch
X443

pair (D791-4)
Solenoid valve, tilt in and out

Indicator lights: Front jacks up and down
Indicator lights: Clamping position front and rear jacks
X444
Combi attachment, right side front
Sensor, clamping position right front jack

Sensor, alignment right front jack
VDRF03.02GB
Connector
Location
Function
X445
Combi attachment, right side rear
Sensor, clamping position right rear jack
41
Sensor, alignment right front jack

X489
Sensor, overheight jacks up and down

Indicator light, overheight jacks up and down
Solenoid valve overheight jacks up and down
X901
Voltage converter, cab
Voltage converters 24V/12V or only joint
X905
Cab panel
12V socket for Com radio
Signal types, general
page
The machines control units use a number of different types of signals

to receive signals from sensors and switches and control solenoid
valves, lights, etc. The table below describes the different signal types.
Signal type
Explanation
Usage area
Rheostat
Resistance input 0200 . 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 to 150 C.
E.g. hydraulic oil temperature sensor and climate

control system temperature sensor.
Analogue inputs
There are two different resistance curves - one for the cab control unit
(D790-1) and one for the frame and attachment control units.
Accuracy is 0.5 C in the interval 0 100 C (sensors measurement inaccuracy not included). Outside of the interval 0 100 C, accuracy is
2 C.
Voltage
An analogue signal 05 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.
A modulated signal is a digital signal translated to an analogue (continuous) signal adapted for a purpose, such as solenoid valve control.
Used when the output

signal actuates proportional solenoid valves.
Analogue outputs
Current feedback
voltage out, PWM
When the slide in a solenoid valve gets hot, resistance drops. This generates a lower current through the valve slide, which can cause the valves
servo pressure to remain constant. An internal ampermeter measures
current in the circuit and regulates the voltage level in order to maintain
the desired current value in the valve slide.
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.
VDRF03.02GB
42
Signal type
Explanation
Usage area
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 signal

with pull down and
search lighting
Signal in, U < 5 V generates logic zero (0)
E.g. input signal from a

breaker with search lighting.

with pull down
Signal in, U < 5 V generates logic zero (0)
Digital inputs
Signal in, U > 16 V generates logic one (1)

If there is no signal in, the input is grounded.
Signal in, U > 12 V generates logic 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
Logic 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

Max. load 5 A
E.g. work lighting and

wiper motors.
Open load 0.9 A

High side driver,
10 A
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

H-bridge
Logic one (1) generates voltage out, U >= 22.5 V or grounded output,
U=0V
Max. load 0.5 A
Open load 0.15 A
The H-bridge works with two outputs in a pair. At logic one (1), one output
gives voltage while the other output is grounded. At logic zero (0), the outputs switch voltage levels.
VDRF03.02GB
E.g. climate control system water valve (works in

both directions).
11 Common electrics 11.6 Communication
11.6
43
Communication
11.6.1
CAN-bus
CAN bus, description
page
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
3
4
U [V]
Communication between the control units takes place using so-called

"CAN buses" (Controller Area Network) based on the ISO 11898
standard and CAN specification 2.0B.
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) can 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.
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
There are two types of messages:
F G
t [S]
Messages are sequential and signal is high (voltage
high) or low (voltage low).
A. Length message
B. Start bit
C. Identity field/Priority
D. Check field (length of data segment)
E. Data segment
F. Checksum for error detection
G. Acknowledgement bit
000027
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)
Indicates that the transmission of a frame, i.e. a message, is now beginning.
Identity field (C)
Indicates what kind of information the message contains, e.g. measurement information on engine speed.
Does not indicate address to control unit. CAN does not work with addressing. All control units receive messages and send them on.
Control field (D)
Indicates how the length of the data segment that follows.
VDRF03.02GB
44
11 Common electrics 11.6.1 CAN-bus
Data segment (E)

Contains the information to be conveyed to control units in the network.
Checksum for error detection (F)
Calculates a checksum for the message. This makes it possible for the
receiving control unit to detect errors in the sent message.
Acknowledge (G)
The transmitting control unit sets a bit to logic one (1) when the message is sent. The first control unit to receive the message sends it on
and sets the bit to logic zero (0).
Communication
The CAN network consists of control units and segment. The segment
(bus) is a twisted pair cable that leads CAN + and CAN - signal levels
from control unit to control unit.
Each control unit measures the potential difference of its two inputs.
The potential difference generates logic zero and logic 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
0.5 V and still be approved. In practice, a potential difference of 2 V is
recommended for reliable communication.
U [V]
3,5 V
0,5 V
Pulse train can only be observed using an oscilloscope, NOT with a

digital multimeter.
t [S]
Potential levels CAN + and CAN -
000028
1,5 V
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:
VDRF03.02GB
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 shall be interpreted
11 Common electrics 11.6.2 Redundant CAN bus
11.6.2
45
Redundant CAN bus
Redundant CAN bus, description
page
CAN R
CAN L
D791-3
CAN R
D790-1
CAN R
CAN L
CAN R
D797-R
CAN L
D791-2
CAN R
D790-2
CAN L
CAN L
CAN R
CAN L
D795
CAN R
CAN L
The redundant CAN bus handles communication between all of the

machines control units except the transmission control unit (D793)
and the engine control unit (D794). These have a separate CAN bus;
see Drivetrain CAN bus, description page 48.
D791-1
CAN R
D797-O
Principle illustration, redundant CAN bus
CAN L
CAN L
CAN R
D797-F
003170
D791-4
Redundant CAN bus means that the control units are connected to a
network that communicates via a CAN bus (see CAN bus, description
page 43) and that there are double communication routes on the network. The network is divided into control units and segments (segments are cables between the control units). The number of active
segments depends on the number of control units the machine has,
which depends on the machines equipment level (options).
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. cab components.
The control units have two CAN bus connections - CAN L (left) and
CAN R (right). The control units are connected to one another in series
in a loop.
The redundant CAN bus can handle the loss of a segment. The link is
analysed upon start-up. If a segment is faulty, 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.
VDRF03.02GB
46
Connection of redundant CAN bus

Condition
Reference value
Reference
In position
1
Battery disconnector, description page 3
Activated.
S5
S2
D791-1
22
10 D790-2
S1
D790-1
S9
1, 11
D797-R
6
D791-2
3
S3
S8
D795
S5
S2
S4
9
S3
D791-3
D797-F
S6
D797-O
S7
S4
D791-4
5
013023
The illustration shows two alternatives for how the segment numbering
is changed depending on the number of control units on the machine:
Solid lines show the CAN-bus with a minimal number of control units.
Dotted lines show the CAN-bus with a maximal number of control
units.
Pos
Explanation
Signal description
Reference
The cab control unit (D790-1) establishes redundant CAN bus communication
by sending a request on the CAN bus
via CAN R.
Checked by control
system, error shown
with error code.

sends a response back on the CAN bus
via CAN L and sends the request on via
CAN R.
A clicking sound is
audible when then
termination resistor is
activated.
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
Attachment control unit, description page 23

Termination resistors in the control

nodes ensure communication segment
by segment.
VDRF03.02GB
47
Pos
Explanation
Signal description
Reference
Control unit, attachment option (D7912) sends a response back on the CAN
bus via CAN L and sends the request on
via CAN R.
A clicking sound is
audible when then
activated.

page 24

by segment.
4

(D791-3) sends a response back on the
CAN bus via CAN L and sends the request on via CAN R.
A clicking sound is
audible when then
activated.

by segment.
5

(D791-4) sends a response back on the
CAN bus via CAN L and sends the request on via CAN R.
A clicking sound is
audible when then
activated.

by segment.
6

a response back on the CAN bus via
CAN L and sends the request on via
CAN R.
A clicking sound is
audible when then
activated.
Control unit, attachment left jack pair, description page 25

Control unit, attachment right jack pair, description page 26



by segment.
7

sends a response back on the CAN bus
via CAN L and sends the request on via
CAN R.
A clicking sound is
audible when then
activated.


by segment.
8

a response back on the CAN bus via
CAN L and sends the request on via
CAN R.
A clicking sound is
audible when then
activated.


by segment.
VDRF03.02GB
48
11 Common electrics 11.6.3 CAN bus drivetrain
Pos
Explanation
Signal description
Reference
The KID control unit (D795) sends a response back on the CAN bus via CAN L
and sends the request on via CAN R.
A clicking sound is
audible when then
activated.
KID control unit, description page 31

by segment.
10
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.
A clicking sound is
audible when then
activated.
KIT control unit, description page 30
11
If all control units have responded, the

cab control unit (D790-1) deactivates
the segment to the attachment control
unit (D791-1).
Checked by control
system, error shown
with error code.
If a control unit has not responded, the

cab control unit (D790-1) uses both
CAN L and CAN R to keep communication open and analyses which segment
is faulty.
11.6.3
CAN bus drivetrain
Drivetrain CAN bus, description
page
D790-1
The drivetrain CAN bus is based on the SAE J1939 standard where
selected messages are used to control engine and transmission.
SAE J1939 is a standard from SAE (Society of Automotive Engineers)

for data communication in vehicles. The standard regulates hardware
interface, bit times and message composition.
Control units for engine and transmission come from the respective
transmission and engine supplier. The control units use the same
standard of communication and therefore the messages for each engine are constructed using the same structure.
Communication with engine control unit (D794) and transmission control unit (D793) are separate from the redundant CAN bus.
000033
The signals can be checked from the diagnostic menu, see section 8
Control system , group 8.4.1.3 CAN/POWER, menu 3.
1. Redundant CAN bus

2. CAN bus drivetrain
3. Control unit, engine
4. Engine
5. Control unit transmission
6. Transmission
VDRF03.02GB
11 Common electrics 11.6.4 Communication between PC and machine
11.6.4
49
Communication between PC and

machine
Communication between PC and machine,

description
page
The machine has three or four sockets for communication between

control units and PC. Two are located in electronic box cab and one or
two in electronic box cab frame. It is the socket for communication with
engine alternative Volvo that varies.
Sockets for programming control units in the cab electrical distribution

box (position 1) are used for programming the control units in the cab,
on the frame, and on the attachment.
The socket for CAN bus drivetrain in the cab electronic box (position
2) is used for communicating with the engine and transmission via
CAN bus.
The VODIA socket in the frame electronic box (position 3) (Volvo engine only) is used to connect the Volvos diagnostic tool - VODIA.
The socket for transmission control unit (D793) programming in the
frame electronic box (position 4) is used to program the transmission
For further details on communication between computer and machine,
contact Cargotec.
006887
1. Diagnostic socket, machine

2. Diagnostic socket engine, CAN bus drivetrain
(engine alternative Cummins QSM11)
3. Diagnostic socket, engine VODIA (Volvo engine)
4. Diagnostic socket, transmission
VDRF03.02GB
50
11 Common electrics 11.6.5 RMI (Remote Machine Interface)
11.6.5
RMI (Remote Machine Interface)
RMI (Remote Machine Interface), description
page
007443
Remote Machine Interface is a tool for reading data from the machine
at a distance. The RMI consists of a control unit which is connected to
the machine, antenna for communication and GPS-antenna (
positioning.
RMI interface (A911)
) for
RMI interface (A911) records communication on the CAN bus and

sends the information to a central RMI server. In the event of a fault in
the machine the control unit can send the information via GSM, GPRS,
WLAN, radio modem, SMS or e-mail.
From the RMI-server, data from the machine can be analysed and
processed for reading out different values. For example, when it is
time for service or if there are error codes stored in the machine.
As an option, there is a GPS-antenna, making it possible to read
off the machines position.
Control unit CAN gateway RMI (D795-2) sends some information from
the machines CAN bus on to the RMI interface (A911), which sends it
on via the RMI server.
010504
NOTE
RMI only sends data from the machine, but no data can be sent
to the machine. RMI cannot be used to control the machine.
Control unit CAN gateway RMI (D795-2)
VDRF03.02GB
11 Common electrics 11.6.6 Kalmar CAN Customer Gateway
11.6.6
51
Kalmar CAN Customer Gateway
page
010504
Kalmar CAN Customer Gateway is an interface to connect an external

equipment in order to store machine data.
The Kalmar CAN Customer Gateway control unit (D795-2) translates
communication on the machines CAN bus to RS232 and CAN for connection to external devices according to a predetermined protocol.
NOTE
Control unit, Kalmar CAN Customer Gateway

(D795-2)
Kalmar CAN Customer Gateway only sends data from the machine, no data can be sent to the machine. Kalmar CAN Customer Gateway cannot be used to control the machine.
The following data are examples of data available to the customer via
Kalmar CAN Customer Gateway:
Operating time
Temperature values
Fuel consumption
Current speed
Current weight of load
Operating time remaining until next service
Number of lifted containers, different counters for different sizes
Position of twistlock (locked/open)
Boom position
VDRF03.02GB
52
VDRF03.02GB
11 Common electrics 11.6.6 Kalmar CAN Customer Gateway
D Error codes
D Error codes
Table of Contents D Error codes

mm mm mm mm mm mm
Error codes ..................................................................................................... 3

Error codes, explanation ........................................................................................ 3
Error code menu, description ................................................................................. 4
Reading out error code ........................................................................................... 7
Engine ............................................................................................................. 9
Error codes engine, general ................................................................................... 9
Error codes engine (engine alternative Volvo) ..................................................... 10
Engine error codes (engine alternative Cummins QSM11) .................................. 27
Transmission................................................................................................ 39
Error codes, transmission .................................................................................... 39
Control system ............................................................................................. 91

Error codes machine ............................................................................................ 91
VDRF03.02GB
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D Error codes
D Error codes D Error codes
D Error codes
mm mm mm mm mm mm
Error codes, explanation
page
The error codes are explained in table form for Engine, Transmission
as well as Control system. They are sorted according to error code
number.
The error code table has the following information:
B
B. Error code level (symbol)
C. Error code number
D. Error cause (symbol)
E. Function (symbol)
Code, error code's number, shown in field C on display.
Description, explanation of the error code and when it's

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 fix the

problem, read signal value or check the function.
E
000389
In addition to the explanation of the display figure, the description

of the diagnostic menus contains reference to circuit diagrams
that are found in section E Schematics and reference to function
group for further information about functions and components.
Function group is a reference to which function group the error

code is connected. This field is used to search for more 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 position and work instructions for different
work.
VDRF03.02GB
page
The control systems display is divided into four fields that show information (see figure to the left).
C
D
E
000389
Field B: Error code level shown with a symbol.
Field C: Indicates error code.
Field D: Indicates type of error.
Field E: Indicates which function is affected by error code.
The book symbol means that there's information in the operator's

manual.
Field B: Error code level

The control system gives error code information in three levels which
are indicated with a symbol in the lower left corner (B) on the display
unit.
Indicates a serious malfunction that may affect operator safety or

cause machine breakdown. The error code must be taken care of
immediately. Stop working with the machine and contact service
immediately.
E
000350
C
E
C
E
000352
VDRF03.02GB
Warning
Indicates machine malfunction that should be taken care of as
soon as possible. After finished work shift with the machine, contact service as soon as possible.
000351
Stop
Information
Information to the operator that something should be fixed, e.g.,
broken bulb. Fix the cause of the error code as soon as possible.
See section 6 Inspection and maintenance in the Operators
manual.
The error code is stored in the error code list under operating
menu for service.
Field C: Error code number

The control system gives error codes from three sub-systems:
Machine:
Shown with error code number XXX on display.
E
000389
XX/YY
Engine:
Shown with error code number XXX/YY on display.
NOTE
If several error codes come from the engine, the error code
level is shown for the most serious error code.
001343
XXX/YY
Transmission:
Shown with error code number XX/YY on display.
D
001344
Field D: Type of error
1.
Too high/too low temperature.
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
VDRF03.02GB
Field E: Affected function
1.
Attachment
2.
Rotation of attachment
3.
Side shift of attachment
4.
Length adjustment attachment
5.
Levelling attachment
6.
Twistlocks
7.
Tilt attachment
8.
9.
Bottom lift-attachment, clamping position
10. Bottom lift-attachment, jacks up/down
10
11
11. Boom up/down
12
12. Boom in/out

13. Pressure sensor lift cylinder (overload system, OP)
13
14
14. No overload system
15
15. Support jacks up/down

16. Hydraulic functions
16
17
17. Brake system
18
18. Steering
19. Engine
20. Transmission
19
20
21
21. Central lubrication

22. Control unit
23. Hardware-related error
22
23
24
24. Cab
25. Air conditioning system
26. Fuel system
25
26
27
27. Headlights
28. Windscreen wipers
29. Battery voltage
29
30. Bulb for lighting
30
000397
28
VDRF03.02GB
Reading out error code
page
NOTE
In case of an error code, perform the actions recommended in the
error code table to find the problem.
Error codes are stored as active and inactive. Active errors are
shown in the error code menu.
Always use error code menus for reading out error codes, otherwise there is a risk of missing error codes.
1 Turn the start key to position I.
WARN IN G
Risk of machine damage.
In case of error codes of level WARNING and
STOP, serious machine damage may result if the
engine is started.
Do not start the engine until the cause of the error
code has been identified or repaired.
000056
2 Navigate to the service menu and press Enter.
3 Safety menu is shown. Hold Enter depressed for at least two

seconds.
000060
1 23
4 5
001998
4 The error code list is shown on the display. Active error code is
shown on display where field C shows error code number together with X(Y). X shows sequence number for shown error code
and (Y) shows number of active error codes.
Scroll between error codes with key 1 and 2 (arrow function).
Error codes disappear from the list when the cause has been
remedied.
VDRF03.02GB
5 Note error code number (field C) to not forget.
E
000389
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
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
operators manual.
6 Use the error code tables to find more information about the error
code.
7 After action, check that no active error codes remain for the function in question.
VDRF03.02GB
D Error codes 1 Engine
1 Engine
mm mm mm mm mm mm
Error codes engine, general
page
When contacting engine suppliers, use Volvo/Cummins codes.
Display indicates error code according to SAE J1939

SPN/FMI
J1587 indicates error code according to SAE J1587 (for Volvo:

Vodia).
PID, PPID, SID, PSID/FMI
Table 1. Specification FMI
FMI
Description
SAE-text
Too high value.
Valid data, but higher than normal operating range.
Too low value.
Valid data, but lower than normal operating range.
Incorrect data.
Intermittent or incorrect data.
Electrical problem.
Abnormally high voltage or short-circuiting to higher voltage.
Electrical problem.
Abnormally low voltage or short-circuiting to lower voltage.
Electrical problem.
Abnormally low current or open circuit.
Electrical problem.
Abnormally high current or short-circuiting to frame ground.
Mechanical problem.
Incorrect response from mechanical system.
Mechanical problem or electrical problem.
Abnormal frequency.
Communication error.
Abnormal update rate.
10
Mechanical problem or electrical problem.
Abnormally wide variations.
11
Unknown malfunction.
Non-identifiable error.
12
Component error.
Defective unit or component.
13
Incorrect calibration.
Values outside calibration values.
14
Special instructions.
15
Reserved for future use.
VDRF03.02GB
10
Error codes engine (engine

alternative Volvo)
page
Code
94/FMI
94/FMI
Description
Limitation
Action
Connections and
components
Diagnostic menu
Fuel pressure
sensor, short
circuited to voltage, ground, or
open circuit.
No limitation.
Check cabling between

control unit and component.
Volvo
TWD1240VE:
D794/2:3
Check the sensor.
Volvo
TAD1250VE:
D794/B:16
Low fuel pressure

(feed).
No limitation.
Change fuel filter.

Volvo
TWD1240VE:
D794/2:4
Check the sensor.
Volvo
TAD1250VE:
D794/B:8
J1587
PID94/
FMI
PID94/
FMI
Change fuel pre-filter.

Check if pressure can be
built up with the hand
pump.
97/1
PID97/1
Water in fuel.
No limitation.
Drain water separator.

Clean metal filter in the
fuel feeds hose connection on the engine.
Check fuel filter and fuel
pre-filter.
97/3
PID97/3
Water-in-fuel sensor short circuited

to ground or open
circuit.
No limitation.
98/FMI
PID98/
FMI
Low oil level.
No limitation.
Check oil level.
ENGINE,
menu 6
98/FMI
PID98/
FMI
Oil level sensor,

short circuited to
voltage, ground,
or open circuit.
No limitation.

ENGINE,
menu 6
Check the sensor.
Volvo
TAD1250VE:
D794/B:3, B:4,
A:31
Low engine oil

pressure.
Engine will shut

down.
Check oil level.
ENGINE,
menu 6
100/1
PID100/1
Change oil filter.

Check the system pressure valves and the safety valve in the lubrication
system.
Check the sensor.
VDRF03.02GB
Code
100/3
100/4
102/0
11
Description
Limitation
Action
Connections and
components
Diagnostic menu
Sensor oil pressure, cable short

circuited to supply
voltage.
No limitation.

control unit and
component.
Volvo
TWD1240VE:
D794/1:14
ENGINE,
menu 6
Check the sensor.
Volvo
TAD1250VE:
D794/B:11
Oil pressure sensor, open circuit

or short circuit to
ground.
No limitation.

control unit and
component.
Volvo
TWD1240VE:
D794/1:14
Check the sensor.
Volvo
TAD1250VE:
D794/B:11
Boost pressure
high.
No limitation.
Check the turbocharger.
ENGINE,
menu 6
ENGINE,
menu 6
ENGINE,
menu 7
J1587
PID100/3
PID100/4
PID102/0
Check the sensor.
ENGINE,
menu 6
Check fuel quality and

injectors.
102/1
PID102/1
Boost pressure
low.
Reduced engine power.
Check the air filter.

Check the turbocharger.
Check the sensor.
Check the fuel feed
pressure.
102/3
102/4
105/0
PID102/3
PID102/4
PID105/0
Sensor boost
pressure, cable
short-circuited to
voltage.
The engine jerks

more than normal during acceleration or
under load.

Volvo
TWD1240VE:
D794/1:3
Check the sensor.
Volvo
TAD1250VE:
D794/A:22
Boost pressure
sensor, cable
short circuited to
ground or open
circuit.
The engine jerks

under load.

Volvo
TWD1240VE:
D794/1:3
Check the sensor.
Volvo
TAD1250VE:
D794/A:22
High charge-air
temperature.
Engine will shut

down.
Check coolant level.
Check that the charge-air

cooler is clean.
ENGINE,
menu 7
ENGINE,
menu 7
Check thermostat.
Check the sensor.
VDRF03.02GB
12
Code
105/3
105/4
106/FMI
106/FMI
Description
Limitation
Action
Connections and
components
Diagnostic menu
Charge air temperature sensor,

cable short
circuited to supply
voltage or open
circuit.
No limitation.

Volvo
TWD1240VE:
D794/1:2
ENGINE,
menu 7
Check the sensor.
Volvo
TAD1250VE:
D794/A:47
Charge air temperature sensor,

cable short
circuited to
ground or open
circuit.
No limitation.

Volvo
TWD1240VE:
D794/1:2
Check the sensor.
Volvo
TAD1250VE:
D794/A:47
Boost pressure
sensor, short circuit to voltage,
ground or open
circuit.
The engine jerks

under load.

Volvo
TWD1240VE:
D794/1:3
Check the sensor.
Volvo
TAD1250VE:
D794/A:22
Boost pressure
too high.
No limitation.

ENGINE,
menu 6
ENGINE,
menu 7

Volvo
TWD1240VE:
D794/1:25
ENGINE,
menu 7
Check the sensor.
Volvo
TAD1250VE:
D794/B:27
J1587
PID105/3
PID105/4
PID106/
FMI
PID106/
FMI
ENGINE,
menu 7
ENGINE,
menu 6
Check the sensor.

110/0
PID110/0
High coolant temperature.
Volvo
TWD1240VE:
Engine will shut
down.
Volvo
TAD1250VE: No
limitation.

Check that radiator is
clean.
Check thermostat.
Check the cap on the expansion tank.
Check if theres air in
coolant system.
Check the sensor.
110/3
VDRF03.02GB
PID110/3
Coolant temperature sensor, cable

short circuited to
supply voltage or
open circuit.
Preheating is activated even if

engine is warm.
Code
110/4
111/1
13
Description
Limitation
Action
Connections and
components
Diagnostic menu
Coolant temperature sensor, cable

short circuited to
ground.
Preheating is activated even if

engine is warm.

Volvo
TWD1240VE:
D794/1:25
ENGINE,
menu 7
Check the sensor.
Volvo
TAD1250VE:
D794/B:27
Low coolant level.
Volvo
TAD1250VE:
Engine will shut
down.
Check the coolant level,

top up if needed.

Volvo
TWD1240VE:
D794/2:7
Check the sensor.
Volvo
TAD1250VE:
D794/B:23
Clean the crankcase

ventilation.
Volvo
TAD1250VE:
D794/B:28
J1587
PID110/4
PID111/1
Check the sensor.
Volvo
TAD1250VE: No
limitation.
111/FMI
PID111/
FMI
Coolant level sensor, short

circuited to
voltage.
Volvo
TWD1240VE:
Engine will shut
down.
Volvo
TAD1250VE: No
limitation.
153/FMI
153/FMI
158/FMI
PID153/
FMI
PID153/
FMI
PID158/
FMI
Crankcase ventilation pressure

too high.
No limitation.
Crankcase ventilation pressure

sensor, short circuit to voltage,
ground or open
circuit.
No limitation.
Low battery
voltage.
Engine may be
difficult to start.
Check for wear on the

cylinder liner, piston and
piston rings.
Check the sensor.
Check and charge the

batteries.
Check the alternator.
Check the battery cables.
VDRF03.02GB
14
Code
J1587
172/FMI
PID172/
FMI
175/0
PID175/0
Description
Limitation
Action
Connections and
components
Diagnostic menu
Intake air temperature sensor,

short circuit to
voltage, ground,
or open circuit.
No limitation.

Volvo
TWD1240VE:
D794/1:2
ENGINE,
menu 7
Check the sensor.
Volvo
TAD1250VE:
D794/A:47
High engine oil

temperature.
Check oil level.
ENGINE,
menu 7

Volvo
TWD1240VE:
D794/1:1
ENGINE,
menu 7
Check the sensor.
Volvo
TAD1250VE:
D794/A:31,
B:3, B:4

Volvo
TWD1240VE:
D794/1:1
Check the sensor.
Volvo
TAD1250VE:
D794/A:31,
B:3, B:4
Check the lubrication

systems thermostat.
Check the sensor.
175/3
175/4
PID175/3
PID175/4
Oil temperature
sensor, cable
short circuited to
supply voltage or
open circuit.
No limitation.
Oil temperature
sensor, cable
short circuited to
ground.
No limitation.
ENGINE,
menu 7
190/FMI
PID190/
FMI
Engine rpm too

high.
No limitation.
Ease off throttle or select

higher gear.
608/FMI
PPID98/
FMI
Signal error for

start and stop.
No limitation.
Check the CAN bus drivetrain.
CAN/
POWER,
menu 3
620/3
SID232/3
Voltage feed to
sensor, cable
short circuited to
voltage.
Several error
codes for sensor
error.

Volvo
TWD1240VE:
D794/1:5
1079/2

Incorrect instrument values.
VDRF03.02GB
Volvo
TAD1250VE:
D794/B:17
Code
620/4
Description
Limitation
Action
Connections and
components
Diagnostic menu
Voltage feed to
sensor, cable
short circuited to
ground.
Several error
codes for sensor
error.

Volvo
TWD1240VE:
D794/1:4
J1587
SID232/4
1079/3
Volvo
TAD1250VE.
D794/B:17
Incorrect instrument values.

626/3
626/4
626/5
629/FMI
15
PID45/3
PID45/4
PID45/5
SID254/
FMI
Preheating relay,
cable short
circuited to voltage.
Preheating cannot be activated.
Preheating relay,
cable short
circuited to
ground.
Preheating is
continually activated.
Preheating relay,
open circuit on cable or defective
component.
Preheating cannot be activated.
Engine control
unit (D794), internal fault.
The engine will

not start.

Volvo
TWD1240VE:
D794/2:36
ENGINE,
menu 5
Check the relay.
Volvo
TAD1250VE:
D794/B:25

Volvo
TWD1240VE:
D794/2:36
Check the relay.
Volvo
TAD1250VE:
D794/B:25

Volvo
TWD1240VE:
D794/2:36
Check the relay.
Volvo
TAD1250VE:
D794/B:25
Change the control unit.
ENGINE,
menu 5
ENGINE,
menu 5
Engine runs
roughly.
630/FMI
SID253/
FMI
Engine control
unit (D794), memory error.
The engine will

not start.
Re-program the control

unit.
636/3
SID21/3
Sensor rpm camshaft, no signal.
Engine takes
longer time to
start than normal. Engine runs
normally when it
has started.

Volvo
TWD1240VE:
D794/1:7, 1:18
Check the sensor.
Volvo
TAD1250VE:
D794/B:45,
B:46
VDRF03.02GB
16
Code
636/8
637/2
Description
Limitation
Action
Connections and
components
Diagnostic menu
Sensor engine
rpm, camshaft,
abnormal frequency.
Engine takes
longer time to
start than normal. Engine runs
normally when it
has started.

Volvo
TWD1240VE:
D794/1:7, 1:18
Check the sensor.
Volvo
TAD1250VE:
D794/B:45,
B:46
Engine speed
sensor, flywheel,
irregular signal.
Engine is extremely difficult

to start and runs
rough, if it starts.

Volvo
TWD1240VE:
D794/1:30,
1:31
J1587
SID21/8
SID22/2
Check the sensor.
ENGINE,
menu 2
Volvo
TAD1250VE:
D794/B:37,
B:38
637/3
SID22/3
Sensor engine
rpm, flywheel, abnormal frequency.

to start and runs

Check the sensor.
Volvo
TWD1240VE:
D794/1:30,
1:31
ENGINE,
menu 2
Volvo
TAD1250VE:
D794/B:37,
B:38
637/8
639/FMI
VDRF03.02GB
SID22/8
SID231/
FMI
Sensor engine
rpm, flywheel, abnormal frequency.
Communication
error with Engine
control unit
(D794), configuration error.

to start and runs
Engine off: engine cannot be

started.
Engine on: engine goes to idle
and can only be
stopped by using the emergency stop.

Check that the sensor is
connected correctly.
Use diagnostic menu to

find incorrect segment.
Check the control unit.
Volvo
TWD1240VE:
D794/1:30,
1:31
ENGINE,
menu 2
Volvo
TAD1250VE:
D794/B:37,
B:38
Volvo
TWD1240VE:
D794/2:1, 2:2
Volvo
TAD1250VE:
D794/B:51,
B:55
CAN/
POWER,
menu 3
Code
J1587
639/FMI
SID231/
FMI
17
Description
Limitation
Action
Connections and
components
Diagnostic menu
Communication
error with Engine
control unit
Instruments and
controls do not
work.

CAN/
POWER,
menu 3

639/FMI
SID240/
FMI
Engine control
unit, memory error.
It may not be
possible to start
the engine.
Re-program the control

unit.
651/2
SID1/2
Electric failure, injector cylinder 1.
Engine runs on 5
cylinders,
sounds rough
and has reduced
power.

Volvo
TWD1240VE:
D794/1:11,
1:12
Engine runs on 5
cylinders,
sounds rough
and has reduced
power.

Engine runs on 5
cylinders,
sounds rough
and has reduced
power.

Engine runs on 5
cylinders,
sounds rough
and has reduced
power.

651/3
651/4
651/5
SID1/3
SID1/4
SID1/5
Check the injector.
Volvo
TAD1250VE:
D794/A:20,
A:24
Check the injector.
Volvo
TWD1240VE:
D794/1:11,
1:12
Volvo
TAD1250VE:
D794/A:20,
A:24
Check the injector.
Volvo
TWD1240VE:
D794/1:11,
1:12
Volvo
TAD1250VE:
D794/A:20,
A:24
Check the injector.
Volvo
TWD1240VE:
D794/1:11,
1:12
Volvo
TAD1250VE:
D794/A:20,
A:24
VDRF03.02GB
18
Code
651/7
Description
Limitation
Action
Connections and
components
Diagnostic menu
Incorrect compression or defective injector

cylinder 1.
Runs rough at
low rpm and low
load.
Check fuel pressure.
Volvo
TWD1240VE:
D794/1:11,
1:12
J1587
SID1/7
Check valve clearance.

Check the injector.
Perform compression
test and check cylinder 1.
651/11
652/2
652/3
652/4
VDRF03.02GB
SID1/11
SID2/2
SID2/3
SID2/4
Engine runs on 5
cylinders,
sounds rough
and has reduced
power.

Engine runs on 5
cylinders,
sounds rough
and has reduced
power.

Engine runs on 5
cylinders,
sounds rough
and has reduced
power.

Engine runs on 5
cylinders,
sounds rough
and has reduced
power.

Check the injector.
Volvo
TAD1250VE:
D794/A:20,
A:24
Volvo
TWD1240VE:
D794/1:11,
1:12
Volvo
TAD1250VE:
D794/A:20,
A:24
Check the injector.
Volvo
TWD1240VE:
D794/1:22,
1:12
Volvo
TAD1250VE:
D794/A:20,
A:24
Check the injector.
Volvo
TWD1240VE:
D794/1:22,
1:12
Volvo
TAD1250VE:
D794/A:12,
A:16
Check the injector.
Volvo
TWD1240VE:
D794/1:22,
1:12
Volvo
TAD1250VE:
D794/A:12,
A:16
Code
652/5
652/7
Description
Limitation
Action
Connections and
components
Diagnostic menu
Engine runs on 5
cylinders,
sounds rough
and has reduced
power.

Volvo
TWD1240VE:
D794/1:22,
1:12
Runs rough at
low rpm and low
load.
J1587
SID2/5
SID2/7

cylinder 2.
Check the injector.
Volvo
TAD1250VE:
D794/A:12,
A:16

Check the injector.
Perform compression
652/11
653/2
653/3
19
SID2/11
SID3/2
SID3/3
Engine runs on 5
cylinders,
sounds rough
and has reduced
power.

Engine runs on 5
cylinders,
sounds rough
and has reduced
power.

Engine runs on 5
cylinders,
sounds rough
and has reduced
power.

Check the injector.
Volvo
TWD1240VE:
D794/1:22,
1:12
Volvo
TAD1250VE:
D794/A:12,
A:16
Volvo
TWD1240VE:
D794/1:22,
1:12
Volvo
TAD1250VE:
D794/A:12,
A:16
Check the injector.
Volvo
TWD1240VE:
D794/1:23,
1:12
Volvo
TAD1250VE:
D794/A:28,
A:32
Check the injector.
Volvo
TWD1240VE.
D794/1:23,
1:12
Volvo
TAD1250VE:
D794/A:28,
A:32
VDRF03.02GB
20
Code
653/4
653/5
653/7
Description
Limitation
Action
Connections and
components
Diagnostic menu
Engine runs on 5
cylinders,
sounds rough
and has reduced
power.

Volvo
TWD1240VE:
D794/1:23,
1:12
Engine runs on 5
cylinders,
sounds rough
and has reduced
power.

Runs rough at
low rpm and low
load.
J1587
SID3/4
SID3/5
SID3/7

cylinder 3.
Check the injector.
Volvo
TAD1250VE:
D794/A:28,
A:32
Check the injector.

Perform compression
654/2
VDRF03.02GB
SID3/11
SID4/2
Volvo
TAD1250VE:
D794/A:28,
A:32
Check the injector.
653/11
Volvo
TWD1240VE:
D794/1:23,
1:12
Engine runs on 5
cylinders,
sounds rough
and has reduced
power.

Engine runs on 5
cylinders,
sounds rough
and has reduced
power.

Check the injector.
Volvo
TWD1240VE:
D794/1:23,
1:12
Volvo
TAD1250VE:
D794/A:28,
A:32
Volvo
TWD1240VE:
D794/1:23,
1:12
Volvo
TAD1250VE:
D794/A:28,
A:32
Check the injector.
Volvo
TWD1240VE:
D794/1:34,
1:24
Volvo
TAD1250VE:
D794/A:52,
A:56
Code
654/3
654/4
654/5
654/7
Description
Limitation
Action
Connections and
components
Diagnostic menu
Engine runs on 5
cylinders,
sounds rough
and has reduced
power.

Volvo
TWD1240VE:
D794/1:34,
1:24
Engine runs on 5
cylinders,
sounds rough
and has reduced
power.

Engine runs on 5
cylinders,
sounds rough
and has reduced
power.

Runs rough at
low rpm and low
load.
J1587
SID4/3
SID4/4
SID4/5
SID4/7

cylinder 4.
Check the injector.
Volvo
TAD1250VE:
D794/A:52,
A:56
Check the injector.
Check the injector.
Engine runs on 5
cylinders,
sounds rough
and has reduced
power.
Volvo
TWD1240VE:
D794/1:34,
1:24
Volvo
TAD1250VE:
D794/A:52,
A:56

Perform compression
SID4/11
Volvo
TWD1240VE:
D794/1:34,
1:24
Volvo
TAD1250VE:
D794/A:52,
A:56
Check the injector.
654/11
21

Check the injector.
Volvo
TWD1240VE:
D794/1:34,
1:24
Volvo
TAD1250VE:
D794/A:52,
A:56
Volvo
TWD1240VE:
D794/1:34,
1:24
Volvo
TAD1250VE:
D794/A:52,
A:56
VDRF03.02GB
22
Code
655/2
655/3
655/4
655/5
655/7
Description
Limitation
Action
Connections and
components
Diagnostic menu
Engine runs on 5
cylinders,
sounds rough
and has reduced
power.

Volvo
TWD1240VE:
D794/1:35,
1:24
Engine runs on 5
cylinders,
sounds rough
and has reduced
power.

Engine runs on 5
cylinders,
sounds rough
and has reduced
power.

Engine runs on 5
cylinders,
sounds rough
and has reduced
power.

Engine runs on 5
cylinders,
sounds rough
and has reduced
power.
Check that cabling to the

injectors is not damaged.
J1587
SID5/2
SID5/3
SID5/4
SID5/5
SID5/7

cylinder 5.
Check the injector.
Volvo
TAD1250VE:
D794/A:44,
A:48
Check the injector.
Volvo
TAD1250VE:
D794/A:44,
A:48
Check the injector.
Volvo
TWD1240VE:
D794/1:35,
1:24
Volvo
TAD1250VE:
D794/A:44,
A:48
Check the injector.
Volvo
TWD1240VE:
D794/1:35,
1:24
Volvo
TAD1250VE:
D794/A:44,
A:48

Check the injector.
Perform compression
VDRF03.02GB
Volvo
TWD1240VE:
D794/1:35,
1:24
Volvo
TWD1240VE:
D794/1:35,
1:24
Volvo
TAD1250VE:
D794/A:44,
A:48
Code
655/11
656/2
656/3
656/4
656/5
23
Description
Limitation
Action
Connections and
components
Diagnostic menu
Engine runs on 5
cylinders,
sounds rough
and has reduced
power.

Volvo
TWD1240VE:
D794/1:35,
1:24
Engine runs on 5
cylinders,
sounds rough
and has reduced
power.

Engine runs on 5
cylinders,
sounds rough
and has reduced
power.

Engine runs on 5
cylinders,
sounds rough
and has reduced
power.

Engine runs on 5
cylinders,
sounds rough
and has reduced
power.

J1587
SID5/11
SID6/2
SID6/3
SID6/4
SID6/5
Check the injector.
Volvo
TAD1250VE:
D794/A:44,
A:48
Check the component.
Volvo
TWD1240VE:
D794/1:36,
1:24
Volvo
TAD1250VE:
D794/A:36,
A:40
Check the injector.
Volvo
TWD1240VE:
D794/1:36,
1:24
Volvo
TAD1250VE:
D794/A:36,
A:40
Check the injector.
Volvo
TWD1240VE:
D794/1:36,
1:24
Volvo
TAD1250VE:
D794/A:36,
A:40
Check the injector.
Volvo
TWD1240VE:
D794/1:36,
1:24
Volvo
TAD1250VE:
D794/A:36,
A:40
VDRF03.02GB
24
Code
656/7
Description
Limitation
Action
Connections and
components
Diagnostic menu

cylinder 6.
Runs rough at
low rpm and low
load.
Volvo
TWD1240VE:
D794/1:36,
1:24
J1587
SID6/7

Check the injector.
Perform compression
656/11
677/FMI
SID6/11
PPID3/
FMI
SID39/
FMI
1485/3
2017/
FMI
VDRF03.02GB
PPID5/3
PSID201
/FMI
Starter motor relay, short circuit to

voltage/ground.
Main relay, cable

short circuited to
voltage.
Communication
error with Engine
control unit
Volvo
TAD1250VE:
D794/A:36,
A:40
Engine runs on 5
cylinders,
sounds rough
and has reduced
power.

The engine will

not start.

Volvo
TWD1240VE:
D794/2:31
Check the motor.
Volvo
TAD1250VE
D794/B:29
The instrument
panel loses voltage when the ignition key is
turned to the
start position.
The engine will
not start.

Volvo
TWD1240VE:
D794/1:32
Check the relay.
Volvo
TAD1250VE:
D794/A:8
Engine off: engine cannot be

started.

Volvo
TWD1240VE:
D794/2:1, 2:2
Engine starts immediately when

ignition is turned
on.
Engine on: engine goes to idle

and can only be
stopped by using the emergency stop.
Check the injector.
Volvo
TWD1240VE:
D794/1:36,
1:24
Volvo
TAD1250VE
D794/A:36,
A:40

Volvo
TAD1250VE:
D794/B:51,
B:55
ENGINE,
menu 5
CAN/
POWER,
menu 3
Code
25
Description
Limitation
Action
Connections and
components
Diagnostic menu
Undetectable error code from the

engine.
Contact the engine supplier for further information.
D794
The engine control unit limits engine output.
Check the wiring (boost

pressure sensor).
Volvo
TAD1250VE:
D794/B:30
Volvo
TAD1250VE:
D794/B:30
Volvo
TAD1250VE:
D794/B:30
Volvo
TAD1250VE:
D794/B:30
Volvo
TAD1250VE:
D794/B:14
J1587
2047/xx
Error codes
above 2047 cannot be shown in
the display.
Possible error
codes: 2791,
520192, 520194,
520195.
2791/3
PPID19
Internal EGR:
Wiring error
(boost pressure
sensor).
Mechanical error
on IEGR.
2791/4
PPID19
Internal EGR:
Wiring error
(boost pressure
sensor).
Mechanical error
on IEGR.
2791/5
PPID19
Internal EGR:
Wiring error
(boost pressure
sensor).
Mechanical error
on IEGR.
2791/7
PPID19
Internal EGR:
Mechanical error
on IEGR.
520192/
1
PPID8
Piston cooling
pressure sensor,
short circuited to
voltage, ground,
or open circuit.
IEGR cannot be
activated.

IEGR cannot be
activated.

IEGR cannot be
activated.
Contact an authorised
Volvo Penta workshop.
Check the component
(IEGR).
pressure sensor).
Check the component
(IEGR).
pressure sensor).
Check the component
(IEGR).
Could damage
the turbine
wheel of the turbocharger and
increase force
and emissions.

pressure sensor).
No limitation.

Check the component
(IEGR).
Check the sensor.
VDRF03.02GB
26
Description
Limitation
Action
Connections and
components
Diagnostic menu
Code
J1587
520192/
3
PPID8
Low piston cooling pressure.
No limitation.
Check that engine oil

pressure is over 175 kPa.
520194/
3
PPID4
Start input CIU:
Engine cannot
be started.
Check that start key connections are not damaged.
D794
D794
Volvo
TAD1250VE:
D794/B:27
Short circuited to
minus (-).
Activated too
long.
520194/
4
PPID4
Start input CIU:

Short circuited to
minus (-).
Activated too
long.
520195/
4
PPID6
Stop input on control unit:

Short circuited to
minus (-).

the ignition is
switched on.
Engine cannot
be started.
the ignition is
switched on.
The engine can
only be stopped
with the auxiliary
stop.
Check that the start key

wiring is not damaged.
Check that start key connections are not damaged.

Check that the start key
wiring is not damaged.
Check that the connections and wiring are not

damaged.
Activated too
long.
VDRF03.02GB
Volvo
TWD1240VE:
D794/2:6
27
Engine error codes (engine

alternative Cummins QSM11)
page
Code
84/2
84/10
91/3
91/4
91/8
Description
Limitation
Action
Connections and
components
Diagnostic menu
Electrical error,
speed sensor, invalid
data.
Engine speed is
limited to maximum rpm without
gear.

Electrical error,
speed sensor, signal
manipulation detected.
Engine speed is
limited to maximum rpm without
gear.

Electrical error, accelerator pedal, cable short circuited to

supply voltage.
Engine does not

respond to throttle.

Electrical error, accelerator pedal, cable short circuited to

ground.
Engine does not

Electrical error, accelerator pedal, low

frequency.
Engine does not

J1587
PID084/2
PID084/
10
PID091/3
PID091/4
PID091/8
Check the sensor.
Check the sensor.

91/8
PID091/8
Electrical error, accelerator pedal, high

frequency.
Engine does not


91/19
SID091/2
Communication error with cab control

unit (D790-1), electrical error, accelerator
pedal.
Engine will only

idle.

CAN/
POWER,
menu 3
97/3
PID097/3
Electrical error, water-in-fuel sensor,

cable short circuited
to supply voltage.
No limitation.

D794/Sensor:09
VDRF03.02GB
28
Code
97/4
Description
Limitation
Action
Connections and
components
Diagnostic menu
Electrical error, water-in-fuel sensor,

to ground.
No limitation.

D794/Sensor:09
J1587
PID097/4
97/15
PID097/
15
Water in fuel.
Risk of white exhaust smoke and

reduced engine
output.
Drain water from the fuel

filter.
100/1
PID100/1
Low engine oil pressure.
Engine output is
reduced gradually.
The engine is
switched off after
30 seconds.
Check the engine oil level; fill as necessary.
ENGINE,
menu 6
100/2
PID100/2
Oil pressure sensor,

data error.
No warning of low
engine oil pressure.
Check the sensor.
D794/Sensor:44
ENGINE,
menu 6
100/3
PID100/3
Sensor oil pressure,

to supply voltage.
No warning of low

D794/Sensor:44
ENGINE,
menu 6
D794/
Black:14
ENGINE,
menu 6
ENGINE,
menu 6
D794/Sensor:39
ENGINE,
menu 7
D794/Sensor:39
ENGINE,
menu 7
Check the sensor.

100/4
PID100/4
Oil pressure sensor,

open circuit or short
circuit to ground.
No warning of low

Check the sensor.
100/18
PID100/1
Low engine oil pressure.
No limitation.
Check oil level in the engine, top up as needed.

Check the sensor.
102/2
102/3
PID102/2
PID102/3
Boost pressure sensor indicates high

boost pressure but
other engine data indicates that pressure
should be normal.
Reduced engine
power.
Sensor boost pressure, cable shortcircuited to voltage.
Reduced engine
power.

Check the sensor.

Check the sensor.
VDRF03.02GB
Code
102/4
29
Description
Limitation
Action
Connections and
components
Diagnostic menu
Boost pressure sensor, cable short

circuited to ground or
open circuit.
Reduced engine
power.

D794/
Black:3
ENGINE,
menu 7
J1587
PID102/4
Check the boost pressure sensor.
103/16
PID103/0
Over-rev protection,
turbo.
Reduced engine
power.
105/0
PID105/0
Intake air too hot.
Engine output is
reduced gradually.
The engine is
switched off after
30 seconds.
Check the coolant level in

the engine, top up as
needed.
ENGINE,
menu 7
D794/Sensor:38
ENGINE,
menu 7
D794/Sensor:38
ENGINE,
menu 7
Check that the charge-air

cooler is clean, clean as
needed.
Check that the fan belts
are intact. Check the intake air temperature sensor.
105/3
PID105/3
Charge air temperature sensor, cable

short circuited to
supply voltage or
open circuit.
Risk of white exhaust smoke. No

warning of high
coolant temperature.

Check that the charge air
temperature sensor is
correctly installed and
connected.
Check the charge air
temperature sensor.
105/4
PID105/4
Charge air temperature sensor, cable

short circuited to
ground or open circuit.
Risk of white exhaust smoke. No

warning of high
coolant temperature.

correctly installed and
connected.
Check the sensor.
108/2
PID108/2
Electrical error, air

pressure sensor,
data error.
Reduced engine
power.
Check the sensor.
108/3
PID108/3

pressure sensor, cable short circuited to
supply voltage.
Reduced engine
power.

D794/Sensor:06
Check the sensor.
VDRF03.02GB
30
Code
108/4
110/0
Description
Limitation
Action
Connections and
components
Diagnostic menu

pressure sensor, cable short circuited to
ground.
Reduced engine
power.

D794/Sensor:06
High coolant temperature.
Engine output is
reduced gradually.
The engine is
switched off after
30 seconds.
ENGINE,
menu 7
J1587
PID108/4
PID110/0
Check the sensor.

Check that radiator is
clean.
Check if theres air in
coolant system.
Check the cap on the expansion tank.
Check the sensor.
Check thermostat.
110/3
PID110/3
Coolant temperature
sensor, cable short
circuited to supply
voltage or open
circuit.
No indication of
engine temperature.

control unit and
component.
D794/Sensor:02
ENGINE,
menu 7
110/4
PID110/4
Coolant temperature
sensor, cable short
circuited to ground.
No indication of
engine temperature.

D794/Sensor:02
ENGINE,
menu 7
D794/Sensor:09

Check the sensor.
111/1
111/2
PID111/1
PID111/2
Low coolant level.
Electrical error, coolant level sensor,

data error.
Engine output is
reduced gradually.
The engine is
switched off after
30 seconds.
Check the coolant level,

top up if needed.
No warning of low
coolant level.

Check the sensor.
Check the sensor.

166/2
VDRF03.02GB
PID116/2
Output imbalance
between cylinders.
Uneven idling.
Check the fuel quality.

The error code could be
generated if the fuel system is opened, allowing
air to enter the system.
Troubleshoot the engine.
Code
31
Description
Limitation
Action
Connections and
components
Diagnostic menu
J1587
167/1
PID167/1
Low battery voltage.
Warning active
until voltage is correct.
Check batteries and alternator.
D794/
OEM:7, 8,
17, 18, 28
167/16
PID167/0
Warning active
until voltage is correct.
Check fuses. Check batteries and alternator.
D794/
OEM:7, 8,
17, 18, 28
167/18
PID167/1
High battery voltage.
Warning active
until voltage is correct. The engine
runs at increased
idle to increase
voltage.
D794/
OEM:7, 8,
17, 18, 28
168/16
PID168/0
High voltage supply

to control unit.
No limitation.
D794/
OEM:7, 8,
17, 18, 28
168/18
PID168/1
Low voltage supply

to control unit.
Uneven idling.
D794/
OEM:7, 8,
17, 18, 28
175/0
PID175/0
High engine oil temperature.
Engine output is
reduced gradually.
The engine is
switched off after
30 seconds.
Check the engine coolant

and oil level. Top up as
necessary.
ENGINE,
menu 7
D794/Sensor:42
ENGINE,
menu 7
D794/Sensor:42
ENGINE,
menu 7
Check that the oil cooler

is clean; clean as needed.
Check that the fan belts
are intact.
Check the sensor.
175/3
175/4
PID175/3
PID175/4
Oil temperature sensor, cable short

circuited to supply
voltage or open circuit.
No indication of
engine oil temperature.
Oil temperature sensor, cable short

No indication of
engine oil temperature.

Check the sensor.
VDRF03.02GB
32
Code
188/4
Description
Limitation
Action
Connections and
components
Electrical error,
wastegate solenoid
valve 1 short
Reduced engine
power.

D794/Actuator: 24
Diagnostic menu
J1587
SID032/4
Check the solenoid

valve.
190/0
PID190/0
Engine rpm too high.
Fuel supply restricted until engine speed is

below permitted
value.
Ease off throttle or select

higher gear.
190/2
PID190/2
Electrical error, rpm/

ignition mode sensor; no signal from
any sensors.
Engine stops and

cannot be restarted.

D794/Sensor:47, 50
Electrical error, rpm/

ignition mode sensor, one of two signals missing.
No limitation.
D794/Sensor: 47, 50
190/10
PID190/
10
Check the sensor.

Check the sensor.
191/16
PID191/0
Speed limitation activated.
Speed is reduced.
Reduce throttle application.
191/18
PID191/1
Speed warning for

low speed.
Engine will only

idle.
Increase throttle application.
251/2
PID251/2
Internal error, Control unit, engine.
441/3
PID441/3
Auxiliary temperature sensor short

No warning of high
temperature, Control unit, engine
(D794).

D794/Sensor: 12
Auxiliary temperature sensor short

circuited to supply
voltage.
No warning of high
temperature, Control unit, engine
(D794).

Electrical error, accelerator pedal sensor, idling contact,

data error.
No limitation.
Check cable between

441/4
558/2
VDRF03.02GB
PID441/4
SID230/2
Check the sensor.

D794/Sensor: 12
Check the sensor.
Check component.
D794/
OEM: 03,
13
Code
558/4
558/13
33
Description
Limitation
Action
Connections and
components
Diagnostic menu
Electrical error, accelerator pedal sensor, idling contact

to ground.
Engine does not

Check cable between

D794/
OEM: 03,
13
Electrical error, accelerator pedal sensor, idling contact,

calibration error.
Engine will only

idle.
D794/
OEM: 13
J1587
SID230/4
SID230/
13
Check component.
Check cable between
Check component.
608/2
SID250/2
Communication error with Control unit

engine (D794).
No limitation.
D794/
OEM: 26,
27, 36, 37,
46
608/9
SID250/9

engine (D794).
No limitation.
D794/
OEM: 26,
27, 36, 37,
46
620/3
SID232/3
Electrical error, reference voltage to sensor short circuited to

supply voltage.
Reduced engine
output. No warning of low oil pressure or low
coolant level.

D794/Sensor: 18, 25,

45

ground.
Reduced engine
output. No warning of low oil pressure or low
coolant level.

D794/Sensor: 18, 25,

45
Electrical error to
control of preheating
relay.
Preheating not
working. Risk of
white smoke.

D794/Actuator: 34
ENGINE,
menu 5
1080/3
620/4
SID232/4
1081/4
626/11
SID237/
11

627/2
SID251/2
Voltage supply to
control unit disappears but ignition not
off.
Reduced engine
output. Engine difficult to start or
dies.
Check the fuses.

D794/
OEM:7, 8,
17, 18, 28
629/12
SID254/
12
The engine will not

start.
629/12
SID254/
12
No limitation.
VDRF03.02GB
34
Code
Description
Limitation
Action
Connections and
components
Diagnostic menu
J1587
630/2
SID253/2
Software error, Control unit, engine

(D794).
Reduced engine
output. Engine difficult to start or
dies.
Re-program the software

in Control unit, engine
(D794).
632/3
SID017/3
Electrical error, fuel

cut-off solenoid
valve, cable short
circuited to supply
voltage.
No limitation.

D794/Actuator: 33
Electrical error, fuel

cut-off solenoid
valve, cable short
Engine will shut

down.
D794/Actuator: 33
632/4
SID017/4
Check the solenoid

valve.
Check the solenoid
valve.
639/2
SID231/2

engine (D794).
Functions via CAN

bus not working.

CAN/
POWER,
menu 2
639/9
SID231/9

engine (D794).
Functions via CAN

bus not working.

CAN/
POWER,
menu 2
639/9
SID231/9
Communication error with Control unit,

engine (D794), timeout error.
Functions via CAN

bus not working.

CAN/
POWER,
menu 2
639/13
SID231/
13
Communication error with Engine control unit (D794),

configuration error.
Functions via CAN

bus not working.

CAN/
POWER,
menu 2
644/2
SID030/2
Electrical error, accelerator pedal, signal not within valid

interval.
Engine will shut

down.

Electrical error, fan

connection, cable
short circuited to
ground.
Cooling fan runs

constantly.
D794/Actuator:10,
Actuator: 9
Electrical error, cylinder 1 injector, open

circuit on cable.
Engine runs on 5
cylinders, sounds
rough and has reduced power.
D794/Actuator:10,
Actuator: 9
647/4
651/5
VDRF03.02GB
SID033/4
SID001/5

Check the injector.
Code
651/6
652/5
652/6
653/5
653/6
654/5
654/6
655/5
655/6
35
Description
Limitation
Action
Connections and
components
Diagnostic menu
Electrical error, cylinder 1 injector, cable

short circuited to
ground.
Engine runs on 5
cylinders, sounds

D794/Actuator:10,
Actuator: 9

circuit on cable.
Engine runs on 5
cylinders, sounds

D794/Actuator: 7, 8

short circuited to
ground.
Engine runs on 5
cylinders, sounds

D794/Actuator:7, 8

circuit on cable.
Engine runs on 5
cylinders, sounds

D794/Actuator:6,
16

short circuited to
ground.
Engine runs on 5
cylinders, sounds
Check cable between

D794/Actuator:6,
16

circuit on cable.
Engine runs on 5
cylinders, sounds

D794/Actuator:26,
36

short circuited to
ground.
Engine runs on 5
cylinders, sounds

D794/Actuator:26,
36

circuit on cable.
Engine runs on 5
cylinders, sounds

D794/Actuator: 3, 4
Engine runs on 5
cylinders, sounds
Check cable between

D794/Actuator: 3, 4
J1587
SID001/7
SID002/5
SID002/6
SID003/5
SID003/6
SID004/5
SID004/6
SID005/5
SID005/6

short circuited to
ground.
Check the injector.
Check the injector.
Check the injector.
Check the injector.
Check component.
Check the injector.
Check the injector.
Check the injector.
Check component.
VDRF03.02GB
36
Code
656/5
656/6
702/3
974/3
974/4
Limitation
Action
Connections and
components
Diagnostic menu

circuit on cable.
Engine runs on 5
cylinders, sounds
Check cable between

D794/Actuator: 1, 2

short circuited to
ground.
Engine runs on 5
cylinders, sounds

D794/Actuator: 1, 2
Electrical error, auxiliary output 2, cable

short circuited to
supply voltage.
No limitation.

D794/Actuator: 14
Electrical error, auxiliary output 2, cable

short circuited to
supply voltage.
No limitation.
D794/Actuator: 45
Electrical error, auxiliary accelerator pedal, cable short

circuited to supply
voltage.
Engine does not

D794/
OEM: 21
Electrical error, auxiliary accelerator pedal, cable short

Engine does not

D794/
OEM: 21
J1587
SID006/5
SID006/6
SID040/3
PID154/3
703/3
Description
SID051/3
SID029/3
SID029/4
Check component.
Check the injector.

974/19
SID029/2
Communication error with cab control

unit (D790-1), electrical error, accelerator
pedal.
Engine does not


CAN/
POWER,
menu 2
1043/3
PID221/3
Electrical error, accelerator pedal reference voltage, cable

short circuited to
supply voltage.
Engine will only

idle.

D794/
OEM: 48
Electrical error, accelerator pedal reference voltage, cable

short circuited to
ground.
Engine will only

idle.
D794/
OEM: 48
1043/4
VDRF03.02GB
PID221/4

Code
J1587
1072/11
SID070/
11
37
Description
Limitation
Action
Connections and
components
Diagnostic menu
Electrical error, solenoid valve engine

brake 2.
Engine brake 1
cannot be activated.

D794/Actuator: 44
D794/Actuator: 44
D794/Sensor: 17, 37
D794/Sensor: 17, 37
D794/Actuator: 24
Check the solenoid

valve.
1073/11
SID029/
11
Electrical error, solenoid valve engine

brake 2.
Engine brake 2
cannot be activated.

Check the solenoid
valve.
1079/3
1079/4
1188/3
1189/3
1189/4
1265/4
SID232/3
SID232/4
SID032/3
SID088/3
SID88/4
SID085/4

supply voltage.
Reduced engine
power.

ground.
Reduced engine
power.
Electrical error,
wastegate solenoid
valve 1 short
circuited to supply
voltage.
Reduced engine
power.
Electrical error,
wastegate solenoid
valve 2 short
circuited to supply
voltage.
Reduced engine
power.
Electrical error,
wastegate solenoid
valve 2 short
Reduced engine
power.
Electrical error, oilburn solenoid valve,

to ground.
No limitation.

Check the sensor.
Check the sensor.
Check the solenoid
valve.
D794/Actuator: 23
Check the solenoid

valve.
D794/Actuator: 23
Check the solenoid

valve.
Check the solenoid

valve.
VDRF03.02GB
38
Code
1319/2
Description
Limitation
Action
Connections and
components
Diagnostic menu
Electrical error,
boost pressure sensor.
Reduced engine
power.

D794/Sensor: 9
J1587
PID102/2
Check the sensor.

1380/1
PID017/1
Low engine oil level.
No limitation.
Check the engine oil level; fill as necessary.
1383/31
SID151/
11
Engine shut off other

than with start key,
causing load.
No limitation.
Switch of the engine with

the start key.
1384/31
SID029/
14
Engine shut off other

than with start key,
causing load.
No limitation.
Switch of the engine with

the start key.
1387/3
PID223/3
Electrical error, auxiliary pressure sensor,

to supply voltage.
No pressure guard
(customer-specific option).

D794/Sensor: 19
Electrical error, auxiliary pressure sensor,

to ground.
No pressure guard
(customer-specific option).
D794/Sensor: 19
Error codes in other

control units.
No limitation.
1387/4
1484/31
VDRF03.02GB
PID223/4
SID216/
11
Check the sensor.

Check the sensor.
Check error codes for
other machine control
units, particularly the cab
control unit (D790-1) and
transmission control unit
(D793).
D Error codes 2 Transmission
39
2 Transmission
mm mm mm mm mm mm
Error codes, transmission
page
The machine is available with two transmission alternatives, transmission alternative Dana and transmission alternative Dana full flow. Both
alternatives use the same error codes, but some error codes are related to different components depending on the transmission alternative.
In this case there are two different descriptions marked "Dana" and
"Dana full flow" respectively.
Control unit transmission can generate two modes with reduced functionality to protect the transmission in case of serious malfunctions:
"Limp-home".
In this mode only 1-2 gear in both directions can be used. If the
malfunction occurs in a higher gear then downshifting has to be
performed manually to 1st gear or 2nd.
"Shut-down"
In this mode, the transmission is in permanent neutral position as
there is no oil pressure to enable selection of a gear.
Code
Description
Limitation
Action
Connections and
components
Diagnostic
menu
SPN/FM1
00/50
7F09D/C
Memory error in control

unit transmission.
Transmission
locked in neutral
(Shut-down).
00/51
7F09D/C

unit transmission.
Transmission
locked in neutral
(Shut-down).
00/52
7F09D/C

unit transmission.
Transmission
locked in neutral
(Shut-down).
00/53
7F09D/C

unit transmission.
Transmission
locked in neutral
(Shut-down).
VDRF03.02GB
40
Code
20/60
Description
Limitation
Action
Dana
Transmission
locked in neutral
(Shut-down).
Check cabling
between control
unit and sensor.
7F065/1
Dana
TRANSM,
menu 10
7F065/0
7F069/1
D793/A2 X253
Check the
sensor.
Dana full flow
Dana full flow
Sensor gear 1/3

(B6067) indicates low oil
pressure when there
should be pressure.
D793/A2 B6067
Dana
Sensor oil pressure indicates oil pressure when
there should not be
pressure.
21/00
Diagnostic
menu
SPN/FM1
Sensor oil pressure indicates low oil pressure

when there should be
pressure.
20/61
Connections and
components
Transmission
locked in neutral
(Shut-down).
Check cabling
between control
unit and sensor.
Dana
D793/A2 X253
Check the
sensor.
Dana full flow
Dana full flow
Sensor gear 1/3

(B6067) indicates oil
pressure when there
should not be oil pressure.
D793/A2 B6067
Oil pressure sensor (1)

has too low oil pressure.
TRANSM,
menu 10
Transmission
locked in neutral
(Shut-down).
Check the feed

pressure to the
transmission.
Save information about actual

pressure when
the problem occurred.
21/01
7F069/0

has too high oil pressure.
Transmission
locked in neutral
(Shut-down).
Check the feed

pressure to the
transmission.
pressure when
VDRF03.02GB
Code
SPN/FM1
22/00
7F06A/1
Description
Limitation
Action

Transmission
locked in neutral
(Shut-down).
Check the feed

pressure to the
transmission.
41
Connections and
components
Diagnostic
menu

pressure when
22/01
7F06A/0

Transmission
locked in neutral
(Shut-down).
Check the feed

pressure to the
transmission.
pressure when
23/00
7F06B/1

Transmission
locked in neutral
(Shut-down).
Check the feed

pressure to the
transmission.
pressure when
23/01
7F06B/0

Transmission
locked in neutral
(Shut-down).
Check the feed

pressure to the
transmission.
pressure when
24/00
7F06C/1

Transmission
locked in neutral
(Shut-down).
Check the feed

pressure to the
transmission.
pressure when
VDRF03.02GB
42
Code
SPN/FM1
24/01
7F06C/0
Description
Limitation
Action

Transmission
locked in neutral
(Shut-down).
Check the feed

pressure to the
transmission.
Connections and
components
Diagnostic
menu
CAN/
POWER,
menu 15
CAN/
POWER,
menu 15
CAN/
POWER,
menu 15
CAN/
POWER,
menu 15
TRANSM,
menu 6

pressure when
30/04
30/05
31/00
31/01
34/00
7F090/1
7F090/0
7F093/1
7F093/0
7F0BB/1F
High battery voltage.
Reference voltage sensor 8 V, too low.
Reference voltage sensor 8 V, too high.
Sensor, drum rpm

(B752) incorrect.
Control unit saves

stored information
to flash memory
and restarts to clear
memory.
Check cabling
to control unit.
Control unit receives reduced proportional control

precision depending on reduced
PWM work cycle.
Check voltage
feed.
Control unit receives reduced sensor signals.
Check voltage
feed.
Control unit receives reduced sensor signals.
Check voltage
feed.
Transmission
locked in gear 1 and
2 (Limp-home).
Check cabling
between gear
control and sensor.
Check alternator, battery and

cabling between
battery and alternator.
If auxiliary start
equipment is
connected, disconnect it.
Check the sensor.
VDRF03.02GB
Code
SPN/FM1
34/01
7F0BC/1
Description
Limitation
Action
Measured turbine speed

during start-up is too
low.
Transmission
locked in neutral
(Shut-down).
Check cabling
between gear
control and sensor.
43
Connections and
components
Diagnostic
menu
TRANSM,
menu 2
Check the
sensor.
Check the feed
pressure to the
transmission.
34/02
7F0BD/0
Measured turbine speed

during start-up is too
high.
Transmission
locked in neutral
(Shut-down).
Check cabling
between the
gear control and
drum rpm
sensor.
Check the
sensor.
34/03
7F0BE/1
Transmission indicates
that system pressure is
absent when it should
be present.
Transmission
locked in neutral
(Shut-down).
Check drum
rpm sensor.
Check Solenoid
valve RSP Drive
(Y6066).
Feed pressure
to transmission
too low.
34/04
7F0BE/0
Transmission indicates
that system pressure is
present when it should
be absent.
Transmission
locked in neutral
(Shut-down).
Check cabling
between the
gear control and
drum rpm
sensor.
Check the
sensor.
Check Solenoid
valve RSP Drive
(Y6066).
40/06
7F05E/2
Incorrect direction from

gear selector.
Control unit locks

transmission in
neutral.
Check cabling
to gear selector
with regards to
forward and reverse signal.
VDRF03.02GB
44
Description
Limitation
Action
Connections and
components
Diagnostic
menu
Code
SPN/FM1
40/08
7F041/1F
Seat direction was

changed when the parking brake was not activated and/or the gear
control was not in neutral position, and/or the
machine was not stationary.
Transmission
locked in neutral
(Shut-down).
Check seat direction or show

the driver how
the seat is
turned as per
the correct procedure.
41/06
7F05F/2
Incorrect gear selection

from gear selector.
Control unit doesnt

allow change of
range, however, operation of machine
is possible.
Check cabling
to gear selector
with regards to
signal range.
TRANSM,
menu 2
42/04
7F080/1
Actual gear ratio too

low.
Control unit indicates that one or

several clutches are
slipping.
Check transmission with purpose to

understand if
and, if that is the
case, which
clutch is slipping.
TRANSM,
menu 6
TRANSM,
menu 6
Check the set

gear ratio for the
control unit.
42/05
7F080/0
Actual gear ratio too

high.
Control unit indicates that one or

several clutches are
slipping.
Check transmission with purpose to

understand if
and, if that is the
case, which
clutch is slipping.
Check the set
gear ratio for the
control unit.
VDRF03.02GB
Code
43/03
Description
Limitation
Action
Dana
Control unit indicates the error.
Check cabling
between control
unit and component.
43/08
Connections and
components
Diagnostic
menu
Dana
TRANSM,
menu 10
SPN/FM1
7F063/0
Signal from Sensor engine rpm and oil temperature transmission

(B758/766) outside valid
interval.
43/07
45
7F063/10
7F063/0
D793/H3 B758/766
Check the sensor.
Dana full flow
Dana full flow
The signal from Sensor

oil temperature (B7660)
outside valid interval.
D793/H3 B7660
Torque converter temperature exceeds

100 C.
Torque converter temperature exceeds

120 C.
Control unit indicates the error to

make operator
aware of the warnings level.
The control unit protects the transmission and does not

allow the temperature in the torque
converter to exceed
the limit value.
The control unit
locks the transmission in neutral position, the engine is
restricted to 50% of
max. rpm.
Check transmission oil cooler,

clean as needed.
Check the thermostat in the
transmission oil
cooler.
Check transmission oil cooler,
clean as needed.
Check the thermostat in the
transmission oil
cooler.
Dana
D793/H3 B758/766
TRANSM,
menu 10
Dana full flow

D793/H3 B7660
Dana
D793/H3 B758/766
TRANSM,
menu 10
Dana full flow

D793/H3 B7660
44/10
7F0C6/9
Faulty signal for accelerator pedal position from

engine control unit
(D794).
Use diagnostic
menu to find incorrect segment.
CAN/
POWER,
menu 3
45/06
7F048/2
Invalid combination for

redundant digital speed
inputs.
The control unit limits machine speed

to the reduced
speed.
Check the
speed sensors.
46/05
7F036/F
Max. torque for inching

has been exceeded.
VDRF03.02GB
46
Description
Limitation
Action
Connections and
components
Diagnostic
menu
Code
SPN/FM1
47/01
7F07B/10
The transmission has

exceeded the limit value
for top speed.
Release the accelerator pedal

and slow down
the machine.
48/00
7F0B3/0
Disengaged 4WD/2WD
selector stuck in engaged mode, or the
feedback signal is incorrect.
Check the 4WD/

2WD selector.
Engaged 4WD/2WD selector stuck in engaged

mode, or the return signal is incorrect.
Disengaged Low/High
selector stuck in engaged mode, or the
feedback signal is incorrect.
Engaged Low/High selector stuck in engaged

mode, or the return signal is incorrect.
48/01
49/00
49/01
7F0B3/1
7F0B4/0
7F0B4/1
VDRF03.02GB
Check whether
digital feedback
is switched on
and connected
to the control
unit.
Check the 4WD/
2WD selector.
Check whether
digital feedback
is switched on
and connected
to the control
unit.
Check the Low/
High gear selector.
Check whether
digital feedback
is switched on
and connected
to the control
unit.
Check the Low/
High gear
selector.
Check whether
digital feedback
is switched on
and connected
to the control
unit.
Code
50/00
Description
Limitation
Action
Dana
Transmission
2 (Limp-home).
Check cabling
between control
unit and sensor.
7F010/4
Check the sensor.
Dana full flow

Sensor gear 1/3
(B6067), short circuited
to ground.
7F010/3
Dana
Sensor oil pressure, not
connected or open circuit.
Diagnostic
menu
Dana
TRANSM,
menu 10
Transmission
2 (Limp-home).
Check cabling
between control
unit and component.
Check the sensor.
Sensor gear 1/3

(B6067), not connected
or open circuit.
7F010/11
Sensor gear 1/3

(B6067), the value is below the lowest calibrated
value.
D793/A2 X253
Dana full flow

D793/A2 B6067
Dana full flow
50/04
Connections and
components
SPN/FM1
Sensor oil pressure,

short circuited to
ground.
50/01
47
Dana
D793/A2 X253
TRANSM,
menu 10
Dana full flow

D793/A2 B6067
The control unit

identifies the error
and use the lowest
value in its settings.
Check cabling
between control
unit and component.
D793/A2 B6067
TRANSM,
menu 10
Check the sensor.

50/05
7F010/F
Sensor gear 1/3

(B6067), the value is
above the highest calibrated value.
The control unit

and use the highest
Check cabling
between control
unit and component.
D793/A2 B6067
Check the sensor.

51/00
7F011/4
Dana
Sensor engine rpm and
oil temperature transmission (B758/766)
short-circuited to
ground.
Dana full flow
Oil temperature sensor
(B7660) short circuited
to ground.
The control unit limits the transmissions temperature

measurement to the
lowest value in its
settings, which results in poor temperature
compensation.
Check cabling
between control
unit and sensor.
Dana
D793/H3 B758/766
TRANSM,
menu 10
Check the sensor.
Dana full flow

D793/H3 B7660
VDRF03.02GB
48
Code
51/01
Description
Limitation
Action
Dana

measurement to the
highest value in its
compensation.
Check cabling
between control
unit and sensor.

measurement to the
lowest value in its
settings.
Check cabling
between control
unit and component.
7F011/3

measurement to the
settings.
Check cabling
between control
unit and component.

measurement to the
compensation.
Check cabling
between control
unit and sensor.

measurement to the
compensation.
Check cabling
between control
unit and sensor.
Dana full flow

Sensor oil temperature
(7660), not connected or
open circuit.
51/05
52/00
7F011/11
7F011/F
7F012/4

(B7660), the value is below the lowest calibrated
value.

(B7660), the value is
Dana
(S221) short-circuited to
ground.
Dana full flow
Temperature switch
torque converter
(S2210) short circuited
to ground.
52/01
Diagnostic
menu
Dana
TRANSM,
menu 10
SPN/FM1
Sensor engine rpm and

oil temperature transmission (B758/766) not
connected or open circuit.
51/04
Connections and
components
7F012/3
Dana
(S221) open circuit.
Dana full flow
Temperature switch
torque converter
(S2210) is not
connected.
VDRF03.02GB
D793/H3 B758/766
Check the sensor.
Dana full flow

D793/H3 B7660
D793/H3 B7660
TRANSM,
menu 10
D793/H3 B7660
TRANSM,
menu 10
Dana
TRANSM,
menu 10
Check the sensor.
Check the sensor.
Check the sensor.
D793/J3 - S221
Dana full flow

D793/J3 S2210
Check the sensor.
Dana
D793/J3 - S221
Dana full flow

D793/J3 S2210
TRANSM,
menu 10
Code
SPN/FM1
52/04
7F012/11
52/05
53/00
7F012/F
7F013/4
Description
Limitation
Action
Temperature switch
torque converter
(S2210), the value is below the lowest calibrated
value.

measurement to the
lowest value in its
compensation.
Check cabling
between control
unit and component.
Temperature switch
torque converter
(S2210), the value is

measurement to the
compensation.
Check cabling
between control
unit and component.
Analogue input signal 3,

short circuited to
ground.
Depending on the
function that is assigned to the pin:
Check cabling
between control
unit and component.
Pressure feedback:
Transmission
2 (Limp-home).
49
Connections and
components
Diagnostic
menu
D793/J3B S2210
TRANSM,
menu 10
D793/J3B S2210
TRANSM,
menu 10
Check the sensor.
Check the sensor.
Oil pressure sensor:

The control unit
locks the transmission in neutral
position.
Other: The control
unit uses the lowest
VDRF03.02GB
50
Code
53/01
Description
Limitation
Action

is not connected.
Depending on function assigned to the

pin:
Check cabling
between control
unit and component.
Connections and
components
Diagnostic
menu
D793/M1 S2210, B7667,

B6069
CAN/
POWER,
menu 15
D793/M1 S2210, B7667,

B6069
CAN/
POWER,
menu 15
SPN/FM1
7F013/3
Pressure feedback:
Transmission
2 (Limp-home).

The control unit
locks the transmission in neutral
position.
Other: The control
53/04
7F013/11

the value is below the
lowest calibrated value.
The control unit

and use the lowest
Check cabling
between control
unit and component.
53/05
7F013/F

the value is above the
highest calibrated value.
The control unit

and use the highest
Check cabling
between control
unit and component.
54/00
7F014/4
Reference voltage sensor 5 V short-circuiting

to frame ground.
Check cabling
between control
unit and component.
Check the
sensor.
54/01
7F014/3
Reference voltage sensor 5 V short circuited to

voltage.
Check cabling
between control
unit and component.
Check the sensor.
VDRF03.02GB
Code
55/00
Description
Limitation
Action

short circuited to
ground.
Depending on the
Check cabling
between control
unit and component.
51
Connections and
components
Diagnostic
menu
SPN/FM1
7F015/4
Pressure feedback:
Transmission
2 (Limp-home).

The control unit
locks the transmission in neutral position.
Other: The control
55/01
7F015/3

is not connected.
Depending on the
Pressure feedback:
Transmission
2 (Limp-home).
Check cabling
between control
unit and component.

The control unit
Other: The control
55/04
7F015/11

The control unit

and use the lowest
Check cabling
between control
unit and component.
55/05
7F015/F

The control unit

and use the highest
Check cabling
between control
unit and component.
VDRF03.02GB
52
Code
56/00
Description
Limitation
Action
Pressure sensor gear 2/

4 (B6069), short
Depending on the
Check cabling
between control
unit and component.
Connections and
components
Diagnostic
menu
D793/S1 B6069
TRANSM,
menu 10
D793/S1 B6069
TRANSM,
menu 10
D793/S1 B6069
TRANSM,
menu 10
D793/S1 B6069
TRANSM,
menu 10
SPN/FM1
7F016/4
Pressure feedback:
Transmission
2 (Limp-home).

The control unit
Other: The control
56/01
7F016/3

4 (B6069), is not connected.
Depending on the
Pressure feedback:
Transmission
2 (Limp-home).
Check cabling
between control
unit and component.

The control unit
Other: The control
56/04
7F016/11

4 (B6069), the value is
below the lowest calibrated value.
The control unit

and use the lowest
Check cabling
between control
unit and component.
56/05
7F016/F

4 (B6069), the value is
The control unit

and use the highest
Check cabling
between control
unit and component.
VDRF03.02GB
Code
57/00
Description
Limitation
Action

short circuited to
ground.
Depending on the
Check cabling
between control
unit and component.
53
Connections and
components
Diagnostic
menu
SPN/FM1
7F017/4
Pressure feedback:
Transmission
2 (Limp-home).

The control unit
Other: The control
57/01
7F017/3

is not connected.
Depending on the
Pressure feedback:
Transmission
2 (Limp-home).
Check cabling
between control
unit and component.

The control unit
Other: The control
57/04
7F017/11

The control unit

and use the lowest
Check cabling
between control
unit and component.
57/05
7F017/F

The control unit

and use the highest
Check cabling
between control
unit and component.
VDRF03.02GB
54
Code
58/00
Description
Limitation
Action

short circuited to
ground.
Depending on the
Check cabling
between control
unit and component.
Connections and
components
Diagnostic
menu
SPN/FM1
7F018/4
Pressure feedback:
Transmission
2 (Limp-home).

The control unit
Other: The control
58/01
7F018/3

is not connected.
Depending on the
Pressure feedback:
Transmission
2 (Limp-home).
Check cabling
between control
unit and component.

The control unit
Other: The control
58/04
7F018/11

The control unit

and use the lowest
Check cabling
between control
unit and component.
58/05
7F018/F

The control unit

and use the highest
Check cabling
between control
unit and component.
VDRF03.02GB
Code
60/00
Description
Limitation
Action
Dana
When only one rpm

signal that is not the
engine rpm signal is
incorrect, the control unit calculates
the missing rpm.
Check cable between control

unit and sensor.
7F01A/6
Dana full flow
7F01A/5
Sensor rpm drum

(B7520) short-circuited
to ground.
If several rpm signals or if the engine

speed signal are
defective, the control unit locks the
transmission control
unit to gear 1-2
(Limp-home).
Dana
When only one rpm

the missing rpm.
Sensor rpm drum

(B752) not connected.
Dana full flow
Sensor rpm drum
60/03
Connections and
components
Diagnostic
menu
Dana
TRANSM,
menu 6
SPN/FM1
Sensor rpm drum

(B752) short-circuited to
ground.
60/01
55
7F01A/A
Sensor rpm drum

(B7520), value outside
limit values.
Check the sensor.
Dana full flow

D793/C3 B7520

unit and sensor.
Check the sensor.
Dana
D793/C3 B752
TRANSM,
menu 6
Dana full flow

D793/C3 B7520

speed signal are
unit to gear 1-2
(Limp-home).
D793/C3 B752

unit and component.
D793/C3 B7520
TRANSM,
menu 6
Check component.
VDRF03.02GB
56
Code
60/04
Description
Limitation
Action
Sensor rpm drum

(B7520), pulse count too
low.
This message is
provided as supplementary information
for errors in the
transmission.
Check the transmission to find

out if, and
which, clutch is
slipping.
Connections and
components
Diagnostic
menu
D793/C3 B7520
TRANSM,
menu 6
D793/C3 B7520
TRANSM,
menu 6
Dana
TRANSM,
menu 6
SPN/FM1
7F01A/1
Check the transmissions settings for the ratio

in the control
unit.
60/05
7F01A/0
Sensor rpm drum

high.
This message is
for errors in the
transmission.

out if, and
which, clutch is
slipping.
in the control
unit.
61/00
7F01B/6
Dana
Sensor rpm output shaft
ground.
Dana full flow
to ground.
VDRF03.02GB
When only one rpm

the missing rpm.

unit and sensor.
Check the sensor.

speed signal are
unit to gear 1-2
(Limp-home).
D793/E3 B758
Dana full flow

D793/E3 B7580
Code
61/01
Description
Limitation
Action
Dana
When only one rpm

the missing rpm.

unit and sensor.
Connections and
components
Diagnostic
menu
Dana
TRANSM,
menu 6
SPN/FM1
7F01B/5

Dana full flow
61/03
57
7F01B/A

limit values.
Check the sensor.
Dana full flow

D793/E3 B7580

speed signal are
unit to gear 1-2
(Limp-home).
D793/E3 B758

unit and component.
D793/E3 B7580
TRANSM,
menu 6
D793/E3 B7580
TRANSM,
menu 6
D793/E3 B7580
TRANSM,
menu 6
Check the sensor.

61/04
7F01B/1

low.
This message is
for errors in the
transmission.

out if, and
which, clutch is
slipping.
in the control
unit.
61/05
7F01B/0

high.
This message is
for errors in the
transmission.

out if, and
which, clutch is
slipping.
in the control
unit.
VDRF03.02GB
58
Code
62/00
Description
Limitation
Action
Dana
When only one rpm

the missing rpm.

unit and sensor.
7F01C/6
Dana full flow
7F01C/5
Sensor engine speed

(B7530), short circuited
to ground.

speed signal are
unit to gear 1-2
(Limp-home).
Dana
When only one rpm

the missing rpm.
Sensor engine rpm

(B758/766), not connected or has open circuit.
Dana full flow
Sensor engine speed
(B7530), not connected
or has open circuit.
62/03
62/04
Diagnostic
menu
Dana
TRANSM,
menu 6
SPN/FM1
Sensor engine rpm

(B758/766), shortcircuited to ground.
62/01
Connections and
components
Check the sensor.
D793/F3 B758/766
Dana full flow

D793/F3 B7530

unit and sensor.
Dana
D793/F3 B758/766
TRANSM,
menu 6
Check the sensor.

Dana full flow

speed signal are
unit to gear 1-2
(Limp-home).
D793/F3 B7530
7F01C/A
Engine speed information is not available.
Transmission in
Limp-home.
Use diagnostic
menu to find incorrect segment.
7F01C/1
Sensor engine speed

(B7530), pulse count is
too low.
This message is
for errors in the
transmission.

out if, and
which, clutch is
slipping.
D793//F3 B7530
TRANSM,
menu 6

in the control
unit.
VDRF03.02GB
Code
62/05
Description
Limitation
Action
Sensor engine speed

(B7530), pulse count is
too high.
This message is
for errors in the
transmission.

out if, and
which, clutch is
slipping.
59
Connections and
components
Diagnostic
menu
D793/F3 B7530
TRANSM,
menu 6
D793/F3 B7530
TRANSM,
menu 6
Dana
TRANSM,
menu 6
SPN/FM1
7F01C/0

in the control
unit.
62/06
7F07A/1
Incorrect engine speed

information when turbine speed is calculated
Transmission in
Limp-home.
Check sensor
for engine rpm
speed.
Check the components position.
63/00
7F01D/6
Dana
Sensor rpm turbine
ground.
Dana full flow
Sensor rpm turbine
to ground.
When only one rpm

the missing rpm.

unit and sensor.
Check the sensor.

speed signal are
unit to gear 1-2
(Limp-home).
D793/R2 B751
Dana full flow

D793/G3 B7510
VDRF03.02GB
60
Code
63/01
Description
Limitation
Action
Dana
When only one rpm

the missing rpm.

unit and sensor.
Diagnostic
menu
Dana
TRANSM,
menu 6
SPN/FM1
7F01D/5
Sensor rpm turbine

Dana full flow
Sensor rpm turbine
63/03
Connections and
components
7F01D/A
Sensor rpm turbine

limit values.
Check the sensor.
Dana full flow

D793/G3 B7510

speed signal are
unit to gear 1-2
(Limp-home).
D793/R2 B751

unit and component.
D793/G3 B7510
TRANSM,
menu 6
D793/G3 B7510
TRANSM,
menu 6
D793/G3 B7510
TRANSM,
menu 6
Check component.
63/04
7F01D/1
Sensor rpm turbine

low.
This message is
for errors in the
transmission.

out if, and
which, clutch is
slipping.
in the control
unit.
63/05
7F01D/0
Sensor rpm turbine

high.
This message is
for errors in the
transmission.

out if, and
which, clutch is
slipping.
in the control
unit.
VDRF03.02GB
Code
70/00
Description
Limitation
Action
Dana
Transmission
2 (Limp-home).
Check cabling
between control
unit and solenoid valve.
7F020/4
Diagnostic
menu
Dana
TRANSM,
menu 8
7F020/3
Check the solenoid valve.
Dana full flow
Servo valve gear forward and reverse

(Y6300), short-circuited
to each other, signal cable short-circuited to
voltage, or plus-cable
short-circuited to frame
ground.
D793/B1 Y6300, D793/

C1 - Y6300
Dana
Transmission
2 (Limp-home).
Check cabling
between control
Dana full flow

(Y6300) open circuit or
short-circuited voltage.
7F020/6
D793/B1 Y630, D793/C1

- Y630
Dana full flow
Solenoid valve VFS forward (Y630) open circuit

or short-circuited voltage.
70/02
Connections and
components
SPN/FM1
Solenoid valve VFS

front (Y630), shortcircuited to each other,
signal cable shortcircuited to voltage, or
plus-cable shortcircuited to frame
ground.
70/01
61
Dana
Solenoid valve VFS forward (Y630), control
current higher than 1400
mA.
Dana full flow
Dana
D793/B1 Y630, D793/C1
- Y630
TRANSM,
menu 8
TRANSM,
menu 8
Dana full flow

D793/B1 Y6300, D793/
C1 - Y6300
Transmission
2 (Limp-home).
Check cabling
between control

(Y6300), control current
over 1400 mA.
Dana
D793/B1 Y630, C1 Y630
TRANSM,
menu 9
Dana full flow

D793/B1 Y6300, D793/
C1 - Y6300
VDRF03.02GB
62
Code
70/03
Description
Limitation
Action
Dana
Transmission
2 (Limp-home).
Check cabling
between control
Diagnostic
menu
Dana
TRANSM,
menu 9
SPN/FM1
7F020/8
Solenoid valve VFS forward (Y630), control

current outside approved interval. Incorrect impedance.
Dana full flow
outside the approved interval. Incorrect impedance.
70/09
Connections and
components
7F020/5

(Y6300), not connected.
D793/B1 Y630, D793/C1

- Y630

Transmission
locked in neutral
(Shut-down).
Transmission
2 (Limp-home).
Dana full flow

D793/B1 Y6300, D793/
C1 - Y6300
Check cabling
between control
unit and component.
D793/B1 Y6300, D793/

C1 - Y6300
TRANSM,
menu 9
Dana
TRANSM,
menu 8

71/00
7F021/4
Dana
Solenoid valve VFS 2/4
(Y6069), short-circuited
voltage, or plus-cable
ground.
VDRF03.02GB
Transmission
2 (Limp-home).
Check cabling
between control
D793/D1 Y6069, D793/

E1 - Y6069
Dana full flow
Dana full flow
Solenoid valve gear selection 1/3 (Y6067),

short-circuited to each
other, signal cable
short-circuited to voltage, or plus-cable shortcircuited to frame
ground.
D793/D1 Y6067, D793/

E1 - Y6067
Code
71/01
Description
Limitation
Action
Dana
Transmission
2 (Limp-home).
Check cabling
between control
7F021/3
Dana full flow

open circuit or shortcircuited voltage.
7F021/6
Dana
higher than 1400 mA.
Transmission
2 (Limp-home).
Check cabling
between control
Solenoid valve gear selection 1/3 (Y6067), control current higher than
1400 mA.
7F021/8
Dana
outside approved interval (incorrect impedance).
71/09
Diagnostic
menu
Dana
TRANSM,
menu 8
7F021/5
D793/D1 Y6069, D793/

E1 - Y6069
Dana full flow
D793/D1 Y6067, D793/
E1 - Y6067
Dana full flow
71/03
Connections and
components
SPN/FM1

71/02
63
Dana
D793/D1 Y6069, D793/
E1 - Y6069
Dana full flow
D793/D1 Y6067, D793/
E1 - Y6067
Transmission
2 (Limp-home).
Check cabling
between control
Dana
D793/D1 Y6069, D793/
E1 - Y6069
TRANSM,
menu 9
Dana full flow
Dana full flow
Solenoid valve gear selection 1/3 (Y6067), control current outside

approved interval (incorrect impedance).
D793/D1 Y6067, D793/

E1 - Y6067
Solenoid valve gear selection 1/3 (Y6067), not

connected.
TRANSM,
menu 9
Transmission
2 (Limp-home).
Check cabling
between control
unit and component.
D793/D1 Y6067, D793/

E1 - Y6067
TRANSM,
menu 9
VDRF03.02GB
64
Code
72/00
Description
Limitation
Action
Dana
Transmission
2 (Limp-home).
Check cabling
between control
7F022/4
Dana
TRANSM,
menu 8
7F022/3
Dana full flow

other, signal cable
ground.
D793/F1 Y6069, D793/

G1 - Y6069
Dana
Transmission
2 (Limp-home).
Check cabling
between control
Dana full flow

open circuit or shortcircuited voltage.
7F022/6
Dana
Solenoid valve VFS reverse (Y631), control
current higher than 1400
mA.
Dana full flow
Dana
D793/F1 Y631, D793/G1
- Y631
Dana full flow
TRANSM,
menu 8
D793/F1 Y6069, D793/

G1 - Y6069
Transmission
2 (Limp-home).
Check cabling
between control
Solenoid valve gear selection 2/4 (Y6069), control current higher than
1400 mA.
VDRF03.02GB
D793/F1 Y631, D793/G1

- Y631
Dana full flow
Solenoid valve VFS reverse (Y631) open circuit or short-circuited

voltage.
72/02
Diagnostic
menu
SPN/FM1
Solenoid valve VFS reverse (Y631), cables

other, signal cable
ground.
72/01
Connections and
components
Dana
D793/F1 Y631, D793/G1
- Y631
Dana full flow

D793/F1 Y6069, D793/
G1 - Y6069
TRANSM,
menu 9
Code
72/03
Description
Limitation
Action
Dana
Transmission
2 (Limp-home).
Check cabling
between control
Connections and
components
Diagnostic
menu
Dana
TRANSM,
menu 9
SPN/FM1
7F022/8
Solenoid valve VFS reverse (Y631), control

current outside approved interval (incorrect impedance).
72/09
65
7F022/5
D793/F1 Y631, G1 Y631
Dana full flow
Dana full flow
Solenoid valve gear selection 2/4 (Y6069), control current outside

approved interval (incorrect impedance).
D793/F1 Y6069, D793/

G1 - Y6069

connected.
Transmission
2 (Limp-home).
Check cabling
between control
unit and component.
Dana full flow
D793/F1 Y6069, D793/

G1 - Y6069

73/00
7F023/4
Dana
(Y6067), cables shortcircuited to each other,
signal cable shortcircuited to voltage, or
plus-cable shortcircuited to frame
ground.
73/00
Transmission
2 (Limp-home).
Check cabling
between control
Dana
D793/H1 Y6067, D793/
J1 - Y6067
TRANSM,
menu 8
Dana full flow
Dana full flow
Analogue output signal

3, cables short-circuited
voltage or plus-cable
ground.
VDRF03.02GB
66
Code
73/01
Description
Limitation
Action
Dana
Transmission
2 (Limp-home).
Check cabling
between control
7F023/3
Dana full flow

3, open circuit or shortcircuited voltage.
7F023/6
Dana
higher than 1400 mA.
Transmission
2 (Limp-home).
Check cabling
between control

3, control current over
1400 mA.
7F023/8
Dana
outside approved interval (incorrect impedance).
73/09
Dana
TRANSM,
menu 8
7F023/5
D793/H1 Y6067, J1 Y6067

Dana full flow
-
Dana full flow
73/03
Diagnostic
menu
SPN/FM1

73/02
Connections and
components
Dana
D793/H1 Y6067, J1 Y6067
Dana full flow
-
Transmission
2 (Limp-home).
Check cabling
between control
Dana
D793/H1 Y6067, J1 Y6067
TRANSM,
menu 9
Dana full flow
Dana full flow

3, control current outside the approved interval (incorrect
impedance).

3, not connected.
TRANSM,
menu 9
Transmission
2 (Limp-home).
Check cabling
between control
unit and component.

74/00
7F024/4

4, short circuited to
ground.
Check cabling
between control
unit and component.
VDRF03.02GB
Code
SPN/FM1
74/01
7F024/3
Description
Limitation
Action

4 not connected or
Check cabling
between control
unit and component.
67
Connections and
components
Diagnostic
menu

75/00
7F025/4

ground.
Check cabling
between control
unit and component.
75/01
7F025/3

5 not connected or
Check cabling
between control
unit and component.
76/00
7F026/4

ground.
Check cabling
between control
unit and component.
76/01
7F026/3

6, not connected or
Check cabling
between control
unit and component.
76/02
7F026/6

6, control current over
1400 mA.
Check cabling
between control
unit and component.
VDRF03.02GB
68
Code
SPN/FM1
76/03
7F026/8
Description
Limitation
Action

6, output signal outside
the approved interval
(incorrect impedance).
Check cabling
between control
unit and component.
Connections and
components
Diagnostic
menu

76/09
7F026/5

3, not connected.
Check cabling
between control
unit and component.
77/02
7F02F/1F
All gear packs disengaged.
Transmission
locked in neutral
(Shut-down).
80/00
7F027/4
Dana
Transmission
2 (Limp-home).
Check cabling
between control
unit and component.
Dana
Dana
D793/K1 Y6066
TRANSM,
menu 7
Solenoid valve RSP

Drive (Y6066), cable
ground.
Dana full flow

Solenoid valve drive forward (Y6066F), cable
ground.
80/01
7F027/3
Dana
Solenoid valve RSP
Drive (Y6066), cable is
not connected or shortcircuited to voltage.
Dana full flow
D793/K1 Y6066F
Transmission
2 (Limp-home).
Check cabling
between control
unit and component.
Solenoid valve drive forward (Y6066F), cable is

VDRF03.02GB
Dana full flow
Dana
Dana
D793/K1 Y6066
TRANSM,
menu 7
Dana full flow

D793/K1 Y6066F
Code
80/09
Description
Limitation
Action
Solenoid valve drive forward (Y6066F), not connected.
Transmission
2 (Limp-home).
Check cabling
between control
unit and component.
69
Connections and
components
Diagnostic
menu
D793/K1 Y6066F
TRANSM,
menu 7
Dana
TRANSM,
menu 7
SPN/FM1
7F027/5

81/00
7F028/4
Dana
(Y6074), cable shortcircuited to frame
ground.
Transmission
2 (Limp-home).
Check cabling
between control
Dana full flow

Solenoid valve drive reverse (Y6066R), cable
ground.
81/01
7F027/3
Dana
(Y6074), cable is not
connected or shortcircuited to voltage.
Transmission
2 (Limp-home).
Check cabling
between control
Solenoid valve drive reverse (Y6066R), cable

short-circuited to
voltage.
7F027/5
Solenoid valve drive reverse (Y6066R), not

connected.
Dana full flow

D793/E2 Y6066R
Dana full flow
81/09
D793/E2 Y6074
Dana
D793/E2 Y6074
TRANSM,
menu 7
Dana full flow

D793/E2 Y6066R
Transmission
2 (Limp-home).
Check cabling
between control
unit and component.
D793/E2 Y6066R
TRANSM,
menu 7
VDRF03.02GB
70
Code
82/00
Description
Limitation
Action
Dana
Transmission
2 (Limp-home).
Check cabling
between control
7F029/4
Dana full flow

Solenoid valve gear selection 1/3 (Y6075), cable short-circuited to
frame ground.
7F029/3
Dana
(Y6075), cable is not
connected or shortcircuited to voltage.
Dana
TRANSM,
menu 7
Transmission
2 (Limp-home).
Check cabling
between control

voltage.
7F029/5

connected.
D793/F2 Y6075
Dana full flow

D793/F2 Y6075
Dana full flow
82/09
Diagnostic
menu
SPN/FM1

(Y6075), cable shortcircuited to frame
ground.
82/01
Connections and
components
Dana
D793/F2 Y6075
TRANSM,
menu 7
Dana full flow

D793/F2 Y6075
Transmission
2 (Limp-home).
Check cabling
between control
D793/F2 Y6075
TRANSM,
menu 7
Dana
Dana
D793/K2 Y6066
TRANSM,
menu 7

83/00
7F02A/3
Dana
Solenoid valve RSP
Drive (Y6066), cable
ground.
Dana full flow
Transmission
locked in neutral
(Shut-down).
Check cabling
between control
unit and component.

frame ground.
VDRF03.02GB
Dana full flow

D793/K2 Y6074
Code
83/01
Description
Limitation
Action
Dana
Transmission
locked in neutral
(Shut-down).
Check cabling
between control
unit and component.
71
Connections and
components
Diagnostic
menu
Dana
Dana
D793/K2 Y6066
TRANSM,
menu 7
SPN/FM1
7F02A/4
Solenoid valve RSP

Drive (Y6066), cable is
Dana full flow
voltage.
Transmission
locked in neutral
(Shut-down).
Dana full flow

D793/K2 Y6074
90/01
7F0F0/1
Software error Control

unit, transmission
(D793).
90/02
7F0F0/2

unit, transmission
(D793).
90/03
7F0F0/3

unit, transmission
(D793).
90/04
7F0F0/4

unit, transmission
(D793).
90/05
7F0F0/5

unit, transmission
(D793).
90/06
7F0F0/6

unit, transmission
(D793).
90/07
7F0F0/7

unit, transmission
(D793).
90/08
7F0F0/8

unit, transmission
(D793).
90/09
7F0F0/9

unit, transmission
(D793).
90/11
7F0F0/B

unit, transmission
(D793).
VDRF03.02GB
72
Description
Limitation
Action
Connections and
components
Diagnostic
menu
Code
SPN/FM1
90/12
7F0F0/C

unit, transmission
(D793).
90/13
7F0F0/D

unit, transmission
(D793).
90/14
7F0F0/E

unit, transmission
(D793).
90/15
7F0F0/F

unit, transmission
(D793).
90/16
7F0F0/10

unit, transmission
(D793).
90/17
7F0F0/11

unit, transmission
(D793).
90/18
7F0F0/12

unit, transmission
(D793).
90/19
7F0F0/13

unit, transmission
(D793).
90/90
7F0A0/1F
Incorrect software in
Control unit, transmission (D793).
Transmission
locked in neutral
(Shut-down).
90/xx 99/xx
7F000/0
System error.
Transmission
locked in neutral
(Shut-down).
D793/A:20
91/01
7F0F1/1

unit, transmission
(D793).
91/02
7F0F1/2

unit, transmission
(D793).
91/03
7F0F1/3

unit, transmission
(D793).
VDRF03.02GB
73
Description
Limitation
Action
Connections and
components
Diagnostic
menu
Code
SPN/FM1
91/10
7F0F1/6

unit, transmission
(D793).
91/11
7F0F1/7

unit, transmission
(D793).
91/12
7F0F1/8

unit, transmission
(D793).
91/50
7F0F7/A

unit, transmission
(D793).
91/51
7F0F7/B

unit, transmission
(D793).
91/52
7F0F7/C

unit, transmission
(D793).
91/53
7F0F7/D

unit, transmission
(D793).
91/54
7F0F7/E

unit, transmission
(D793).
91/55
7F0F7/F

unit, transmission
(D793).
91/57
7F0F7/11

unit, transmission
(D793).
91/58
7F0F7/12

unit, transmission
(D793).
91/59
7F0F7/13

unit, transmission
(D793).
91/60
7F0F7/14

unit, transmission
(D793).
VDRF03.02GB
74
Description
Limitation
Action
Connections and
components
Diagnostic
menu
Code
SPN/FM1
91/61
7F0F7/15

unit, transmission
(D793).
91/70
7F0F7/1E

unit, transmission
(D793).
92/00
7F0F2/0

unit, transmission
(D793).
92/01
7F0F2/1
The gear has no direction.
Transmission
locked in neutral
(Shut-down).
92/02
7F0F2/2
Duplicated direction.
Transmission
locked in neutral
(Shut-down).
Note the time

and contact
Cargotec support.
92/03
7F0F2/3
Duplicated gear.
Transmission
locked in neutral
(Shut-down).
Note the time

and contact
Cargotec support.
92/04
7F0F2/4
Duplicated shock pattern.
Transmission
locked in neutral
(Shut-down).
Note the time

and contact
Cargotec support.
92/06
7F0F2/6
Incorrect digital input

signal.
Transmission
locked in neutral
(Shut-down).
Note the time

and contact
Cargotec support.
92/07
7F0F2/7
Digital input signal in

conflict with gear control
position.
Transmission
locked in neutral
(Shut-down).
Note the time

and contact
Cargotec support.
92/08
7F0F2/8

"Transmission locked in
neutral position" incorrect.
Transmission
locked in neutral
(Shut-down).
Note the time

and contact
Cargotec support.
92/09
7F0F2/9
Digital input signal duplicated assignment.
Transmission
locked in neutral
(Shut-down).
Note the time

and contact
Cargotec support.
VDRF03.02GB
Description
Limitation
Action
75
Connections and
components
Diagnostic
menu
Code
SPN/FM1
92/10
7F0F2/A
Digital output signal duplicated assignment.
Transmission
locked in neutral
(Shut-down).
Note the time

and contact
Cargotec support.
92/11
7F0F2/B
Digital output signal selected on unconfigured

output.
Transmission
locked in neutral
(Shut-down).
Note the time

and contact
Cargotec support.
92/12
7F0F2/C
Digital output signal incorrect.
Transmission
locked in neutral
(Shut-down).
Note the time

and contact
Cargotec support.
92/13
7F0F2/D
Digital output signal selected on transmission

cable.
Transmission
locked in neutral
(Shut-down).
Note the time

and contact
Cargotec support.
92/14
7F0F2/E
Incorrect assignment in
speed sensors 1-2.
Transmission
locked in neutral
(Shut-down).
Note the time

and contact
Cargotec support.
92/15
7F0F2/F
Incorrect assignment in
speed sensor 3.
Transmission
locked in neutral
(Shut-down).
Note the time

and contact
Cargotec support.
92/16
7F0F2/10
Duplicated assignment
in speed sensors.
Transmission
locked in neutral
(Shut-down).
Note the time

and contact
Cargotec support.
92/17
7F0F2/11
Incorrect feed voltage

selected.
Transmission
locked in neutral
(Shut-down).
Note the time

and contact
Cargotec support.
92/18
7F0F2/12
Duplicated input signal.
Transmission
locked in neutral
(Shut-down).
Note the time

and contact
Cargotec support.
92/19
7F0F2/13
Cabling sensor pressure

in conflict with cabling
analogue input signal.
Transmission
locked in neutral
(Shut-down).
Note the time

and contact
Cargotec support.
VDRF03.02GB
76
Description
Limitation
Action
Connections and
components
Diagnostic
menu
Code
SPN/FM1
92/20
7F0F2/14
Incorrect configuration
regarding servo motor
or brake valve (analogue output signal 4-56).
Transmission
locked in neutral
(Shut-down).
Note the time

and contact
Cargotec support.
92/30
7F0F2/1E
Incorrect configuration
regarding full flow selection and earlier digital
troubleshooting.
Transmission
locked in neutral
(Shut-down).
Note the time

and contact
Cargotec support.
92/50
7F0F8/1

unit, transmission
(D793).
92/51
7F0F8/2

unit, transmission
(D793).
92/52
7F0F8/3

unit, transmission
(D793).
93/00
7F0F3/0
Failed initialisation of
the necessary control
unit data in flash memory, caused by a memory
conflict.
Transmission
locked in neutral
(Shut-down).
Switch off the

machine and
the main electrical power.
93/01
7F0F3/1
conflict.
Transmission
locked in neutral
(Shut-down).
Switch off the

machine and
93/02
7F0F3/2
conflict.
Transmission
locked in neutral
(Shut-down).
Switch off the

machine and
93/03
7F0F3/3
conflict.
Transmission
locked in neutral
(Shut-down).
Switch off the

machine and
VDRF03.02GB
Description
Limitation
Action
77
Connections and
components
Diagnostic
menu
Code
SPN/FM1
93/04
7F0F3/4
conflict.
Transmission
locked in neutral
(Shut-down).
Switch off the

machine and
93/05
7F0F3/5
conflict.
Transmission
locked in neutral
(Shut-down).
Switch off the

machine and
93/09
7F0F3/9
conflict.
Transmission
locked in neutral
(Shut-down).
Switch off the

machine and
93/10
7F0F3/A
Initiation of statistical
data in flash memory,
caused by firmware update or a memory conflict.
Switch off the

machine and
93/11
7F0F3/B
Initiation of stored incorrect data in flash memory, caused by firmware

update or a memory
conflict.
Switch off the

machine and
94/00
7F0F4/0
conflict.
Transmission
locked in neutral
(Shut-down).
Note the time

and contact
Cargotec support.
94/01
7F0F4/1
conflict.
Transmission
locked in neutral
(Shut-down).
Note the time

and contact
Cargotec support.
94/02
7F0F4/2
conflict.
Transmission
locked in neutral
(Shut-down).
Note the time

and contact
Cargotec support.
VDRF03.02GB
78
Description
Limitation
Action
Connections and
components
Diagnostic
menu
Code
SPN/FM1
94/03
7F0F4/3
conflict.
Transmission
locked in neutral
(Shut-down).
Note the time

and contact
Cargotec support.
94/04
7F0F4/4
conflict.
Transmission
locked in neutral
(Shut-down).
Note the time

and contact
Cargotec support.
94/05
7F0F4/5
conflict.
Transmission
locked in neutral
(Shut-down).
Note the time

and contact
Cargotec support.
94/09
7F0F4/9
conflict.
Transmission
locked in neutral
(Shut-down).
Note the time

and contact
Cargotec support.
95/00
7F0F5/0
95/70
7F0F5/14

unit, transmission
(D793).
Transmission
locked in neutral
(Shut-down).
7F09B/1F
Control unit cannot interpret input data.
Transmission
locked in neutral
(Shut-down).
95/72
7F0F5/16

unit, transmission
(D793).
95/73
7F0F5/17

unit, transmission
(D793).
7F0F6/0
Incorrect software in
control unit transmission.
7F0F6/1

unit, transmission
(D793).
95/71
99/90
99/91
VDRF03.02GB
79
Description
Limitation
Action
Connections and
components
Diagnostic
menu
Code
SPN/FM1
99/92
7F0F6/2

unit, transmission
(D793).
99/93
7F0F6/3

unit, transmission
(D793).
99/95
7F0CA/1F
Overload of CAN bus

detected: Control unit,
transmission could not
currently handle all incoming information, because of too many CAN
enquiries.
99/99
7F0F6/9

unit, transmission
(D793).
E0/01
7F0E1/F
Machine speed too high

to be able to change
down.
E1/01
7F0E2/F
Machine speed too high

to be able to change
travel direction.
E2/01
7F0E3/F
The engine speed is too

high to be able to
change travel direction,
or select the same travel
direction again.
E3/00
7F0E4/E
Machine speed limitation is activated.
E3/01
7F0E4/F
Machine speed limitation is activated regardless of whether the

speed is above the limit
value.
E3/02
7F0E4/10
Machine speed is higher

than the upper limit value.
E4/00
7F0E5/11
Abnormal deceleration.
The transmission
disengages automatic gearing for a
time.
VDRF03.02GB
80
Description
Limitation
Action
Connections and
components
Diagnostic
menu
Code
SPN/FM1
E4/01
7F0E5/F
Abnormal acceleration.
The transmission
disengages automatic gearing for a
time.
E5/01
7F0E0/D
The time with active

gear exceeded the time
for re-calibration.
Calibrate transmission.
E6/00
7F0E6/1F
The operator is not in

the drivers seat and the
gear selector is not in
neutral and/or the parking brake is not activated.
E7/01
7F0E7/F
Turbine speed exceeds

the limit value.
The control unit

forces the engine to
idle in order to prevent damage.
E8/01
7F0E8/F
Conditions for shifting

between 2WD and 4WD
are not fulfilled. The machine must be stationary.
E9/01
7F0E9/F
Conditions for shifting

between High and Low
are not fulfilled. The machine must be stationary.
xx/49
Unspecified error.
The control unit

identifies the error the action depends
on the error.
E.1.01
-05
7F0FA 7F0FD
Calibration of drive
mode pressure, unexpected algorithm response.
The calibration is
stopped.
Download the
correct parameters and repeat
calibration.
Make sure that

the machine
does not move.
Check engine
speed response.
VDRF03.02GB
Code
SPN/FM1
E.1.06
7F0FA 7F0FD/6
Description
Limitation
Action
mode pressure, during
calibration the turbine
speed signal does not
reach down to the lowest value.
The control unit

and the calibration
is stopped.
Measure the
clutch pressure
in order to detect leaks.
81
Connections and
components
Diagnostic
menu
Check the signal from the turbine speed

sensor.
Check the stall
speed in order
to detect slipping clutch.
E.1.07
-09
7F0FA 7F0FD
The calibration is
stopped.
Download the
calibration.
Make sure that
the machine
does not move.
Check engine
speed response.
E.1.10
7F0FA 7F0FD/A
mode pressure, transmission error during calibration.
The calibration is
stopped.
Determine the
reason why calibration was
stopped.
E.1.11
-13
7F0FA 7F0FD
The calibration is
stopped.
Download the
calibration.
Make sure that

the machine
does not move.
Check engine
speed response.
VDRF03.02GB
82
Code
SPN/FM1
E.1.14
7F0FA 7F0FD/E
E.1.15
7F0FA 7F0FD
Description
Limitation
Action
mode pressure, during
calibration the turbine
speed does not decrease.
The control unit

and the calibration
is stopped.
Measure the
clutch pressure
The calibration is
stopped.
Connections and
components
Diagnostic
menu

sensor.
Download the
calibration.
Make sure that
the machine
does not move.
Check engine
speed response.
E.1.16
7F0FA 7F0FD/10
mode pressure, the turbine speed is too low to
start calibration.
The control unit

and the calibration
is stopped.
Measure the
clutch pressure
sensor.
E.1.17
-24
7F0FA 7F0FD
The calibration is
stopped.
Download the
correct parameters and resume
calibration.
Check if the machine starts to
move.
Check engine
speed response.
VDRF03.02GB
Code
SPN/FM1
E.1.25
7F0FA 7F0FD/19
Description
Limitation
Action
mode pressure, the
starting point of engagement is too early during
calibration. Too much
traction.
The control unit

and the calibration
is stopped.
Calibrating at
higher temperatures (90100 C).
83
Connections and
components
Diagnostic
menu
Check the
speed sensors
(error code 42/
04 or 42/05).
Check the servo
valves.
E.1.26
7F0FA 7F0FD/1A
mode pressure, engagement starting point
cannot be identified.
The control unit

and the calibration
is stopped.
Calibrating at
Check the
speed sensors
(error code 42/
04 or 42/05).
Check the servo
valves.
E.1.27
7F0FA 7F0FD
The calibration is
stopped.
Download the
calibration.
move.
Check engine
speed response.
E.1.28
7F0FA 7F0FD/1C
mode pressure, turbine
speed does not reach a
value of 0 rpm during the
closing phase of calibration.
The control unit

and the calibration
is stopped.
Measure the
clutch pressure
sensor.
VDRF03.02GB
84
Code
SPN/FM1
E.1.29
7F0FA 7F0FD/1D
Description
Limitation
Action
mode pressure, turbine
speed does not reach
the correct value during
the release phase of the
engagements starting
point during calibration.
The control unit

and the calibration
is stopped.
Calibrating at
Connections and
components
Diagnostic
menu
Check the
speed sensors
(error code 42/
04 or 42/05).
Check the servo
valves.
E.2.01
-05
7F0FA 7F0FD
Calibration optimisation
of filling time, unexpected algorithm response.
The calibration is
stopped.
Download the
calibration.
Make sure that
the machine
does not move.
Check engine
speed response.
E.2.06
7F0FA 7F0FD/6
of filling time, during calibration the turbine
The control unit

and the calibration
is stopped.
Measure the
clutch pressure
sensor.
Check the stall
speed in order
E.2.07
-09
7F0FA 7F0FD
The calibration is
stopped.
Download the
calibration.
Make sure that
the machine
does not move.
Check engine
speed response.
VDRF03.02GB
Description
Limitation
Action
85
Connections and
components
Diagnostic
menu
Code
SPN/FM1
E.2.10
7F0FA 7F0FD/A
of filling time, transmission error during calibration.
The calibration is
stopped.
Determine the
stopped.
E.2.11
-13
7F0FA 7F0FD
The calibration is
stopped.
Download the
calibration.
Make sure that

the machine
does not move.
Check engine
speed response.
E.2.14
E.2.15
7F0FA 7F0FD/E
7F0FA 7F0FD
speed does not decrease.
The control unit

and the calibration
is stopped.
The calibration is
stopped.
Measure the
clutch pressure
sensor.
Download the
calibration.
Make sure that
the machine
does not move.
Check engine
speed response.
E.2.16
7F0FA 7F0FD/10
of filling time, the turbine
speed is too low to start
calibration.
The control unit

and the calibration
is stopped.
Measure the
clutch pressure
sensor.
VDRF03.02GB
86
Code
SPN/FM1
E.2.17
-24
7F0FA 7F0FD
Description
Limitation
Action
The calibration is
stopped.
Download the
calibration.
Connections and
components
Diagnostic
menu

move.
Check engine
speed response.
E.2.25
7F0FA 7F0FD/19
of filling time, the starting point of engagement
is too early during calibration. Too much traction.
The control unit

and the calibration
is stopped.
Calibrating at
Check the
speed sensors
(error code 42/
04 or 42/05).
Check the servo
valves.
E.2.26
7F0FA 7F0FD/1A
of filling time, engagement starting point cannot be identified.
The control unit

and the calibration
is stopped.
Calibrating at
Check the
speed sensors
(error code 42/
04 or 42/05).
Check the servo
valves.
E.2.27
7F0FA 7F0FD
The calibration is
stopped.
Download the
calibration.
move.
Check engine
speed response.
VDRF03.02GB
Code
SPN/FM1
E.2.28
7F0FA 7F0FD/1C
E.229
7F0FA 7F0FD/1D
Description
Limitation
Action
of filling time, turbine
speed does not reach a
value of 0 rpm during the
closing phase of calibration.
The control unit

and the calibration
is stopped.
Measure the
clutch pressure
of filling time, turbine
speed does not reach
the correct value during
the release phase of the
engagements starting
point during calibration.
The control unit

and the calibration
is stopped.
87
Connections and
components
Diagnostic
menu

sensor.
Calibrating at
Check the
speed sensors
(error code 42/
04 or 42/05).
Check the servo
valves.
E.3.01
-05
7F0FA 7F0FD
The calibration is
stopped.
Download the
calibration.
Make sure that
the machine
does not move.
Check engine
speed response.
E.3.06
7F0FA 7F0FD/6
The control unit

and the calibration
is stopped.
Measure the
clutch pressure
sensor.
Check the stall
speed in order
VDRF03.02GB
88
Code
SPN/FM1
E.3.07
-09
7F0FA 7F0FD
Description
Limitation
Action
Calibration of control
current for pressure, unexpected algorithm response.
The calibration is
stopped.
Download the
calibration.
Connections and
components
Diagnostic
menu
Make sure that

the machine
does not move.
Check engine
speed response.
E.3.10
7F0FA 7F0FD/A
current for pressure,
transmission error during calibration.
The calibration is
stopped.
Determine the
stopped.
E.3.11
-13
7F0FA 7F0FD
The calibration is
stopped.
Download the
calibration.
Make sure that

the machine
does not move.
Check engine
speed response.
E.3.14
E.3.15
7F0FA 7F0FD/E
7F0FA 7F0FD
current for pressure,
during calibration the
turbine speed does not
decrease.
The control unit

and the calibration
is stopped.
The calibration is
stopped.
Measure the
clutch pressure
sensor.
Download the
calibration.
Make sure that
the machine
does not move.
Check engine
speed response.
VDRF03.02GB
Code
SPN/FM1
E.3.16
7F0FA 7F0FD/10
Description
Limitation
Action
current for pressure, the
turbine speed is too low
to start calibration.
The control unit

and the calibration
is stopped.
Measure the
clutch pressure
89
Connections and
components
Diagnostic
menu

sensor.
E.3.17
-24
7F0FA 7F0FD
The calibration is
stopped.
Download the
calibration.
move.
Check engine
speed response.
E.3.25
7F0FA 7F0FD/19
current for pressure, the
starting point of engagement is too early during
calibration. Too much
traction.
The control unit

and the calibration
is stopped.
Calibrating at
Check the
speed sensors
(error code 42/
04 or 42/05).
Check the servo
valves.
E.3.26
7F0FA 7F0FD/1A
current for pressure, engagement starting point
cannot be identified.
The control unit

and the calibration
is stopped.
Calibrating at
Check the
speed sensors
(error code 42/
04 or 42/05).
Check the servo
valves.
VDRF03.02GB
90
Code
SPN/FM1
E.3.27
7F0FA 7F0FD
Description
Limitation
Action
The calibration is
stopped.
Download the
calibration.
Connections and
components
Diagnostic
menu

move.
Check engine
speed response.
E.3.28
E.3.29
7F0FA 7F0FD/1C
7F0FA 7F0FD/1D
current for pressure, turbine speed does not
reach a value of 0 rpm
during the closing phase
of calibration.
The control unit

and the calibration
is stopped.
current for pressure, turbine speed does not
reach the correct value
during the release
phase of the engagements starting point
during calibration.
The control unit

and the calibration
is stopped.
Measure the
clutch pressure
sensor.
Calibrating at
Check the
speed sensors
(error code 42/
04 or 42/05).
Check the servo
valves.
VDRF03.02GB
D Error codes 8 Control system
91
8 Control system
mm mm mm mm mm mm
Error codes machine
page
Code
Description
Limitation
Action
Connections and
components
Diagnostic menu
Group
Communication error
with attachment control unit (D791-1).
Attachment
functions not
working.

D791-1
CAN/
POWER,
menu 2
11.6.2 Redundant
CAN-bus
Communication error
with Control unit, attachment option
(D791-2).
Levelling, tilt,
overheight
extension not
working.

D791-2
CAN/
POWER,
menu 2
11.6.2 Redundant
CAN-bus
Communication error
with Control unit, attachment left jack
pair (D791-3).
Left side of
bottom lift not
working.

D791-3
CAN/
POWER,
menu 2
11.6.2 Redundant
CAN-bus
Communication error
with Control unit, attachment right jack
pair (D791-4).
Right side of
bottom lift not
working.

D791-4
CAN/
POWER,
menu 2
11.6.2 Redundant
CAN-bus
Communication error
with Control unit,
Lighting rear,
hydraulic oil
cooling, overload system,
extension not
working.

D797-R
CAN/
POWER,
menu 2
11.6.2 Redundant
CAN-bus
Communication error
with Control unit,
frame front (D797-F).
Front lighting, lift, extension, brake

lights, brake
cooling not
working.

D797-F
CAN/
POWER,
menu 2
11.6.2 Redundant
CAN-bus
Communication error
with Control unit,
frame option (D797O).
Sliding cab,
support jacks,
joystick control miniwheel, cab lift
and cab tilt
not working.

D797-O
CAN/
POWER,
menu 2
11.6.2 Redundant
CAN-bus
Communication error
with KID control unit
(D795)
Controls in
steering
wheel panel
and display
not working.

D795
CAN/
POWER,
menu 2
11.6.2 Redundant
CAN-bus
VDRF03.02GB
92
Description
Limitation
Action
Connections and
components
Diagnostic menu
Group
Communication error
with Control unit, cab
option (D790-3).
Mini-wheel or
joystick control not working

D790-3
CAN/
POWER,
menu 2
11.6.2 Redundant
CAN-bus
11
Wiring fault CAN bus

segment 1.
No limitation.

Varies depending on
machine configuration.
CAN/
POWER,
menu 1
and 21
11.6.2 Redundant
CAN-bus
12

segment 2.
No limitation.

Varies depending on
CAN/
POWER,
menu 1
and 21
11.6.2 Redundant
CAN-bus
13

segment 3.
No limitation.

Varies depending on
CAN/
POWER,
menu 1
and 21
11.6.2 Redundant
CAN-bus
14

segment 4.
No limitation.

Varies depending on
CAN/
POWER,
menu 1
and 21
11.6.2 Redundant
CAN-bus
15

segment 5.
No limitation.

Varies depending on
CAN/
POWER,
menu 1
and 21
11.6.2 Redundant
CAN-bus
16

segment 6.
No limitation.

Varies depending on
CAN/
POWER,
menu 1
and 21
11.6.2 Redundant
CAN-bus
17

segment 7.
No limitation.

Varies depending on
CAN/
POWER,
menu 1
and 21
11.6.2 Redundant
CAN-bus
18

segment 8.
No limitation.

Varies depending on
CAN/
POWER,
menu 1
and 21
11.6.2 Redundant
CAN-bus
20
Accelerator pedal
(B690) not calibrated.
Poor sensitivity in accelerator pedal.
Calibrate the gas pedal, see the section 8

Control system, group
8.5.2.3 Calibrate
DRIVE-TRAIN.
D790-1/K6:11
B690
CALIBRATION:
DRIVETRAIN,
menu 1
and 2
1. Engine
Code
VDRF03.02GB
93
Description
Limitation
Action
Connections and
components
Diagnostic menu
Group
Communication error
with Control unit, cab
option (D790-3).
Mini-wheel or
joystick control not working

D790-3
CAN/
POWER,
menu 2
11.6.2 Redundant
CAN-bus
11

segment 1.
No limitation.

Varies depending on
CAN/
POWER,
menu 1
and 21
11.6.2 Redundant
CAN-bus
12

segment 2.
No limitation.

Varies depending on
CAN/
POWER,
menu 1
and 21
11.6.2 Redundant
CAN-bus
13

segment 3.
No limitation.

Varies depending on
CAN/
POWER,
menu 1
and 21
11.6.2 Redundant
CAN-bus
14

segment 4.
No limitation.

Varies depending on
CAN/
POWER,
menu 1
and 21
11.6.2 Redundant
CAN-bus
15

segment 5.
No limitation.

Varies depending on
CAN/
POWER,
menu 1
and 21
11.6.2 Redundant
CAN-bus
16

segment 6.
No limitation.

Varies depending on
CAN/
POWER,
menu 1
and 21
11.6.2 Redundant
CAN-bus
17

segment 7.
No limitation.

Varies depending on
CAN/
POWER,
menu 1
and 21
11.6.2 Redundant
CAN-bus
18

segment 8.
No limitation.

Varies depending on
CAN/
POWER,
menu 1
and 21
11.6.2 Redundant
CAN-bus
20
Accelerator pedal
(B690) not calibrated.
Poor sensitivity in accelerator pedal.
Calibrate the gas pedal, see the section 8

Control system, group
8.5.2.3 Calibrate
DRIVE-TRAIN.
D790-1/K6:11
B690
CALIBRATION:
DRIVETRAIN,
menu 1
and 2
1. Engine
Code
VDRF03.02GB
94
Code
21
22
Description
Limitation
Action
Connections and
components
Diagnostic menu
Group
Communication error
with transmission
Gear selection not working.

check communication.
D790-1/K13:1
D793/M2
11.6.3 CANbus drivetrain
Check the wiring between cab control unit

(D790-1) and transmission control unit
(D793).
D790-1/K13:2
D793/L2
CAN/
POWER,
menu 3
Communication error
with Control unit engine (D794).
Engine does
not react to
commands
from cab.

check communication.
Volvo: D7901/K13:1,
K13:2 D794/
2, 1
CAN/
POWER,
menu 3
11.6.3 CANbus drivetrain
Check the wiring between cab control unit

(D790-1) and engine
control unit (D794)
Cummins:
D790-1/
K13:1, K13:2
D794/46, 37
23
Setup file cannot be

read in cab control
unit (D790-1).
No controls
working in
cab.
Contact Cargotec support.
D790-1
11.5.3.1 Control unit cab
24
Electric power feed to

cab fan less than 18
V.
Cab fan not

working.
Check fuse F58-5/3.
D790-1/K2:8
58-5/3:2
9.4.3 Cab fan
25
Interference during
software download.
Buffer for error codes
from Control unit, engine (D794), active
error code when
downloading.
Error code
stored in engine control
unit (D794).
Switch the ignition off

and on.
D794
ENGINE,
menu 8
11.5.3.10
Control unit
engine
Incorrect power supply to cab control unit

(D790-1). Voltage under 18 V or over 32 V.
Control 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 6
11.5.1.3 Ignition voltage

(15)
26
27
28
29
Repeat software download.
30
31

the control unit and the
component with diagnostic menu.
VDRF03.02GB
Code
32
33
34
35
36
37
38
39
95
Description
Limitation
Action
Connections and
components
Diagnostic menu
Group
Incorrect 5 V reference voltage to analogue cab controls.

Voltage under 4.9 V
or over 5.1 V.
Analogue
controls in the
cab not working (miniwheel/joystick, control
lever and
controls for
air conditioning).

D790-1/K4:5,
K 5:11, K5:13,
K7:2, K 9:7,
K10:3
CAN/
POWER,
menu 6
11.5.3.1 Control unit cab
No feedback signal
for emergency stop
switch voltage from
emergency stop
switch voltage relay
(K3009-1).
The emergency stop

switch cannot be disengaged. All
hydraulic
functions are
blocked.
Check fuse F58-3/8.
D790-1/
K11:13
K3009-1/87
CAN/
POWER,
menu 5
11.5.1.4
Emergency
stop switch
voltage (15E)
Faulty signal from

parking brake switch
(S107); indicates released and applied at
same time or nothing
at all.
Parking brake
cannot be released.

D791-1/K8:5
S107/7
HYD,
menu 5
4.5 Parking
brake
Interference during
software download.
Buffer for error codes
from Control unit,
transmission (D793),
active error code
when downloading.
Error code
stored in
transmission
control unit
(D793).
Switch the ignition off

and on.
D793
TRANSM,
menu 13
11.5.3.9 Control unit transmission
The transistor has

been triggered due to
short circuit in the circuit for Wiper motor,
rear (M650-2).
Windscreen
wiper rear not
working.

D790-1/K2:4
M650-2/53
CAB,
menu 3
9.5.7 Wiper
motor rear
The transistor has

short circuit in the circuit for Revolving
beacon (H428).
Rotating beacon not working.
D790-1/K2:5
H428
LIGHTS,
menu 9
9.6.8 Rotating beacon

D791-1/K8:13
S107/1
Check the switch.
Repeat software download.
40
41
42
Check the motor.

VDRF03.02GB
96
Code
43
44
45
46
47
48
49
50
Description
Limitation
Action
Connections and
components
Diagnostic menu
Group
The transistor has

short circuit in the circuit for Working light,
cab left (E404-1L).
Working light,
cab left not
working.
Check bulb.
D790-1/K2:6
E404-1L
LIGHTS,
menu 1
9.6.9 Working light, cab
The transistor has

short circuit in the circuit for Working light,
cab right (E404-1R).
Working light,
cab right not
working.
Check bulb.
D790-1/K2:7
E404-1R
LIGHTS,
menu 1
9.6.9 Working light, cab
The transistor has

short circuit in the circuit for Wiper motor,
front (M650-1).
Windscreen
wiper front
not working.

D790-1/K2:1
M650-1/53
CAB,
menu 2
9.5.1 Wiper
front
The transistor has

short circuit in the circuit for Fan motor
(M657-1).
Cab fan not

working.
D790-1/K2:2
M657-1/2
CLIMATE,
menu 6
9.4.3 Cab fan
The transistor has

short circuit in the circuit for Actuator motor, recirculation
(M612).
Recirculation
damper to
ventilation not
working.
D790-1/K2:3
M612/3
CLIMATE,
menu 6
9.4.2 Fresh
air and recirculation
damper
The transistor has

short circuit in the circuit for Water valve
(Y673).
Heat in cab
cannot be adjusted.
D790-1/K4:1
Y673/5
CLIMATE,
menu 7
9.4.5 Water
valve
The transistor has

short circuit in the circuit for Water valve
(Y673).
Heat in cab
cannot be adjusted.
D790-1/K4:2
Y673/6
CLIMATE,
menu 7
9.4.5 Water
valve
The transistor has

short circuit in the circuit for Damper motor
(Y672)
Air distribution in cab

cannot be adjusted.
D790-1/K4:3
Y672/5
CLIMATE,
menu 8
9.4.14 Air distributor
VDRF03.02GB


Check the motor.

Check the motor.
Check the motor.
Check the motor.
Check the motor.
Check the motor.
Code
51
53
54
55
56
57
60
97
Description
Limitation
Action
Connections and
components
Diagnostic menu
Group
The transistor has

short circuit in the circuit for Damper motor
(Y672).
Air distribution in cab

cannot be adjusted.

D790-1/K4:4
Y672/6
CLIMATE,
menu 8
9.4.14 Air distributor
The transistor has

short circuit in the circuit for Washer motor, roof and rear
(M651-2).
Windscreen
washer rear
and roof not
working.
D790-1/K5:4
M651-2
CAB,
menu 1
9.5.4 Washer motor and

reservoir
The transistor has

short circuit or open
circuit in circuit for indicator lamp Switch,
flashing hazard lights
(S109).
Flashing hazard lights not

working.
D790-1/K5:5
S109/9
LIGHTS,
menu 7
9.6.7 Flashing hazard

lights
The transistor has

short circuit in the circuit for background
lighting in switches
and instruments.
Reduced or
no background lighting in
switches and
instruments
Check bulbs for background lighting, change

if needed.
D7901/K6:1,
K 8:15, K 9:2,
K 10:5, all inputs of type A
Digital in
LIGHTS,
menu 13
9.1 Controls
and instruments
The transistor has

circuit in the circuit for
LED indication for tilt
lock in control lever
(S815).
Indication for
tilt lock in control lever not
illuminated.

D790-1/K7:8
S815/5
7.1.1 Control
lever
The transistor has

LED indication for
levelling lock in control lever (S815).
Indication for
levelling lock
in control lever not illuminated.

D790-1/K7:9
S815/7
7.1.1 Control
lever
The transistor has

Relay seat heater
(K383).
Seat heating
not working.

D790-1/K10:7
K383/86
CAB,
menu 8
9.3.3 Heating coils
Check the motor.

Check the motor.
Check the switch.
Check cable harness to

background lighting.
Check the switch.
Check the switch.
VDRF03.02GB
98
Code
61
62
63
64
65
66
Description
Limitation
Action
Connections and
components
Diagnostic menu
Group
The transistor has

Relay extra working
lights boom (K304).
Extra working lights

boom not
working.

D790-1/K10:8
K304/86
LIGHTS,
menu 3
9.6.10 Working lights,

boom
The transistor has

circuit for simulated
D+ feed for hour meter (P708) and Relay
compressor air suspension seat (K358).
Hour meter
and air suspension seat
not working.
D790-1/K10:9
P708, K358/
86
CAN/
POWER,
menu 7
9.3.5 Air suspension
The transistor has

Relay ignition voltage
(K315-1).
No ignition
voltage to the
machines
Control units.
D790-1/
K10:10
K315-1/86
CAN/
POWER,
menu 4

(15)
The transistor has

circuit in circuit for relay for emergency
stop switch voltage
(K3009-1).
No emergency stop switch

voltage to the
machines
control units.

D790-1/
K10:11
K3009-1/86
CAN/
POWER,
menu 5
11.5.1.4
Emergency
stop switch
voltage
The transistor has

circuit in circuit for relay for emergency
stop switch voltage
(K3009-2).
No emergency stop switch

voltage to the
machines
control units.

D790-1/
K10:11
K3009-1/86
CAN/
POWER,
menu 5
11.5.1.4
Emergency
stop switch
voltage
The transistor has

short circuit in the circuit for Washer motor, windscreen
(M651-1).
Windscreen
washer not
working.

D790-1/
K10:13
M651-1
CAB,
menu 1
9.5.4 Washer motor and

reservoir
VDRF03.02GB


Code
67
68
69
71
74
75
99
Description
Limitation
Action
Connections and
components
Diagnostic menu
Group
The transistor has

Wiper motor, roof
(M650-3).
Wiper roof not

working.

D790-1/
K10:14
M650-3/53
CAB,
menu 4
9.5.6 Wiper
motor roof
The transistor has

circuit in circuit for
pause heater circulation pump (M667).
Pause heater
not working.
D790-1/
K10:15
M667
9.4 Heating,
ventilation
and air conditioning
The transistor has

drivetrain (K315-2).
No voltage
feed to engine and
transmission.
D790-1/
K10:16
K315-2/86
CAN/
POWER,
menu 4

(15)
The transistor has

short circuit in the circuit for Interior lighting, cab (E434-1).
Interior lighting in cab not

working.
Check bulb.
D790-1/K11:6
E434-1
LIGHTS,
menu 12
9.6.12 Interior lighting

cab
The transistor has

short circuit in the circuit for horn (H850)
or Relay loud horn
(K3016)
Horn/loud
horn not
working.

D790-1/
K11:11
H850/1,
K3016/86
CAB,
menu 5
9.7.1 Horn

(K315-1) has jammed
in position on.
The cab control unit

(D790-1) is
still energised and is
thereby active.
CAN/
POWER,
menu 4
Check the motor.

Check the motor.


VDRF03.02GB
100
Code
80
Description
Limitation
Action
Connections and
components
Diagnostic menu
Group
No signal from Pressure switch air conditioning (S246),

despite the AC compressor being activated.
Air conditioning not working.
Check drive belt for air

conditioning compressor.
D797-R/
K1:37 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
R690/2
ENGINE,
menu 1
1 Engine
D790-1/K7:3
S815-P1/8
BOOM,
menu 1
7.1.1 Control
lever
D790-1/K7:4
S815-P2/4
BOOM,
menu 1
7.1.1 Control
lever
D790-1/K7:5
S815-P3/11
ATTACH,
menu 1
7.1.1 Control
lever
D790-1/K7:6
S815-P4/1
ATTACH,
menu 1
7.1.1 Control
lever
Check that compressor

for air conditioning is
activated.
81
Faulty signal from Actuating motor (Y672).

Signal voltage under
0.2 V or over 4.8 V.
Air distribution cannot be

changed.

Check the motor.
85
87
88
89
90
Faulty signal from accelerator pedal

(R690). Signal voltage under 0.2 V or
over 4.8 V.
Engine speed
limited to idle.
Faulty signal from

Control lever (S815P1) for lifting/lowering. Signal voltage
under 0.2 V or over
4.8 V.
Lifting/lowering not working.
Faulty signal from

Control lever (S815P2) for extension.
Extension not
working.
Faulty signal from

Control lever (S815P3) for rotation. Signal voltage under 0.2
V or over 4.8 V.
Rotation not
working.
Faulty signal from

Control lever (S815P4) for tilt. Signal
voltage under 0.2 V
or over 4.8 V.
Controllable
tilt not working.
VDRF03.02GB

Check the switch.
Check the switch.
Check the switch.
Check the switch.
Code
92
93
101
Description
Limitation
Action
Connections and
components
Diagnostic menu
Group
Faulty signal from

Steering lever (R8251) or Mini-wheel
(R825-1). Signal voltage under 0.2 V or
over 4.8 V.
Joystick
steering or
mini-wheel
not working.

D790-1/K9:8
R825-1/P2
STEERING, menu
1
5.1.2 Miniwheel
Faulty signal from

Mini-wheel (R825-2).
Joystick
steering or
mini-wheel
not working.
D790-1/K9:9
R825-2/H2
STEERING, menu
1
5.1.2 Miniwheel
D790-1/K10:4
Y673/9
CLIMATE,
menu 4
9.4.5 Water
valve
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 outdoor

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
5.1.3 Joystick
Check the switch.

Check the switch.
94
96
97
98
99
Faulty signal from

Water valve, cab
heating (Y673). Signal voltage under 0.2
V or over 4.8 V.
Cab heat cannot be adjusted.
Faulty signal from

cab temperature sensor (B775-1) Sensor
indicates temperature under -43 C or
over 105 C.
Faulty signal from

outside temperature
sensor (B774). Temperature signal over
105 C.
Faulty signal from

outlet fan temperature sensor (B775-2)
Sensor indicates
temperature under 43 C or over 105 C.
Faulty signal from refrigerant temperature

sensor (B775-3) Sensor indicates temperature under -43 C or
over 105 C.

Check the motor.
Check the sensor.
Check the sensor.
Check the sensor.
Check the sensor.
VDRF03.02GB
102
Code
101
102
103
104
105
106
107
Description
Limitation
Action
Connections and
components
Diagnostic menu
Group
Redundant voltage
feed left to Control
unit, frame front
(D797-F) does not
reach destination.

D797-F/K2:7
CAN/
POWER,
menu 8
11.5.1.2 Redundant voltage feed of

Control units
Redundant voltage
feed right to Control
unit, frame front
(D797-F) does not
reach destination.
D797-F/K2:8
CAN/
POWER,
menu 8

Control units
Incorrect power supply to Control unit,

frame front (D797-F).
Voltage under 18 V or
over 32 V.
No electric
power feed to
components.
Check fuse F58-2/1,

change if needed.
D797-F/K2:1,
K2:9, K2:10
F58-2/1:1, 1:2
CAN/
POWER,
menu 8

(15)
Faulty emergency
stop voltage to Control unit, frame front
(D797-F).
Functions
normally supplied emergency stop
switch voltage have no
feed. All hydraulic functions blocked.
Check fuse F58-3/2,

change if needed.
D797-F/K2:11
F58-3/2:1
CAN/
POWER,
menu 8
11.5.1.4
Emergency
stop switch
voltage
Incorrect 5 V reference voltage to pressure sensor. Voltage

under 4.9 V or over
5.1 V.
Regeneration lifting,
weight indicator and overload system
not working.

D797-F/K1:8
B768-R1/1,
B768-R2/1,
B768-L1/1,
B768-L2/1
CAN/
POWER,
menu 9
8.2.1.7 Sensor hydraulic

pressure lift
cylinder
The transistor has

short circuit in the circuit for Cooling fan,
brake fluid (M674).
Cooling fan
brake oil not
working.

D797-F/K1:14
M674/1
HYD,
menu 2
4.8.8 Cooling
fan
The transistor has

High beam lamp, left
(E402L).
Left high
beam not
working.
D797-F/K1:1
E402L/1
LIGHTS,
menu 6
9.6.1 Headlights
VDRF03.02GB



Check the sensor.
Check the motor.

Check bulb.
Check the lamp holder.
Code
108
110
111
112
113
114
103
Description
Limitation
Action
Connections and
components
Diagnostic menu
Group
The transistor has

High beam lamp,
right (E402R).
Right high
beam not
working.
Check bulb.
D797-F/K1:15
E402R/1
LIGHTS,
menu 6
9.6.1 Headlights
The transistor has

Low beam lamp
(E400L/E400R).
Low beams
not working.
Check bulb.
D797-F/K1:42
E400L/1,
E400R/1
LIGHTS,
menu 6
9.6.1 Headlights
The transistor has

short circuit in the circuit for Solenoid
valve, boom up
(Y6005).
Lift not working.
D797-F/K1:2
Y6005/1
BOOM,
menu 4
7.2.5 Control
valve lift, lower and extension
The transistor has

valve, boom down
(Y6004).
Lower not
working.
D797-F/K1:3
Y6004/1
BOOM,
menu 5
7.2.5 Control
The transistor has

valve, boom out
(Y6006).
Extension out
not working.
D797-F/K1:4
Y6006/1
BOOM,
menu 7
7.3.5 Control
The transistor has

valve, boom in
(Y6007).
Extension in
not working.
D797-F/K1:5
Y6007/1
BOOM,
menu 6
7.3.5 Control


Check the solenoid
valve.
Check the solenoid
valve.
Check the solenoid
valve.
Check the solenoid
valve.
VDRF03.02GB
104
Code
115
116
117
118
119
120
Description
Limitation
Action
Connections and
components
Diagnostic menu
Group
The transistor has

Solenoid valve,
blocking lift, left
(Y6002).

D797-F/K1:30
Y6002/1
BOOM,
menu 2
7.2.7 Valve
block lift cylinder
The transistor has

Solenoid valve,
blocking lift, right
(Y6001).
D797-F/K1:31
Y6001/1
BOOM,
menu 2
7.2.7 Valve
block lift cylinder
The transistor has

Solenoid valve, regeneration lift, right
(Y6051).
Regeneration lift not

working.
D797-F/K1:32
Y6051/1
BOOM,
menu 3
7.2.7 Valve
block lift cylinder
The transistor has

Solenoid valve regeneration lift, left
(Y6052).
Regeneration lift not

working.
D797-F/K1:33
Y6052/1
BOOM,
menu 3
7.2.7 Valve
block lift cylinder
The transistor has

Solenoid valve, parking brake (Y642).
Parking brake
cannot be released.
D797-F/K1:7
Y642/1
HYD,
menu 5
4.5.3 Solenoid valve

parking brake
The transistor has

Lamp, direction indicator, left front
(H422).
Direction indicator front left

not working.
D797-F/K1:9
H422/1
LIGHTS,
menu 8
9.6.6 Direction indicators
VDRF03.02GB
Check the solenoid

valve.
Check the solenoid
valve.
Check the solenoid
valve.
Check the solenoid
valve.
Check the solenoid
valve.
Check bulb.
Code
121
122
123
124
133
105
Description
Limitation
Action
Connections and
components
Diagnostic menu
Group
The transistor has

Lamp, direction indicator, right front
(H423).
Direction indicator front

right not
working.
Check bulb.
D797-F/K1:10
H423/1
LIGHTS,
menu 8
The transistor has

Lamp, position light,
left front (H416-1).
Position light
front left not
working.
Check bulb.
D797-F/K1:25
H416-1/1
LIGHTS,
menu 5
9.6.2 Running lights
The transistor has

right front (H417-1).
Position light
front right not
working.
Check bulb.
D797-F/K1:29
H417-1/1
LIGHTS,
menu 5
Incorrect 24 V reference voltage to NC

switch parking brake
(S200), NC switch
low brake pressure
(S204), NO switch
brake lights (S216)
and NC switch declutch (S220-2).
Indicator light
parking brake
and warning
for low brake
pressure not
switching off.
Brake lights
and declutch
not working.
Gear cannot
be engaged
because the
signal released parking brake is
not working.

D797-F/K1:39
S200/1,
S204/1, S216/
1, S220/1
CAN/
POWER,
menu 9
4.5.5 Parking
brake NC
switch
Faulty signal from

Sensor hydraulic
pressure lift cylinder
left (B768-L1). Signal
voltage under 0.2 V
or over 4.8 V.
Overload system not working. All lift

functions operate at reduced speed.
Error code
150 is activated.




4.3.8 NO
(normally
open) switch,
brake lights
Check the sensor.
4.3.7 NC
(normally
closed)
switch, brake
pressure
Check the sensor.
D797-F/K1:21
B768-L1/3
OP, menu
3 [V]
HYD,
menu 6
[bar]
7.2.9 Sensor
hydraulic
pressure lift
cylinder
VDRF03.02GB
106
Code
134
135
136
137
138
Description
Limitation
Action
Connections and
components
Diagnostic menu
Group
Faulty signal from

Sensor hydraulic
left (B768-L2). Signal
voltage under 0.2 V
or over 4.8 V.

Error code
150 is activated.

D797-F/K1:22
B768-L2/3
OP, menu
3 [V]
7.2.9 Sensor
hydraulic
pressure lift
cylinder
Faulty signal from

Sensor hydraulic
right (B768-R1). Signal voltage under 0.2
V or over 4.8 V.

Error code
150 is activated.

Faulty signal from

Sensor hydraulic
right (B768-R2). Signal voltage under 0.2
V or over 4.8 V.

Error code
150 is activated.

Faulty signal from

Solenoid valve, boom
up (Y6005). Return
current does not
match control current.
Lift not working.

Faulty signal from

down (Y6004). Return current does not
Lower not
working.
VDRF03.02GB
HYD,
menu 6
[bar]
Check the sensor.
D797-F/K1:23
B768-R1/3
OP, menu
3 [V]
HYD,
menu 6
[bar]
Check the sensor.
D797-F/K1:24
B768-R2/3
OP, menu
3 [V]
HYD,
menu 6
[bar]
Check the sensor.
7.2.9 Sensor
hydraulic
pressure lift
cylinder
7.2.9 Sensor
hydraulic
pressure lift
cylinder
D797-F/K1:16
Y6005/2
BOOM,
menu 4
7.2.5 Control
D797-F/K1:17
Y6004/2
BOOM,
menu 5
7.2.5 Control
Check the solenoid

valve.
Check the solenoid
valve.
Code
139
140
145
146
147
107
Description
Limitation
Action
Connections and
components
Diagnostic menu
Group
Faulty signal from

out (Y6006). Return
current does not
Extension out
not working.

D797-F/K1:18
Y6006/2
BOOM,
menu 7
7.3.5 Control
Faulty signal from

in (Y6007). Return
current does not
Extension in
not working.
D797-F/K1:19
Y6007/2
BOOM,
menu 6
7.3.5 Control
Faulty signal from

Sensor, boom angle
(B771). Logical error,
the signal does not
change when lifting
or lowering is activated.

Error code
150 is activated.
Check sensor arm

mounting.
OP, menu
4
Faulty signal from

Sensor, boom length
(B777). Logical error,
the signal does not
change when extension is activated.

Error code
150 is activated.
Check the cable to the

sensor.
OP, menu
4
8.2.1.6 Sensor, boom

length
High brake oil temperature.
Reduced
braking ability.
Check that cooling fan

is working.
D797-F/K2:13
B762/1
HYD,
menu 2
4.8 Temperature control,

cleaning and
brake oil
D797-F/K2:13
B762/1
HYD,
menu 2
4.8.10 Sensor brake oil

temperature
Check the solenoid

valve.
Check the solenoid
valve.
Check the sensor.

Check the sensor.

Check that cooler isnt

clogged.
Check the sensor.
148
Faulty signal from

brake oil temperature
sensor (Y672). Signal
voltage under 0.2 V
or over 4.8 V.
Model year
2009-: Machine speed
limited to 5
km/h.
Check the sensor.

VDRF03.02GB
108
Description
Limitation
Action
Connections and
components
Diagnostic menu
Group
149
Incorrect load curve

or load curve not
present.
Lifting/lowering and extension not

working.
Contact Cargotec support.
7.2 Lifting/
lowering. 7.3
Extension
150
Defective overload
protection.

Check if there are error

codes for sensors in
the overload system.
OP, menu
15
8.2.1 Overload system
Redundant voltage
unit, frame rear
(D797-R) does not
reach destination.

D797-R/K2:7
CAN/
POWER,
menu 10

Control units
Redundant voltage
unit, frame rear
(D797-R) does not
reach destination.
D797-R/K2:8
CAN/
POWER,
menu 10

Control units

over 32 V.
D797-R/K2:1,
K2:9, K2:10
F58-2/3:1
CAN/
POWER,
menu 10

(15)

D797-R/
K2:11 F582/3:2
CAN/
POWER,
menu 10
11.5.1.4
Emergency
stop switch
voltage
Incorrect 5 V reference voltage to analogue sensors.

Voltage under 4.9 V
or over 5.1 V.
Overload systems and

weight indicator not working.
D797-R/K1:8
B771/1,
B777/1
CAN/
POWER,
menu 11
Code
This error code cannot be removed with

Reset.
151
152
153
154
155
VDRF03.02GB

Check fuse F58-2/3,
change if needed.
Check fuse F58-2/3,
change if needed.
Check the sensor.

length, (analogue sensor)
Code
156
157
158
159
160
161
109
Description
Limitation
Action
Connections and
components
Diagnostic menu
Group
The transistor has

short circuit in the circuit for Cooling fan,
hydraulic oil (M668).
Cooling fan
hydraulic oil
not working.

D797-R/
K1:14
M668/1
HYD,
menu 1
10.6.3 Cooling fan
The transistor has

Lamp, working lights,
boom, left front
(E404-3L).
Working light,
boom left not
working.
Check bulb.
D797-R/K1:1
E404-3L
LIGHTS,
menu 3

boom
The transistor has

boom, right front
(E404-3R).
Working light,
boom right
not working.
Check bulb.
D797-R/
K1:15 E4043R
LIGHTS,
menu 3

boom
The transistor has

Lamp, reversing light,
left (E405L).
Left reversing light not

working.
Check bulb.
D797-R/
K1:28
E405L
LIGHTS,
menu 11
9.6.5 Backup light
The transistor has

Lamp, reversing light,
right (E405R).
Right reversing light not

working.
Check bulb.
D797-R/
K1:42
E405R
LIGHTS,
menu 11
9.6.5 Backup light
The transistor has

Sensor, steering axle
load (B7221L and
B7221R).
Overload systems indicates

overload.

D797-R/K1:2
B7221L/A,
B7221R/A
OP, menu
1
8.2.1.4 Sensor, steering

axle load
Check the motor.




Check the sensor.
VDRF03.02GB
110
Code
162
163
164
165
166
167
Description
Limitation
Action
Connections and
components
Diagnostic menu
Group
The transistor has

Sensor, position sensor boom length
Damping in/
out/1.5 m not
working.

D797-R/K1:2
B777/A,
B769-3/A,
B769-4/A
OP, menu
1

length (position sensor)
The transistor has

Solenoid valve, regeneration extension,
(Y6046).
Regeneration extension
not working.
D797-R/K1:4
Y6046/1
BOOM,
menu 3
7.3.7 Valve
block, extension cylinder
The transistor has

Solenoid valve,
blocking extension,
(Y6050).
Extension not
working.
D797-R/K1:5
Y6050/1
BOOM,
menu 2
7.3.7 Valve
block, extension cylinder
The transistor has

circuit in circuit for reversing warning device (H965).
Back-up
alarm not
working.
D797-R/
K1:30 H965/
1
LIGHTS,
menu 11
9.7.5 Backup alarm
The transistor has

Solenoid valve, top
hydraulics (Y6003).
Attachment
functions not
working.
D797-R/
K1:31
Y6003/1
HYD,
menu 6
7.4.2 Valve
block, top lift
hydraulics
The transistor has

Lamp, brake light, left
(H411L).
Brake light
left not working.
D797-R/
K1:32
H411L/1
LIGHTS,
menu 11
9.6.4 Brake
lights
VDRF03.02GB
BOOM,
menu 8
Check the sensor.

Check the solenoid
valve.
Check the solenoid
valve.
Check the solenoid
valve.
Check bulb.
Code
168
169
170
171
172
173
111
Description
Limitation
Action
Connections and
components
Diagnostic menu
Group
The transistor has

Lamp, brake light,
right (H411R).
Brake light
right not
working.
Check bulb.
D797-R/
K1:33
H411R/1
LIGHTS,
menu 11
9.6.4 Brake
lights
The transistor has

left (H416-2).
Position light
left rear not
working.
Check bulb.
D797-R/K1:7
H416-2/1
LIGHTS,
menu 5
The transistor has

right (H417-2).
Position light
right rear not
working.
Check bulb.
D797-R/K1:9
H417-2/1
LIGHTS,
menu 5
The transistor has

Lamp, rear light, left
(E421L).
Left rear light

not working.
Check bulb.
D797-R/
K1:10
H412L/1
LIGHTS,
menu 5
9.6.3 Rear
lights
The transistor has

Lamp, rear light, right
(E421R).
Left rear light

not working.
D797-R/
K1:25
H412R/1
LIGHTS,
menu 5
9.6.3 Rear
lights
The transistor has

Lamp, direction indicator, left rear
(H426).
Direction indicator rear left

not working.
D797-R/
K1:29 H426/
1
LIGHTS,
menu 8




Check bulb.
Check bulb.
VDRF03.02GB
112
Code
174
175
178
183
184
Description
Limitation
Action
Connections and
components
Diagnostic menu
Group
The transistor has

Lamp, direction indicator, right rear
(H426).
Direction indicator rear

right not
working.
Check bulb.
D797-R/
K1:39 H427/
1
LIGHTS,
menu 8
Different signal from

load (B7221L and
B722R) for more than
10 seconds.
Overload systems indicates

overload.
Check sensor adjustment.
D797-R/
K1:11
B7221L/C
OP, menu
1
8.2.1.4 Sensor, steering

axle load
The transistor has

Solenoid valve, pump
unloading (Y6062).
Unloading of
hydraulic oil
pumps at
boom not
working.

D797-R/
K1:40
Y6062/1
BOOM,
menu 2
7.3.8 Valve
block, pump
unloading
Faulty signal from

Sensor, boom angle
(B771). Signal voltage under 0.2 V or
over 4.8 V.

Error code
150 is activated.

D797-R/
K1:21 B771/
3
OP, menu
4
Faulty signal from

Sensor, boom length
(B777). Signal voltage under 0.2 V or
over 4.8 V.

Error code
150 is activated.

D797-R/
K1:22 B777/
3
OP, menu
4

length
VDRF03.02GB

Check the sensor.
D797-R/
K1:12
B7221R/C
Check the solenoid

valve.
Check the sensor.
Check the sensor.
Code
191
192
113
Description
Limitation
Action
Connections and
components
Diagnostic menu
Group
The transistor has

electromagnetic
clutch of AC compressor (M677).

D797-R/
K1:11
M645/1
CLIMATE,
menu 6
9.4.8 Compressor
D797-R/
K1:36 K360/
86
ENGINE,
menu 5
1 Engine
D797-R/
K2:13 B776/
1
HYD,
menu 1
10.6 Temperature control,

cleaning and
hydraulic oil
D797-R/
K2:13 B776/
1
HYD,
menu 1
10.6.4 Sensor, hydraulic oil

temperature
D797-R/
K2:15 B757
CAB,
menu 7
1.2.2 Sensor
fuel level
D797-O/K2:7
CAN/
POWER,
menu 12

Control units
D797-R/
K1:26
M645/1
NOTE! Error code

191 and 192 belong
to the same user.
193
Only engine alternative Cummins

QSM11:
Starter motor
not working.
The transistor has

Relay starter motor
(K360).
197
High hydraulic oil

temperature.

No limitation.
Check that cooling fan

is working.
Check that cooler isnt
clogged.
Check the sensor.
198
199
201
Faulty signal from

Sensor, hydraulic oil
temperature (B776).
Incorrect temperature display.
Check the sensor.
Faulty signal from

fuel level sensor
(B757). Resistance
over 180 .
Incorrect display of fuel

amount (empty or full).
Check the sensor.
Redundant voltage
unit, frame option
(D797-O) does not
reach destination.



VDRF03.02GB
114
Code
202
203
204
211
212
213
Description
Limitation
Action
Connections and
components
Diagnostic menu
Group
Redundant voltage
unit, frame option
(D797-O) does not
reach destination.

D797-O/K2:8
CAN/
POWER,
menu 12

Control units

frame option (D797O). Voltage under 18
V or over 32 V.
D797-O/
K2:10 F582/4:1
CAN/
POWER,
menu 12

(15)
Incorrect emergency
stop switch voltage to
Control unit frame option (D797-O).
Functions
feed. All hydraulic functions blocked.
Check fuse F58-3/4,

change if needed.
D797-O/
K2:11 F583/4:1
CAN/
POWER,
menu 12
11.5.1.4
Emergency
stop switch
voltage
The transistor has

valve, cab forward/up
(Y6016).
Hydraulic cab
sliding or liftable cab not
working.

D797-O/K1:2
Y6016/1
SLIDINGCAB,
menu 3
9.10.4.3 Control valve option frame
The transistor has

valve, cab backward/
down (Y6017).
Hydraulic cab
working.
The transistor has

valve, steering left
(Y636L).
Joystick
steering or
mini-wheel
not working.
VDRF03.02GB

Check fuse F58-2/4,
change if needed.

Check the solenoid

valve.
D797-O/K1:3
Y6017/1
SLIDINGCAB,
menu 4
Check the solenoid

valve.
Check the solenoid
valve.
D797-O/K1:4
Y636L1/1
ELSTEERING, menu
4
5.2.10 Control valve joystick

steering/miniwheel
Code
214
215
216
217
115
Description
Limitation
Action
Connections and
components
Diagnostic menu
Group
The transistor has

valve, steering right
(Y636R).
Joystick
steering or
mini-wheel
not working.

D797-O/K1:5
Y636R1/1
ELSTEERING, menu
5

steering/miniwheel
The transistor has

Solenoid valve, support jacks up,
(Y6053).
Support jacks
not working.
D797-O/
K1:30
Y6063/1
SUPPORTJACKS,
menu 3
The transistor has

Solenoid valve, support jacks down,
(Y6064).
Support jacks
not working.
D797-O/
K1:31
Y6064/1
SUPPORTJACKS,
menu 3
Solenoid valve, cab

tilt up (Y6047).
Tiltable cab
not working.
D797-O/
K1:32
Y6047/1
SLIDINGCAB,
menu 3
MISSING
D797-O/
K1:33
Y6048/1
SLIDINGCAB,
menu 4
MISSING
D797-O/K1:7
Y6057/1
HYD,
menu 6
MISSING
Check the solenoid

valve.
Check the solenoid
valve.
Check the solenoid
valve.
Check the solenoid
valve.
218
Solenoid valve, cab

tilt down (Y6048).
Tiltable cab
not working.

Check the solenoid
valve.
219
Solenoid valve, disengagement of hydraulic oil pumps

(Y6057).
Disengagement of hydraulic oil

pump when
lowering of
tiltable cab is
not working.

Check the solenoid
valve.
VDRF03.02GB
116
Code
220
221
237
238
239
240
Description
Limitation
Action
Connections and
components
Diagnostic menu
Group
Incorrect 24 V reference voltage to Position sensor, support

jacks (B7222L,
B7222R, B7223L and
B7223R).
Indication for
support jacks
up not working. Not possible to select
gear to operate the machine.

D797-O/K1:9
B7222L,
B7222R,
B7223L,
B7223R
SUPPORTJACKS,
menu 2
7.10.1.5 Sensor, raised

support jacks
Incorrect 24 V reference voltage to Position sensor cab lift

(B777-2).
Indication for
Lowered cab
not working.
Door must be
closed so that
the boom can
be lowered.
Speed limitation is activated.

D797-O/
K1:10 B7772/1
SLIDINGCAB,
menu 4
9.10.5.8 Sensor lowered

cab
Faulty signal from

Solenoid valve, cab
forward/up (Y6016).
Return current does
not match control current.
Hydraulic cab
working.

D797-O/
K1:16
Y6016/2
SLIDINGCAB,
menu 3
Faulty signal from

Solenoid valve, cab
backward/down
(Y6017). Return current does not match
control current.
Hydraulic cab
working.
Faulty signal from

Solenoid valve, steering left (Y636L). Return current does not
Joystick
steering or
mini-wheel
not working.
Faulty signal from

Solenoid valve, steering right (Y636R).
Return current does
Joystick
steering or
mini-wheel
not working.
VDRF03.02GB
Check the sensor.
7.10.1.6 Sensor, lowered

support jacks
Check the sensor.
Check the solenoid

valve.
D797-O/
K1:17
Y6017/2
SLIDINGCAB,
menu 4
Check the solenoid

valve.
D797-O/
K1:18
Y636L/2
ELSTEERING, menu
4

steering/miniwheel
D797-O/
K1:19
Y636R/2
ELSTEERING, menu
5

steering/miniwheel
Check the solenoid

valve.
Check the solenoid
valve.
117
Description
Limitation
Action
Connections and
components
Diagnostic menu
Group
251
Redundant voltage
feed left to frame control unit (D791-1)
does not reach destination.

D791-1/K2:7
CAN/
POWER,
menu 16

Control units
252
Redundant voltage
feed left to frame control unit (D791-1)

D791-1/K2:8
CAN/
POWER,
menu 16

Control units
253
Incorrect power supply to attachment

over 32 V.
Functions
feed. No attachment
functions operational.
Check fuse F58-3/1,

change if needed.
D791-1/K2:1/
9/10 F52-1
F58-3/1:1
CAN/
POWER,
menu 16
11.5.1.4
Emergency
stop switch
voltage
Incorrect emergency
Control unit, attachment (D791-1).
Functions
feed. No attachment
functions operational.
Check fuse F58-3/1,

change if needed.
D791-1/K2:11
F58-3/1
CAN/
POWER,
menu 16
11.5.1.4
Emergency
stop switch
voltage
The transistor has

attachment right
(E406R).
Working
lights attachment right not
working.
Check bulb.
D791-1/K1:1
E406R
LIGHTS,
menu 2
9.6.11 Working lights attachment
The transistor has

attachment left
(E406L).
Working
lights attachment left not
working.
Check bulb.
D791-1/K1:15
E406L
LIGHTS,
menu 2
Code
254
257
258
Check fuse F52-1,

change if needed.
Check fuse F52-1,

change if needed.


VDRF03.02GB
118
Code
259
260
261
262
263
264
Description
Limitation
Action
Connections and
components
Diagnostic menu
Group
The transistor has

Buzzer, automatic
spreading 20-40
(H4009).
Automatic
spreading
20'-40' not
working.

D791-1/K1:28
H9003/1
ATTACH,
menu 15
7.5 Spreading
The transistor has

Lamp, extra working
lights, attachment
(E404-4L and E4044R).
Auxiliary attachment
working lights
not working.
Check bulb.
D791-1/K1:42
E404-4L,
E404-4R
LIGHTS,
menu 2
The transistor has

valve, rotation clockwise (Y6008).
Rotation of attachment not

working.

D791-1/K1:2
Y6008/1
ATTACH,
menu 11
7.6.3 Control
valve attachment
The transistor has

valve, rotation anticlockwise (Y6009).

working.
D791-1/K1:3
Y6009/1
ATTACH,
menu 12
7.6.3 Control
valve attachment
The transistor has

valve, spreading out
(Y6018).
Spreading not
working.
D791-1/K1:4
Y6018/1
ATTACH,
menu 13
7.5.3 Control
valve attachment
The transistor has

valve, spreading in
(Y6019).
Spreading not
working.
D791-1/K1:5
Y6019/1
ATTACH,
menu 14
7.5.3 Control
valve attachment
VDRF03.02GB

Check the solenoid

valve.
Check the solenoid
valve.
Check the solenoid
valve.
Check the solenoid
valve.
Code
265
266
267
268
269
270
119
Description
Limitation
Action
Connections and
components
Diagnostic menu
Group
The transistor has

Solenoid valve, side
shift, right (Y6021).
Side shift of
attachment
not working.

D791-1/K1:30
Y6021/1
ATTACH,
menu 8
7.4.3 Control
valve attachment
The transistor has

Solenoid valve, side
shift, left (Y6020).
Side shift of
attachment
not working.
D791-1/K1:31
Y6020/1
ATTACH,
menu 8
7.4.3 Control
valve attachment
The transistor has

Solenoid valve, lock
twistlock, (Y6040).
Twistlock not
working.
D791-1/K1:32
Y6040/1
ATTACH,
menu 9
7.9.1.3 Control valve attachment
The transistor has

Solenoid valve, open
twistlock, (Y6039).
Twistlock not
working.
D791-1/K1:33
Y6039/1
ATTACH,
menu 9
7.9.1.3 Control valve attachment
The transistor has

Solenoid valve, tilt
lock 1 (Y6012-1).
Tilt locked, tilt

damping and
controllable
tilt not working.

D791-1/K1:7
Y6012-1/1
ATTACH,
menu 15
7.7.4 Lock
valve, tilt
The transistor has

lock 2 (Y6012-2).
Tilt locked, tilt

damping and
controllable
tilt not working.

D791-1/K1:9
Y6012-2/1
ATTACH,
menu 15
7.7.4 Lock
valve, tilt
Check the solenoid

valve.
Check the solenoid
valve.
Check the solenoid
valve.
Check the solenoid
valve.
Check the solenoid

valve.
Check the solenoid

valve.
VDRF03.02GB
120
Code
271
272
273
274
287
Description
Limitation
Action
Connections and
components
Diagnostic menu
Group
The transistor has

voltage feed to attachment position
sensor.
Twistlocks,
rotation stop,
and spreading not working.

D791-1/K1:10
B769/A,
B777-2/A,
B7225/A,
B7202R/A,
B7204R/A,
B7205R/A,
B7203R/A,
B7202L/A,
B7204L/A,
B7205L/A,
B7203L/A,
B7224/A
ATTACH,
menu 5, 6,
7, 21
7.5.10 Position sensor,

spreading
D791-1/K1:25
H562/1
ATTACH,
menu 10
7.9.1 Twistlocks
D791-1/K1:29
H564/1
ATTACH,
menu 10
7.9.1 Twistlocks
D791-1/K1:39
H563/1
ATTACH,
menu 10
7.9.1 Twistlocks
D791-1/K1:16
Y6008/2
ATTACH,
menu 11
7.6.3 Control
valve attachment
Check the sensor.
The transistor has

Indicator light, open
twistlocks (H562).
Indicator light,
open twistlocks, not
working.
Check bulb.
The transistor has

alignment indicator
light (H564).
Indicator light
alignment
twistlock not
working.
Check bulb.
The transistor has

Indicator light, locked
twistlocks (H563).
Indicator light,
locked twistlocks, not
working.
Check bulb.
Faulty signal from

Solenoid valve, rotation clockwise
control current.

working.

VDRF03.02GB
7.6.10 Sensor, rotation

stop
7.9.1.8 Sensor alignment
7.9.1.9 Sensor, twistlocks
length (position sensor)



Check the solenoid

valve.
Code
288
289
290
298
299
300
121
Description
Limitation
Action
Connections and
components
Diagnostic menu
Group
Faulty signal from

Solenoid valve, rotation anticlockwise
control current.

working.

D791-1/K1:17
Y6009/2
ATTACH,
menu 12
7.6.3 Control
valve attachment
Faulty signal from

Solenoid valve,
spreading out
control current.
Spreading not
working.
D791-1/K1:18
Y6018/2
ATTACH,
menu 13
7.5.3 Control
valve attachment
Faulty signal from

Solenoid valve,
spreading in (Y6019).
Return current does
Spreading not
working.
D791-1/K1:19
Y6019/2
ATTACH,
menu 14
7.5.3 Control
valve attachment
Twistlock sensor indicates that left twistlock is between open

and locked position.
Lifting and extension not

working.
ATTACH,
menu 7
7.9.1.9 Sensor twistlocks
Twistlock sensor indicates that right twistlock is between open

and locked position.
Lifting and extension not

working.
ATTACH,
menu 7
7.9.1.9 Sensor twistlocks
Alignment sensor indicates unreasonable

distance.
Twistlock not
working.
ATTACH,
menu 6
7.9.1.8 Sensor alignment
Check the solenoid

valve.
Check the solenoid
valve.
Check the solenoid
valve.
Check that Sensors
twistlock are clean and
correctly adjusted.
Check that Sensors
twistlock are clean and
correctly adjusted.
Check that the alignment sensors are clean
and correctly adjusted.
Check that alignment
pin runs smoothly.
VDRF03.02GB
122
Code
301
302
303
304
311
312
Description
Limitation
Action
Connections and
components
Diagnostic menu
Group
Redundant voltage
unit, attachment option (D791-2) does
not reach destination.

D791-2/K2:7
CAN/
POWER,
menu 17

Control units
Redundant voltage
unit, attachment option (D791-2) does
D791-2/K2:8
CAN/
POWER,
menu 17

Control units
Incorrect power supply to Control unit, attachment option

(D791-2). Voltage under 18 V or over 32 V.
Levelling, tilt
and special
function not
working.
Check fuse F58-3/1

and F52-1, change if
needed.
D791-2/K2:1,
K2:9, K2:10
F52-1 F583/1
CAN/
POWER,
menu 17
11.5.1.4
Emergency
stop switch
voltage
Incorrect emergency
Control unit, attachment option (D7912).
Functions
supplied with
emergency
stop switch
voltage lack
feed. Levelling, tilt and
special function not working.
Check fuse F58-3/1

needed.
D791-2/K2:11
F52-1
F58-3/1
CAN/
POWER,
menu 17
11.5.1.4
Emergency
stop switch
voltage
The transistor has

valve, levelling right
(Y6035).
Levelling not
working.

D791-2/K1:2
Y6035/1
ATTACH,
menu 19
7.8.3 Control
valve attachment
The transistor has

valve, levelling left
(Y6036).
Levelling not
working.
D791-2/K1:3
Y6036/1
ATTACH,
menu 20
7.8.3 Control
valve attachment
VDRF03.02GB



Check the solenoid

valve.
Check the solenoid
valve.
Code
313
314
315
316
123
Description
Limitation
Action
Connections and
components
Diagnostic menu
Group
The transistor has

valve, tilt out (Y6010).
Controllable
tilt not working.

D791-2/K1:4
Y6010/1
ATTACH,
menu 16
7.7.5 Control
valve attachment
The transistor has

Controllable
tilt not working.
D791-2/K1:5
Y6011/1
ATTACH,
menu 17
7.7.5 Control
valve attachment
The transistor has

Solenoid valve, levelling lock(Y6034-1).
Levelling is
locked, controllable levelling and float
position not
working.

D791-2/K1:30
Y6034-1/1
ATTACH,
menu 18
7.8.6 Valve
block, levelling cylinders
The transistor has

Solenoid valve, levelling lock (Y6034-2).
Levelling is
position not
working.

D791-2/K1:31
Y6034-2/1
ATTACH,
menu 18
7.8.6 Valve
Check the solenoid

valve.
Check the solenoid
valve.
Check the solenoid

valve.
Check the solenoid

valve.
317
Incorrect output signal special function.
WARNING
D791-2/K1:32
318
WARNING
D791-2/K1:33
319
WARNING
D791-2/K1:7
320
WARNING
D791-2/K1:9
321
WARNING
D791-2/K1:10
322
WARNING
D791-2/K1:25
VDRF03.02GB
124
Code
337
338
339
340
351
352
353
Description
Limitation
Action
Connections and
components
Diagnostic menu
Group
Faulty signal from

Solenoid valve, levelling right (Y6035).
Return current does
Levelling not
working.

D791-2/K1:16
Y6035/2
ATTACH,
menu 17
7.8.3 Control
valve attachment
Faulty signal from

Solenoid valve, levelling left (Y6036). Return current does not
Levelling not
working.
D791-2/K1:17
Y6036/2
ATTACH,
menu 18
7.8.3 Control
valve attachment
Faulty signal from

out (Y6010). Return
current does not
Controllable
tilt not working.
D791-2/K1:18
Y6010/2
ATTACH,
menu 14
7.7.5 Control
valve attachment
Faulty signal from

Solenoid valve, tilt in
control current.
Controllable
tilt not working.
D791-2/K1:19
Y6011/2
ATTACH,
menu 15
7.7.5 Control
valve attachment
Redundant voltage
unit, attachment left
jack pair (D791-3)
D791-3/K2:7
CAN/
POWER,
menu 18

Control units
Redundant voltage
unit, attachment left
jack pair (D791-3)
D791-3/K2:8
CAN/
POWER,
menu 18

Control units
Incorrect power supply to Control unit, attachment left jack

pair (D791-3). Voltage under 18 V or
over 32 V.
Left lifting
jacks not
working.
D791-3/K2:1
F52-2
F58-3/1
CAN/
POWER,
menu 18
11.5.1.4
Emergency
stop switch
voltage
VDRF03.02GB
Check the solenoid

valve.
Check the solenoid
valve.
Check the solenoid
valve.
Check the solenoid
valve.
Check fuse F58-3/1
needed.
Code
354
357
358
360
361
362
125
Description
Limitation
Action
Connections and
components
Diagnostic menu
Group
Incorrect emergency
(D791-3).
Functions
supplied with
emergency
stop switch
voltage lack
feed. Left lifting jacks not
working.
Check fuse F58-3/1

needed.
D791-3/K2:11
F52-2
F58-3/1
CAN/
POWER,
menu 18
11.5.1.4
Emergency
stop switch
voltage
The transistor has

Working lights left lifting jacks (E404-6L).
Working
lights left lifting jacks not
working.
Check bulb.
D791-3/K1:1
E404-6L/1
The transistor has

Solenoid valve, levelling lock(Y6034-1)
and Solenoid valve,
levelling lock(Y60342).
Levelling is
position not
working.

D791-3/K1:15
Y6034-1/1,
Y6034-2/1
ATTACH,
menu 18
7.8.6 Valve
The transistor has

Solenoid valve, operating position
(Y6053L).
Left lifting
jacks not
working.

D791-3/K1:42
Y6053L/1
COMBI,
menu 16
7.9.2.5
The transistor has

valve, levelling right
(Y6035).
Levelling not
working.
D791-3/K1:2
Y6035/1
ATTACH,
menu 19
7.8.3 Control
valve attachment
The transistor has

valve, levelling left
(Y6036).
Levelling not
working.
D791-3/K1:3
Y6036/1
ATTACH,
menu 20
7.8.3 Control
valve attachment


Check the solenoid

valve.
Check the solenoid

valve.
Check the solenoid
valve.
Check the solenoid
valve.
VDRF03.02GB
126
Code
363
364
365
366
367
368
Description
Limitation
Action
Connections and
components
Diagnostic menu
Group
The transistor has

Solenoid valve, front
knee in (Y6057L).
Left lifting
jacks not
working.

D791-3/K1:4
Y6057L/1
COMBI,
menu 11
7.9.2.3 Control valve, lifting jacks
The transistor has

knee out (Y6056L).
Left lifting
jacks not
working.
D791-3/K1:5
Y6056L/1
COMBI,
menu 10
The transistor has

Solenoid valve, rear
knee in (Y6059L).
Left lifting
jacks not
working.
D791-3/K1:30
Y6059L/1
COMBI,
menu 13
The transistor has

knee out (Y6058L).
Left lifting
jacks not
working.
D791-3/K1:31
Y6058L/1
COMBI,
menu 12
The transistor has

Solenoid valve, lowering front jack
(Y6013L).
Left lifting
jacks not
working.
D791-3/K1:32
Y6013L/1
COMBI,
menu 10
The transistor has

jack up (Y6060L).
Left lifting
jacks not
working.
D791-3/K1:33
Y6060L/1
COMBI,
menu 11
VDRF03.02GB
Check the solenoid

valve.
Check the solenoid
valve.
Check the solenoid
valve.
Check the solenoid
valve.
Check the solenoid
valve.
Check the solenoid
valve.
Code
369
370
371
372
373
374
127
Description
Limitation
Action
Connections and
components
Diagnostic menu
Group
The transistor has

Solenoid valve, lowering rear jack
(Y6014L).
Left lifting
jacks not
working.

D791-3/K1:7
Y6014L/1
COMBI,
menu 12
The transistor has

jack up (Y6061L).
Left lifting
jacks not
working.
D791-3/K1:9
Y6061L/1
COMBI,
menu 13
The transistor has

Indicator light
(H566R).
Indicator light
alignment lifting jack right
front not
working.
Check bulb.
D791-3/K1:10
H566R/1
COMBI,
menu 7
7.9.2 Lifting
jacks
The transistor has

Indicator light
(H567R).
Indicator light
alignment lifting jack right
rear not working.
Check bulb.
D791-3/K1:25
H567R/1
COMBI,
menu 7
7.9.2 Lifting
jacks
The transistor has

Indicator light
(H556L).
Indicator light
alignment lifting jack left
front not
working.
Check bulb.
D791-3/K1:29
H566L/1
COMBI,
menu 7
7.9.2 Lifting
jacks
The transistor has

Indicator light
(H556L).
Indicator light
alignment lifting jack left
rear not working.
Check bulb.
D791-3/K1:39
H567L/1
COMBI,
menu 7
7.9.2 Lifting
jacks
Check the solenoid

valve.
Check the solenoid
valve.




VDRF03.02GB
128
Code
375
376
377
Description
Limitation
Action
Connections and
components
Diagnostic menu
Group
The transistor has

Solenoid valve,
clamp (Y6054L).
Left lifting
jacks not
working.

D791-3/K1:11
Y6054L/1
COMBI,
menu 15
The transistor has

Solenoid valve,
clamp release
(Y6055L).
Left lifting
jacks not
working.
D791-3/K1:12
Y6055L/1
COMBI,
menu 15
The transistor has

voltage feed to position sensor, left jack
pair.
Left lifting
jacks not
working.
D791-3/K1:26
B7212L/A,
B7213L/A,
B7214L/A,
B7215L/A,
B7216L/A,
B7217L/A,
B7218L/A,
B7219L/A,
B7220L/A
COMBI,
menu 2, 3,
4, 5, 6
7.9.2.9 Sensor, operating position
Check the solenoid

valve.
Check the solenoid
valve.
Check the sensor.
7.9.2.10 Sensor, knee

7.9.2.13 Sensor, lifting
jacks
7.9.2.15 Sensor, alignment
7.9.2.16 Sensor, clamping position
387
388
Faulty signal from

Solenoid valve, levelling right (Y6035).
Return current does
Levelling not
working.
Faulty signal from

Solenoid valve, levelling left (Y6036). Return current does not
Levelling not
working.
VDRF03.02GB

D791-3/K1:16
Y6035/2
ATTACH,
menu 19
7.8.3 Control
valve attachment
D791-3/K1:17
Y6036/2
ATTACH,
menu 20
7.8.3 Control
valve attachment
Check the solenoid

valve.
Check the solenoid
valve.
Code
401
402
403
404
407
410
129
Description
Limitation
Action
Connections and
components
Diagnostic menu
Group
Redundant voltage
unit, attachment right
jack pair (D791-4)

D791-4/K2:7
CAN/
POWER,
menu 19

Control units
Redundant voltage
unit, attachment right
jack pair (D791-4)
D791-4/K2:8
CAN/
POWER,
menu 19

Control units
Incorrect power supply to Control unit, attachment right jack

pair (D791-4). Voltage under 18 V or
over 32 V.
Right lifting
jacks and
controllable
tilt not working.
Check fuse F58-3/1

needed.
D791-4/K2:1
F52-2
F58-3/1
CAN/
POWER,
menu 19
11.5.1.4
Emergency
stop switch
voltage
Incorrect emergency
(D791-4).
Control
switch cannot be disengaged. Right
lifting jacks
and controllable tilt not
working.
Check fuse F58-3/1

needed.
D791-4/K2:11
F52-2
F58-3/1
CAN/
POWER,
menu 19
11.5.1.4
Emergency
stop switch
voltage
The transistor has

Working lights left lifting jacks (E404-6R).
Working
lights left lifting jacks not
working.
Check bulb.
D791-4/K1:1
E404-6R
The transistor has

Solenoid valve, operating position
(Y6053R).
Right lifting
jacks not
working.

D791-4/K1:42
Y6053R/1
COMBI,
menu 16
7.9.2.5




Check the solenoid

valve.
VDRF03.02GB
130
Code
411
412
413
414
415
416
417
Description
Limitation
Action
Connections and
components
Diagnostic menu
Group
The transistor has

valve, tilt out (Y6010).
Controllable
tilt not working.

D791-4/K1:15
Y6010/1
ATTACH,
menu 16
7.7.5 Control
valve attachment
The transistor has

Controllable
tilt not working.
D791-4/K1:15
Y6011/1
ATTACH,
menu 17
7.7.5 Control
valve attachment
The transistor has

knee in (Y6057R).
Right lifting
jacks not
working.
D791-4/K1:4
Y6057R/1
COMBI,
menu 11
The transistor has

knee out (Y6056R).
Right lifting
jacks not
working.
D791-4/K1:5
Y6056R/1
COMBI,
menu 10
The transistor has

knee in (Y6059R).
Right lifting
jacks not
working.
D791-4/K1:30
Y6059R/1
COMBI,
menu 13
The transistor has

valve, rear knee out
(Y6058L).
Right lifting
jacks not
working.
D791-4/K1:31
Y6058R/1
COMBI,
menu 12
The transistor has

Solenoid valve, lowering front jack
(Y6013R).
Right lifting
jacks not
working.
D791-4/K1:32
Y6013R/1
COMBI,
menu 10
VDRF03.02GB
Check the solenoid

valve.
Check the solenoid
valve.
Check the solenoid
valve.
Check the solenoid
valve.
Check the solenoid
valve.
Check the solenoid
valve.
Check the solenoid
valve.
Code
418
419
420
421
422
423
131
Description
Limitation
Action
Connections and
components
Diagnostic menu
Group
The transistor has

jack up (Y6060R).
Right lifting
jacks not
working.

D791-4/K1:33
Y6060R/1
COMBI,
menu 11
The transistor has

Solenoid valve, lowering rear jack
(Y6014R).
Right lifting
jacks not
working.
D791-4/K1:7
Y6014R/1
COMBI,
menu 12
The transistor has

jack up (Y6061R).
Right lifting
jacks not
working.
D791-4/K1:9
Y6061R/1
COMBI,
menu 13
The transistor has

Indicator light (H580).
Indicator light
front jacks
raised not
working.
Check bulb.
D791-4/K1:10
H580/1
COMBI,
menu 9
7.9.2 Lifting
jacks
The transistor has

Indicator light
front jacks
lowered not
working.
Check bulb.
D791-4/K1:25
H581/1
COMBI,
menu 9
7.9.2 Lifting
jacks
The transistor has

Indicator light
clamping position lifting
jacks front not
working.
Check bulb.
D791-4/K1:29
H578/1
COMBI,
menu 8
7.9.2 Lifting
jacks
Check the solenoid

valve.
Check the solenoid
valve.
Check the solenoid
valve.



VDRF03.02GB
132
Description
Limitation
Action
Connections and
components
Diagnostic menu
Group
The transistor has

Indicator light
clamping position lifting
jacks rear not
working.
Check bulb.
D791-4/K1:39
H579/1
COMBI,
menu 8
7.9.2 Lifting
jacks
425
The transistor has

Solenoid valve,
clamp (Y6054R).
Right lifting
jacks not
working.
D791-4/K1:2
Y6054R
COMBI,
menu 15
426
The transistor has

Solenoid valve,
clamp release
(Y6055R).
Right lifting
jacks not
working.
D791-4/K1:3
Y6055R
COMBI,
menu 15
427
The transistor has

voltage feed to position sensor, right jack
pair.
Right lifting
jacks not
working.
D791-4/K1:26
B7212R/A,
B7213R/A,
B7214R/A,
B7215R/A,
B7216R/A,
B7217R/A,
B7218R/A,
B7219R/A,
B7220R/A
COMBI,
menu 2, 3,
4, 5, 6
7.9.2.9 Sensor, operating position
Code
424


Check the sensor.
7.9.2.10 Sensor, knee

7.9.2.13 Sensor, lifting
jacks
7.9.2.15 Sensor, alignment
7.9.2.16 Sensor, clamping position
437
Faulty signal from

out (Y6010). Return
current does not
VDRF03.02GB
Controllable
tilt not working.

Check the solenoid
valve.
D791-4/K1:16
Y6010/2
ATTACH,
menu 16
7.7.5 Control
valve attachment
133
Description
Limitation
Action
Connections and
components
Diagnostic menu
Group
Faulty signal from

control current.
Controllable
tilt not working.

D791-4/K1:17
Y6011/2
ATTACH,
menu 17
7.7.5 Control
valve attachment
451
Redundant voltage
feed left to KID control unit (D795) does

795/K1:7
CAN/
POWER,
menu 14

Control units
452
Redundant voltage
feed right to KID control unit (D795) does

795/K1:8
CAN/
POWER,
menu 14

Control units
460
No messages received on CAN-buffer

1.
Incorrect values in operating menus.

check CAN-bus
D795/K1:10,
K1:11, K1:12,
K1:13
CAN/
POWER,
menu 1, 2,
21
11.6.2 Redundant
CAN-bus
461
No messages received on CAN-buffer

2.
Error codes
from other
Control units
cannot be
shown.

check CAN-bus
D795/K1:5,
K1:6
CAN/
POWER,
menu 1, 2,
21
11.6.2 Redundant
CAN-bus
500
Time for service.
Check that servicing

has been performed. If
servicing has been performed following the
Cargotec service
schedule, reset the
service indicator; see
section 8 Control system, group 8.2.6 Service indicator.
8.2.6 Service
indicator
Code
438
Check the solenoid

valve.
VDRF03.02GB
134
VDRF03.02GB
E Schematics
E Schematics
Table of Contents E Schematics

mm mm mm mm mm mm
10
Common hydraulics....................................................................................... 3
Hydraulic diagrams, compilation ............................................................................ 3
Hydraulic diagram base machine (hydraulic oil pump alternative Rexroth) ........... 4
Hydraulic diagram base machine (hydraulic oil pump alternative Sauer-Danfoss) 6
Hydraulic diagram joystick control (hydraulic oil pump alternative Rexroth) .......... 8
Hydraulic diagram joystick control (hydraulic oil pump alternative
Sauer-Danfoss) .................................................................................................... 10
Hydraulic diagram top lift (hydraulic oil pump alternative Rexroth) ...................... 12
Hydraulic diagram top lift (hydraulic oil pump alternative Sauer-Danfoss) ........... 14
Hydraulic diagram top lift, tilt lock and controllable tilt (hydraulic oil pump
alternative Rexroth) .............................................................................................. 16
Hydraulic diagram top lift, tilt lock and controllable tilt (hydraulic oil pump
alternative Sauer-Danfoss) ................................................................................... 18
Hydraulic diagram top lift, tilt lock, controllable tilt and hydraulic levelling
(hydraulic oil pump alternative Rexroth) ............................................................... 20
Hydraulic diagram top lift, tilt lock, controllable tilt and hydraulic levelling
(hydraulic oil pump alternative Sauer-Danfoss) ................................................... 22
Hydraulic diagram combi yoke (part 1 of 3)
Hydraulic diagram combi yoke (part 2 of 3) ......................................................... 28
Hydraulic diagram combi yoke (part 3 of 3) ......................................................... 30
Hydraulic diagram sliding cab (hydraulic oil pump alternative Rexroth) ............... 32
Hydraulic diagram sliding cab (hydraulic oil pump alternative Sauer-Danfoss) ... 34
Hydraulic diagram cab lift and support jacks
Hydraulic diagram cab lift and support jacks
Hydraulic diagram sliding cab and support jacks
11
Common electrics ........................................................................................ 44

Circuit diagram, description ................................................................................. 44
Component designations ...................................................................................... 46
Circuit diagrams, compilation ............................................................................... 46
VDRF03.02GB
VDRF03.02GB
E Schematics
E Schematics 10 Common hydraulics
mm mm mm mm mm mm
Hydraulic diagrams, compilation
page
Designation
Drawing number
Hydraulic diagram base machine (hydraulic oil pump alternative Rexroth) page 4
A40740.0100
Hydraulic diagram base machine (hydraulic oil pump alternative Sauer-Danfoss) page 6
A40740.0400
Hydraulic diagram joystick control (hydraulic oil pump alternative Rexroth) page 8
A48056.0100
Hydraulic diagram joystick control (hydraulic oil pump alternative Sauer-Danfoss) page 10
Hydraulic diagram top lift (hydraulic oil pump alternative Rexroth) page 12
A40853.0100
Hydraulic diagram top lift (hydraulic oil pump alternative Sauer-Danfoss) page 14
Hydraulic diagram top lift, tilt lock and controllable tilt (hydraulic oil pump alternative Rexroth) page
16
A40853.0200
Hydraulic diagram top lift, tilt lock and controllable tilt (hydraulic oil pump alternative Sauer-Danfoss)
page 18
Hydraulic diagram top lift, tilt lock, controllable tilt and hydraulic levelling (hydraulic oil pump alternative Rexroth) page 20
A43123.0100
Hydraulic diagram top lift, tilt lock, controllable tilt and hydraulic levelling (hydraulic oil pump alternative Sauer-Danfoss) page 22
Hydraulic diagram combi yoke (part 1 of 3) (hydraulic oil pump alternative Rexroth) page 24
A41791.0100
Hydraulic diagram combi yoke (part 1 of 3) (hydraulic oil pump alternative Sauer-Danfoss) page 26
Hydraulic diagram combi yoke (part 2 of 3) page 28
A41791.0100
Hydraulic diagram combi yoke (part 3 of 3) page 30
A41791.0100
Hydraulic diagram sliding cab (hydraulic oil pump alternative Rexroth) page 32
A40855.0100
Hydraulic diagram sliding cab (hydraulic oil pump alternative Sauer-Danfoss) page 34
A54505.0100
Hydraulic diagram cab lift and support jacks (hydraulic oil pump alternative Rexroth) page 36
A43276.0100
Hydraulic diagram cab lift and support jacks (hydraulic oil pump alternative Sauer-Danfoss) page 38
Hydraulic diagram sliding cab and support jacks (hydraulic oil pump alternative Rexroth) page 40
A40854.0100
Hydraulic diagram sliding cab and support jacks (hydraulic oil pump alternative Sauer-Danfoss)
page 42
VDRF03.02GB
VDRF03.02GB
42
43
44
VA
S L1
X1
L2
B2
33 33
41
B1
40
38
36
B1
B1
A1
PS
L2
VA
B2
34
B2
32
VB
A2
L4
L3
X2
39
37
33
35
S L1
X1
L4
L3
33 X2
30
29
31 LS CF
PSS
47
VA
C-
33
C-
C+
LS
46 PP
45
C+
EF
28
VA
C+
PP
27
25
26
C-
24
L
P
LS
17
PT
22
23
ACC
16
20
21
18
13
15 14
19
10
9 10
11
12
11
page
010869 (A40740.0100 ver. 8)
4
Hydraulic diagram base machine

(hydraulic oil pump alternative
Rexroth)
1. Lift cylinder
25. Oil return from attachment
2. Valve block lift cylinder
26. Oil filter brake system
27. Oil filter
4. Valve block extension cylinder
28. Cooler hydraulic oil
5. Lift cylinder
29. Bypass valve, hydraulic oil cooler
30. Hydraulic oil fine-filter
7. Brake pressure accumulator
31. Priority valve
8. Brake valve
32. Pump cooling and filtration of hydraulic oil
9. Parking brake caliper
10. Brake cylinder
34. Pressure supply to attachment
11. Wheel brake
35. Hydraulic oil pumps 3 and 4
12. Drive axle block
36. Shuttle valve
13. NO (normally open) switch, disengagement
37. Oil pump brake system
14. NO (normally open) switch, brake lights
38. Valve block top lift hydraulics
15. NO (normally open) switch, parking brake
39. Shuttle valve
16. Accumulator charging valve
40. Attachment relief valve
17. NC (normally closed) switch, brake pressure
18. Cooler brake system
43. Valve block pump unloading
44. Pressure reducer
21. Oil tank brake system
46. Servo filter
23. Steering valve
47. Control valve lifting/lowering and extension
VDRF03.02GB
VDRF03.02GB
1
3
42
43
44
45
B1
33
33
41
48
LS
46 PP
VA
C+
S L2 L1
1
3
37
38
392
40
PSS
X1
C-
36
B1
35
33
B1
VA
PS
A1
VA
C+
X1
32
VB
B2
S L2 L1
34
C-
A2
29
48
31
C+
PP
28
VB
LS CF EF
30
47
27
25
26
C-
23
24
22
P
LS
17 ACC
16
20
21
18
13
15 14
19
10
9 10
11
12
11
page
012445 [A40470.0400 ver 01]
6
Hydraulic diagram base machine

Sauer-Danfoss)
1. Lift cylinder
25. Oil return from attachment
26. Oil filter brake system
27. Oil filter
4. Valve block extension cylinder
28. Cooler hydraulic oil
5. Lift cylinder
29. Bypass valve, hydraulic oil cooler
30. Hydraulic oil fine-filter
7. Brake pressure accumulator
31. Priority valve
8. Brake valve
32. Oil pump brake system
9. Parking brake caliper
10. Brake cylinder
34. Pressure supply to attachment
11. Wheel brake
12. Drive axle block
36. Shuttle valve
13. NO (normally open) switch, disengagement
37. Pump cooling and filtration of hydraulic oil
14. NO (normally open) switch, brake lights
15. NO (normally open) switch, parking brake
39. Shuttle valve
16. Accumulator charging valve
17. NC (normally closed) switch, brake pressure
18. Cooler brake system
43. Valve block pump unloading
44. Pressure reducer
21. Oil tank brake system
46. Servo filter
23. Steering valve
47. Control valve lifting/lowering and extension
48. High-pressure filter
VDRF03.02GB
VDRF03.02GB
010516 (A40856.0100 ver. 2)
B1
L1
X1
L2
B2
T1
L4
X2
L3
LS
PP
CF
EF
TP
LS
LS
Hydraulic diagram joystick control

Rexroth)
page
1.
Control valve option frame
2.
Steering cylinder
3.
Steering valve
4.
Priority valve
5.
Shuttle valve
6.
Shuttle valve joystick control
7.
Hydraulic oil pumps 3 and 4
VDRF03.02GB
10
013012
B1
L2
X1
L1
T1
LS
PP
CF
EF
TP
LS
LS
Hydraulic diagram joystick control

Sauer-Danfoss)
page
VDRF03.02GB
1.
2.
Steering cylinder
3.
Steering valve
4.
Priority valve
5.
Shuttle valve
6.
Shuttle valve joystick control
7.
Non-return valve
8.
Hydraulic oil pump 2
11
VDRF03.02GB
12
Hydraulic diagram top lift (hydraulic

oil pump alternative Rexroth)
T2B
T3B
P2B
A
L3
13
S L1
B1
14
VDRF03.02GB
010512 (A40853.0100 ver. 4)
L2
X1
C1-
PP
B2
C2+ C1+
L4
X2
C2-
12
10
11
T1
P1
LSPB
PS
TPB
page
1.
Tilt cylinder
2.
Damping block
3.
Rotation motor unit
4.
Valve block rotation motor
5.
Side shift cylinders
6.
Spreading motor
7.
Valve block spreading motor
8.
Twistlock cylinders
9.
13
10. Filter hydraulic oil

11. Filter hydraulic oil (high-pressure filter)
13. Shuttle valve
VDRF03.02GB
14
Hydraulic diagram top lift (hydraulic

oil pump alternative Sauer-Danfoss)
T2B
T3B
P2B
L1
12
L2
X1
1
2
13
16
B1
15
15
012496
C1-
PP
C2+ C1+
C2-
14
10
11
T1
P1
LSPB
PS
TPB
page
VDRF03.02GB
1.
Tilt cylinder
2.
Damping block
3.
Rotation motor unit
4.
5.
6.
Spreading motor
7.
8.
Twistlock cylinders
9.
15

13. Shuttle valve
VDRF03.02GB
16
T2B
P2B
TPB
L3
L4
B1
14
VDRF03.02GB
010514 (A40853.0200 ver. 5)
L2
S L1
X1
PP
B2
C2+
P
C1-
C1+ C2-
X2
13
12
11
10
T1
P1
LSPB
PS
T3B
Hydraulic diagram top lift, tilt lock

and controllable tilt (hydraulic oil
page
1.
Tilt cylinder
2.
Damping block
3.
Rotation motor unit
4.
5.
6.
Spreading motor
7.
8.
Twistlock cylinders
9.
17

13. Shuttle valve
VDRF03.02GB
18
T2B
P2B
TPB
L2 L1
12
X1
13 2
013010
16
B1
15
15
P
B
VDRF03.02GB
14
T
PP
C2+
P
C1-
C1+ C2-
11
10
T1
P1
LSPB
PS
T3B
Hydraulic diagram top lift, tilt lock

and controllable tilt (hydraulic oil
pump alternative Sauer-Danfoss)
page
1.
Tilt cylinder
2.
Damping block
3.
Rotation motor unit
4.
5.
6.
Spreading motor
7.
8.
Twistlock cylinders
9.
19

13. Shuttle valve
VDRF03.02GB
20
T2
TP
A
16
PP
C2+
VDRF03.02GB
010515 (A431213.0100 ver. 3)
13
L4 L3
B1
X1
L1 L2
B2
X2
11
10
12
T1
P1
C1-
C1+
C2-
14
15
14
PS
T3
Hydraulic diagram top lift, tilt lock,

controllable tilt and hydraulic
levelling (hydraulic oil pump
page
1.
Tilt cylinder
2.
Damping block
3.
Rotation motor unit
4.
5.
6.
Spreading motor
7.
8.
Twistlock cylinders
9.
21

11. Shuttle valve
12. Oil filter
14. Levelling cylinders
15. Valve block, levelling cylinders
16. Overcentre valve, levelling
VDRF03.02GB
22
T2
TP
B
A
11
PP
C2+
VDRF03.02GB
013011
18
B1
17
17
16
L2
X1
L1
14
15
13
T1
P1
C1-
C1+
C2-
12
10
PS
T3
Hydraulic diagram top lift, tilt lock,

controllable tilt and hydraulic
levelling (hydraulic oil pump
page
1.
Tilt cylinder
2.
Damping block
3.
Rotation motor unit
4.
5.
6.
Spreading motor
7.
8.
Twistlock cylinders
9.
Levelling cylinders
23

13. Oil filter
15. Shuttle valve
VDRF03.02GB
VDRF03.02GB
L1
X1
L2
B2
L4
L3
X2
010520 (A41791.0100 ver. 1 - part 1/3)
B1
15
T1
P1
010526:C
PP
C1-
2C1+
C2+
C2-
12
11
10
T3
T2
P2
TP
PS
010532:F
010532 :E
010532:D
page
1413
010526:B
010526:A
24
Hydraulic diagram combi yoke

(part 1 of 3) (hydraulic oil pump
1.
Tilt cylinder
2.
Damping block
3.
Rotation motor unit
4.
5.
6.
Spreading motor
7.
8.
Twistlock cylinders
9.
Levelling cylinders
25

14. Shuttle valve
VDRF03.02GB
26

(part 1 of 3) (hydraulic oil pump
T3
T2
010532:F
P2
TP
11
12
A
T
VDRF03.02GB
L1
13
013016
B1
16
15
15
L2
X1
14
010526:A
T1
P1
010526:B
010526:C
PP
C2+
P
C1-
2C1+
C2-
10
PS
010532:D
010532 :E
page
1.
Tilt cylinder
2.
Damping block
3.
Rotation motor unit
4.
5.
6.
Spreading motor
7.
8.
Twistlock cylinders
9.
Levelling cylinders
27

14. Shuttle valve
VDRF03.02GB
28

(part 2 of 3)
page
TP
P2
T2
Rexroth: 010520:A
Sauer-Danfoss: 013016:A
T3
2
3
5
B
P T
7
8
10
P1
Rexroth: 010520:B
Sauer-Danfoss: 013016B
VDRF03.02GB
Rexroth: 010520:C
Sauer-Danfoss: 013016:C
010526 (A41791.0100 ver. 2 - part 2/3)
1.
Control valve lifting jacks left
2.
Lowering cylinder front lifting jacks
3.
Valve block lowering front lifting jacks
4.
Valve block extension front lifting jacks
5.
Clamping cylinder front lifting jacks
6.
Valve block operating position front lifting jacks
7.
Clamping cylinder rear lifting jacks
8.
Valve block extension rear lifting jacks
9.
Valve block lowering rear lifting jacks
29
10. Lowering cylinder rear lifting jacks
VDRF03.02GB
30

(part 3 of 3)
page
Rexroth: 010520:D
Sauer-Danfoss: 013016:D
T3
T2
TP
P2
1
2
A
4
A
7
8
10
P1
T1
Rexroth: 010520:E
Sauer-Danfoss: 013016:E
VDRF03.02GB
Rexroth: 010520:F
Sauer-Danfoss: 013016:F
010532 (A41791.0100 ver. 1 - part 3/3)
1.
Control valve lifting jacks right
2.
Lowering cylinder front lifting jacks
3.
Valve block lowering front lifting jacks
4.
Valve block extension front lifting jacks
5.
Clamping cylinder front lifting jacks
6.
Valve block operating position front lifting jacks
7.
Clamping cylinder rear lifting jacks
8.
Valve block extension rear lifting jacks
9.
Valve block lowering rear lifting jacks
31
10. Lowering cylinder rear lifting jacks
VDRF03.02GB
32
Hydraulic diagram sliding cab

Rexroth)
VDRF03.02GB
010517 (A40855.0100 ver. 1)
B1
L1
X1
L2
B2
T1
L4
X2
L3
LS
TP
page
1.
2.
Hydraulic motor sliding cab
3.
Solenoid valve, engagement of hydraulic pressure
4.
Shuttle valve
5.
Shuttle valve option
6.
33
VDRF03.02GB
34

Sauer-Danfoss)
VDRF03.02GB
013013 (A54505.0100 ver. 1)
L2
L1
page
1.
2.
3.
4.
Shuttle valve
5.
6.
7.
Non-return valve
35
VDRF03.02GB
36
Hydraulic diagram cab lift and

support jacks (hydraulic oil pump
L3
VDRF03.02GB
11
010518 (A43276.0100 ver. 1)
B1
L1
X1
L2
B2
T1
L4
X2
LS
10
T3
TP
page
1.
2.
Accumulator
3.
Hydraulic cylinder support jacks
4.
Valve block support jacks
5.
Load control valve
6.
Hydraulic cylinder vertically adjustable cab
7.
Restriction
8.
9.
Shuttle valve
37

VDRF03.02GB
38
Hydraulic diagram cab lift and

013014
11
10
T1
L2
L1
LS
T3
TP
page
VDRF03.02GB
1.
2.
Accumulator
3.
4.
Valve block support jacks
5.
Load control valve
6.
Hydraulic cylinder vertically adjustable cab
7.
8.
Shuttle valve
9.
Shuttle valve option frame
39

VDRF03.02GB
40
Hydraulic diagram sliding cab and

VDRF03.02GB
010519 (A40854.0100 ver.1)
B1
X1
L1 L2
B2
T1
X2
L4 L3
LS
page
1.
2.
3.
Overcentre valve support jacks
4.
5.
Restriction
6.
7.
Shuttle valve
8.
9.
41
VDRF03.02GB
42
013015
T1
L2
L1
LS
Hydraulic diagram sliding cab and

page
VDRF03.02GB
1.
2.
3.
Overcentre valve support jacks
4.
5.
6.
Shuttle valve
7.
8.
Non-return valve
9.
43
VDRF03.02GB
44
E Schematics 11 Common electrics
11 Common electrics
mm mm mm mm mm mm
Circuit diagram, description
page
A circuit diagram is divided into circuit names (drawing numbers) and

consists of a set of numbered pages.
The circuits and their contents are governed by the following set of
rules:
20015.0001 electrical drawings-post designations K-standard.
K-standard 1: norms, rules
K-standard 2: cables, general physical
K-standard 5: Designation and marking system, item designations

circuit drawings
The following is an explanation of symbols and texts in a circuit diagram:
Connectors
-XM674m
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 connectors
number, e.g. XB72002Rm which is the connector for Sensor alignment front right (B7202R).
-XM674f
-X37-201
013017
Under the connectors 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 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.
+CHASSIS
-S220-2
P
1
DECLUCHING
3,0MPa
VDRF03.02GB
1
013018
S indicates the type of component, see Component designations

page 46.
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.
45
Cable labelling
A01012
0525
W212D
A01011
0524
W212C
A01010
0523
Cable numbering is interpreted as follows:
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.
W212B
0527
W212E
013019
A01016
All cables are either white (ground signal) or grey (other wiring) and labelled with numbers.
W212A
References
0
013020
/9.10_1.A2
00816
00816
Example: /11.5_1.D3 means page 11.5_1 coordinate D3.
Connection to control unit
-X411
21
K1:21
Analog In 0-5V
/0.0_4.D5
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 units connections. Together
with this there are descriptive texts that specify control unit and signal.
+BOOM
-D791-1
MEASUREPOINT SCALE
013021
/4.0_1.B1
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.
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.
VDRF03.02GB
46
Component designations
page
The components in circuit diagrams have a prefix and number, the

prefix describes the type of component, the number which component.
Component list with component number, prefix and designation is provided as an appendix after the circuit diagrams.
Prefix
Description
Converter from non-electric to electric signals or vice versa. Example: inductive sensor.
Binary element, delay unit, memory. Example: control unit.
White light. Example: work lighting.
Protective device. Example: fuse.
Alternator, power supply device. Example: battery.
Signal device. Example: horn, brake lights.
Relay, contactor. Example: power relay ignition key lock.
Motor. Example: electric motor.
Measuring instrument, testing equipment. Example: operating hour gauge.
Resistor. Example: potentiometer.
Electric switch for control circuit, selector. Example: switch.
Outlet/socket, connecting device Example: connection terminal.
Electrically controlled mechanical device: Example: solenoid valve, hydraulic valve.
Circuit diagrams, compilation
page
Circuit diagrams are attached as an appendix in the following order.
Sheet
Designation
0.0-1
Circuit Cross references
0.0-2
Circuit Cross references
0.0-3
Circuit Cross references Opt
0.0-4
Circuit Cross references Att
0.0-5
Circuit Cross references Att
0.0-6
Circuit Cross references Att Combi
1.0-1
Circuit Engine 1240&1250
1.0-2
Circuit Engine Cummins
1.0-3
Circuit Engine Cummins
1.1-1
Circuit drivetrain
2.0-1
Circuit Dana TE 32000
2.0-2
VDRF03.02GB
Sheet
Designation
2.0-3
2.0-1A1
Circuit Dana TE 32000FF
2.0-2A2
2.0-3A3
2.1-1
Circuit drivetrain
4.0-1
Circuit Brake system
4.0-2
Circuit Brake system
5.2-1
Circuit Steering lever/mini-wheel
5.2-2
Circuit Steering lever/mini-wheel
5.2-3
Circuit Steering lever/mini-wheel and Combi att
5.2-4
Circuit Steering lever/mini-wheel and Combi att
7.1-1
Circuit Joystick
7.2-1
Circuit Boom Up/Down
7.3-1
Circuit Boom In/Out
7.5-1
Circuit Spreading Valves
7.5-2
Circuit Spreading Auto
7.5-3
Circuit Spreading Sensor
7.6-1
Circuit Rotation
7.7-1
Circuit Tilt locking
7.7-2
Circuit Tilt + Levelling
7.7-3
Circuit Tilt + Levelling
7.9-1
Circuit Twistlocks
7.9-2
Circuit Twistlocks
7.9-3
Circuit Combi Att
7.9-4
Circuit Combi Att
7.9-5
Circuit Combi Att
7.9-6
Circuit Combi Att
7.9-7
Circuit Combi Att
7.9-8
Circuit Combi Att
7.9-9
Circuit Combi Att
7.9-10
Circuit Combi Att
7.9-11
Circuit Combi Att
7.9-12
Circuit Combi Att
7.9-13
Circuit Combi Att
47
VDRF03.02GB
48
Sheet
Designation
7.9-14
Circuit Combi Att
7.9-15
Circuit Over Height
7.9-16
Circuit Over Height
7.9-17
Circuit Combi Att
7.10-1
Circuit Hyd Support jacks
7.10-2
Circuit Hyd Support jacks
7.10-3
Circuit Printer
8.2-1
Circuit OP + Scale
8.2-2
Circuit OP + Scale
8.2-3
Circuit Bypassing
8.2-4
Circuit RMI
9.1-1
Circuit Extra Sensor Instr.
9.1-2
Circuit Extra Equipment
9.1-3
9.1-4
Circuit Sensor Instr.
9.1-5
Circuit Option Cab
9.1-6
Circuit Extra Equipment Boom nose
9.1-7
9.3-1
Circuit Cab Drivers Seat
9.3-2
Circuit Cab Drivers Seat
9.4-1
Circuit Climate system
9.4-2
Circuit Climate system
9.5-1
Circuit Wipers
9.6-1
Circuit Work lighting
9.6-2
Circuit Extra Work Light Att
9.6-3
Circuit Extra Work Light Boom
9.6-5
Circuit Lighting
9.6-6
Circuit Lighting
9.6-7
Circuit Lighting
9.6-8
Circuit Lighting
9.6-9
Circuit Entry lighting
9.6-10
Circuit Extra Work Light Frame
9.7-1
Circuit Alarm Audible signals
9.7-2
Circuit Alarm Audible signals
VDRF03.02GB
Sheet
Designation
9.7-3
Circuit Indicators, Hazard flashers
9.7-4
Circuit Back-up alarm
9.8-1
Circuit Radio
9.9-9
Circuit Camera
9.10-1
Circuit Sliding/Vertically adjustable cab
9.10-2
Circuit Tiltable cab
9.14
Circuit Central lubrication
10.0-1
Circuit Hydraulics
11.5-1
Circuit Current
11.5-2
Circuit Current
11.5-3
Circuit Current
11.5-4
Circuit Current
11.5-5
Circuit Current Att
11.5-6
Circuit Current KDU OPT
11.5-7
Circuit 24 V
11.5-8
Circuit 12V + Comm. Radio
11.5-9
Circuit Current Att
11.6-3
Circuit CAN BUS opt. Frame KDU
11.6-4
Circuit CAN BUS Att
11.6-5
Circuit CAN BUS Att
11.6-6
Circuit CAN BUS Att
49
Electrically operated mirrors

1
Circuit diagram Mirrors
Cab tilt
1
Circuit diagram Cab tilt
VDRF03.02GB
50
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E Schema - Koponentfrteckning / 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 terladdning (EC)
Logik interface 2 drivmotorer
Logik interface gaspdrag
Logik interface bromsregl
Logik interface styrsystem
Servofrstrkare styrsystem
Logik allm (option)
Aggregat klimatanlggning
Kondensor AC, flkt
Vxellda
Radio/bandspelare
Kommunikationsradio
Monitor
Kamera
Skrivare
Dataterminal
Alkols
Logik batterivakt
Logik transistortndning
Logik vervarvningsskydd (LPG)
Logik rev-sprr/aut-vxl
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
961
6850
7790
7800
7810
7820
7830
7840
7850
7860
7990
8100
9002
9050
9070
9080
9090
9110
9400
9500
9550
9600
Motor/kupevrmare
Reglerenhet termostat AC
Reglersystem terladdning (EC)
Reglersystem drivmotor (EC)
Reglersystem pumpmotor (EC)
Logik interface 2 drivmotorer
Logik interface gaspdrag
Logik interface bromsregl
Logik interface styrsystem
Servofrstrkare styrsystem
Logik allm (option)
Kondensor AC flkt
Radio/bandspelare
Kommunikationsradio
Monitor
Kamera
Skrivare
Dataterminal
Logik batterivakt
Logik transistortndning
Logik vervarvningsskydd (LPG)
Logik rev-sprr/aut-vxl
A
A
A
A
B
B
B
B
B
9610
9620
9888
9932
649
690
697
751
752
Logik Motor/kupevrmare
Logik slitageind kol elmotor
test
Kretskort elcentral
Termostat klimatannlggning
Fartreglage (EC)
Elbroms
Givare varvtal turbin
Givare varvtal inre vxellda
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
Control unit termostat AC
Control system recharging (EC)
Control system main motor (EC)
Control system pump motor (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)
Condensor AC fan
Radio/tape recorder
Communication radio
Monitor
Camera
Printer
Dataterminal
Logic switch battery watch
Logic transistor ignition
Logic overspeed protection (LPG)
Logic unit reversing interlock/automatic gear
changing
Logic engine- and cab heater
Logic indication of wear brush electrical motor
Printed circuit board Junction box
Thermostat, air condition
Speed control (EC)
Electric brake
Transmitter, speed turbin
Transmitter, speed internal gear chain
Verkstadsmanual / Workshop manual DRF 400450
VDRF03.02SE/GB
NUMBER
B 753
B 754
B 755
B 756
B 757
B 758
B 759
B 760
SVENSKA
Varvtalsgivare motor
Givare lufttryck
Givare hydraulfilter indikering
Temperatur kylvtska motor
Brnslenivgivare
Varvtalsgivare v-lda
Nivindikator kylvtska
Givare rev-sprr/aut-vxl trans
B 761
Givare rev-sprr/aut-vxl motor
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
Givare temp,spolkrets bromsar

Givare niv hydraulolja
Givare servotryck vxellda
Givare oljetryck v-lda
Givare oljetemp. v-lda
Givare oljetryck motor
Givare oljetryck hydraulik
Givare ndlge
Givare rattutslag
Givare vinkel
Givare temp bromsolja
Givare nrvaro
Givare utomhustemp
Givare temp klimatanlggning
Givare temp hydraulolja
Givare lge
Givare drivbrytning
Givare allmn
Hgtalare
Termostat klimatannlggning
Fartreglage
Elbroms
Givare axeltryck
Givare, mtlge vg
Givare, rotationsstopp
Givare, tryck lyftcylinder
Givare, tryck klmma
Givare lyfthjd analog
Givare tiltvinkel analog
Givare ultraljud last position
Givare, Over Height, Ben uppe
Givare,IR Last position
Givare lambda sond
Givare vatten i brnsle
Givare temp avgaser
Givare kraft
Givare tryck avgaser
Givare varvtal turbin
Givare varvtal inre vxellda
Givare varvtal motor
Givare lufttryck
Givare hydraulfilter indikering
Givare temperatur kylvtska motor
Givare brnsleniv
Givare kardanaxel varvtal
762
763
764
765
766
767
768
769
770
771
772
773
774
775
776
777
778
789
902
6490
6900
6970
7200
7224
7225
7226
7227
7228
7229
7230
7231
7232
7233
7234
7235
7235
7236
7510
7520
7530
7540
7550
7560
7570
7580
ENGLISH
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
Transmitter, presence
Transmitter, ambient temperature
Transmitter, temperature air condition
Transmitter, hydraulic temperature
Transmitter, position
Transmitter, drive break
Transmitter, common
Loud speaker
Thermostat air condition
Speed control
Electric brake
Sensor axle pressure
Sensor, measurepoint scale
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 force
Sensor exhaust pressure
Transmitter speed turbin
Transmitter speed internal gear chain
Transmitter engine speed
Transmitter air pressure
Transmitter hydraulics filter indication
Transmitter engine coolant temperature
Transmitter fuel level
Transmitter drive shaft speed
VDRF03.02SE/GB
NUMBER SVENSKA
B 7590 Givare nivindikator kylvtska
B 7600 Givare rev-sprr/aut-vxl trans
B 7610
Givare rev-sprr/aut-vxl motor
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
C
C
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
E
E
E
Givare temp,spolkrets bromsar

Givare niv hydraulolja
Givare servotryck vxellda
Givare oljetryck v-lda
Givare oljetemp. v-lda
Givare oljetryck motor
Givare oljetryck hydraulik
Givare ndlge
Givare rattutslag
Givare vinkel
Givare temp bromsolja
Givare nrvaro
Givare temp omgivning
Givare temp klimatanlggning
Givare temp hydraulolja
Givare lge
Givare varvtal flkt
Givare allmn
Hgtalare
KONDENSATOR
Kondensator
FleetManager kontrollenhet
FleetManager kortlsare
FleetManager accelerations givare
Galvaniskt isolerad CAN brygga
Reglersystem drivmotor
Reglersystem pumpmotor
Elektronisk kontrollenhet ECU, hytt
Elektronisk kontrollenhet aggregat
Elektronisk kontrollenhet styrning
Elektronisk kontrollenhet vxellda
Elektronisk kontrollenhet motor
Elektronisk kontrollenhet, lasthantering
Elektronisk kontrollenhet, ram
Elektronisk kontrollenhet, stolvndning
Elektronisk kontrollenhet, proportionalventil
Kortlsare
Accelerations givare
Elektronisk Kontrollenhet ECU
Elektronisk Kontrollenhet aggregat
Elektronisk Kontrollenhet styrning
Elektronisk Kontrollenhet vxellda
Elektronisk Kontrollenhet motor
Elektronisk kontrollenhet Display
Elektronisk Kontrollenhet lasthantering
Elektronisk Kontrollenhet ram
Elektronisk Kontrollenhet stolvndning
Fjrrkontroll
G-lampa v fram
G-lampa h fram
G-lampa v bak
7620
7630
7640
7650
7660
7670
7680
7690
7700
7710
7720
7730
7740
7750
7760
7770
7780
7890
9020
821
8210
740
742
743
744
780
781
790
791
792
793
794
796
797
798
2000
7420
7430
7900
7910
7920
7930
7940
7950
7960
7970
7980
9001
400
400
401
ENGLISH
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
Transmitter presence
Transmitter ambient temperature
Transmitter temperature air condition
Transmitter hydraulic temperature
Transmitter position
Transmitter fan speed
Transmitter common
Loud speaker
CAPACITOR
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
Card device
Acceleration sensor
Electronic Control Unit, ECU
Electronic Control Unit attachment
Electronic Control Unit steering system
Electronic Control Unit gearbox
Electronic Control Unit engine
Electronic Control Unit Display
Electronic Control Unit Loadhandling
Electronic Control Unit frame
Electronic Control Unit seat rotation
Remote Control
Light bulb, roading light left hand front
Light bulb, roading light right hand rear
Light bulb, roading light left hand front
VDRF03.02SE/GB
NUMBER
E 401
E 402
E 403
E 404
E 405
E 406
E 406
E 408
E 408
E 429
E 431
E 432
E 433
E 434
E 435
E 436
E 437
E 438
E 439
E 440
E 456
E 456
E 458
E 458
E 459
E 459
E 460
E 460
E 461
E 461
E 462
E 462
E 464
E 464
E 669
E 802
E 803
E 804
E 805
E 808
E 835
E 888
E 962
E 4000
E 4020
E 4040
E 4050
E 4080
E 4290
E 4310
E 4320
E 4330
E 4340
E 4350
E 4360
E 4370
SVENSKA
G-lampa h bak
G-lampa fjrrljus
G-lampa lastljus
G-lampa arbetsljus
G-lampa backljus
G-lampa cont belysning vnster
G-lampa cont belysning hger
G-lampa park ljus v fram
G-lampa park ljus h fram
G-lampa cigarettndare belysning
G-lampa instrument belysning
G-lampa handsfack belysning
G-lampa instegs belysning
G-lampa innerbelysning
G-lampa lsbelysning
G-lampa identifikationsljus
G-lampa identifikationsljus/takskylt
G-lampa motorrumsbelysning
Nummerskyltsbelysning
G-lampa vrmereglage belysning
G-lampa backljus blackout IR vnster
G-lampa backljus blackout IR hger
G-lampa fram blackout vnster
G-lampa fram blackout hger
G-lampa fram blackout IR vnster
G-lampa fram blackout IR hger
G-lampa arb.belysning hytt blackout IR v
G-lampa arb.belysning hytt blackout IR h
G-lampa arb.bel. bom 20' blackout IR v
G-lampa arb.bel. bom 20' blackout IR h
G-lampa arb.bel. bom 40' blackout IR v
G-lampa arb.bel. bom 40' blackout IR h
G-lampa cont belysning IR vnster
G-lampa cont belysning IR hger
Vrmare kupe/ motor diesel
Eluppvrmd backspegel
Eluppvrmd stol
Cigarettndare
Elvrme hytt
Eluppvrmd lufttorkare
Tndstift
Lufttork, kompressor
Logik slitageind kol elmotor
Gldlampa halvljus
Gldlampa helljus
Gldlampa arbetsljus
Gldlampa backljus
Gldlampa park ljus fram
Gldlampa cigarettndare belysning
Gldlampa instrument belysning
Gldlampa handsfack belysning
Gldlampa instegs belysning
Gldlampa innerbelysning
Gldlampa lsbelysning
Gldlampa identifikationsljus
Gldlampa skljus
ENGLISH
Light bulb, roading light right hand rear
Light bulb, distance light
Light bulb, mast light
Light bulb, working light
Light bulb, rear light
Container light left-hand
Container light right-hand
Light bulb, parking light, left-hand forward
Light bulb, parking light, right-hand forward
Light bulb, cigarett lighter illumination
Light bulb, instrument illumination
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 left-hand
Light bulb, roading light blackout IR right-hand
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
Light bulb dipped light
Light bulb Headlight
Light bulb working light
Light bulb rear light
Light bulb parking light forward
Light bulb cigarett lighter illumination
Light bulb instrument illumination
Light bulb glove pocket light
Light bulb step-in lighting
Light bulb interior lighting
Light bulb reading lighting
Light bulb identification light
Light bulb search light
VDRF03.02SE/GB
NUMBER
E 4380
E 4390
E 6690
E 8000
E 8020
E 8030
E 8040
E 8050
E 8091
E 8092
E 8350
E 8881
F 51
F 52
F 56
F 58
F 59
F 62
F 64
F 9951
F 9952
F 9954
F 9956
F 9958
F 9959
G 30
G 658
G 659
G 660
G 662
G 6600
G 6620
G 9930
H 410
H 410
H 411
H 411
H 412
H 412
H 413
H 413
H 416
H 416
H 417
SVENSKA
Gldlampa motorrumsbelysning
Nummerskyltsbelysning
Vrmare kupe/ motor diesel
Frvrmare motor
Eluppvrmd backspegel
Eluppvrmd stol
Cigarettndare
Elvrme hytt
Eluppvrmd lufttorkare
Eluppvrmd ruta
Tndstift
Elektrisk vrme ruta
Skringshllare 1-polig
Batterihandske 2-polig
Batterihandske 4-polig
Skringshllare
Batteri
Generator (extra)
Generator utan laddregulator
Generator med laddregulator
Laddregulator
Generator
Laddregulator
Batteri
G-lampa broms ljus v fram
G-lampa broms ljus h fram
G-lampa broms ljus v bak
G-lampa broms ljus h bak
G-lampa bak ljus v bak
G-lampa bak ljus h bak
G-lampa bak ljus v fram (VBFS)
G-lampa bak ljus h fram (VBFS)
G-lampa sidomarkering v fram
G-lampa sidomarkering v bak
G-lampa sidomarkering h fram
ENGLISH
Light bulb engine compartment light
Light license plate
Heater compartment/engine diesel
Start element
Electrical heated observation mirror
Electrical heated seat
Cigarett lighter
Electrical heating cab
Electrical heater air dryer
Electrical heated window
Ignition plug
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
Fuse holder 1-pole
Fuse holder 2-pole
Fuse holder 4-pole
Fuse holder 6-pole
Fuse holder 8-pole
Fuse holder
Battery
Alternator extra
Alternator without loading regulator
Alternator with loading regulator
Loading regulator
Alternator with loading regulator
Loading regulator
Battery
Light bulb, brake light, left-hand forward
Light bulb, brake light, right-hand forward
Light bulb, brake light, left-hand rear
Light bulb, brake light, right-hand rear
Light bulb, rear light, left-hand rear
Light bulb, rear light right-hand rear
Light bulb, rear light, left-hand forward (VBFS)
Light bulb, rear light,right-hand forward (VBFS)
Light bulb, side position light, left-hand forward
Light bulb, side position light, left-hand rear
Light bulb, side position light, right -hand forward
H
H
H
H
H
H
H
H
H
H
H
G-lampa sidomarkering h bak

G-lampa positionsljus vnster
G-lampa positionsljus hger
G-lampa krvisare v fram
G-lampa krvisare h fram
G-lampa krvisare v bak
G-lampa krvisare h bak
G-lampa roterande varningsljus
G-lampa krvisare v (extra)
G-lampa krvisare h (extra)
G-lampa dimbakljus vnster
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
417
420
421
422
423
426
427
428
445
446
451
VDRF03.02SE/GB
NUMBER
H 452
H 453
H 453
H 454
H 454
H 457
H 457
H 463
H 463
H 465
H 466
H 467
H 468
H 500
H 501
H 503
H 504
H 505
H 506
H 507
H 508
H 509
H 510
H 512
H 514
H 519
H 524
H 525
H 528
H 530
H 531
H 532
H 533
H 547
H 549
H 550
H 551
H 552
H 554
H 555
H 556
H 560
H 561
H 562
H 563
H 564
H 565
H 569
H 569
H 570
H 571
H 572
H 573
H 574
H 575
SVENSKA
G-lampa dimbakljus hger
G-lampa bromsljus/krvisare vnster
G-lampa bromsljus/krvisare hger
G-lampa bromsljus blackout vnster
G-lampa bromsljus blackout hger
G-lampa positionsljus blackout vnster
G-lampa positionsljus blackout hger
G-lampa bak ljus vnster bak, blackout
G-lampa bak ljus hger bak, blackout
G-lampa rd saxagregat ute
G-lampa orange vertikalhlning p
G-lampa grn klmtryck OK
G-Lampa Rd Maxlast
Kont lampa krvisare
Kont lampa krvisare (extra)
Varn lampa oljetryck motor
Kont lampa helljus
Varn lampa laddning
Varn lampa laddning (extra)
Varn lampa frdbroms
Varn lampa parkerings broms
Varn lampa niv kylvatten
Kont lampa diff sprr
Varn lampa temp momentfrst
Kont lampa vervxel
Kont lampa halvljus
Kont lampa luftfilter
Kont lampa UNIKAT
Kont lampa frvrmning
Kont lampa framhjuls styrning
Kont lampa 4-hjuls styrning
Kont lampa crab styrning
Kont lampa hyd.pump
Varn lampa centralvarning
Varn lampa oljetryck v-lda
Varn lampa hyttlsning
Varn lampa temp v-lda
Varn lampa bromstryck
Varn lampa temp spolkrets bromsar
Varn lampa temp kylvatten mot
Varn lampa lsning vndskiva
Varn lampa temp drivmotor el
Varn lampa temp pumpmotor el
Varn lampa ppen twistlock
Varn lampa lst twistlock
Varn lampa anliggning
Varn lampa temp motor el
Kont lampa elvrme
Kont lampa elvrme
Varn lampa verkoppling skerhetssystem
Kont lampa brnsleniv
Varningslampa lyfthjd
Kontroll lampa motor information
Kontroll lampa stdben nere
Kontroll lampa stdben ur arb.lge
ENGLISH
Light bulb, fog light rear right
Light bulb, brake light/dir. indicator left-hand
Light bulb, brake light/dir. indicator right-hand
Light bulb, brake light blackout left-hand
Light bulb, brake light blackout right-hand
Light bulb, position light blackout left-hand
Light bulb, position light blackout right-hand
Light bulb, rear light left-hand rear, blackout
Light bulb, rear light right-hand rear, blackout
Light-bulb, red extender exended
Light bulb, orange vertical hold on
Light bulb, green clamp pressure OK
Light bulb,Red Overload
Indicating lamp, direction indicator
Indicating lamp, direction indicator extra
Warning lamp, oil pressure engine
Indicating lamp, main beam
Warning lamp, loading
Warning lamp, loading extra
Warning lamp, brake
Warning lamp, parking brake
Warning lamp, coolant level
Indicating lamp, diff. interlock
Warning lamp, temperature converter
Indicating lamp, overdrive clutch
Indicating lamp, dipped lights
Indicating lamp, air filter
Indicating lamp, UNIKAT
Indicating lamp, preheating
Indicating lamp, forward wheel steering
Indicating lamp, 4-wheel steering
Indicating lamp, crab steering
Indicating lamp, emergency hyd. pump
Warning lamp, central warning
Warning lamp, oil pressure gear box
Warning lamp, cab lock
Warning lamp, temperature gear box
Warning lamp, brake pressure
Warning lamp, temp. cooling system brakes
Warning lamp, temperature coolant engine
Warning lamp, interlocking of turntable
Warning lamp, temperature, drive motor
Warning lamp, temperature, pump motor
Warning lamp, unlocked twist lock
Warning lamp, locked twist lock
Warning lamp, alignement
Warning lamp ,temperature motor
Indicating lamp, electric heater
Indicating lamp, electric heater
Warning lamp, by-pass safety system
Indicating lamp, fuel level
Warning lamp lifting height
Indicator lamp engine information
Indicator lamp support jacks down
Indicator lamp support jacks out of working pos
VDRF03.02SE/GB
NUMBER
H 576
H 577
H 578
H 579
H 580
H 581
H 582
H 583
H 584
H 599
H 850
H 853
H 965
H 4110
H 4120
H 4130
H 4160
H 4200
H 4220
H 4280
H 4510
H 4650
H 4660
H 4670
H 4680
H 5000
H 5001
H 5002
H 5030
H 5040
H 5050
H 5070
H 5080
H 5090
H 5100
H 5120
H 5140
H 5190
H 5240
H 5250
H 5280
H 5300
H 5310
H 5320
H 5330
H 5470
H 5490
H 5500
H 5510
H 5520
H 5540
H 5550
H 5560
H 5600
H 5610
H 5620
SVENSKA
Kontroll lampa anliggning frmre ben
Kontroll lampa anliggning bakre ben
Kontroll lampa klmlge frmre ben
Kontroll lampa klmlge bakre ben
Kontroll lampa frmre ben uppe
Kontroll lampa frmre ben nere
Varningslampa verlast
Kontroll lampa anliggning ett ben
Kontroll lampa anliggning alla ben
Kont lampa option
Signalhorn
Summer
Backvarnare
Gldlampa broms ljus
Gldlampa bakljus
Gldlampa bakljus fram (VBFS)
Gldlampa sidomarkering
Gldlampa positionsljus
Gldlampa krriktningsvisare
Gldlampa roterande varningsljus
Gldlampa dimljus
Gldlampa saxaggregat
Gldlampa vertikalhllning
Gldlampa klmtryck
Gldlampa Maxlast
Kontrollampa tryck lyfttng
Varningslampa Over Height ben uppe
Kontrollampa kriktningsvisare
Varningslampa oljetryck motor
Kontrollampa helljus
Varningslampa laddning
Varningslampa frdbroms
Varningslampa parkerings broms
Varningslampa niv kylvtska
Kontrollampa diff sprr
Varningslampa temp momentfrst
Kontrollampa vervxel
Kontrollampa halvljus
Kontrollampa luftfilter
Kontrollampa avgasfilter
Kontrollampa frvrmning
Kontrollampa framhjuls styrning
Kontrollampa 4-hjuls styrning
Kontrollampa crab styrning
Kontrollampa hyd.pump
Varningslampa central varning
Varningslampa oljetryck v-lda
Varningslampa hyttlsning
Varningslampa temp v-lda
Varningslampa bromstryck
Varningslampa temp spolkrets bromsar
Varningslampa temp kylvatten motor
Varningslampa lsning vndskiva
Varningslampa temp drivmotor el
Varningslampa temp pumpmotor el
Varningslampa ppen twistlock
ENGLISH
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
Horn
Buzzer
Reversing alarm
Light bulb brake light
Light bulb rear light
Light bulb rear light forward (turnable seat)
Light bulb side position light
Light bulb position light
Light bulb direction indicator
Light bulb flashing beacon lamp
Light bulb fog light
Light-bulb extender
Light bulb vertical hold
Light bulb clamp pressure
Light bulb Overload
Indicating lamp pressure lift tong
Warn. Lamp Over Height leg upper pos
Indicating lamp direction indicator
Warning lamp oil pressure engine
Indicating lamp main beam
Warning lamp charging
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 exhaust filter
Indicating lamp preheating
Indicating lamp forward wheel steering
Indicating lamp 4-wheel steering
Indicating lamp crab steering
Indicating lamp emergency hyd. pump
Warning lamp central warning
Warning lamp oil pressure gear box
Warning lamp cab lock
Warning lamp temperature gear box
Warning lamp brake pressure
Warning lamp temp. cooling system brakes
Warning lamp temperature coolant engine
Warning lamp interlocking of turntable
Warning lamp temperature drive motor
Warning lamp temperature pump motor
Warning lamp unlocked twist lock
VDRF03.02SE/GB
NUMBER
H 5630
H 5640
H 5650
H 5690
H 5700
H 5710
H 5720
H 5730
H 5740
H 5750
SVENSKA
Varningslampa lst twistlock
Varningslampa anliggning
Varningslampa temp motor el
Kontrollampa elvrme
Varningslampa frbikoppling skerhetssystem
Kontrollampa brnsleniv
Varningsingslampa lyfthjd
Kontrollampa motor information
kontrollampa stdben nere
Kontrollampa stdben ur arb.lge
ENGLISH
Warning lamp locked twist lock
Warning lamp alignement
Warning lamp ,temperature motor
Indicating lamp electric heater
Warning lamp by-pass safety system
Indicating lamp fuel level
Warning lamp lifting height
Indicator lamp engine information
Indicator lamp support jacks down
Indicator lamp support jacks out of working pos
H
H
H
H
H
H
H
H
H
H
H
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
K
Kontrollampa anliggning ben

Kontrollampa klmlge ben
Kontrollampa ben uppe
Varningsingslampa verlast
Kontrollampa option
Kontrollampa skerhetsblte
Kontrollampa ministyrning
Signalhorn
Summer
Varningssignal aut. rrelse
Backalarm
Rel hel/halvljus
Rel dimljus
Rel fjrrljus
Rel lastljus
Rel arbetsljus
Rel backljus
Rel helljus
Rel halvljus
Rel bromsljus
Rel parkeringsbroms
Rel krvisare v
Rel krvisare h
Rel startelement
Rel vndbar frarstol
Rel parkeringsbroms
Rel tndningsls
Rel torkare
Rel strlkastartorkare
Rel AT-regulator
Rel varningsblinkers
Rel elektrisk stopp
Rel intervalltorkare
Rel kylvtskeniv
Rel blinkers
Rel rangesprr
Rel blinkande bromsljus (back)
Rel blinkande bromsljus (runt)
Rel vxel neutral
Rel vxelskifte
Rel vxel hg/lg
Rel startsprr
Rel drivning fram
Rel drivning bak
Tidrel frvrmning
Indicator lamp alignment leg

Indicator lamp clamp position leg
Indicator lamp legs upper position
Warning lamp overload
Indicating lamp option
Indicating lamp fasten seat belt
Indicating lamp micro steering
Horn
Buzzer
Warning alarm aut. movement
Reversing alarm
Relay, main/dipped beam
Relay, fog light
Relay, distance light
Relay, mast light
Relay, working light
Relay, reversing light
Relay, main beam
Relay, dipped beam
Relay, brake light
Relay, parking light
Relay, direction indicator left
Relay, direction indicator right
Relay,element preheater
Relay, rotating drivers seat (VBFS)
Relay, parking brake
Relay, ignition key
Relay, wiper
Relay, roading lights wiper
Relay, AT-regulator
Relay, hazard blinkers
Relay, electical stop
Relay, intermittent wiper
Relay, coolant level
Relay, blinkers
Relay, range interlock
Relay, flashing brake lights (reversing)
Relay, flashing hazard brake lights
Relay, gear neutral
Relay, gear shift
Relay, high/low gear
Relay, start interlock
Relay, forward driving
Relay, reversing driving
Time relay, automatically preheating
5760
5780
5800
5820
5990
5991
5992
8500
8530
9003
9650
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
VDRF03.02SE/GB
NUMBER
K 334
K 335
K 336
K 337
K 338
K 339
K 340
K 341
K 342
K 343
K 344
K 345
K 346
K 347
K 348
K 349
K 350
K 351
K 352
K 353
K 354
K 355
K 356
K 357
K 358
K 359
K 360
K 361
K 362
K 363
K 364
K 365
K 366
K 367
K 368
K 369
K 370
K 371
K 372
K 373
K 375
K 376
K 377
K 378
SVENSKA
Rel frikoppling/drivbrytning
Rel vxelventil 1:a (diesel, gas)
Rel vxelventil 2:a (diesel, gas)
Rel drivriktning motor
Rel kylflkt drivmotor
Rel kylflkt elskp
Tidrel frdrjt tillslag
Tidrel frdrjt frnslag
Rel drivning 2/4 hjul
Rel dimbakljus
Rel momentfrstrkare
Rel lsning vndskiva
Rel frikoppling stollsning
Rel stolvndning/ljussignal
Rel flktmotor vrmare
Rel fartreglage
Rel pumpkontaktor/pumpkontroll
Rel hyttlyft upp
Rel hyttlyft ner
Rel skerhetsslinga
Rel styrsystem
Rel sensorstyrning
Skiftrel lngskrning/tvrskrning
Rel roterande varningsljus
Rel komressor luft
Rel Hydrauloljekylare
Rel startsolenoid
Rel kompressor AC
Rel vattenventil AC
Rel kondensor AC
Rel stolsbrytare
Rel fnsterhiss upp
Rel fnsterhiss ner
Rel styrning
Rel lgt bromstryck
Rel centralsmrjning
Rel centralsmrjning, aggregat
Rel lyfthjd
Rel blinkande varn.ljus, hjdbegrnsn.
Rel bakljus
Huvudkontaktor reglersystem
Kontaktor fram reglersystem
Kontaktor bak reglersystem
Kontaktor by-pass reglersystem/Fltfrsvagning
K
K
K
K
K
K
K
K
K
K
K
Kontaktor pumpmotor
Kontaktor
Kontaktor terladdning
Rel, frbikoppling skerhetssystem
Rel, Stolsvrme
Rel vattenseparator
Rel brnslepump insprutning
Rel, hg motortemperatur.
Rel alternativ gaspedal
Rel, Extra frdriktningsvljare
Rel, Pausvrme
379
380
381
382
383
384
385
386
387
388
389
ENGLISH
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
Relay, releasing of seat interlocking
Relay, multifunction, seat rotation/light signal
Relay, fan heating
Relay, speed control
Relay, pump contactor/pump control
Relay, cab hoist up
Relay, cab hoist down
Relay, safety loop
Relay, signal control system
Relay, sensor control
Shift relay, length/sideways driving
Relay, hazard beacon
Relay, compressor air
Relay hydraulic oil cooler
Relay, starting solenoid
Relay, compressor air conditione
Relay, water valve air conditioner
Relay, condenser air conditione
Relay seat switch
Relay, electrical screen elevator up
Relay, electrical screen elevator down
Relay, steerin
Relay, low brake pressure
Relay, central lubrication
Relay, central lubrication, attatchment
Relay, liftheight
Relay, flashing beacon, lifting height limiter
Relay light
Main contactor, operating control
Contactor, forward operating control
Contactor, reversing operating control
Contactor, by-pass operating control/ Field
weakening
Contactor, pump motor
Contactor
Contactor, recharging
Relay, by-pass safety system
Relay, heated seat
Relay, waterseparator
Relay, fuel injection pump
Relay, high motor temperature
Relay alternative throttle pedal
Relay, Extra direction selector
Relay, Paus heat
VDRF03.02SE/GB
10
NUMBER
K 399
K 3000
K 3001
K 3001
K 3002
K 3002
K 3003
K 3004
K 3005
K 3006
K 3007
K 3008
K 3009
K 3010
K 3010
K 3011
K 3012
K 3013
K 3014
K 3015
K 3015
K 3016
K 3017
K 3018
K 3040
K 3050
K 3060
K 3070
K 3080
K 3090
K 3100
K 3120
K 3130
K 3140
K 3150
K 3160
K 3170
K 3190
K 3200
K 3210
K 3220
K 3230
K 3270
K 3280
K 3290
K 3300
K 3305
K 3306
K 3307
K 3308
K 3310
SVENSKA
Rel option
Rel hel/halvljus
Rel rotation
Rel rotation
Rel tilt
Rel tilt
Rel sidofring
Rel lngdinstllning
Rel twist lock
Rel spridning
Rel lyft/snk
Rel hydraulfunktion extra
Rel manverbrytare hydr
Rel bromsljus vxl std/blackout
Rel dimljus
Rel backljus vxl std/blackout
Rel arb.bel hytt vxl std/blackout
Rel arb.bel. bom 20' vxl std/blackout
Rel arb.bel. bom 40' vxl std/blackout
Rel vxl bromsljus/blinkers v
Rel vxl bromsljus/blinkers h
Rel signalhorn
Rel containerbelysning
Rel containerbelysning IR
Rel arbetsljus
Rel backljus
Rel helljus
Rel halvljus
Rel bromsljus
Rel parkeringsbroms
Rel krriktningsvisare
Rel frvrmning
Rel vndbar frarstol
Rel parkeringsbroms
Rel tndningsls
Rel torkare
Rel strlkastartorkare
Rel varningsingsblinkers
Rel elektrisk stopp
Rel intervalltorkare
Rel kylvtskeniv
Rel blink
Rel vxel neutral
Rel vxelskifte
Rel vxel hg/lg
Rel startsprr
Rel VBFS, backljus
Rel VBFS, helljus
Rel VBFS, halvljus
Rel VBFS, bromsljus
Rel VBFS, krvisare v
ENGLISH
Relay, option
Relay main/dipped beam
Relay, rotation
Relay rotation
Relay, tilt
Relay tilt
Relay, side shifting
Relay, length adjustment
Relay, twist lock
Relay, spreading
Relay, lifting/lowering
Relay, extra hydraulic function
Relay, operating switch
Relay, brake light shift std/blackout
Relay fog light
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 working light
Relay reversing light
Relay main beam
Relay dipped beam
Relay brake light
Relay parking light
Relay direction indicator
Relay preheater
Relay rotating drivers seat (VBFS)
Relay parking brake
Relay ignition key
Relay wiper
Relay roading lights wiper
Relay hazard blinkers
Relay electical stop
Relay intermittent wiper
Relay coolant level
Relay blinkers
Relay gear neutral
Relay gear shift
Relay high/low gear
Relay start interlock
Relay, rotating drivers seat, reversing light
Relay, rotating drivers seat, main beam
Relay, rotating drivers seat, dipped beam
Relay, rotating drivers seat, brake light
Relay, rotating drivers seat, direction indicator left
K 3311
Rel VBFS, krvisare h
K 3312
K 3320
Rel drivning fram

Rel drivning bak
Relay, rotating drivers seat, direction indicator

right
Relay forward driving
Relay reversing driving
VDRF03.02SE/GB
NUMBER
K 3330
K 3331
K 3332
K 3333
K 3340
K 3349
K 3350
K 3360
K 3370
K 3380
K 3390
K 3400
K 3404
K 3405
K 3412
K 3420
K 3440
K 3450
K 3460
K 3480
K 3490
K 3500
K 3510
K 3530
K 3540
K 3560
K 3570
K 3580
K 3590
K 3600
K 3610
K 3620
K 3630
K 3640
K 3650
K 3670
K 3680
K 3690
K 3710
K 3730
K 3750
K 3760
K 3768
K 3769
K 3770
K 3771
K 3772
K 3773
K 3774
K 3775
K 3776
K 3776
K 3780
SVENSKA
Rel, skerhetsblte
Rel VBFS, drivning fram
Rel VBFS, drivning bak
Tidrel frvrmning
Rel frikoppling/drivbrytning
Rel VBFS, fartreglage
Rel vxelventil 1:a (diesel gas)
Rel vxelventil 2:a (diesel gas)
Rel drivriktning motor
Rel kylflkt drivmotor
Rel kylflkt elskp
Tidrel
Rel VBFS, mastljus
Rel,backalarm
Rel VBFS bakljus
Rel drivning 2/4 hjul
Rel momentfrstrkare
Rel lsning vndskiva
Rel frikoppling stollsning
Rel flktmotor vrmare
Rel fartreglage
Rel pumpKontaktor/pumpKontroll
Rel hyttfrflyttning
Rel skerhetsslinga
Rel styrsystem
Skiftrel lngskrning/tvrskrning
Rel roterande Varningsingsljus
Rel kompressor luft
Rel hydrauloljekylare
Rel startsolenoid
Rel kompressor AC
Rel vattenventil AC
Rel kondensor AC
Rel stolsbrytare
Rel fnsterhiss
Rel styrning
Rel bromstryck
Rel centralsmrjning
Rel lyfthjd
Rel bakljus
Huvudkontaktor reglersystem
Kontaktor fram reglersystem
Rel oljetryck hydraulik
Rel, blockering av hyttilt
Rel anliggning
Rel Krok
Rel laddsignal (D+)
Rel 12V fr minne radio
Rel kylflkt olja
Kontaktor bak reglersystem
Rel vrmare ruta
Rel hllkrets
Kontaktor by-pass reglersystem/Fltfrsvagning
K 3790
K 3800
Kontaktor pumpmotor
Kontaktor
11
ENGLISH
Relay, seat belt
Relay, rotating drivers seat, forward driving
Relay, rotating drivers seat, reversing driving
Time relay automatically preheating
Relay free wheel/drive disconnection
Relay, rotating drivers seat, speed control
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
Relay, rotating drivers seat, mast light
Relay,reversealarm
Relay rotating drivers seat rear light
Relay switching 2/4 WD
Relay torque amplifier
Relay interlocking of turntable
Relay releasing of seat interlocking
Relay fan heating
Relay speed control
Relay pump contactor/pump control
Relay cab moving
Relay safety loop
Relay signal control system
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
Relay steerin
Relay brake pressure
Relay central lubrication
Relay liftheight
Relay light
Main contactor operating control
Contactor forward operating control
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
Contactor reversing operating control
Relay heated window
Relay Holdcircuit
Contactor by-pass operating control/ Field
weakening
Contactor pump motor
Contactor
VDRF03.02SE/GB
NUMBER
K 3810
K 3820
K 3830
K 3840
K 3850
K 3860
K 3870
K 3880
K 3890
K 3990
K 3991
K 93774
L 830
L 8300
M 608
M 609
M 612
M 650
M 650
M 650
M 650
M 651
M 652
M 653
M 654
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 6085
M 6090
M 6120
M 6500
M 6510
M 6520
M 6540
M 6550
M 6560
M 6570
M 6610
SVENSKA
Kontaktor terladdning
Rel frbikoppling skerhetssystem
Rel Stolsvrme
Rel vattenseparator
Rel brnslepump insprutning
Rel motortemperatur.
Rel alternativ gaspedal
Rel Extra frdriktningsvljare
Rel Pausvrme
Rel option
Rel elektrisk vrme ruta
Rel hllkrets
Tndspole
Tndspole
Pumpaggregat hyttlyft
Stllmotor gaspdrag
Stllmotor recirkulation
Torkarmotor fram
Torkarmotor fram
Torkarmotor fram
Torkarmotor fram
Vindrutespolarmotor
Strlkastarmotor
Strlkastarspolarmotor
Startmotor
Kylflkt drivmotor (EC)
Kylflkt elskp (EC)
Flktmotor vrme
Fnsterhissmotor
Doseringspump klimatanlggning
Cirk pump klimatanlggning
Flktmotor cirkulation
Cirkulationspump vrmesystem
Kylflkt hydraulolja
Kompressor
Doseringspump diesel
Spjll motor, ECC
Kylflkt bromsolja
Motor, Stolsvndning
Motor Lsning stolsvridning
Pump centralsmrjning
Styrmotor
Drivmotor (EC)
Pumpaggregate ndstyrning
Pumpmotor (EC)
Pumpaggregat hyttfrflyttning
Stllmotor gaspdrag
Stllmotor recirkulation
Torkarmotor
Spolarmotor
Strlkastarmotor
Startmotor
Kylflkt drivmotor (EC)
Kylflkt elskp (EC)
Flktmotor
Fnsterhissmotor
12
ENGLISH
Contactor recharging
Relay by-pass safety system
Relay heated seat
Relay waterseparator
Relay fuel injection pump
Relay motor temperature
Relay alternative throttle pedal
Relay Extra direction selector
Relay Paus heat
Relay option
Relay electrical heated window
Relay, Holdcircuit
Ignition coil
Ignition coil
Pump unit, cab hoist
Regulating motor, throttle
Regulating motor, re-circulation
Washer motor
Light motor
Light washer motor
Starter motor
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)
Pump unit cab hoist
Regulating motor throttle
Regulating motor re-circulation
Wiper motor
Washer motor
Light motor
Starter motor
Cooling fan main motor (EC)
Cooling fan electrical box (EC)
Fan motor
Screenelevator motor
VDRF03.02SE/GB
NUMBER
M 6630
M 6670
M 6680
M 6700
M 6710
M 6720
M 6740
M 6750
M 6930
M 6940
M 6950
M 6960
M 6980
M 8880
M 9000
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
P 7000
P 7010
P 7020
P 7030
P 7040
P 7050
P 7060
P 7070
P 7080
P 7090
P 7100
P 7110
P 7120
P 7140
P 7150
Q 144
R 807
R 820
R 825
R 828
R 8070
R 8071
R 8072
R 8073
SVENSKA
Doseringspump klimatanlggning
Cirkulationspump vrmesystem
Kylflkt hydraulolja
Kompressor
Doseringspump diesel
Spjll motor luftfrdelning
Kylflkt bromsolja
Motor Stolsvndning
Pump centralsmrjning
Styrmotor
Drivmotor (EC)
Pumpaggregat ndstyrning
Pumpmotor (EC)
Lufttork kompressor
Motor hj/snkbar stolspelare
Motor hj/snkbar stolspelare
Hastighetsmtare
Mtare oljetemp v-lda
Klocka
Varvtalsmtare
Tryckluftsmtare
Mtare oljetryck v-lda
Termometer temp kylvtska motor
Brnslemtare
Timrknare
Kapacitetsmtare batteri
Tidur motor/kupevrmare
Rknare, impuls
Mtare oljetryck motor
Mtare, temp. Hydraulolja
Extra instrument allm
Display
Hastighetsmtare
Mtare oljetemp v-lda
Klocka
Varvtalsmtare
Tryckluftsmtare
Mtare oljetryck v-lda
Mtare temp kylvtska motor
Brnslemtare
Timrknare
Kapacitetsmtare batteri
Tidur motor/kupevrmare
Rknare impuls
Mtare oljetryck motor
Mtare temp hydraulolja
Extra instrument allm
Batterifrnskiljare
Potentiometer
Motstnd
Reglage spakstyrning
Shuntmotstnd
Potentiometer
Potentiometer lyft/snk
Potentiometer tilt
Potentiometer sidofring
13
ENGLISH
Dosage pump air condition
Circulation pump heating system
Cooling fan hydraulic oil
Compressor
Dosage pump diesel
Draught valve motor
Cooling fan brake fluid
Motor Seat rotation
Pump central lubrication
Steering motor
Drive motor (EC)
Pump emergency steering
Pump motor (EC)
Air Dryer Compressor
Motor rise/lower seat column
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
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
Battery disconnecting switch
Potentiometer
Resistor
Controls, (steering with control levers).
Shunt-resitor
Potentiometer
Potentiometer lift/lower
Potentiometer tilt
Potentiometer side shifting
VDRF03.02SE/GB
NUMBER
R 8074
R 8075
R 8076
R 8077
R 8078
R 8079
R 8080
R 8081
R 8082
R 8083
R 8084
R 8085
R 8086
R 8087
R 8088
R 8089
R 8200
R 8250
R 8280
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
SVENSKA
Potentiometer spridning
Potentiometer extra
Potentiometer mast in/ut
Potentiometer hger framhjul
Potentiometer vnster framhjul
Potentiometer hger bakhjul
Potentiometer vnster bakhjul
Potentiometer tiltvinkel
Potentiometer flkthastighet, ECC
Potentiometer temperatur, ECC
Potentiometer spjll, ECC
Potentiometer rotation
Potentiometer sax
Potentiometer klmma
Potentiometer skevning
Potentiometer kroklsning
Motstnd
Reglage spakstyrning
Shuntmotstnd
Strmstllare ljus
Strmstllare omk hel/halvljus
Strmstllare dimljus
Strmstllare fjrrljus
Strmstllare lastljus
Strmstllare arbetsljus
Strmstllare containerljus
Strmstllare park broms
Strmstllare centr smrjning
Strmstllare varningsljus
Strmstllare rot varningsljus
Strmstllare fnsterhiss
Strmstllare kylanlggning (AC)
Strmstllare styrning alt
Strmstllare lsbelysning
Strmstllare instr belysning
Strmstllare innerbelysning
Strmstllare vrme
Strmstllare flktm vrme
Strmstllare vindrutetorkare
Strmstllare spolare
Strmstllare blackout
Strmstllare nd hydraulpump
Strmstllare backspegel
Strmstllare kallstart
Strmstllare avgasbroms
Strmstllare diff sprr/broms
Strmstllare vrmesystem diesel
Strmstllare kraftuttag sida
Strmstllare kraftuttag bak
Strmstllare hg/lgvxel
Strmstllare frdvljare fram
Strmstllare frdvljare bak
Strmstllare vxelvljare
Strmstllare framhjuls styrning
Strmstllare 4-hjuls styrning
Strmstllare crab styrning
14
ENGLISH
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
Potentiometer temperature, ECC
Potentiometer draught valve, ECC
Potentiometer rotation
Potentiometer extender
Potentiometer clamp
Potentiometer levelling
Potentiometer flaps
Resistor
Controls (steering with control levers).
Shunt-resitor
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
VDRF03.02SE/GB
NUMBER
S 139
S 141
S 142
S 143
S 145
S 147
S 149
S 150
S 152
S 156
S 157
S 158
S 159
S 160
S 161
15
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
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
201
202
SVENSKA
Strmstllare defroster
Strmstllare Stegbelysning
Strmstllare fot
Strmstllare sitsvrme
Strmstllare AT-regulator
Strmstllare krvisare
Strmstllare signalhorn
Strmstllare startls/ellas
Strmstllare intervalltorkare
Strmstllare kupevrmare
Strmstllare stoltilt
Strmstllare dimbakljus
Strmstllare extra fram/back vljare
Strmstllare komb fram/back
Strmstllare komb signal, ljus hel/halv
spol,torkare m intervall krvisare
Strmstllare komb signal ljus hel/halv, spol,
torkare m 2 int, fram/bacK
Strmstllare start p 2-an
Strmstllare stolvrme
Strmstllare lsning vndskiva
Strmstllare luftfjdring
Strmstllare lsn stol
Strmstllare stolsvndning
Strmstllare frngare (LPG)
Strmstllare v-skiva upp/ner
Strmstllare v-skiva fr/back
Strmstllare v-skiva skevning
Strmstllare,utskjut
Strmstllare hyttlyft upp
Strmstllare hyttlyft ner
Strmstllare hyttskjutning
Strmstllare nollstllning
Strmstllare Aut/man vxling
Strmstllare fyrhjulsdrift
Strmstllare klimatanlggning
Strmstllare recirkulation
Strmstllare vattenavskiljare
Strmstllare joy-stick X
Strmstllare joy-stick X+Y
Strmstllare lngs/tvrskrning
Strmstllare flytlge skevning
Strmstllare option
Brytkontakt lampa park broms
Brytkontakt lampa frdbroms
Brytkontakt lampa oljetryck motor
S
S
S
S
S
204
205
206
207
208
Brytkontakt tryck ackumulator

Brytkontakt innerbelysning
Brytkontakt handskfack belysning
Slutkontakt diff sprr
Slutkontakt lampa temperatur spolkrets bromsar
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
Slutkontakt vervxel
Slutkontakt temp motor
Slutkontakt bromsljus
Contact, making, over drive

Contact, making, temperature engine
Contact, making, brake lights
S 162
S 214
S 215
S 216
ENGLISH
Switch, defroster
Switch, Steplight
Switch, foot
Switch, seat heater
Switch, AT-regulator
Switch, horn
Switch, main key switch
Switch, intermittent wiper
Switch, cab heating
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
VDRF03.02SE/GB
NUMBER
S 217
S 218
S 219
S 220
S 221
S 222
SVENSKA
Slutkontakt backljus
Slutkontakt AT-regulator
Slutkontakt lampa luftfilter
Brytkontakt drivning
Slutkontakt temp vxellda
Slutkontakt lampa temp moment - frstrkare
S
S
S
S
S
S
S
S
S
S
S
S
S
S
Slpkontakt signal
Slutkontakt insprutningspump
Brytkontakt skerhetsblte
Slutkontakt hyttlsning
Slutkontakt stolslsning
Brytkontakt stol
Slutkontakt fotkontroll stolvndning
Brytkontakt lampa luftanslutning slp
Slutkontakt lampa lsning vndskiva
Slutkontakt sidoskjutning stol
Slutkontakt vattenniv
Brytkontakt termisk
Slutkontakt termisk
Brytkontakt lampa luftmatning slp
16
S 242
Slutkontakt lampa oljetryck v-lda
S 243
Brytkontakt tryck kylmedia AC
ENGLISH
Contact, making, reversing light
Contact, making, AT-control
Contact, making, indicating light air filter
Contact, breaking, drive cut off
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)
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
Slutkontakt hydraulik aktiverad

Slutkontakt hydraultryck styrning
Slutkontakt tryck kylmedia
Manverbrytare
Slutkontakt vndbar frarstol
Slutkontakt lyft steg 1
Slutkontakt lyft steg 2
Slutkontakt tilt
Slutkontakt gaffelspridning
Slutkontakt sidofring
Slutkontakt stativ in/ut
Brytkontakt hyttdrr
Slutkontakt bromstryck
Slutkontakt kompressor
Slutkontakt sax inne
Slutkontakt verlastskydd
Slutkontakt, filter vxellda
Slut/brytkontakt option
Givare vndbar frarstol
Startelement
Manverspak
Strmfrdelare
Strmstllare, TW
Strmstllare, lossa TW
Strmstllare, lsa TW
Strmstllare, stopp vid 30'-35'
Strmstllare, frbikoppling av skerhetssystem
Contact, making, hydraulics

Contact, making, hydraulic pressure control
Contact, pressure refrigerant
Operating Switch
Contact, making, VBFS
Contact, making, hoist step 1
Contact, making, hoist step 2
Contact, making, tilting
Contact, making, fork positioning
Contact, making, sideshift
Contact, making, lifting mast in-out
Contact, breaking cab door
Contact, making, brake pressure
Contact, making, Compressor
Contact, making extender in
Contact, making, overload protection
Contact, making, filter gearbox
Contact, making/braking option
Transmitter, revolving drivers seat (VBFS)
Start element
Control lever
Distributor
Switch, TW
Switch, unlocking of TW
Switch, locking of TW
Switch, stop at 30 -35
Switch, overriding of the safety system
Strmstllare, fllning frmre ben

Strmstllare, fllning bakre ben
Switch, front legs down

Switch, rear legs down
223
224
225
228
229
230
231
232
233
235
236
239
240
241
244
245
246
250
251
260
261
262
263
264
265
266
267
268
269
270
271
299
720
800
815
840
1001
1002
1003
1004
1005
S 1006
S 1007
VDRF03.02SE/GB
17
NUMBER
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 1021
S 1022
S 1023
S 1024
S 1025
S 1026
SVENSKA
Strmstllare, klmma/lossa ben
Strmstllare, Motor information
Srmstllare, tilt av hytt
Strmstllare IR ljus
Strmstllare utskjut 20-40
Strmstllare stdben
Strmstllare frbikoppling rotationstopp
Strmstllare frbikoppling hjdbeg/tp-beg
Strmstllare diagnostik ka/minska
Strmstllare diagnostik on/off
Strmstllare rastvrme
Strmstllare automatisk slpp/klm funktion
Strmstllare sax
Strmstllare vertikalhllning
Strmstllare lsning vre arm
Strmstllare Korta Armen av/p
Strmstllare pappersfunktioner av/p
Strmstllare omkoppling pappers/klmmagregat
ENGLISH
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
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
Strmstllare lyfthjdsfrval
Strmstllare lyfthjdsfrval ka
Strmstllare lyfthjdsfrval minska
Strmstllare lraringng givare ultraljud
Strmstllare, Over Height Upp/Ned
Brytare backljus
Flytta korta armen
Strmstllare frbikoppling startsprr
Strmstllare Val av klmtryck
Strmstllare Korta Armen av/p
Strmstllare lsning skevning
Strmstllare vre armpar/Sidofring
Strmstllare Inching
Switch stopp motor
Strmstllare motorrumsbelysning
Strmstllare hjdjustering stol
Strmstllare lngdjustering stol
Strmstllare Tankvljare
Strmstllare Avstngning backalarm
Strmstllare eluppvrmd ruta
Henrik testar en brytare!
Strmstllare fjrrstyrning
Strmstllare styrning spegel
Huvudstrmbrytare
Kontakt park broms
Kontakt frdbroms
Kontakt oljetryck motor
Kontakt kylvtskeniv
Kontakt bromstryck ackumulator
Kontakt handskfack belysning
Kontakt diff sprr
Kontakt temperatur spolkrets bromsar
Kontakt vervxel
Kontakt temp kylvtska motor
Kontakt bromsljus
Kontakt backljus
Kontakt luftfilter
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
1027
1028
1029
1030
1031
1032
1033
1034
1035
1036
1037
1038
1039
1040
1041
1042
1043
1044
1045
1046
1047
1048
1049
1440
2000
2010
2020
2030
2040
2060
2070
2080
2140
2150
2160
2170
2190
Switch remote control

Switch mirror control
Contact parking brake
Contact service brake
Contact engine oil pressure
Contact coolant level
Contact breaking pressure accumulatortank
Contact breaking glove
Contact making diff. interlock
Contact temperature brake
Contact over drive
Contact engine coolant temperature
Contact brake lights
Contact reversing light
Contact indicating light air filter
VDRF03.02SE/GB
NUMBER
S 2200
S 2210
S 2220
S 2240
S 2250
S 2280
S 2290
S 2300
S 2310
S 2320
S 2350
S 2360
S 2420
S 2440
S 2450
S 2460
S 2500
S 2510
S 2600
S 2610
S 2620
S 2630
S 2640
S 2650
S 2660
S 2680
S 2690
S 2700
S 2710
S 2990
S 2991
S 7200
S 7201
S 7201
S 7202
S 7202
S 7203
S 7203
S 7204
S 7204
S 7205
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
SVENSKA
Kontakt drivning
Kontakt temp vxellda
Kontakt temp moment - frstrkare
Kontakt insprutningspump
Kontakt skerhetsblte
Kontakt hyttlsning
Kontakt stolslsning
Kontakt stol
Kontakt Fotkontroll stolvndning
Kontakt luftanslutning slp
Kontakt sidoskjutning stol
Kontakt vattenniv
Kontakt oljetryck v-lda
Kontakt hydraulik aktiverad
Kontakt hydraultryck styrning
Kontakt tryck kylmedia
Manverbrytare
Kontakt vndbar frarstol
Kontakt lyft steg 1
Kontakt lyft steg 2
Kontakt tilt
Kontakt gaffelspridning
Kontakt sidofring
Kontakt stativ in/ut
Kontakt hyttdrr
Kontakt kompressor
Kontakt sax inne
Kontakt verlastskydd
Kontakt, filter
Kontakt option
Kontakt niv spolarvtska
Givare, axeltryck hger
Givare, axeltryck vnster
Givare vndbar frarstol
Givare, anliggning vnster fram
Givare, anliggning hger fram
Givare, anliggning vnster bak
Givare, anliggning hger bak
Givare, ppen vnster twistlock
Givare, ppen hger twistlock
Givare, lst vnster twistlock
Givare, lst hger twistlock
Givare, gaffel aggregat
Givare, 2WD/4WD
Givare, hytt i krlge
Givare, oljefilter indikering
Givare, hytt i transportlge
Givare, lyfthjd
Givare, krlge
Givare, Anliggning frmre ben
Givare, Anliggning bakre ben
Givare, klm frmre ben
Givare, klm bakre ben
Givare, frmnre kn
Givare, bakre kn
Givare, frmre ben
18
ENGLISH
Contact breaking drive cut off
Contact transmission temperature
Contact temperature torque amplifier.
Contact injection pump
Contact seat belt
Contact cab locking
Contact seat locking
Contact seat
Contact making seat rotation foot switch
Contact air connection trailer
Contact side shifting of seat
Contact water level (out side vehicle)
Contact transmission oil pressure
Contact hydraulic activated
Contact hydraulic steering pressure
Contact pressure refrigerant
Operating Switch
Contact turnable seat
Contact hoist step 1
Contact hoist step 2
Contact tilting
Contact fork spreader
Contact sideshift
Contact lifting mast in-out
Contact cab door
Contact making Compressor
Contact extender inner position
Contact overload protection
Contact, filter
Contact option
Contact level washer fluid
Sensor, axle pressure right
Sensor, axle pressure left
Transmitter revolving drivers seat (VBFS)
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
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
VDRF03.02SE/GB
NUMBER
S 7219
S 7220
S 7221
S 7222
S 7223
S 8150
S 8400
U 741
U 823
U 824
U 901
U 910
U 941
U 7410
U 8230
U 9010
U 9100
U 9410
V 665
V 6650
V 8090
W 903
W 906
W 8093
W 9030
W 9060
X 37
X 39
X 72
X 77
X 78
X 9937
X 9939
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
Y 623
Y 624
Y 625
Y 626
SVENSKA
Givare lyftben ben
Givare, bakre ben
Givare, styraxel
Givare, stdben uppe
Givare, stdben nere
Manverspak
Strmfrdelare
FleetManager batterifilter
Signalomvandlare hger
Signalomvandlare vnster
Spnningsomvandlare
Spnningsomvandlare 80V/24V
Laddningsutjmnare
Batterifilter
Signalomvandlare
Spnningsomvandlare
Spnningsomvandlare 80V/24V
Laddningsutjmnare
Diod
Diod
Laser, pappersaggretgat
Antenn radio
Antenn kommunikationsradio
Genomfring, kablage
Antenn radio
Antenn kommunikationsradio
Terminal stomanslutning
Terminal minusanslutning
Stickuttag 2-polig
Stickuttag 7-polig
Stickuttag extra 7-polig
Terminal stomanslutning
Terminal minusanslutning
M-ventil avgasbroms
M-ventil diff sprr
M-ventil broms
M-ventil vrme
M-ventil kraftuttag sida
M-ventil kraftuttag bak
M-ventil 2/4 hjulsdrift
M-ventil hg/lg vxel
M-ventil hydraulsystem allm
M-ventil fldesbegrnsning
M-ventil momentfrstrkare
M-ventil rangesprr
M-ventil hjulvridning
M-ventil kallstart
M-ventil AT-regulator by-pass
M-ventil vatten klimatanlggning
M-ventil vndskiva upp
M-ventil vndskiva ner
M-ventil vndskiva fram
M-ventil vndskiva bak
M-ventil skevning h
M-ventil skevning v
M-ventil AT-regulator
19
ENGLISH
Sensor legs
Sensor, rear legs
Sensor, brace up
Sensor, brace down
Control lever
Distributor
FleetManager battery filter
Signal amplifier, right
Signal amplifier, left
Voltage converter
Voltage converter 80 V / 24 V
Even charger
Battery filter
Signal amplifier
Voltage converter
Voltage converter 80 V / 24 V
Even charger
Diode
Diode
Lase, Pulp an Paper
Aerial, radio
Aerial, communication radio
Lead-through, harness
Aerial radio
Aerial communication radio
Earthing terminal on chassis
Terminal, negative terminal
Outlet, 2-pole
Outlet, 7-pole
Outlet, extra, 7-pole
Earthing terminal on chassis
Terminal negative terminal
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
Solenoid valve, fifth wheel rear
Solenoid valve, levelling right hand
Solenoid valve, levelling left hand
Solenoid valve, AT-regulator
VDRF03.02SE/GB
NUMBER
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 6000
Y 6001
Y 6002
Y 6003
Y 6004
Y 6005
Y 6005
Y 6006
Y 6007
Y 6008
Y 6009
Y 6010
Y 6011
Y 6012
Y 6013
Y 6014
Y 6015
Y 6016
Y 6017
Y 6018
Y 6019
Y 6020
Y 6021
Y 6022
Y 6023
Y 6024
Y 6025
Y 6026
Y 6027
Y 6028
Y 6029
SVENSKA
M-ventil vakuum
M-ventil brnsleblandning
M-ventil v-lda fram
M-ventil v-lda back
M-ventil v-lda spole 1
M-ventil klmtryck
M-ventil styrning
M-ventil flytlge skevning
M-ventil stopp insprut pump
M-ventil lsning orbitrol ls
M-ventil gasol
M-ventil frngare (LPG)
M-ventil park broms
M-ventil lsning stol (VBFS)
M-ventil lsning vndskiva
Magnetkoppling komp AC
M-ventil stolsvndning
M-ventil stolstilt
M-ventil luftfjdring
Vatten ventil motor, ECC
M-ventil Broms stolsvndning
M-ventil option
Ventil spakstyrning
M-ventil avgasbroms
M-ventil blockering hger
M-ventil blockering vnster
M-ventil inkoppling av hydraulik till topplyft
M-ventil snk
M-ventil lyft
M-ventil lyft
M-ventil bom ut
M-ventil bom in
M-ventil vridning medsols
M-ventil vridning motsols
M-ventil tilt ut
M-ventil tilt in
M-ventil tilt
M-ventil fllning frmre ben
M-ventil fllning bakre ben
M-ventil klmma/lossa ben
M-ventil Hyttskjutning fram
M-ventil Hyttskjutning bak
M-ventil spridning ut
M-ventil spridning in
M-ventil sidofring vnster
M-ventil sidofring hger
M-ventil extra hydraulfunktion ut
M-ventil extra hydraulfunktion in
M-ventil stativ ut
M-ventil stativ in
M-ventil hger framhjul styrning vnster
M-ventil hger framhjul styrning hger
M-ventil vnster framhjul styrning vnster
M-ventil vnster framhjul styrning hger
20
ENGLISH
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, 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 exhaust brake
Solenoid valve, blocking right
Solenoid valve, blocking left
Solenoid valve, activation of toplift hydraulics
Solenoid valve, lower
Solenoid valve, lift
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, 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
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
VDRF03.02SE/GB
NUMBER
Y 6030
Y 6031
Y 6032
Y 6033
Y 6034
Y 6035
Y 6036
Y 6037
Y 6038
Y 6039
Y 6040
Y 6041
Y 6042
Y 6043
Y 6044
Y 6045
Y 6046
Y 6047
Y 6048
Y 6049
Y 6050
Y 6051
Y 6052
Y 6052
Y 6053
Y 6054
Y 6055
Y 6056
Y 6057
Y 6058
Y 6059
Y 6060
Y 6061
Y 6062
Y 6063
Y 6064
Y 6065
Y 6066
Y 6067
SVENSKA
M-ventil hger bakhjul styrning vnster
M-ventil hger bakhjul styrning hger
M-ventil vnster bakhjul styrning vnster
M-ventil vnster bakhjul styrning hger
M-ventil skevning
M-ventil skevning hger upp / c.c.w
M-ventil skevning vnster upp / c.w.
M-ventil kylflkt
M-ventil frikoppling koppling
M-ventil ppna twistlock
M-ventil lsa twistlock
M-ventil ndstyrning twistlock
M-ventil mellan bom
Magnetventil, fllning torn (RTCH)
M-ventil blockering twistlock
M-ventil blockering lyft
M-ventil utskjut
M-ventil, hyttilt upp
M-ventil, hyttilt ner
M-ventil, kylkrets broms
M-ventil blockering utskjut
M-ventil, regenerering hger
M-ventil, regenerering vnster
M-ventil broms
M-ventil, krlge
M-ventil, klmma ihop
M-ventil, klmma isr
M-ventil, frmre kn ut
M-ventil, frmre kn in
M-ventil, bakre kn ut
M-ventil, bakre kn in
M-ventil, frmre ben upp
M-ventil, bakre ben upp
M-ventil, urkoppling hydraulpump
M-ventil, stdben upp
M-ventil, stdben ner
M-ventil, frikoppling vridbroms
M-ventil, v-lda, drivning
M-ventil, v-lda, oljetryck till 1:a/3:e vxeln
Y 6068
Y 6069
M-ventil sax/rotation
M-ventil, v-lda, oljetryck till 2:a/4:e vxeln
Y
Y
Y
Y
Y
Y
6070
6071
6072
6073
6073
6074
M-ventil Over Height upp

M-ventil Over Height ner
M-ventil klmtryck
Propertional ventil, Opti speed
M-ventil Opti speed
M-ventil, v-lda, vxelvljare fr 2:a/4:e vxeln
Y 6075
M-ventil, v-lda, vxelvljare fr 1:a/3:e vxeln
Y 6076
Y 6077
Y 6078
M-ventil blockering snk

M-ventil Inching
M-ventil Pappersaggregat avstngning vre
klmarm
21
ENGLISH
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 side up / c.c.w
Solenoid valve levelling left side up / c.w.
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 brake
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
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 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
VDRF03.02SE/GB
22
NUMBER SVENSKA
Y 6079 M-Ventil Pappersaggregat sidofring/vre armar
ENGLISH
Solenoid valve Sideshift/Upper arms
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Z
Z
Solenoid valve, activate sliding cab

Solenoid valve, accumulator charge
Solenoid valve heater
Solenoid valve, pressure restriction
Solenoid valve power take off
Solenoid valve 2/4WD
Solenoid valve high/low gear
Solenoid valve flow restriction
Solenoid valve torque amplifier
Solenoid valve ranging interlock
Solenoid valve wheel turning
Solenoid valve cold start aid
Solenoid valve water air conditioner
Solenoid valve fifth wheel
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 clamping pressure
Solenoid valve steering
Solenoid valve equalizing fifth wheel
Solenoid valve stop injection pump
Solenoid valve locking 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
Solenoid brake seat rotation
Solenoid valve option
Signal filter
Signal filter
6080
6081
6081
6082
6082
6083
6084
6110
6130
6140
6150
6160
6180
6200
6270
6280
6300
6310
6320
6330
6340
6350
6360
6370
6380
6390
6400
6410
6420
6430
6440
6450
6460
6470
6480
6730
6760
6990
822
8220
M-ventil, aktivering hyttkrning

M-ventil, ackumulatorladdning
M-ventil vrme
M-ventil tryckbegrnsning
M-ventil kraftuttag
M-ventil 2/4 hjulsdrift
M-ventil hg/lg vxel
M-ventil fldesbegrnsning
M-ventil momentfrstrkare
M-ventil rangesprr
M-ventil hjulvridning
M-ventil kallstart
M-ventil vatten klimatanlggning
M-ventil vndskiva
M-ventil vakuum
M-ventil brnsleblandning
M-ventil v-lda fram
M-ventil v-lda back
M-ventil klmtryck
M-ventil styrning
M-ventil flytlge skevning
M-ventil stopp insprut pump
M-ventil lsning orbitrol
M-ventil gasol
M-ventil frngare (LPG)
M-ventil park broms
M-ventil lsning stol (VBFS)
M-ventil lsning vndskiva
Magnetkoppling kompressor AC
M-ventil stolsvndning
M-ventil stolstilt
M-ventil luftfjdring
Spjll motor kylvtska
Solenoid Broms stolsvndning
M-ventil option
Signalfilter
Signalfilter
VDRF03.02SE/GB
F Technical data
F Technical data
Table of Contents F Technical data

mm mm mm mm mm mm
Technical data ................................................................................................ 3

Data and volume .................................................................................................... 3
Lift capacity and dimensions (model year -2008) ................................................... 7
Lift capacity and dimensions (model year 2009-) ................................................. 10
Oils and lubricants, recommendation ................................................................... 13
Tightening torques, recommendations ................................................................. 15
Tightening torques, ORFS-couplings ................................................................... 17
Tightening torque, climate control system connections ........................................ 18
Unit explanations .................................................................................................. 19
Conversion table, SI-units .................................................................................... 20
Conversion table, length ....................................................................................... 21
Conversion table, area ......................................................................................... 21
Conversion table, volume ..................................................................................... 21
Conversion table, weight ...................................................................................... 22
Conversion table, pressure .................................................................................. 22
VDRF03.02GB
VDRF03.02GB
F Technical data
F Technical data Technical data
mm mm mm mm mm mm
Technical data
Data and volume
page
Data
1 Engine
Volvo TWD1240VE
Volvo TAD1250VE
Cummins QSM11
Power acc. to ISO 3046 (net power)
256 kW at 2000 rpm
247 kW at 1900 rpm
261 kW at 2000 rpm
1751 Nm at 1200 rpm
1760 Nm at 1400 rpm
1830 Nm at 1100-1400
rpm
Torque ISO 3046
Alternator
2240 W (28 V / 80 A)
System voltage
24 V (2 x 12 V / 140 Ah)
2 Transmission
Dana TE32
No. of gears forward reverse
3 Driveline/axle
44
Meritor PRC7534
Kessler D102
Wet Disc Brakes - Drive wheels
4 Brakes
Parking brake
Spring brake - Drive wheels
Hydraulic servo
5 Steering
6 Suspension
Dimensions, front-rear
DRF420
DRF400/450
DRF450, X
18.00x25/36
18.00x25/40
18.00x33/36
Tyre pressure (also see pressure plate)

Tyre type front and rear
9 Cab
Equivalent sound pressure level in cab according to EN12053 with measurement uncertainty, k = 2.5 dB (A). Measurement value
with standard engine.
2800 W (28 V / 100 A)
1.0 MPa
Air inflated. Spare and replacement tyres must be from a manufacturer approved by Cargotec.
Volvo TWD1240VE
Volvo TAD1250VE
Cummins QSM11
max. 73 db(A)
max. 74 db(A)
max. 73 db(A)
Whole-body vibration according to EN13059

with measurement uncertainty k=0.3.
0.5
VDRF03.02GB
9.6 Frame, body, cab and accessories, lighting system

Bulb
Output (W)
Socket
Control lights
1.2
W2x4.6d
Interior lighting
10
S8.5
Tail light
BA15s
Brake light
21
BA15s
21
BA15s
Replaced as a single unit
Running lights
W2.1x9.5d
Position lamp LED
Model year -2008: 55/50
P43t-38 (H4)
Tail lights, brake lights & LED direction indicator

lamps
Headlamps main and dipped beam
Model year 2009-: 75/70

Reversing light
70
Model year -2008: P14.5s (H1)

Model year 2009-: PK22s (H3)
Working lights
70
PK22s (H3)
Xenon working lights
35
D1S Xenon tubes. The insert and

ballast must be replaced as a single unit.
LED working lights
Revolving beacon
70
PK22s (H3)
VDRF03.02GB
Volumes
Any deviation from this table must be supported with written approval
from Cargotec.
1 Engine
Volvo TWD1240VE
Volvo TAD1250VE
Fuel tank
550 l
Fuel quality
Cooling system
Coolant, refilling and changing
Cummins QSM11
Diesel according to EN590

68 l
40 l
40 l
Distilled water, add at

least 40% glycol.
Volvo Penta Coolant

VCS, ready mixed
(yellow). If the machine has coolant filter
use distilled water,
add at least 40% ethylene glycol (green).
ES Compleat, Premix.
BEWARE!
Risk of engine damage, if different types of coolant are mixed.
When changing and refilling the coolant the coolant must be of the same
type as was previously used.
Oil type, quality
Engine oil, volume
For oil types see Oils and lubricants, recommendation page 13.
35 l
35 l
Dana TE32
2 Transmission
Oil type, quality
Transmission oil, volume
3 Driveline/axle
Oil type, quality
Differential
Hub reduction
34 l
60 l at replacement (80 l total)
Meritor PRC7534
Kessler D102
50 l
65 l
2x10 l
2x12 l
4 Brakes
Oil type, quality
Brake system
140 l
VDRF03.02GB
7 Load handling
Oil type, quality
Planet gear hydraulic motor attachment
1.6 l
Brake hydraulic motor attachment
0.6 l
Volvo TWD1240VE
Volvo TAD1250VE
Air conditioning, refrigerant

Air conditioning, lubricants
Cummins QSM11
2000 g, R134a
Filled with correct volume.
Washer fluid
1.7 dl ZXL100 PAGoil
5l
Oil type, quality
Hydraulic oil tank
600 l
Hydraulic system
940 l (total including tank)
VDRF03.02GB
Lift capacity and dimensions (model

year -2008)
page
Capacity (tonnes)
**
**
H5
**
H4
(1)
(1)
1865
1865
3815
3815
6315
6315
A. Container 86
005113
B. Container 96
Container 86
Lifting height
top lift
Container 96
Model
Line 1
Line 2
Line 3
Line 1
Line 2
Line 3
H4
(mm)
H5
(mm)
DRF400-60C5
38*/40
25**
10**
37**/40*
25*
10*
14900
18100
DRF420-60S5
41*/42
25*
11*
40*/42
25*
11*
15100
18100
DRF450-60S5
43*/45
27*
13*
42*/45
27*
13*
15100
18100
DRF450-60S5X
43*/45
35*
18*
42*/45
35*
18*
15200
18200
DRF450-60C5X
42*/45
32**
14**
41**/44*/45
32*
14*
15000
18200
DRF420-65S5
41*/42
28*
13*
40*/42
28*
13*
15100
18100
DRF420-65S6
39**/41*/42
28*
13*
40*/42
28**
13**
16200
19250
DRF450-65S5
43*/45
30*
15*
42*/45
30*
15*
15100
18100
DRF450-65S6
42**/44*/45
30*
15*
43*/45
30**
15**
16200
19250
DRF450-65S5X
45*
36*/38*
21*
43*/45
37*/38
21*
15200
18200
DRF450-65C5X
42*/45
33**/34*
16**
41**/44*/45
34*
16*
15000
18200
DRF450-65S6X
42**/45*
35*/38
21*
43*/45
34**/36*/38
21**
16300
19350
DRF420-70S5
41*/42
30*
15*
40*/42
30*
15*
15100
18100
DRF450-70S5X
45*
39*/41
23*
45*
40*/41
23*
15100
18200
DRF45070S5XS
45*
39*/41
23*/(31*)
45*
40*/41
23*/(31*)
15100
18200
DRF45070C5XS
45*
36**/38*
20**/(27**)
43**/45*
37*/38
20*/(27*)
14900
18200
VDRF03.02GB
Container 86
Lifting height
top lift
Container 96
Model
Line 1
Line 2
Line 3
Line 1
Line 2
Line 3
H4
(mm)
H5
(mm)
DRF45075S5XS
45*
43*/45
26*/(34*)
45
45*
26*/(34*)
15200
18400
DRF45075C5XS
45*
40**/42*/43
24**/(32**)
45**
41*/43
24/(32*)
15000
18400
( ) = Support jacks down

Dimensions (mm)
A1
A2
H3
R1
B
R3
100
003191
100
Aisle width
Turning radius
Main dimensions
Service
weight
(kg)
A1-20'
A2-40'
R1-20'
R3-40'
H3
Groun
d
clearance
DRF400-60C5
11200
13600
8100
9400
4150
605512185
11200
4500
250
18.00x
25/40
72700
DRF420-60S5
11200
13600
8100
9400
4150
605512185
11200
4500
250
18.00x
25/36
64500
DRF450-60S5
11200
13600
8100
9400
4150
605512185
11200
4500
250
18.00x
25/40
66400
DRF450-60S5X
11200
13600
8100
9400
4150
605512185
11200
4600
300
18.00x
33/36
76500
DRF450-60C5X
11200
13600
8100
9400
4150
605512185
11200
4600
300
18.00x
33/36
81100
DRF420-65S5
11600
13600
8500
9400
4150
605512185
11700
4500
250
18.00x
25/36
65000
DRF420-65S6
11900
13900
8500
9450
4150
605512185
12000
4500
250
18.00x
25/36
66200
DRF450-65S5
11600
13600
8500
9400
4150
605512185
11700
4500
250
18.00x
25/40
66800
Model
VDRF03.02GB
Tyres
Aisle width
Turning radius
Main dimensions
Service
weight
(kg)
A1-20'
A2-40'
R1-20'
R3-40'
H3
Groun
d
clearance
DRF450-65S6
11900
13900
8500
9450
4150
605512185
12000
4500
250
18.00x
25/40
67800
DRF450-65S5X
11600
13600
8500
9400
4150
605512185
11700
4600
300
18.00x
33/36
76300
DRF450-65C5X
11600
13600
8500
9400
4150
60551258
11700
4600
300
18.00x
33/36
80500
DRF450-65S6X
11900
13900
8500
9450
4150
605512185
12000
4600
300
18.00x
33/36
77200
DRF420-70S5
12100
13600
9000
9400
4150
605512185
12200
4500
250
18.00x
25/36
65800
DRF450-70S5X
12100
13600
9000
9400
4150
605512185
12200
4700
300
18.00x
33/36
77800
DRF45070S5XS
12100
13600
9000
9400
4150
605512185
12200
4700
300
18.00x
33/36
79300
DRF45070C5XS
12100
13600
9000
9400
4150
605512185
12200
4700
300
18.00x
33/36
84200
DRF45075S5XS
12500
13600
9400
9400
4150
605512185
12700
4750
300
18.00x
33/36
82100
DRF45075C5XS
12500
13600
9400
9400
4150
605512185
12700
4750
300
18.00x
33/36
88100
Model
Tyres
VDRF03.02GB
10
Lift capacity and dimensions (model

year 2009-)
page
Capacity (tonnes)
**
**
H5
**
H4
005113
(1)
(1)
1865
1865
3815
3815
6315
6315
A. Container 86
B. Container 96
Container 86
Lifting height
top lift
Container 96
Model
Line 1
Line 2
Line 3
Line 1
Line 2
Line 3
H4
(mm)
H5
(mm)
DRF400-60C5
38*/40
25**
10**
37**/40*
25*
10*
14900
18100
DRF420-60S5
41*/42
25*
11*
40*/42
25*
11*
15100
18100
DRF450-60S5
43*/45
27*
13*
42*/45
27*
13*
15100
18100
DRF450-60S5M
42*/45
30*
15*
42*/45
30*
15*
15100
18100
DRF450-60S5X
43*/45
35*
18*
42*/45
35*
18*
15200
18200
DRF450-60C5X
42*/45
32**
14**
41**/44*/45
32*
14*
15000
18200
DRF420-65S5
41*/42
28*
14*
40*/42
28*
14*
15100
18100
DRF420-65S6
39**/41*/42
28*
14*
40*/42
28**
14**
16200
19250
DRF450-65S5
43*/45
31*
16*
42*/45
31*
16*
15100
18100
DRF450-65S6
42**/44*/45
31*
16*
43*/45
31**
16**
16200
19250
DRF450-65S5X
45*
36*/38*
21*
43*/45
37*/38
21*
15200
18200
DRF450-65C5X
42*/45
33**/34*
16**
41**/44*/45
34*
16*
15000
18200
DRF450-65S6X
42**/45*
35*/38
21*
43*/45
34**/36*/38
21**
16300
19350
DRF450-70S5
45*
34*
18*
45*
34*
18*
15100
18100
DRF450-70S5X
45*
39*/41
23*
45*
40*/41
23*
15100
18100
DRF45070S5XS
45*
39*/41
23*/(31*)
45*
40*/41
23*/(31*)
15100
18200
VDRF03.02GB
Container 86
11
Lifting height
top lift
Container 96
Model
Line 1
Line 2
Line 3
Line 1
Line 2
Line 3
H4
(mm)
H5
(mm)
DRF45070C5XS
45*
36**/38*
20**/(27**)
43**/45*
37*/38
20*/(27*)
14900
18200
DRF45075S5XS
45*
43*/45
26*/(34*)
45
45*
26*/(34*)
15200
18400
DRF45075C5XS
45*
40**/42*/
43
24**/(32**)
45**
41*/43
24/(32*)
15000
18400
( ) = Support jacks down

Dimensions (mm)
A1
A2
H3
R1
B
R3
100
003191
100
Aisle width
Turning radius
Main dimensions
Service
weight
(kg)
A1-20'
A2-40'
R1-20'
R3-40'
H3
Ground
clearance
DRF400-60C5
11200
13600
8100
9400
4150
605512185
11200
4500
250
18.00x2
72700
5/40
DRF420-60S5
11200
13600
8100
9400
4150
605512185
11200
4500
250
18.00x2
64500
5/36
DRF450-60S5
11200
13600
8100
9400
4150
605512185
11200
4500
250
18.00x2
66400
5/40
DRF450-60SM
11200
13600
8100
9400
4150
605512185
11200
4500
250
18.00x2
69400
5/40
DRF450-60S5X
11200
13600
8100
9400
4150
605512185
11200
4600
300
18.00x3
76500
3/36
DRF450-60C5X
11200
13600
8100
9400
4150
605512185
11200
4600
300
18.00x3
81100
3/36
DRF420-65S5
11600
13600
8500
9400
4150
605512185
11700
4500
250
18.00x2
66500
5/36
Model
Tyres
VDRF03.02GB
12
Aisle width
Turning radius
Main dimensions
Service
weight
(kg)
A1-20'
A2-40'
R1-20'
R3-40'
H3
Ground
clearance
DRF420-65S6
11900
13900
8500
9450
4150
605512185
12000
4500
250
18.00x2
67700
5/36
DRF450-65S5
11600
13600
8500
9400
4150
605512185
11700
4500
250
18.00x2
69000
5/40
DRF450-65S6
11900
13900
8500
9450
4150
605512185
12000
4500
250
18.00x2
69800
5/40
DRF450-65S5X
11600
13600
8500
9400
4150
605512185
11700
4600
300
18.00x3
76300
3/36
DRF450-65C5X
11600
13600
8500
9400
4150
60551258
11700
4600
300
18.00x3
80500
3/36
DRF450-65S6X
11900
13900
8500
9450
4150
605512185
12000
4600
300
18.00x3
77200
3/36
DRF450-70S5
12000
13600
8900
9400
4050
605512185
12200
4500
250
18.00x3
69400
3/36
DRF450-70S5X
12100
13600
9000
9400
4150
605512185
12200
4700
300
18.00x3
77800
3/36
DRF450-70S5XS 12100
13600
9000
9400
4150
605512185
12200
4700
300
18.00x3
79300
3/36
DRF45070C5XS
12100
13600
9000
9400
4150
605512185
12200
4700
300
18.00x3
84200
3/36
DRF450-75S5XS 12500
13600
9400
9400
4150
605512185
12700
4750
300
18.00x3
82100
3/36
DRF45075C5XS
13600
9400
9400
4150
605512185
12700
4750
300
18.00x3
88100
3/36
Model
VDRF03.02GB
12500
Tyres
13
Oils and lubricants,

recommendation
page
The service intervals indicated by Cargotec in the maintenance manual only apply if oils are selected according to the table below. The table indicates recommended viscosity for different oil types and
qualities depending on the ambient temperature.
Any deviation from this table must be approved in writing by Cargotec,
and may mean changed service intervals.
Oil type, quality
-40
-30
-20
-10
+10
+20
+30
+40
-40
-22
-4
+14
+32
+50
+68
+86
+104
1.8 Engine, lubrication

Volvo TWD1240VE: VDS-2 and ACEA E5*
Volvo TAD1250VE: VDS-3**
SAE 15W40 (engine oil)

SAE 5W30 (engine oil)
Cummins QSM11: API CH-4 or ACEA E5

2.6 Transmission, lubrication system
ATF DEXRON III
DEXRON III
3.3 Driveline/axle, drive axle

API GL-5
SAE 80W140
SAE 75W90
4 Brakes (UTTO-oil) ***)

GM Allison C-4
SAE 5W30 (transmission oil)
John Deere J20 C, D

Caterpillar TO-4
7 Load handling
Planetary gear, hydraulic motor, hypoid oil
API GL-5
SAE 80W140
SAE 75W90
Disc brake, hydraulic engine, see "10 Common hydraulics" below.

DIN 51524 Part 3 HVLP
ISO VG 68
ISO VG 46 HV
ISO VG 32
NOTE
The change interval for engine oils is conditional on the sulphur
content in the fuel does not exceed 0.5%.
Oil filters shall always be changed in connection with oil change.
VDRF03.02GB
14
*) The lubricating oil must fulfil both requirements. NOTE! API: CH-4
or CI-4 is approved for markets outside of Europe (instead of
ACEA E5).
**) The same oil as for the Volvo TWD1240VE may be used provided
that the change interval is reduced to 400 hours.
***) The fluid in the brake system must fulfil one of the quality requirements and be a UTTO oil (Universal Tractor Transmission Oil).
ACEA = Association des Constructeurs Europenne dAutomobiles
API = American Petroleum Institute
VDS = Volvo Drain Specification
Grease
Use a universal grease type EP according to NLGI Grade 2 with 3-5 %
molybdenum sulphide content for all grease points except slide plates
where lubrication paste Gleitmo 805 or the equivalent shall be used.
Electronic cleaner 923836.0826 and connector grease 923836.0552
must be used for electric connections.
Sealant silicone
Use Loctite 5972 or Loctite 598 (or equivalent). If uncertain, contact
Cargotec.
Locking fluid
Use Loctite 542 (or equivalent). If uncertain, contact Cargotec.
VDRF03.02GB
15
Coolant
The coolant shall consist of distilled water mixed with 40-60 % glycol.
If glycol is not used, then anti-corrosion agent must always be added.
However, anti-corrosion agent does not contain anti-freeze and may
only be used if the outdoor temperature always is above 0 C.
NOTE
It is important that the coolant is mixed correctly all year to ensure
adequate corrosion protection. The corrosion-protective properties decline with time which is why the coolant has to be changed
according to given intervals.
A mixture of 60% distilled water and 40% glycol withstands temperatures down to -28 C.
A mixture of 40% distilled water and 60% glycol withstands temperatures down to -54 C.
C AUTION
Risk of engine damage, if different types of coolant
are mixed.
Tightening torques,
recommendations
page
The tightening torques in the following table are recommendations

when tightening bolts and nuts.
When torquing using a machine, for example, bolt runner, the tightening torque should be reduced by approx. 5%.
For mild 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 according to the table below.
State
Bolt
Nut
Lubrication
untreated
untreated
oil
bright-galvanised
untreated or bright-galvanised
dry or oil
hot-galvanised
untreated
dry or oil
VDRF03.02GB
16
Quality
State
8.8
10.9
12.9
M8x1
27 Nm
24 Nm
30 Nm
39 Nm
46 Nm
M10x1.25
54 Nm
48 Nm
61 Nm
78 Nm
91 Nm
M12x1.25
96 Nm
85 Nm
108 Nm
135 Nm
162 Nm
M16x1.5
230 Nm
205 Nm
260 Nm
323 Nm
388 Nm
M18x1.5
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
3/4
370 Nm
390 Nm
418 Nm
524 Nm
619 Nm
7/8
594 Nm
528 Nm
671 Nm
839 Nm
990 Nm
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
Fine M-thread
M-thread
UNC-thread
VDRF03.02GB
page
17
Tightening torques, ORFScouplings

Pipe and hose coupling
Pipe diameter
mm
Tightening torques
inch
Nm
1/4
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
Socket width
mm
Tightening torques
inch
Nm
17
11/16
23-25
22
13/16
33-38
24
15/16
51-57
36
1 3/8
120-130
41
1 5/8
150-170
VDRF03.02GB
18
Flange coupling
UNF-UN
Metric-ISO
BSPP
Thread (inch)
Tightening torques
(Nm)
Thread (mm)
Tightening torques
(Nm)
Thread (inch)
Tightening torques
(Nm)
7/16-20
21
10x1
20
1/8-28
20
1/2-20
27
12x1.5
35
1/4-19
35
9/16-18
40
14x1.5
45
3/8-19
70
3/4-16
78
16x1.5
55
1/2-14
100
7/8-14
110
18x1.5
68
3/4-14
190
1"1/16-12
180
20x1.5
80
1"-11
300
1"3/16-12
230
22x1.5
98
1"1/4-11
330
1"5/16-12
285
26x1.5
170
1"1/2-11
400
1"5/8-12
320
27x2
180
1"7/8-12
400
33x2
310
42x2
330
48x2
400
Tightening torque, climate control

system connections
page
O-rings, radiator hoses

Hose diameter
Thread
Tightening torques
mm
inch
inch
Nm
1/4"
7/16"
7-14 Nm
10
3/8"
5/8"
14-20 Nm
10
3/8"
11/16"
14-20 Nm
12
1/2"
3/4"
14-27 Nm
16
5/8"
7/8"
27-41 Nm
19
3/4"
1 1/16"
34-47 Nm
3/8"
7-14 Nm
Pressure switch
The above values are to be considered guidelines and may vary depending on installation.
VDRF03.02GB
19
Unit explanations
page
Unit
Abbreviation
Newton metre
Nm
Kilo pound metre
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
Kilometre
km
VDRF03.02GB
20
Conversion table, SI-units
page
SI-unit
Recalculation factor
Non-SI
Recalculation factor
SI
Nm
x 10.2
= kgcm
x 0.8664
= lbin
Nm
x 0.74
= lbfft
x 1.36
= Nm
Nm
x 0.102
= kgm
x 7.22
= lbft
kPa
x 4.0
= in.H2O
x 0.249
= kPa
kPa
x 0.30
= in.Hg
x 3.38
= kPa
kPa
x 0.145
= psi
x 6.89
= kPa
bar
x 14.5
= psi
x 0.069
= bar
kp / cm2
x 14.22
= psi
x 0.070
= kp/cm2
N/ mm2
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
x 0.74
= ftlb/s
x 1.36
=W
kJ
x 0.948
= Btu
x 1.055
= kJ
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
Torque
Pressure (Pa = N/ m2)
MPa
Power (W = J/s)
Energy (J = Nm)
Speed and acceleration
Horsepower/ torque
Bhp x 5252 rpm= TQ (lbft)
TQ x rpm 5252 = bhp
Temperature
C = (F 32)/1.8
F = (C x 1.8) + 32
Flow factor
l / min (dm3 / min)
VDRF03.02GB
x 0.264
= US gal / min x 3.785
= litre/min
21
Conversion table, length
page
Unit
cm
km
in
ft
yd
mile
cm
0.01
0.00001
0.3937
0.03281
0.01094
0.000006
100
0.001
39.37
3.2808
1.0936
0.00062
km
100000
1000
39370.7
3280.8
1093.6
0.62137
in
2.54
0.0254
0.000025
0.08333
0.02777
0.000015
ft
30.48
0.3048
0.000304
12
0.3333
0.000189
yd
91.44
0.9144
0.000914
36
0.000568
160930
1609.3
1.6093
63360
5280
1760
mile
1 mm = 0.1 cm - 1 mm = 0.001 m
Conversion table, area
page
Unit
cm2
m2
km2
ft2
yd2
in2
cm2
0.0001
0.000001
0.001076
0.000012
0.155000
m2
10000
0.000001
0.01
10.764
1.1958
1550.000
km2
1000000
10000
1076400
1195800
0.01
100
0.0001
1076.4
119.58
ft2
0.092903
0.000929
0.1111
144.000
yd2
0.83613
0.008361
1296.00
in2
6.4516
0.000645
0.006943
0.000771
1 ha = 100 a - 1 mile2 = 259 ha = 2.59 km2
Conversion table, volume
page
Unit
cm3 = cc
m3
in3
ft3
yd3
0.000001
0.001
0.061024
0.000035
0.000001
1000000
1000
61024
35.315
1.30796
1000
0.001
61.024
0.035315
0.001308
in3
16.387
0.000016
0.01638
0.000578
0.000021
ft3
28316.8
0.028317
28.317
1728
0.03704
yd3
764529.8
0.76453
764.53
46656
27
cm3 = ml
m3
dm3 (l)
1 gal (US) = 3785.41 cm3 = 231 in3 = 0.83267 gal (UK)
VDRF03.02GB
22
Conversion table, weight
page
Unit
kg
oz
lb
0.001
0.000001
0.03527
0.0022
kg
1000
0.001
35.273
2.20459
1000000
1000
35273
2204.59
oz
28.3495
0.02835
0.000028
0.0625
lb
453.592
0.45359
0.000454
16
1 tonne (metric) = 1.1023 ton (US) = 0.9842 ton (UK)
Conversion table, pressure
page
Unit
kp/cm2
bar
Pa = N/m2
kPa
lbf/in2
lbf/ft2
0.98067
98066.5
98.0665
14.2233
2048.16
bar
1.01972
100000
100
14.5037
2088.6
Pa = N/ m2
0.00001
0.001
0.001
0.00015
0.02086
kPa
0.01020
0.01
1000
0.14504
20.886
lbf/in2
0.07032
0.0689
6894.76
6.89476
144
lbf/ft2
0.00047
0.00047
47.88028
0.04788
0.00694
kp / cm2
1 kg/cm2 = 735.56 Torr (mmHg) = 0.96784 atm
VDRF03.02GB
G Terminology and index
Table of Contents G Terminology and index

mm mm mm mm mm mm
Terminology and index.................................................................................. 3

Terminology ............................................................................................................ 3
Index ....................................................................................................................... 6
VDRF03.02GB
VDRF03.02GB
G Terminology and index Terminology and index
Terminology and index
mm mm mm mm mm mm
Terminology
page
Term
Description
Accumulator
Reservoir that stores (accumulates) pressure for i.e. hydraulic functions.
Anti-corrosion compound
Prevents oxidation, in simple terms, rustproofing.
Attachment
The part of the machine that grips the load when lifting.
Axle distance
Distance between drive axle and steering axle.
Bar
Unit to express pressure.
Cuts off current from battery.
Boom
Lift boom movable vertically and longitudinally. Bracket for attachment.
Vertically adjustable "lifting jacks" for the handling of loads. Grabs the load from below.
Buzzer
Acoustic alarm to catch the operators attention.
Control valve
Valves that can be used to control something, e.g., release pressure and thus lower a
boom or a fork. Also see control valve.
Daily inspection
The actions that should be performed daily to ensure the machines functionality.
Decitonne
Tenth of a tonne; measure of the machines lift capacity.
Display
"Window" showing digital information on steering wheel panel in cab.
Drive axle
Driving axle that receives the torque from the drivetrain.
Drivetrain
Parts in the machine involved in power transmission; engine, torque converter, transmission, propeller shaft and drive axle with differential and hub reduction.
Dust reservoir
The air filter collects the coarsest particles in a dust reservoir, which empties automatically while driving.
ECC
Electric Climate Control. Climate control system with thermostat-controlled cooling, dehumidification and heating.
EHC
Electric Heat Control. Heater system with automatic heating control.
Electrolyte level
Fluid level in battery cells.
Environmental waste
Used oils, filters, etc., must be handled according to governing national laws and
regulations.
Expansion tank
Tank for coolant.
Fixed displacement
Pump with fixed pump volume.
Hanging load
Raised load.
Hub reduction
Type of final drive (often next to drive wheel) that reduces rpm and increases torque from
the drivetrain.
Hydraulic oil
Oil for hydraulic system. See specifications in section F Technical data.
Hydraulic oil pump
Pump in the hydraulic system.
VDRF03.02GB
Term
Description
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.
LC
Load centre.
Levelling
Attachment is tilted, for example, if load stands on uneven ground.
Lift capacity
Indicates machines maximum lifting capacity.
Lifting point
Attaching point for lifting device when lifting an object.
Low emission engine
Engine with low emissions of hazardous substances. Manufactured in accordance with

regulations.
Machine model
Machine type. Indicated as, for example: DRF 400-450. See also type designation.
Main fuse
Located by battery. Cuts off current to all systems in machine.
Maintenance
Periodic maintenance operations so that the machine functions safely and lasts well.
OP
Overload Protection. Overload system to warn in case of overloading of machine.
Operating time
Number of hours machine has been in operation, shown on hour meter in cab.
Option
Optional equipment for machine.
Overload system
See OP (Overload Protection).
Pilot oil pressure
A low control pressure to, for example, a valve.
Planetary gear
Type of gearbox with the gears in constant mesh.
Product alternative
One of several alternatives selected for a machine, i.e. engine alternative.
Proportional valve
An electromagnetically controlled valve. If a current is applied, the valve is activated in

proportion to the currents amplitude. In simple terms, infinitely variable valve, as opposed to on/off valve. For example, on the transmission valve housing.
Reachstacker
Machine with special top lift attachment for containers.
Refrigerant
Fluid/gas in the climate control system. Must only be handled by authorised trained personnel.
Rotation yoke
Rotating unit on attachment, rotates attachment in relation to lift boom.
Securing machine for transport
Actions before transporting machine.
Serial number
Unique machine designation. On the machine plate.
Service position
How machine should be safely positioned before service may be started.
Servo
A small user movement results in a big machine movement, e.g., power steering.
Servo pressure
A low control pressure to control a higher pressure, for example to a valve.
Side shift
Parallel sideways movement of attachment.
Solenoid valve
An electro magnetically controlled valve. See also proportional valve.
Spirit Delta
Enclosed type of cab.
Spreading
Widening of attachment.
Start-up
Start-up procedure for the control system (from de-energised to energised).
VDRF03.02GB
Term
Description
Steering axle
Wheel axle with steering.
Tilting
The load is tilted forwards or backwards.
Torque converter
Hydraulic, stepless clutch.
Transmission oil
Oil for gearbox and torque converter. See specifications in section F Technical data.
Twistlocks
Four lock pins - one in each corner of the attachment - pushed down in corresponding
holes in the container and twisted to lock the container when lifting.
Type designation
Indicates machine type and capacity. See also machine model.
Valve spool
Movable part in valve. Determines oils path.
Variable displacement.
Adjustable volume (capacity) of a pump.
Variable pump
Pump with adjustable flow rate.
Wet brakes
Brake friction plates in an oil bath.
Working hydraulics
All load handling functions, i.e. lift and lower, tilt, side shift, spreading and levelling.
VDRF03.02GB
Index
page
Designation
Section
Group
A near accident is a warning!
B Safety
About the documentation
A Foreword
About the machine version
A Foreword
About the Workshop Manual
A Foreword
Accelerator pedal
1 Engine
1.1.2
Accumulator
4 Brakes
4.3.4
4 Brakes
4.3.3
4 Brakes
4.8.4
Accumulator drain valve
10.2.1
7 Load handling
7.2.4
7 Load handling
7.3.4
Air cleaning system
1 Engine
1.6.1
Air distributor
9.4.14
Air intake and exhaust outlet
1 Engine
1.6
Air pollution
B Safety
Air suspension
9.3.5
Air vents
9.4.15
Alternator
11 Common electrics
11.4
Alternator
11 Common electrics
11.4.1
Armrest
9.3.8
ATTACH
8 Control system
8.4.9
10.2.2
7 Load handling
7.4.8
7 Load handling
7.5.11
7 Load handling
7.6.11
7 Load handling
7.7.10
7 Load handling
7.8.9
Auxiliaries
10.7
10.4.2
Back cushion
9.3.2
Batteries
11 Common electrics
11.3
11 Common electrics
11.2.1
VDRF03.02GB
Designation
Section
Group
Body
9.13
BOOM
8 Control system
8.4.8
Brake fluid filter
4 Brakes
4.3.2
Brake fluid filter
4 Brakes
4.5.2
Brake fluid filter
4 Brakes
4.8.12
Brake fluid pump
4 Brakes
4.3.1
Brake fluid pump
4 Brakes
4.5.1
Brake fluid pump
4 Brakes
4.8.3
Brake fluid tank
4 Brakes
4.8.1
Brake light
9.6.4
Brake pedal
4 Brakes
4.1.1
Brake system fluid
4 Brakes
4.8.14
Brake valve
4 Brakes
4.3.5
Brakes
4 Brakes
Breather filter
4 Brakes
4.8.11
Breather filter hydraulic oil tank
10.6.6
Buzzer
9.2.4
Buzzer, automatic spreading 20'-40'
7 Load handling
7.5.13
Bypass
8 Control system
8.2.2
CAB
8 Control system
8.4.3
Cab fan
9.4.3
Cab frame
9.10.1
Cab interior
9.11
Cab structure and suspension
9.10
Cab undercarriage
9.10.3
Cables
11 Common electrics
11.5.5
Calibration
8 Control system
8.5.2
CAN bus drivetrain
11 Common electrics
11.6.3
CAN/POWER
8 Control system
8.4.1
CAN-bus
11 Common electrics
11.6.1
Central lubrication
9.14
Circuit diagram, description
E Diagram
11
Circuit diagrams, compilation
E Diagram
11
CLIMATE
8 Control system
8.4.4
VDRF03.02GB
Designation
Section
Group
Clothing, etc.
B Safety
Collecting block, filtered returns
10.5.4
Collecting block, unfiltered returns
10.5.5
Common electrics
11 Common electrics
11
Common electrics
E Diagram
11
Common hydraulics
10
Common hydraulics
E Diagram
10
Communication
11 Common electrics
11.6
Communication between PC and machine
11 Common electrics
11.6.4
Complete machine
0 Complete machine
Complete machine, description
0 Complete machine
Component designations
E Diagram
11
Compressor
9.4.7
Condenser
9.4.8
Conditions
A Foreword
Container counter
7 Load handling
7.10.3
Control lever
7 Load handling
7.1.1
Control system
8 Control system
Control system
D Error codes
2 Transmission
2.8.1
1 Engine
1.9.1
Control units
11 Common electrics
11.5.3
7 Load handling
7.4.3
7 Load handling
7.5.3
7 Load handling
7.6.3
7 Load handling
7.7.5
7 Load handling
7.8.3
7 Load handling
7.2.5
Control valve lift, lower, extension
7 Load handling
7.3.5
Control valve mini-wheel/joystick control
5 Steering
5.2.10
1 Engine
1.1
2 Transmission
2.1
4 Brakes
4.1
5 Steering
5.1
VDRF03.02GB
Designation
Section
Group
7 Load handling
7.1
8 Control system
8.1
9.1
Conversion table, area
F Technical data
Conversion table, length
F Technical data
Conversion table, pressure
F Technical data
Conversion table, SI-units
F Technical data
Conversion table, weight
F Technical data
Conversion table, volume
F Technical data
Coolant
1 Engine
1.7.7
Coolant
B Safety
Cooling fan
1 Engine
1.7.5
Cooling fan
10.6.3
Cooling fan
4 Brakes
4.8.8
Cooling system
1 Engine
1.7
Cooling system
2 Transmission
2.7
Copyright
A Foreword
Counterweights
9.13.4
Damping block, tilt
7 Load handling
7.7.3
Data and volume
F Technical data
Diagnostics
8 Control system
8.4
Distribution block
9.14.2
Distribution of electricity
11 Common electrics
11.5
Documentation sections
A Foreword
Doors
9.10.2
Drive axle
3 Driveline/axle
3.3
Drive axle block
4 Brakes
4.3.6
Drive axle block
4 Brakes
4.8.5
Driveline/axle
3 Driveline/axle
9.6.6
Electric heater
9.3.3
Electric motors
B Safety
Electric protection
11 Common electrics
11.2
Electronic box
11 Common electrics
11.5.2
VDRF03.02GB
10
Designation
Section
Group
Engine
1 Engine
Engine
D Error codes
ENGINE
8 Control system
8.4.6
Engine control system
1 Engine
1.9
Engine error codes (engine alternative Cummins QSM11)
D Error codes
Engine heater
1 Engine
1.7.10
Engine temperature sensor
9.4.6
Entertainment and communication
9.8
Environment
B Safety
Error code menu
8 Control system
8.1.10
D Error codes
Error codes
D Error codes
Error codes engine (engine alternative Volvo)
D Error codes
Error codes engine, general
D Error codes
Error codes machine
D Error codes
Error codes, explanation
D Error codes
Error codes, transmission
D Error codes
Exhaust system
1 Engine
1.6.3
Expansion valve
9.4.11
Extension
7 Load handling
7.3
Extension cylinder
7 Load handling
7.3.8
EXTRA
8 Control system
8.4.11
Feedback
A Foreword
Fire and explosion risks
B Safety
Fire extinguisher
9.2.3
9.6.7
9.7.2
Flex plates
2 Transmission
2.2.1
Floor covering
9.11.4
Fluid or gas under pressure
B Safety
Footstep and rail
9.13.3
Foreword
A Foreword
Form for copying
A Foreword
Frame
9.12
VDRF03.02GB
11
Designation
Section
Group
Frame, body, cab and accessories
9.4.2
Fresh air filter
9.4.1
Fuel system
1 Engine
1.2
Fuel system
B Safety
Fuel tank
1 Engine
1.2.1
A Foreword
Function group structure
A Foreword
Fuses
11 Common electrics
11.2.2
Gear pump with fixed displacement
10.4.1
Gear selector and multi-function lever
2 Transmission
2.1.1
Gear selector and multi-function lever
9.1.1
General
A Foreword
General
B Safety
General
B Safety
General safety information
B Safety
Glass/windows/mirrors
9.9
Headlights
9.6.1
Heat exchanger cooling
9.4.13
Heat exchanger heat
9.4.4
Heating, ventilation and air conditioning
9.4
Height limitation
8 Control system
8.2.4
9.13.2
Horn
9.7.1
Hoses, pipes and valves
10.5
HYD
8 Control system
8.4.5
Hydraulic and brake systems, depressurising
B Safety
Hydraulic cylinders
10.7.1
E Diagram
10
E Diagram
10
E Diagram
10
E Diagram
10
E Diagram
10
E Diagram
10
VDRF03.02GB
12
Designation
Section
Group
Hydraulic diagram, cab lift and support jacks
E Diagram
10
E Diagram
10
E Diagram
10
E Diagram
10
levelling
E Diagram
10
Hydraulic diagrams, compilation
E Diagram
10
Hydraulic oil
10.6.8
Hydraulic oil cooler
10.6.2
Hydraulic oil fine-filter
10.6.9
Hydraulic oil pump
5 Steering
5.2.1
Hydraulic oil pump
7 Load handling
7.2.1
Hydraulic oil pump
7 Load handling
7.3.1
Hydraulic oil pump
7 Load handling
7.4.1
Hydraulic oil pump
7 Load handling
7.5.1
Hydraulic oil pump
7 Load handling
7.6.1
Hydraulic oil pump
7 Load handling
7.7.1
Hydraulic oil pump
7 Load handling
7.8.1
Ignition switch
1 Engine
1.1.1
Important information
A Foreword
Initiation
8 Control system
8.5.1
Instrument and control panels
9.11.1
Insulation
9.11.5
Intercooler
1 Engine
1.6.4
Interior details, plastic
9.11.2
Interior details, textile
9.11.3
Interior lighting
9.6.12
Joystick
5 Steering
5.1.3
11 Common electrics
11.6.6
Levelling
7 Load handling
7.8
Levelling cylinders
7 Load handling
7.8.7
Lift boom
7 Load handling
7.2.10
Lift boom
7 Load handling
7.3.10
Lift boom
7 Load handling
7.7.8
VDRF03.02GB
13
Designation
Section
Group
Lift capacity and dimensions
F Technical data
Lift cylinder
7 Load handling
7.2.8
Lifting equipment
B Safety
Lifting heavy components
B Safety
Lifting jacks
7 Load handling
7.9.2
Lifting/lowering
7 Load handling
7.2
Lighting system
9.6
LIGHTS
8 Control system
8.4.2
Lines
9.14.3
Link arm
5 Steering
5.2.6
Load carrier
7 Load handling
7.9
8 Control system
8.2.3
Load handling
7 Load handling
Lock valve, tilt
7 Load handling
7.7.4
Lubrication system
2 Transmission
2.6
Machine card
A Foreword
7 Load handling
7.4.7
7 Load handling
7.5.9
Mechanical seat adjustment
9.3.6
Mini-wheel
5 Steering
5.1.2
Moisture filter
9.4.9
Monitor, reversing camera
9.9.7
Monitoring
8 Control system
8.2
M-valve parking brake
4 Brakes
4.5.3
NC switch, brake fluid pressure
4 Brakes
4.3.7
NO (normally open) switch, brake lights
4 Brakes
4.3.8
Noise
B Safety
Non-ionised radiation
B Safety
Normally closed (NC) switch, disengagement
2 Transmission
2.8.2
Nut, washer and clamp
6 Suspension
6.3.3
Oil cooler
2 Transmission
2.6.3
Oil cooler
2 Transmission
2.7.3
Oil cooler
4 Brakes
4.8.7
Oil filter
10.6.7
VDRF03.02GB
14
Designation
Section
Group
Oils
B Safety
Oils and lubricants, recommendation
F Technical data
OP
8 Control system
8.4.10
Ordering of documentation
A Foreword
Other functions
7 Load handling
7.10
Overcentre valve, levelling
7 Load handling
7.8.5
Overload system
8 Control system
8.2.1
Paint/coatings
9.15
Parking brake NC switch
4 Brakes
4.5.5
Parking brake system
4 Brakes
4.5
Parking brake unit
4 Brakes
4.5.4
Passenger seat
9.3.7
Pipes and hoses
10.2.3
Pipes and hoses
10.3.2
Pipes and hoses
10.4.3
Pipes and hoses
10.5.1
Pipes and hoses
10.6.10
Pipes and hoses
4 Brakes
4.3.10
Pipes and hoses
4 Brakes
4.5.6
Pipes and hoses
4 Brakes
4.8.13
Pipes and hoses
5 Steering
5.2.13
Pipes and hoses
7 Load handling
7.2.12
Pipes and hoses
7 Load handling
7.3.12
Pipes and hoses
7 Load handling
7.4.9
Pipes and hoses
7 Load handling
7.5.12
Pipes and hoses
7 Load handling
7.6.12
Pipes and hoses
7 Load handling
7.7.11
Pipes and hoses
7 Load handling
7.8.10
Position sensor, spreading
7 Load handling
7.5.10
Power assisted system
5 Steering
5.2
Power-assisted brake system
4 Brakes
4.3
Pressure reducer
7 Load handling
7.2.3
Pressure reducer
7 Load handling
7.3.3
Pressure switch
9.4.10
VDRF03.02GB
15
Designation
Section
Group
Priority valve
10.5.2
Priority valve
5 Steering
5.2.2
Product alternatives and optional equipment
A Foreword
Propeller shaft
3 Driveline/axle
3.2
Pump unit
9.14.1
Pumps
10.4
Radiator and expansion tank
1 Engine
1.7.4
Radiator bypass valve
10.6.5
A Foreword
A Foreword
Reading instructions
A Foreword
Reading out error code
D Error codes
Rear window
9.9.4
Rearview mirror
9.9.5
Redundant CAN bus
11 Common electrics
11.6.2
References between different information types
A Foreword
Refrigerant
B Safety
Reverse alarm
9.7.5
Reversing camera
9.9.6
Reversing light
9.6.5
Revolving beacon
9.6.8
Revolving beacon
9.7.3
Rims
6 Suspension
6.3.2
Ring gear
7 Load handling
7.6.8
RMI
8 Control system
8.4.13
RMI (Remote Machine Interface)
11 Common electrics
11.6.5
Roof window
9.9.3
Rotating components and tools
B Safety
Rotation
7 Load handling
7.6
Rotation motor unit
7 Load handling
7.6.6
Rotation yoke
7 Load handling
7.6.7
Rotation yoke
7 Load handling
7.7.9
Running light
9.6.2
Safety
B Safety
VDRF03.02GB
16
Designation
Section
Group
Safety and emergency equipment
9.2
Safety concerns everyone!
B Safety
Safety instructions
B Safety
Safety switch
11 Common electrics
11.2.3
Safety switch
9.2.1
Safety valves
10.2
Seat
9.3
Seat belt
9.2.2
Seat cushion
9.3.1
Sensor brake oil temperature
4 Brakes
4.8.10
9.4.17
7 Load handling
7.2.9
Sensor operator in seat
9.3.9
9.4.18
9.4.16
9.4.12
Sensor, attachment damping
7 Load handling
7.2.16
Sensor, boom angle
7 Load handling
7.2.11
Sensor, boom length
7 Load handling
7.3.11
Sensor, fuel level
1 Engine
1.2.2
Sensor, hydraulic oil temperature
10.6.4
7 Load handling
7.6.10
Service indicator
8 Control system
8.2.6
Service position
B Safety
Servo filter
7 Load handling
7.2.2
Servo filter
7 Load handling
7.3.2
Setup
8 Control system
8.5
Several mechanics on the same machine
B Safety
Shock absorbers
9.3.4
Shuttle valve
10.5.3
Shuttle valve
5 Steering
5.2.9
Shuttle valve
7 Load handling
7.2.6
Shuttle valve
7 Load handling
7.3.6
Shuttle valve
7 Load handling
7.4.4
VDRF03.02GB
17
Designation
Section
Group
Shuttle valve
7 Load handling
7.5.4
Shuttle valve
7 Load handling
7.6.4
Shuttle valve
7 Load handling
7.7.6
Shuttle valve
7 Load handling
7.8.4
Shuttle valve, mini-wheel/lever steering
5 Steering
5.2.11
Side shift
7 Load handling
7.4
Side shift cylinder
7 Load handling
7.4.5
Side shift frame
7 Load handling
7.4.6
Side shift frame
7 Load handling
7.6.9
Side shift frame
7 Load handling
7.8.8
Side window
9.9.2
Signalling system
9.7
Sliding cab
9.10.4
Solvents
B Safety
Spare parts
B Safety
Speed limitation
8 Control system
8.2.5
Spreader beam
7 Load handling
7.5.8
Spreader chains
7 Load handling
7.5.7
Spreading
7 Load handling
7.5
Spreading motor
7 Load handling
7.5.6
Start battery
11 Common electrics
11.3.1
Start/stop
1 Engine
1.11
Starter motor
1 Engine
1.11.1
Steering
5 Steering
5 Steering
5.2.12
5 Steering
5.2.5
6 Suspension
6.2.1
Steering cylinder
5 Steering
5.2.4
Steering valve
5 Steering
5.2.3
Stopping device
1 Engine
1.11.2
Storage
A Foreword
Sun blinds
9.11.6
Support jacks
7 Load handling
7.10.1
Suspension
6 Suspension
VDRF03.02GB
18
Designation
Section
Group
Suspension
6 Suspension
6.2
Switch, automatic spreading
7 Load handling
7.1.3
Switch, bypass of load centre and height limitation
8 Control system
8.1.4
9.1.22
Switch, lock twistlocks
7 Load handling
7.1.2
Switch, stop at 30' or 35'
7 Load handling
7.1.5
Synchronised lift
7 Load handling
7.10.4
Tail light
9.6.3
Tank
10.3.1
Tank heater
10.6.1
Tank heater
4 Brakes
4.8.2
Tanks and accumulators
10.3
Technical data
F Technical data
Temperature control, cleaning and brake oil
4 Brakes
4.8
Temperature control, cleaning and hydraulic oil
10.6
Tensioned springs
B Safety
Terminal console
9.11.7
Thermal bypass valve
4 Brakes
4.8.9
Tightening torque, climate control system connections
F Technical data
Tightening torques, ORFS-couplings
F Technical data
Tightening torques, recommendations
F Technical data
Tilt
7 Load handling
7.7
Tilt cylinder
7 Load handling
7.7.7
Torque converter/Clutch system
2 Transmission
2.2
TRANSM
8 Control system
8.4.7
Transmission
2 Transmission
Transmission
D Error codes
Transmission cable harness
2 Transmission
2.8.3
Transmission control system
2 Transmission
2.8
Troubleshooting cable harness
0 Complete machine
Troubleshooting hydraulic hoses
0 Complete machine
Troubleshooting with error code, example
0 Complete machine
Troubleshooting without an error code, example
0 Complete machine
Troubleshooting, general work instructions
0 Complete machine
VDRF03.02GB
19
Designation
Section
Group
Twistlocks
7 Load handling
7.9.1
Tyres
6 Suspension
6.3.1
Tyres and rims
6 Suspension
6.3
Tyres and rims
B Safety
Unit explanations
F Technical data
Valve block lift cylinder
7 Load handling
7.2.7
Valve block, extension cylinder
7 Load handling
7.3.7
Valve block, levelling cylinders
7 Load handling
7.8.6
Valve block, pump unloading
7 Load handling
7.3.9
Valve block, rotation motor
7 Load handling
7.6.5
Valve block, spreading motor
7 Load handling
7.5.5
7 Load handling
7.4.2
7 Load handling
7.5.2
7 Load handling
7.6.2
7 Load handling
7.7.2
7 Load handling
7.8.2
Warning information
A Foreword
Warning parking brake
9.7.4
Washer motor and reservoir
9.5.4
Water valve
9.4.5
Weight indicator
7 Load handling
7.10.2
Vertically adjustable cab
9.10.5
Wheel brake
4 Brakes
4.3.9
Wheel brake
4 Brakes
4.8.6
Wheel hub
5 Steering
5.2.8
Wheel hub
6 Suspension
6.2.3
Wheel spindle
5 Steering
5.2.7
Wheel spindle
6 Suspension
6.2.2
Vibrations
B Safety
Windscreen
9.9.1
Wings
9.13.1
Wiper front
9.5.1
Wiper motor, front
9.5.5
Wiper motor, rear
9.5.7
VDRF03.02GB
20
Designation
Section
Group
Wiper motor, roof
9.5.6
Wiper rear
9.5.3
Wiper roof
9.5.2
Wiper/washer system
9.5
Voltage feed
11 Common electrics
11.5.1
Working lights, attachment
9.6.11
9.6.10
Working lights, cab
9.6.9
Working under machine
B Safety
Workshop manual contents
A Foreword
Writing desk
9.11.8
VDRF03.02GB
Cargotec improves the efficiency of cargo flows by offering solutions for

the loading and unloading of goods on land and at sea wherever cargo
is on the move. Cargotecs main daughter brands for cargo handling
Hiab, Kalmar and MacGregor are global market leaders in their fields.
Cargotecs global network offers extensive services that ensure the
continuous, reliable and sustainable performance of equipment.
Cargotec Sweden AB
Torggatan 3
SE-340 10, Lidhult, Sweden
tel. +46 372 260 00
fax +46 372 263 90
www.cargotec.com

DRF Manual de Taller - Workshop

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DRF Manual de Taller - Workshop

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Reachstackers 40-45 tonnes

Workshop Manual in original

Table of Contents A Foreword

Reading instructions ................................................................................... 4

About the documentation ......................................................................... 12

Workshop manual DRF 400-450

Workshop manual DRF 400-450

About the machine version

Workshop manual DRF 400-450

A Foreword Reading instructions

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

Important information marked with NOTE facilitates the work process,

Read the Operators Manual

Read the Operators Manual

Read the Maintenance Manual

The symbol to the left is sometimes found on the machine. It refers to

Read the Maintenance Manual

Workshop manual DRF 400-450

A Foreword Reading instructions

Workshop manual contents

The Workshop Manual contains information to facilitate maintenance

Keep in mind for your safety.

Reference to maintenance manual: Preventive maintenance.

Frame, body, cab and

Wiring diagrams, hydraulic diagrams and list of electrical components.

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

Terminology and index

General terminology and abbreviations, explanation of terms and abbreviations that

Technical description, comprehensive function descriptions and a description of the

Workshop manual DRF 400-450

A Foreword Reading instructions

Function group structure

Workshop manual DRF 400-450

A Foreword Reading instructions

References between different information types

The maintenance manual and workshop manual are mainly divided

(Technical description, usually in Workshop manual)

(Technical description, group 8.4)

From Function description to Component description, to enable

From Function description to Hydraulic diagram, to enable fast

From Diagnostics to Wiring diagrams. to enable fast finding of the

From Error codes to Diagnostics, to enable fast finding of the right

Workshop manual DRF 400-450

A Foreword Reading instructions

Product alternatives and optional equipment

Symbol for optional equipment

Optional equipment refers to options that can be added to standard

Workshop manual DRF 400-450

A Foreword Reading instructions

Function descriptions are schematic overviews that describe how a

Workshop manual DRF 400-450

A Foreword Reading instructions

Example of function description

Hydraulic force (solid double line)

Flag pressure check connection (Check point), indicates that

Illustration of function, (apply brake)

Reference to description of component

Signal description, reference value for signal out from component

Description of component's function

Position number, reference to position in illustration

Position number in illustration, reference to row in table

10. Electric power (solid single line)

Workshop manual DRF 400-450